Abstract:
An apparatus for forming and filling pouches of varying dimensions, said apparatus comprising a forming drum and a filling drum, wherein at least one of said forming drum and said filling drum further comprise members capable of being adjusted radially. A method of manufacturing pouches of varying dimensions, comprising the steps of: a) forming pouches having a first width on a device comprising a forming drum, wherein multiple forming members on said drum are initially positioned at a first distance from the center of said drum; b) re-positioning each of said forming members to a second distance from the center of said drum; c) forming pouches having a second width different from said first width on said device.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
         [0001]    Not Applicable.  
         STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
         [0002]    Not Applicable.  
         REFERENCE TO A MICROFICHE APPENDIX  
         [0003]    Not Applicable.  
           [0004]    The present invention relates to apparatuses and methods for forming and filling pouches of varying dimensions using forming and filling drums having radially adjustable forming and filling heads.  
         BACKGROUND OF THE INVENTION  
         [0005]    Pouches are today commonly used in connection with the packaging of foods, drinks, nutritional supplements, pharmaceutical and medicinal products, cosmetics, household cleaners, chemicals, seeds, small hardware such as nails, screws and nuts, and virtually any other wet product or dry product of appropriate dimensions for packaging within a pouch. The materials used to form pouches include metal foils and polymers of various compositions and thicknesses, and laminates—which might comprise polymer and foil layers. Of course, other materials are also used.  
           [0006]    Because of recognized benefits in using pouches (including decreased material and processing costs, increased processing speed, ease of shipping, and sterility) pouches are increasingly being used in place of other packaging, such as steel, tin and aluminum cans, cardboard boxes and cartons, bottles, jars, and other containers. Along with this increasing usage of pouches, however, there exists a demand for an ever-increasing variety of pouch sizes and dimensions. A food manufacturer, for instance, may seek to market a single product in “family”, “individual” and “snack” sized pouches. Similarly, a pet food manufacturer may seek to market dog food in single serving pouches appropriate for small, medium and large sized dogs. Manufacturers of multiple products desire to market pouches of differing sizes appropriate to the different products contained therein. For instance, a pouch for a serving of a condiment such as mayonnaise or mustard might be relatively small compared to a pouch meant to hold a meal-sized serving of a food product such as tuna fish.  
           [0007]    In most modem pouch forming devices such as those made by R A Jones &amp; Co., Inc., pouches are formed from a continuous strip of material such as a polymer, foil or laminate which at the beginning of the forming process is on a roll. The strip is first folded, with the fold typically forming the bottom of the pouch. The bottom fold may be a simple fold, or optionally a gusset may be formed (with an additional forming plow or a more sophisticated single forming plow). Typically, the gusseting plow imparts a “W” or “accordion” shape to the pouch bottom.  
           [0008]    The height of the to-be-formed pouch is determined first and foremost by the height of the continuous strip (height being defined as the distance between the two continuous edges of the continuous strip). Because the strip is folded in half in the initial pouch forming step, the pouch height typically approximates one half of the edge-to-edge distance of the strip. The filled pouch height will vary somewhat depending on the volume of the pouch contents, whether a gusset is formed in the pouch and other similar considerations.  
           [0009]    The folded strip is then placed in contact with forming heads positioned around the circumference of a “forming” drum to form the side walls of a “belt” of pouches. The width of the pouch is the distance between these side walls. The distance from side wall to side wall, and hence the width of the ultimately formed pouch, depends on the number of forming heads used to form these side walls, and the circumference of the forming drum. For example, if ten forming heads are evenly spaced around a forming drum with a circumference of fifty centimeters, the pouches produced would have a width of approximately five centimeters, but if the same ten heads are evenly spaced around an eighty centimeter drum, pouch width would be approximately eight centimeters.  
           [0010]    After the side walls are created by the forming heads the pouches are filled at filling heads, typically arranged about the circumference of a “filling” drum. To ensure an efficient filling operation, the filling heads must be spaced so as to correspond to the middle of the pouch opening created between the recently-formed side walls. Thus, the position of the heads on the filling drum must correspond in some fashion to the dimensions of the pouch created at the forming drum.  
           [0011]    Prior to the subject invention, a manufacturer wishing to make pouches of varying widths had two options, neither of which was economical. One option was to simply purchase multiple pouch forming machines. This, of course, was wasteful in terms of space and capital costs. A second option was to purchase, for each pouch width desired, entirely different drum components, to be installed and uninstalled as the demands of manufacturing dictated, on a single pouch forming machine. This was still expensive, however, and had the additional disadvantage of being wasteful in terms of time since no pouches could be made while the drum was being changed.  
         OBJECTS OF THE INVENTION  
         [0012]    It is an object of the present invention to provide a pouch forming apparatus which avoids the inefficiencies of known pouch forming machines by providing a rotatable forming drum on which the radial distance of the forming heads from the center of the drum may be varied to produce pouches of varying widths.  
           [0013]    It is an other object of this invention to provide a pouch filling apparatus which avoids the inefficiencies of known pouch filling machines by providing a rotatable filling drum on which the radial distance of the filling heads from the center of the drum may be varied to fill pouches of varying widths.  
           [0014]    It is a further object of the invention to provide forming and filling drums capable of being used in the manufacture of pouches of varying widths.  
           [0015]    It is yet another object of the invention to provide a method of producing pouches by which pouches of varying widths may be produced by varying the distance between forming heads.  
           [0016]    Various other objects of the present invention will become readily apparent from the ensuing detailed description and from the accompanying figures and drawings.  
         SUMMARY OF THE INVENTION  
         [0017]    The present invention relates to a pouch forming apparatus and a method of forming pouches wherein the forming heads on a forming drum, and the gripping arms and filling heads on a filling drum, are radially adjustable and/or capable of inactivation.  
           [0018]    Referring first to the forming heads and drum, decreasing the radius of the forming heads (distance from the heads to the center of the forming drum) effectively reduces the radius of the forming drum and brings each forming head closer to its neighboring forming head. This permits side wall seals to be formed at reduced intervals resulting in narrower width pouches. Conversely, increasing the radial distance of the forming heads causes seals to be formed at greater intervals resulting in wider width pouches. Forming heads can also be selectively deactivated to permit the formation of wider pouches, or belts of pouches of non-uniform width.  
           [0019]    Gripping arms and filling heads on the filling drum are similarly adjustable and capable of deactivation, permitting the efficient filling of pouches and pouch belts of greater, lesser and non-uniform widths. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    The following detailed description, given by way of example, and not intended to limit the present invention solely thereto, will be best be understood in conjunction with the accompanying drawings:  
         [0021]    [0021]FIG. 1 is a schematic diagram which demonstrates the benefits of the radially adjustable forming heads of the instant invention.  
         [0022]    [0022]FIG. 2 is a schematic diagram of one possible apparatus embodiment of the invention.  
         [0023]    [0023]FIG. 3 is a schematic diagram which demonstrates the benefits of the radially adjustable gripping arms and filling heads of the instant invention. 
     
    
     DETAILED DESCRIPTION  
       [0024]    The invention employs multiple forming and/or filling heads each of which is located at an adjustable distance from the geometrical center of a “drum”. These forming and/or filling drums need not be any particular shape, but are preferably circular so as to easily permit rotation. Non-circular drums are also useable if capable of being rotated. Preferably, the forming heads are on a first drum, and the filling heads are on a second drum.  
         [0025]    The above-described benefits of the invention, particularly the ability to make pouches of varying widths on a single apparatus without the need to change forming and/or filling drums, are derived from the geometrical arrangement of adjustable heads. One such possible arrangement is shown in FIG. 1. The diagram of FIG. 1 demonstrates how adjustable forming heads result in pouches of varying widths. Drum  30  is a drum equipped with eight forming heads—one head being positioned every 45 degrees around the center “C” of the drum. (Only forming heads  31  and  32  are shown in the diagram.) Of course drums may have a greater or lesser number of forming heads, arranged uniformly or non-uniformly at angles greater than or less than 45 degrees.  
         [0026]    The radial distance “r” between the forming head and the drum&#39;s center point is adjustable by any known mechanical or electromechanical means, such as telescoping arms, folding arms, or servo-driven arms. The invention is not limited by the manner in which the distance r of the heads are adjusted. In FIG. 1, three possible radial distance values, r 1 , r 2  and r 3  are depicted. Of course, r can be any value achievable by the mechanics of a particular forming drum.  
         [0027]    The forming heads are typically adjusted in concert with one another, with all heads being at a particular uniform distance r from center point C during a pouch forming run. For instance, when one head is at distance r 1  all heads will typically be at this distance, where one head is at distance r 2  all heads will be at that distance, and so on.  
         [0028]    In a typical uniform head configuration (i.e., an arrangement of multiple forming heads wherein the heads are evenly spaced around the circumference of the drum) side wall seals are formed by passing the pouch material over the forming heads of a rotating forming drum. The actual formation of side walls is accomplished by any known means, such as heat or melting, application of adhesives with pressure, mechanical means, or otherwise.  
         [0029]    The distance between seals, which correlates directly to the ultimate pouch width, depends upon the distance between forming heads. In FIG. 1, this distance “D” between forming heads varies, according to well known geometrical formulae, with the distance r of the heads from the center point C. (Three possible values for D are depicted in the figure as D 1 , D 2  and D 3 , although the actual value of D is not limited to any set of particular values.) If the value of r is large, the value D will be large, and a wider pouch will be formed. Conversely, a small r value results in a small D value and a more narrow pouch. As shown in FIG. 1, increasing values r 1 , r 2  and r 3  correspond to increasing values D 1 , D 2  and D 3 . Actual distances D may be calculated in accordance with well known geometrical formulae pertaining to the dimensions of triangles, (such as the law of cosines, the law of sines, and many others), or may be determined or confirmed by direct measurement.  
         [0030]    It may be advantageous in certain applications to place forming heads at non-uniform distances r from one another. In such applications, the heads at lesser distances will effectively be inactivated (i.e., only the heads on the “outside” of the drum will be capable of forming side wall seals.) Embodiments are contemplated where individual heads are not merely inactivated by retraction to a lesser radius, but instead are angled or otherwise moved away from the “active” heads, or are temporarily removed completely from the forming drum. Inactivation of certain heads but not others gives the operator significant flexibility in regard to both the size of the pouches formed, and the configuration of the belt of formed pouches. For example, a drum having forty (evenly spaced) forming heads and a circumference of one hundred centimeters would form a belt of pouches having widths of approximately 2.5 centimeters (100÷40=2.5). If every other head (half of the heads) is inactivated, the pouch width would increase to approximately 5 centimeters (100÷20=5). In another embodiment, every fourth head would be inactivated to create a belt of pouches on which two 2.5 centimeter pouches are followed by a single 5 centimeter pouch, which in turn is followed by two 2.5 centimeter pouches, and so on. Many other configurations are possible for the creation of uniform or non-uniform belts of pouches.  
         [0031]    Similar considerations apply to the adjustable filling heads  41  and the adjustable gripping arms  44  positioned in a comparable manner around a filling drum  40 . In configuring the filling drum there are two requirements. First, the ends of gripping arms  44  should align as closely as possible with the pouch side walls formed at the forming heads. Second, filling heads  41  should align as closely as possible with the pouch openings formed (between the side walls) at the forming drum.  
         [0032]    The gripping arms  44  are used to anchor the side walls of the pouch during the filling operation. The positions of the gripping arms  44  (only two of which are identified in the figure) must be adjustable so that their respective ends align with, and are thus able to anchor, the pouch side walls. Adjustment of the pouch width at the forming drum will in most instances require a corresponding adjustment of the gripping arms. In FIG. 3, respective radii r 1 ′, r 2 ′ and r 3 ′ are meant to depict the radii necessary for the gripping arms  44  to align with side walls formed when the forming heads are positioned at respective radii r 1 , r 2  and r 3  (as shown in FIG. 1). (If the number of forming heads is similar to the number of gripping arms, then r 1  will approximate r 1 ′, r 2  will approximate r 2 ′, and so on. If the number of forming heads is dissimilar to the number of arms, then this may not be the case.) Like the forming heads, the gripping arms may be positioned at any mechanically achievable position, their positioning not being limited to the three exemplary positions shown in the figure. Moreover, the gripping arms need not be of any particular shape, nor must they be directly connected to the center of the filling drum. It is important only that the outermost portion of the “arm” (i.e., the portion that contacts the pouch material) be adjustable as described above.  
         [0033]    The filling heads  41  also must be radially adjustable so as to be in alignment with the pouch opening formed at the forming drum, preferably the center of such opening. The filling head thus should be positioned approximately equidistant from the side walls, and therefore approximately equidistant from the ends of the gripping arms. (The filling head must dispense product in close proximity to the pouch opening to avoid product spillage.)  
         [0034]    In FIG. 3, two filling heads  41  are depicted. In the figure each filling head is shown at three possible positions  41   a ,  41   b  and  41   c . In practice, of course, the filling heads may be positioned at any mechanically achievable position, their positioning not being limited to the three positions shown in the figure. When the ends of the gripping arms  44  are positioned at radial distance r 3 ′ from the center of the filling drum, the filling heads are placed at positions  41   a , approximately equidistant from the ends of the gripping arms  44 . When the pouch material is on the filling drum, this corresponds to the center of the pouch opening. (Because the pouch material is pulled between the gripping arms, the filling head is not positioned at distance r 3 ′, but rather is positioned at a radius less than r 3 ′ along the chord  45  formed between adjacent arms.) The filling head radius obviously varies with the radii of the gripping arms it is positioned between.  
         [0035]    During the filling operation, the side walls on the pouch belt contact the gripping arms on the filling drum. Prior to or during this contact a pouch opening device ensures that the pouch opening is and remains sufficiently wide so as to accept the product or products to be dispensed by the filling head. The opening device may be any such device now used in the industry.  
         [0036]    It may be desirable to employ multiple filling heads to dispense multiple products into individual pouches, for instance where water and concentrated juice are added to a pouch. In such instances, the two (or more) filling heads are made to contact the pouch opening at different positions on the filling drum, or are configured so as to be simultaneously positionable as close as possible to the center of the pouch opening. It may also be desirable to employ multiple filling heads to dispense multiple products into multiple adjoining pouches. One example of this might be three adjoining pouched products such as pasta, parmasan cheese and tomato sauce in a single meal kit. This would be accomplished via multiple filling heads. Thus, the invention encompasses not only single adjustable filling heads but also groups of adjustable filling heads.  
         [0037]    [0037]FIG. 2 shows one possible embodiment of the invention. Material used to form pouches is initially on a roll ( 4 ). An forming plow ( 5 ) causes the material to be folded. The folded material then contacts forming heads ( 1 ) located around the circumference of a forming drum ( 21 ). These heads form the side walls of the pouches as the pouch material is contacted. In the configuration shown, the forming heads ( 1 ) are at position “a” which represents a “greater” distance from the center of the drum ( 21 ). As discussed above with regard to FIG. 1, the forming heads are adjustable to a variety of positions including the position represented by “b”. The pouches formed by forming heads at position “a” will be wider than pouches formed with the heads at position “b”.  
         [0038]    The material now consists of a belt of pouches with a bottom formed from a fold, sides formed by forming heads. These pouches are “open” at the top. The ribbon optionally passes over a bottom sealer ( 6 ) (to reinforce and better define the bottom of the pouch) before contacting the filling heads ( 2 ) on the filling drum ( 22 ).  
         [0039]    Like the heads ( 1 ) on the forming drum ( 21 ), the filling heads ( 2 ) are adjustable radially. Here, “a f ” represents the filling head position required to fill the pouches formed when the forming heads are at position “a”, and “b f ” represents the filling head position required to fill the pouches formed when the forming heads are at position “b”. A feeder ( 8 ) works in conjunction with the filling heads to open and fill the pouches. A top sealer ( 9 ,  10 ) then seals the pouch tops.  
         [0040]    Optionally the pouches are separated by a knife ( 11 ). In another embodiment, the knife separates sets of pouches, with each pouch set comprising multiple pouches. This embodiment is particularly useful in applications where related products are sold in the same container. For example, a first pouch could contain a solid food, while a second attached pouch could contain gravy intended for use with the solid food, or a first pouch could contain nuts, and a second attached pouch could contain bolts to be used with the nuts.  
         [0041]    The invention may also be employed in conjunction with other apparatuses used in the production of foods. For instance, a device designed to perform a method of producing solid or semi-solid food chunks could be coupled to the filling drum and filling heads so as to form food chunks immediately or shortly prior to the filling operation. Such devices and methods could include (1) devices and methods for forming distinctive shaped meat chunks by ultrasonic or other forming technique wherein the forming equipment geometry is a pipe and wherein a combination of ultrasonic and thermal energy is used in forming; (2) devices and methods wherein the close coupling of a forming device and filling head allows the last minute creation of multiple flavors from a common base chunk by addition flavors (e.g., gravy) just as the chunks are introduced into the package; (3) devices and methods of applying “grill marks” or flavoring to a food product using inkjet printing techniques; (4) devices and methods of introducing grill marks to food product by using a forming device which incorporates high energy transfer sections to introduce “grill marks” simultaneously with chunk forming, wherein forming device is a forming pipe type system and the marks are applied to a rope of chunk material as it exits a forming pipe; (5) devices and methods of forming comminuted meat chunks using cold set plasma based gelation system; and (6) devices and methods employing a shaped ultrasonic former to create hollow shapes where the ultrasonic former incorporates an ultrasonic horn as an external pipe and an internal pipe is an anvil, including where the ultrasonic former is used to form a “skin” on the formed product wherein the center of the formed product remains less solid, or where the center of hollow formed piece can be filled with another material and the center filling is used a flavor carrier; and other devices.  
         [0042]    While the present invention has been particularly described with respect to the illustrated embodiment, it will be appreciated that various alterations, modifications and adaptations may be made on the present disclosure, and are intended to be within the scope of the present invention. It is intended that the appended claims be interpreted as including the embodiment discussed above, those various alternatives, which have been described, and all equivalents thereto.