Patent Abstract:
This is a double acting, multi-lane machine and method for the forming, filling and sealing of plastic or paper film pouches of various sizes commonly used to hold liquid viscous, dry, particulated or powdery materials or other substances. The machine includes a four roll film dispensing station, a multi unit pump or dispensing station, one of each double acting stations such as side seal station, pull wheel station, cross seal station, and cross cut station. The invention provides for production of a multitude of pouches in a manner of two sets of two films allowing to double the production output of current machinery without any change to cycle time or increase of operational time. Coordination and movement of the various stations is accomplished through electronic computer control, working in conjunction with multiple motion controlling devices such as servo motors, air cylinders, belts, linkages and the like. The machines stations and components are adjustable or interchangeable so that pouches of various lengths and widths may be formed.

Full Description:
This application claims the benefit of U.S. Provisional Application No. 60/727,898, filed on Oct. 17, 2005. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an apparatus for manufacturing pouches made of webbed plastic, foil, or paper film, and more particularly, to an apparatus for forming, filling and sealing such pouches or sachets utilizing a double action apparatus allowing to double the output or production of current apparatuses or machines without the need to increase the cycle speed or operational time of the machine. 
   2. Description of the Prior Art 
   Pouches, also known as packets or sachets are commonly used throughout many industries to package and distribute individual single serve or institutional portions of liquids or viscous materials, as well as dry, particulated and or powdery materials, such as condiments, foods, beverages, pharmaceutical, personal care products, and chemicals. Such single serve or institutional size pouches are also used to package and distribute other products or commodities, such as candy, nuts, salt, pepper, rice and the like. The widespread popularity of such single serve or institutional pouches, combined with the convenience and their ease of distribution, has led to a ever increasing interest in machines and methods for forming, filling and sealing such pouches in a much more efficient way combined with and increased production output. 
   The traditional apparatus for manufacturing pouches uses two rolls for dispensing sheets of webbed foil or plastic film, of equal dimensions, multiple sealing devices appropriate for such film, and means for inserting such product into the film pouches. The apparatus first receives film from the film rolls, then matches and aligns their respective edges. The sealing devices are then applied to all but one of the edges, forming a pouch or sachet with a cavity and topside opening. The products (liquids, viscous materials, particulated or dry powdery products or substances) are then released and inserted into the cavity through the opening. The pouch or sachet opening is then closed, sealed and separated from the film. This process is then repeated. 
   Nonetheless, such traditional apparatuses are generally unsuitable for manufacturing large volumes of pouches at very high speeds. To be specific, traditional apparatuses are using two film dispensing rolls, one for the front creating the front part of the pouch cavity and one for the back creating the back of the pouch cavity. The machine stops every cycle while the side and/or leading and trailing edges of the pouches are pressed, sealed, and cut. With every delay (i.e., stop) without any action even only for a few milliseconds per cycle, these delays or stops accumulate over time and create a significant shortfall of product output resulting in decreased revenue for the manufacturer utilizing such apparatuses. 
   Various devices have been developed to increase the production rate of such film pouches. For example, U.S. Pat. No. 4,726,171 utilizes a vertically moving combination advancement-sealing-separation mechanism that travels between various locations within the apparatus, advancing the film from the film roll, sealing the ends of a pouch, or separating a pouch from the fill, depending upon the particular engagement point. U.S. Pat. Nos. 4,004,397 and 6,178,719 both utilize rotary presses and sealers to minimize delays in the pouch manufacturing process. 
   Unfortunately, none of these devices are particularly suited for very high-volume production of film pouches. None of the devices disclose an apparatus capable of a double action alternating sequence during operational cycles, in that the apparatus uses four rolls of film and produces, two sets of pouches in an alternating sequence per cycle. While one set of pouches are stationary and are in the sealing and cutting sequence of the cycle, the other opposing or second set of pouches are in a advancing and filling sequence of the cycle. This happens repeatedly in an alternating sequence every cycle of the machine. While the first set of two films are stationary during the first sequence of operation, concurrently the second set of two films are being advanced during the fill sequence of its cycle, until such set is ready and in a position to be stopped and horizontally sealed and cut. Such alternating operation sequencing makes the apparatus capable of producing two times the amount of product output in comparison to the existing single stage apparatus currently on the market. 
   Hence the desire to provide an apparatus for forming, filling and sealing large volumes of film pouches within a minimal amount of time. It is further desirable that such film pouches be manufactured in an alternating sequence and speed rate so as to maximize production volume. It is further desirable that the apparatus be capable of simultaneously manufacturing multiple film pouches per machine cycle, so as to further maximize production volume. It is further desirable that such film pouches are produced with no-leakage or breakage. It is further desirable that the apparatus is of small footprint and utilizes a minimal amount of operational floor space. 
   SUMMARY OF THE INVENTION 
   The present invention is a double action, multi-lane method and apparatus for the forming, filling and sealing of film, plastic, foil or paper pouches or sachets of various sizes commonly used to hold fluids, liquids, viscous materials (e.g. ketchup, mayonnaise, salsa, etc.), dry products in form of particulated or powdery materials (e.g. peanuts, candy, sugar, salt, peper etc.) or other substances. The invention is made up of the following distinct stations: a four film roll station; a multiple pump station; a double action side seal station; a double action pull wheel station; a double action cross seal station; and a double action cross cut station. The invention provides a production of multiple pouches or sachets by utilizing one or more moveable double action carriages. These carriages independently supporting each of the double action side sealing, double action cross sealing and double action cross cutting apparatuses. Coordination of the various stations movements is accomplished through electronic computer control (e.g., PLC), working in conjunction with multiple units of motion imparting devices such as servo motors, belt systems, air cylinders, linkages and the like. The various components of the machine are interchangeable or adjustable so that pouches of various lengths and/or widths may be formed using the same machine. 
   Two pair of film dispensing rolls are provided at the film roll station. Film is removed from each roll and used to form the fronts and backs, respectively, of the pouches. Sheets of film from all four rolls are advanced through the apparatus by the double action pull-wheel station. The film from each roll is guided so that all four sheets of film ending up in pairs and close proximity to and in a parallel relationship with one another as they are advanced through the machine. 
   The pump station consisting of multiple fill dispensers. These dispensers are capable of drawing a pre-determined quantity of material or product from an overhead reservoir or piping and depositing such material or product into the cavities of the film pouches formed by the machine. The pump stations and dispensers are each driven by one motion-controlled servomotor. The quantity of dispensed product may be changed by changing the stroke distance of the pistons contained within the pump. Exchanging the dispensers (with different dispensers having more or less capacity), also allows for larger or smaller product output not within the dispensing range of the first dispensing unit. This allows for different quantities of materials to be dispensed depending upon the size and capacity of the pouches to be formed by the machine. 
   In one embodiment, a servo motor and gearbox translate a rotary motion into a linear motion through a vertically arranged belt and pulley system, which allow the pumping pistons to move in a linear up and down motion. This upwards linear vertical motion of the pistons draws product into the cylinder body&#39;s of the pump station, by reversing this vertical motion of the pistons the product is discharged into a set of fill tubes which, in turn, dispense the product into the formed pouches. The servomotor allows the motion of these pistons to be controlled very precisely which controls the product flow. The amount of product can be varied by increasing or decreasing the stroke length of the piston. 
   The quantity of product to be deposited into the film pouches is communicated to the pump station servomotors and its controller, adjusting their movement accordingly, by entering or changing a setting into the electronic control panel operated by the machine operator. 
   The double action side seal station consisting of two sets of two opposing sealing frames, both sets positioned in such a manner that the two sets of film one front and one back films each advance between each of the two sets of the two opposing pads. A plurality of linearly vertically oriented sealing pads, each pad containing a heating element, are affixed to each frame forming a multiplicity of pairs of pads. The sealing pads are each aligned in close proximity to each of the corresponding opposing sealing pad on the opposing frame, and are arranged along the path of the film through the machine. Each pair of opposing pads is positioned so as to apply heat and pressure to the two films between them, causing the contacted surface areas of such films to be pressed together and sealed. The double action side seal station forms multiple seals. Once the front set of sealing pads are in the seal cycle of the operation using the front set of front and back films creating a seal, while at the same time, the rear set of sealing pads are retracted or open allowing the rear set of film with the just completed seals with the set of rear front and back films to advance to the next station. The motion is then reversed and repeated. This movement may be driven by one motion-controlled servomotor, or with a double stage air cylinder. 
   The double acting pull wheel station consisting of two sets of two opposing rotating roller shafts containing multiple pull wheels, both sets are positioned in such a manner that the two sets of two films each is capable of paired and independent advancement between the opposing shaft. The shafts may be retracted/opened so that the two sets of two films may be fed between them. When the shafts are in a closed position, pressure is applied to the rollers of each pair so that they come into contact with each other, pinching the films between them. This pinching action provides a gripping friction upon the film surfaces pulling the films through this station. The double acting pull wheel station is driven by two independent motion-controlled servomotors, each driving a pair of shafts with said pull wheels attached. 
   The double action cross seal station consisting of two sets of two opposing sealing frames, both sets positioned in such a manner that the two sets of films, one front and one back film, each advance between each of the two sets of the two opposing pads. Two opposing horizontally oriented pairs of sealing pads each pad containing a heating element, extending across the film path, are affixed to each set of frames. The sealing pads are aligned in close proximity to the corresponding sealing pad on the opposing frame, and are arranged across the path of the film. Each pair of opposing pads is positioned so as to apply when closed heat and pressure to the films between them, causing the contacted surface areas of such films to be pressed together and sealed. The double acting cross seal station forms a single seal each across the two sets of two films forming simultaneously the bottom of the set of pouches to be filled as well as the top/closing of the previously filled set of pouches. Once the front set of sealing pads are in the seal cycle of the operation closing and sealing the just filled set of pouches, the rear set of sealing pads, at the same time, are retracted/open allowing the rear set of just completed seals to advance and fill the just created set of top open pouches. The motion is then reversed and repeated. This movement may be driven by one motion-controlled servomotor, or with a double stage air cylinder. 
   The double acting cross cut station consisting of two sets of cutting devices/knifes positioned to receive the formed, filled and sealed pouches from the double acting cross seal station. The devices/knifes are capable of separating each row of pouches by cutting along the midpoints of the horizontally sealed surface areas created by the double acting cross seal station above. During the front set of knifes cutting cycle the rear set of knifes is retracted/open allowing the rear set of just completed filled and sealed pouches to advance and be positioned to be cut. The motion is then reversed and repeated. This movement may be driven by one motion-controlled servomotor, or with a double stage air cylinder. 
   The flexibility and independence of the machine and its various stations permits the operator to adjust and or set up the machine to create pouches of different horizontal and vertical dimensions, dos changing the fluid capacity, lengths and widths of the pouches. This is accomplished by adjusting such values as the quantity of product pumped into the pouches, the number and spacing of the side seals (defining the number of pouches per row and the frequency of cross seals (defining the length of the pouches), the movements of the servomotors, belts and pulley ratios of the system, etc. 
   In use, four sheets or two pairs of film in close proximity to each other are pulled from four large film dispensing rolls through the double acting side seal station through and by the rollers of the double acting pull wheel station. The two sets of films are parallel to and each other and each set is in close proximity with, one another, such that the first set or front set of two films may form, for example, the fronts of the pouches, while the second forms the backs thereof, while the second set of two films or rear of machine set of films form, for example, the fronts of the pouches, while the second forms the backs thereof. Activation of the front set of rollers of the double acting pull wheel station causes the rollers to advance the front set of two films to advance and unwind film from the first set of two dispensing rolls, while the other side or back side of machine of the double acting pull wheel station is halted and is awaiting a signal from the controller to advance the second set of films. Before each of the two sets of films is pulled through the double acting side seal station, they are aligned and pass along either side of two sets of a multiple fill tubes used to deposit the product into the top open or 3 sided pouches. Thus, the side seals are formed around the fill tubes. 
   At the double acting side seal station, containing a multitude of pairs of longitudinally elongated heated sealing pads, which when come together then apply pressure and heat upon the contacted film surfaces areas, causing the affected surfaces to adhere to one another creating multiple continuous vertical fill tubes, thereby defining cavities between the continuous fill tubes. The number and width of these fill tubes is determined by the distance between the vertically oriented and elongated heated sealing pads. Each of these cavities surrounds one of the fill tubes. 
   The double acting side seal station first forms a front set of multiple pouches, by applying sufficient momentary pressure upon the affected film surface area for a sufficient time to bond the two sides of film together at such contact area, while at the same time the rear set of film and previously formed elongated tubes are being advanced. This process is then reversed, repeated and so on. Each set of film front and rear forming multiple continuous longitudinal cavities or tubes of film. Each set of sealed film, now in the form of multiple tubes, continues, to be pulled in an alternating front set of films and then back set of film by the double acting pull wheel station, and advances to the double acting cross seal station. It is to be noted that during subsequent cycles, there is a moderate overlap of the sealed area of the tubes where the heating pads of the double acting side seal station will seal over the previously created side seals in order to provide continuous side seals on the films and to avoid any leakage of pouches. 
   Two sets of multiple, vertically oriented blades are provided along the film path just ahead of the double acting pull wheel station, with each blade ahead (above) of each pull wheel (pair). These blades are positioned at the mid-points of each of the freshly created side seals, in order to cut and separate the two sealed film sheets into multiple individual vertical tubes as they are pulled through the double acting pull wheel station. These separated tubes are then transferred to the double acting cross seal station. 
   The two sets of sealing pads of the double action cross seal station are mounted horizontally and perpendicularly to those of the double action side seal station. These cross sealing pads apply heat and pressure to the film across a transverse section of the surface area, causing the affected surfaces to adhere to one another in a perpendicular relationship to the continuous vertical longitudinal tubes formed by the double action side seal station. In the first cycle, such perpendicular adhesion defines the leading edge of a row of individual film pouches. In subsequent cycles, each such perpendicular adhesion defines both the trailing edge of the pouches of the current cycle, as well as the leading edge of the pouches of the subsequent cycle. As heat and pressure at the front of machine set of films is applied, the rear of machine set of film and set of sealing pads are open allowing the rear set of films to be advanced to the next station. The action of the double action seal station is then reversed and the rear set of sealing pads are applying heat and pressure to the rear set of films creating a horizontal seal, while the front set of sealing pads are open allowing the film to advance to the double acting cross cut station. This process is then reversed and repeated on and on. 
   Once a cross seal is formed, the pre-measured amount of product contained within the pump station then is deposited into the cavities of the film pouches through the fill tubes. 
   The top edge of the current row of just filled pouches being sealed by the double acting cross seal created in the subsequent cycle, also creates the bottom seals for the next set of pouches which was also created by the subsequent cycle. 
   The double acting cross cut station separates a horizontal row of each of the two individual set of films front and back of machine by cutting the pouches along the midpoint of the cross seal for each front and back film. The side seals between the now-filled film tubes of each row were previously cut by a multiplicity of vertical blades ahead of the double acting pull wheel station. Following the cross cut, the now separated and individual pouches then exit from the machine onto a takeoff conveyor or into a hopper or other appropriate receptacle. 
   It is therefore the primary object of the present invention to provide methods and apparatus for forming, filling and sealing large volumes of pouches in a minimal amount of time. 
   It is another object of the present invention to provide methods and apparatus capable of simultaneously manufacturing multiple filled pouches, so as to further maximize the volume of production. 
   It is another object of the present invention to provide an apparatus that utilizes a minimal amount of operational floor space. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric view of the present invention. 
       FIG. 2  is a front plan view of the present invention. 
       FIG. 3  is an isometric view of a typical pump station of the present invention. 
       FIG. 4  is a top plan view of a typical pump station of the present invention. 
       FIG. 5  is an isometric view of a typical double acting side seal station of the present invention. 
       FIG. 6  is an isometric view of a typical double acting pull wheel station of the present invention. 
       FIG. 7  is an isometric view of a typical double acting cross seal station of the present invention. 
       FIG. 8  is an isometric view of a typical double acting cross cut station of the present invention. 
       FIG. 9  is a side cut view of the present invention. 
       FIG. 10  is an isometric view of a typical drive mechanism for the typical double acting station of the present invention. 
   

   DETAILED DESCRIPTION 
   In  FIGS. 1 ,  2  and  9  it is seen that the apparatus of the present invention includes a four film dispensing roll station  10  to dispense films to the apparatus; a pump station  20  for insertion of product such as fluids, liquids, viscous, particulated, and dry materials, or other substances into the individual film pouch cavities; a double action side seal station  30  forming the side seals of the individual pouches; a double action pull wheel station  40  advancing (pulling) the films through the machine; a double action cross seal station  50  sealing simultaneously the leading and trailing edges of the pouches; a double action cross cut station  60  separating rows of individual pouches from the film. The preferred way of operation for the various stations is to use servomotors. A alternative way, or combination thereof utilizing two air cylinders  31  to operate the various stations as shown in  FIG. 5  may be used to operate one or more of the stations. 
   As shown in  FIGS. 1 ,  2  and  9 , a first film roll  11 , a second film roll  12 , a third film roll  13  and a fourth film roll  14  are mounted on the machine in such a manner as to allow the double action pull wheel station  FIG. 6  to pull and unroll the film of the four film rolls through the machine, preferably such that the film two sheets each one set of two and a second set of two films that unroll are in parallel relationship to each other as illustrated in  FIG. 9 . The film from each roll is pulled by the rollers  43  of the double action pull wheel station  40  as shown in  FIG. 6 . The rotational operation of rollers  43  of the double action pull wheel station  40  results in film from each roll  11 ,  12 ,  13 , and  14  to be released at an programmed rate of speed. Roll  11  provides film for the back surfaces of the pouches or sachets to be formed in the front half of the machine, while roll  12  provides film for front surfaces thereof. Roll  13  provides film for the back surfaces of the pouches or sachets to be formed in the rear half of the machine, while roll  14  provides film for front surfaces thereof. 
   Devices such as multiple rollers  15  as depicted in  FIG. 9  and four 24 VDC motors  16  as seen in  FIG. 1  are provided to properly align and position the sheets of film unrolling off rolls  11 ,  12 ,  13  and  14 . As illustrated in  FIG. 9  the film from roll  11  and  12  are guided to the front main body of the present invention, while the film from roll  13  and  14  are guided to the rear main body of the present invention. As the films are pulled through the double action side seal station  30  they are parallel to, and in close proximity with one another. It is to be understood that several sets of rollers  15  are used to route the two sets of two film layers into the machine into close parallel proximity to each other. 
   As seen in  FIGS. 1 ,  3  and  4 , the pump station  20  contains at least one product dispenser  22 , each for front side of machine and backside of machine such dispensers  22  having a product input manifold  23  as seen in  FIGS. 3 and 4  attached thereto for receiving the product material (such as mayonnaise, mustard, ketchup etc.) from a overhead tank, pipe or reservoir (not shown). In the current configuration, four such dispensers  22  are provided. A set of output nozzles  24  as seen in  FIG. 4  are provided on the other side of the dispensers body and opposite to the intake manifold  23  on station  20 , such nozzles  24  are used for discharging product into the individual film pouches formed by the machine. A fill tube  29  is attached to each nozzle  24  as seen in  FIG. 2  to deposit the product into each pouch formed, such number of pouches side to side varies depending of the setup configuration of the machine, as shown in the current configuration of the invention the number of pouches formed across the film are twelve. The two sets of fill tubes  29  one set for the front of the machine and one set for the rear of the machine as shown in  FIGS. 2 and 9  extend between the two sets of film sheets through the double action side seal station  30 , and end between and below the double action pull wheel station  40  seen in  FIG. 2  but above the double action cross seal station shown in  FIG. 2   
   The number of fill tubes  29  and distance between them is determined and dependent on the width and number of cavities formed by the machine. For different sized pouches, different dispensers  22  may be used having more or less cavities and different distances between them. If other materials, such as particulated and dry products (e.g. peanuts, rice, sugar, salt, crushed nuts or the like) are to be dispensed a different set of dispensers  22  for the fill station  20  may be substituted, such a configuration requires different intake manifold  23  output nozzles  24  and fill tubes  29 . 
   The preferred method of pumping materials through pump station  20  is accomplished by using servo-motors  26  in conjunction with pistons  27  attached to cross over bars  28  as seen in  FIGS. 3 and 4 . Each dispenser  22  contains one rotary cutoff valve with multiple ports (not shown) one port for each output nozzle  24 . The rotary valve allows in a first position product to enter the dispenser  22  through the manifold  23 , and in a second position such product to exit through nozzles  24 . The two set of two dispensers  22  independently driven by one servo-motor each  26  one set for the front section of the machine and one set for the rear section of machine are provided so that each set of two is dispensing in conjunction with the rotary valves, output nozzles  24  and fill tubes  29  a measured amount of product from the overhead tank or pipe through the intake manifold  23  into the pouches formed through the stations below. 
   Each set of two dispensers  22  has two movable levers one for each dispenser (not shown) attached and connected together by a connector and pin  29 . 1  to operate the internal rotary valve as seen in  FIG. 3 . One air cylinders  25  each per set of dispensers is used for operation of aforementioned levers. The up and down movement of pistons  27  attached to and controlled by cross over bars  28  are achieved by a set of timing belts (not shown) and pulleys  29 . 2  which are driven by a servo motor  26  as shown in  FIG. 3 . 
   As illustrated in  FIG. 5 , the double action side seal station  30  includes a first or front sealing frame  32  and second or rear sealing frame  33  and a third center sealing frame  34 , all positioned in such a manner that the first set of two sets of two films advance between the first frame  32  and third frame  34  while the second set of the two sets of two films advances between frame  33  and frame  34 . Multiple vertically oriented sealing pads  35  are affixed to each frame  32 ,  33  and  34  in a way that pairs of such pads one pad mounted on frame  32  and the second pad of the pair directly mounted opposite on frame  34 . The same is repeated between frame  33  and frame  34 . The parallel sheets of film from rollers  11  and  12  pass between frames  32  and  34 , while the parallel sheets of film from rollers  13  and  14  pass between frames  33  and  34 . As the first set of two films passes between the heated pads  35  of frame  32  and  34  each pair of pads pressed together, causes the two films to seal together forming a multitude of longitudinal vertically oriented seals. At the same time the second set of film is being advanced between frame  33  and  34 . Once the first set of film has been sealed, the double action station drive system then reverses and the second set of film between pads  35  and frame  33  and  34  is being sealed, while the first set of film as soon as free from contact between the pads  35  and frame  32  and  34  is being advanced and positioned for the next sealing cycle. This process is then repeated over and over. The discharge tubes, also known as fill tubes  29  are positioned so they are located inside the just sealed and formed tubes of film by station  30 . Sealing pads  35  are heated using internal heating elements (heater cartridge not shown) and thermocouples (not shown) to control the heat generated by such heater cartridges. The heat generated activates a glue layer incorporated in the film structure allowing the film to adhere to each other creating a seal when heated and pressed together by the sealing pads  35 . Referring in more detail to  FIG. 5  the sealing frames  32  and  34  and sealing frames  33  and  34  may be in either a release (open) or sealing (closed) position by manipulating the double action side seal station shafts  36  as shown in  FIG. 10  which can either be driven by two air cylinders  31  as seen in  FIG. 5 , or by a servo motor  37  as seen in  FIG. 10 . The alternating motion between open and close position of the sealing frames  32 ,  34  and  33 ,  34  is achieved by rotating shaft  36  approximately 15 degrees in a counter clockwise or 15 degrees in a clockwise direction starting at a neutral center position. Rotating shaft  36  activates lever  38 , which in turn is connected to and activates bridge  39 . 2 , and slide block  39 . 1 . Lever  38  which is interconnected to adjustable link  39 . 3  connecting elbow linkage  39 . 4  and slide blocks  39 . 5  and  39 . 6  which are sliding on shaft  39 . 7 . Rotating lever  38  in any direction causes all interconnected parts to move simultaneously either in a forward or reverse motion on and guided by shaft  39 . 7 . Rotating shaft  36  counter clockwise results in slide block  39 . 1  connected to lever  38  (connection not visible) to move outward toward the front of machine and slide block  39 . 5  to move inwards closing the gap applying heat and pressure between the sealing frames  32  and  34 , at the same time slide block  39 . 6  will move outward or in an opposite direction of slide block  39 . 1  and open the gap between sealing frame  33  and  34  hereby releasing the film from its sealing action grip. Rotating shaft  36  clockwise results in slide block  39 . 1  to reverse its previous move and move toward the rear of machine and slide block  39 . 6  to move inwards closing the gap applying heat and pressure between the sealing frames  33  and  34 , at the same time slide block  39 . 5  will move outward or in an opposite direction of slide block  39 . 1  toward the front of machine and open the gap between sealing frame  32  and  34  hereby releasing the film from its sealing action grip. These motions are repeated time and time again creating 2 sets longitudinal tubes. During each cycle of machine the two sets of two films are either being sealed or advanced, these actions are simultaneous and take place at the same time, while one set of film is being sealed the other set of film is being advanced. Each time the sealing frames  32 ,  34  and  33 ,  34  close multiple vertical seals are created hereby forming longitudinal tubes into which after a cross seal  50  is applied the product will be deposited. A neutral position or open position between both sets of sealing frames  32  and  34  and sealing frame  33  and  34  is generally utilized when the apparatus is being prepared for use or when machine maintenance needs to be performed. During such machine setup procedures the operator insert the first set of films from rolls  11  and  12  between the first frames  32  and  34  at the same time the second set of film from rolls  13  and  14  between frame  33  and  34 , such films are then brought into contact with the double action pull wheel station  40 . 
   During each cycle of the double action side seal station  30  the sealing pads  35  are forming a predetermined longitudinal seal of approximately eight inches (standard sealing pad length), the film advances a predetermined distance, but never more then, one (1) inch less then the total length of the sealing pads  35 , this assures a overlapping of the seals in order to avoid any leaking of the pouches or tubes formed by the sealing pads  35 . This motion continues over and over as long as machine is in operation. 
   The vertical length of sealing pads  35  may be changed so as to provide longer or shorter longitudinal seals, the standard pad length is eight inches. It is to be noted that the cyclical motion of all stations such as double action side seal station  30 , double action cross seal station  50  or double action cross cut station  60  are independent from each other and can be operated at different intervals in order to accommodate the various pouch lengths as described below. 
   Two set of vertically aligned blades, one set for the front of machine and set of films and one for the rear of machine and set of films, theses blades or slitters numbering 1 to 11 on each such set, depending on the configuration of machine are provided just ahead of the double action pull wheel station  40 , these blades are cutting along the film path as the film is pulled through the machine separating the newly-formed longitudinal tubes into individual tubes or strips. These blades are situated at the centers of each of the side seals (except at the two outside edges or end seals where no cut is necessary). 
   As seen in  FIG. 6 , the double action pull wheel station  40  includes four (4) rotating shafts  41 ,  42 ,  44  and  45  each with multiple rollers known as pull wheels  43  positioned in such a manner that each set of opposing rollers  43  pinches one set of film at the same distance matching the distance and position of the just created side seals above matching the with of the to be created pouch and through rotation of the shafts advancing the film through the machine. By rotating shaft  41  clockwise and shaft  42  counter clockwise the rear set of film is being pulled through machine at a predetermined speed and distance. By rotating shaft  44  counter clockwise and shaft  45  clockwise the front set of film is being pulled through machine at a predetermined speed and distance. Roller shafts  41 ,  42 ,  44 , and  45  are each driven by a servo motor  46  that operates aforementioned shafts by means of a timing belts  47  for operation of the two front shafts and  48  for operation of the rear shafts these belts working in conjunction with timing belt pulleys and the correct routing of such belt causes the shafts to rotate in opposite directions of one another. The speed settings for the pull wheel servos  46  is achieved by the operator entering a setting for the machine speed on the operator interface control panel (not shown) and through the computer controls of the machine which automatically calculates, matches and adjusts the speed or revolutions per minute of the double action pull wheel station  40  to match the cycle speed of the machine. 
   The double action cross seal station  50 , shown in  FIG. 7  which is located downstream along the film path from the double action side seal station  30  and just below the double action pull wheel station  40 . The station  50  includes a first cross sealing pad  51  and an opposing second cross sealing pad  52 . A third cross sealing pad  53  and a fourth opposing cross sealing pad  54 . Pads  51  and  52  are positioned so that the first or front set of two sheets of film advance between them and pads  53  and  54  are positioned so that the second or rear set of two sheets of film advance between them. Sealing pads  51 ,  52 ,  53  and  54  are heated using internal heating elements (heater cartridge not shown) and thermocouples (not shown) to control the heat generated by such heater cartridges. The heat generated activates a glue layer incorporated in the film structure allowing the film to adhere to each other creating a seal when heated and pressed together by the sealing pads  51 ,  52 ,  53  and  54 . Closing sealing pads  51 ,  52  causes the pads to contact the film surface, providing a combination of heat and pressure upon the contacted surface areas and bonding them to one another to form a transverse or cross seal (typically horizontal) that is perpendicular to the longitudinal or side seals. By reversing the rotation of the servo motor  55  the sealing pads  51  and  52  are releasing their grip on the first or front set of film and as the motion of the servo motor continues sealing pads  53  and  54  are providing a combination of heat and pressure upon the contacted surface areas and bonding them to one another forming a transverse or cross seal for the second or rear set of film hereby completing one full cycle of station  50 . This station  50  can be operated with 2 air cylinders  31 , which would be used in place of the servo motor  55 . 
   This cycle is then repeated over and over creating 2 sets of cross seals per cycle. The cyclical motion of the double action cross seal station  50  is completely independent from that of the double action side seal station  30  described above, and from that of the double action cross cut station  60 , described below. This independence is necessary in order to be able to create longer or multiple seals without cross cutting therefore creating a blanket of pouches rather then independent single pouches. 
   After the cross seal formation, each longitudinal film tube created by station  30  has now a sealed bottom and sides. As soon as the double action cross seal station  50  releases its grip on the film just sealed the double action pull wheel station  40  is activated and advances the film, simultaneously the pumping or dispensing units from station  20  are also activated and deposit through the fill tubes  29  a predetermined amount of product into the partially finished pouch. This happens at the same time as the other or opposing side of station  50  is creating a cross seal and as described previously ones station  50  releases its grip on the other set of film just sealed the second set of dispensers from station  20  deposits its predetermined amount of product through the second set of fill tubes  29  into the cavities created by the double action side seal station  30  and the double acting cross seal station  50 . This process is then repeated over and over as long as the machine is in operation. It is to be noted that each time the double action cross seal station  50  creates a seal it seals the bottom of the longitudinal tubes in order to allow product to be filled into these tubes, at the same time it also creates the top seal of the previously filled pouch hereby sealing the pouch completely on all  4  sides. 
   The double action cross cut station  60 , shown in  FIG. 8  which is located downstream along the film path from the double action cross seal station  50 . The station  60  includes a first cross cutting blade  61  and an opposing second cross cutting blade  62 . A third cross cutting blade  63  and a fourth opposing cross cutting blade  64 . Blades  61  and  62  are positioned so that the first or front set of two sheets of film advance between them and blades  63  and  64  are positioned so that the second or rear set of two sheets of film advance between them. Closing cutting blades  61 ,  62  causes the blades to cut the film, at the previously created transverse or cross seal separating the pouch or pouches from the film. The cut is administered at the center position of the previously created cross seal cutting the seal in half leaving half of the seal which represents the top seal of the pouch or pouches previously sealed by station  50 . The other half of the just cut cross seal portion remaining attached to the set of film of the seal previously created by station  50  representing the bottom seal of the pouch or pouches previously sealed by station  50 . By reversing the rotation of the servo motor  65  the cutting blades  61  and  62  are retracting while with the continuation of the servo motor  65  rotation cutting blades  63  and  64  are administering their cut to the transverse or cross seal of the second or rear set of film hereby completing one full cycle of station  60 . This station  60  can be operated with 2 air cylinders  31 , which would be used in place of the servo motor  65 . 
   This cycle is then repeated over and over creating 2 cross cuts per cycle. The cyclical motion of the double action cross cut station  60  is completely independent from that of the double action side seal station  30  and the double action cross seal station  50  described above. This independence is necessary in order to be able to create longer or multiple seals without cross cutting therefore creating a blanket of pouches rather then independent single pouches. 
   As soon as the double action cross cut station  60  retracts by reversing its motion or rotation from servo motor  65  to move across to make the opposite set of film cut the double action pull wheel station  40  is activated and advances the just cut set of film. This happens at the same time as the other or opposing side of station  60  is creating a cross cut and as described previously ones station  60  retract and reverses its direction to cross over to cut again the first and previously described set of film the double acting pull wheel station  40  will then advance the second set of film. This process is then repeated over and over as long as the machine is in operation. It is to be noted that each time the double action cross cut station  60  cuts a transverse or cross seal it cuts the transverse cross seal in half the lower half of the cut seal now being finished pouches are then discharged out of the machine through various means, such as take of conveyors or containers. The other half of the just cut transverse seal, representing the bottom seal of the next pouch or set of pouches, continues to be attached to the film until the next cycle of the station will cut it or them and so on. 
   It is to be appreciated that the machine of the present invention is capable of producing pouches of various dimensions. To be specific, pouches formed by the machine have a maximum length limited to 12″ the widths of the pouches are limited by the width of the film maximum of 19.5″ that may be run through the machine. Depending upon the dimensions of the pouches to be formed the minimum would be 1 pouch and the maximum would be 12 pouches per set of film. The machine is running 2 sets of 2 films through machine and therefore capable of creating anywhere from 2 to 24 pouches per machine cycle. 
   It is to be understood that other variations and modifications of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein, but only in accordance with the appended claims read in light of the foregoing specification.

Technology Classification (CPC): 1