Patent Description:
The invention relates to a heat-sealed squeezable dispensing pouch according to claim <NUM>. The pouch includes an outer sheet having a front wall, a rear wall and a folded edge located between the front wall and the rear wall. The outer sheet is folded along the folded edge such that an inner surface of the front wall faces an inner surface of the rear wall. The pouch includes a first heat seal coupling the inner surface of a peripheral section of the front wall to a peripheral section of the inner surface of the rear wall such that the inner surfaces of the front and rear walls define an interior chamber. The pouch includes a rupturable inner membrane formed from a contiguous, single monolayer of thermoplastic material, and the rupturable inner membrane is located within the interior chamber. The rupturable inner membrane divides the interior chamber into a contents compartment and a dispensing channel. The first heat seal defines an edge of the contents compartment and the folded edge defines an edge of the dispensing channel. A second heat seal couples the rupturable inner membrane to the inner surface of the front wall, and a third heat seal couples the rupturable inner membrane to the inner surface of the rear wall. The rupturable inner membrane is configured to break when the pressure within the contents compartment is greater than a rupture threshold, and the first, second and third heat seals are configured to remain sealed when the inner membrane breaks.

A fluid dispensing container, not part of the invention as claimed, includes a container body formed from a first flexible material, and the container body includes an outer surface, an inner surface, a filling end and a dispensing end. The inner surface of the container body defines an interior cavity. The container includes a membrane formed from a second flexible material and a seal coupling the membrane to the inner surface of the container body at a position located between the filling end and the dispensing end. The membrane divides the interior cavity into a contents chamber and a dispensing chamber, and the membrane and the seal are configured to be fluid tight to maintain fluid within the contents chamber prior to rupture of the membrane. The rupture stress of the second flexible material is less than the rupture stress of the first flexible material such that, as fluid pressure within the contents chamber increases, the membrane is configured to rupture without the container body rupturing.

A method of forming a container, not part of the invention as claimed, includes the step of providing a first sheet of first flexible material and a second sheet of second flexible material. The method includes the step of folding the first sheet creating a folded edge that divides the first sheet into a front wall and a rear wall. The front wall and the rear wall each have an upper edge opposite the folded edge. The method includes the step of positioning the second sheet between the front wall and the rear wall of the folded first sheet. The method includes the step of creating a first heat seal attaching a front surface of the second sheet to an inner surface of the front wall of the first sheet. The method includes the step of creating a second heat seal attaching a rear surface of the second sheet to an inner surface of the rear wall of the first sheet and the step of creating a third heat seal attaching a left side of the front wall to a left side of the rear wall to seal the left side of the container. The method includes the step of creating a fourth heat seal attaching a right side of the front wall to a right side of the rear wall to seal the right side of the container. The method includes the step of filling the container through a filling opening defined by the upper edges of the front and rear walls of the first sheet. The method includes the step of creating a fifth heat seal attaching the upper edge of the front wall to the upper edge of the rear wall sealing the filling opening.

Alternative exemplary embodiments relate to other features and combinations of features are recited in the claims.

This invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:.

Referring generally to the figures, various embodiments of a dispensing container are shown. Generally the various embodiments of the container include an outer container body or sidewall and an internal wall or membrane that is located within the container body. The membrane separates the interior cavity of the container into two portions or subsections, a contents compartment and a dispensing passage. Container contents, for example, fluid or liquid contents are stored within the contents compartment prior to use of the container. When the container is to be opened, the user creates an opening in the portion of the container body defining the dispensing passage. At this point, the fluid contents of the container are maintained within the contents chamber by the membrane. To dispense the fluid, pressure within the contents chamber is increased, for example by squeezing the portion of the outer container body over the contents chamber. When the pressure reaches the rupture stress of the membrane, the membrane ruptures allowing the contents of the container to flow from the contents chamber into the dispensing passage and out through the opening. The material of the membrane is selected to be weaker than the material of the outer container body and weaker than the attachment points of the membrane such that the membrane will rupture while the outer container body and attachment points (e.g., heat seals) remain intact, providing for controlled dispensing of fluids from the container.

Referring to <FIG>, a dispensing container, shown as fluid dispensing pouch <NUM>, is depicted according to an exemplary embodiment. Dispensing pouch <NUM> includes a container body, shown as body <NUM>. Generally, body <NUM> includes a front portion or wall <NUM> and a rear portion or wall <NUM> opposite front wall <NUM>. Pouch <NUM> includes a filling end, shown as upper end <NUM>, and a dispensing end, shown as lower end <NUM>. As explained in more detail below, upper end <NUM> is open prior to being sealed allowing pouch <NUM> to be filled, and lower end <NUM> is opened by the user such that fluid may be dispensed from pouch <NUM> at the time of use.

In the embodiment shown, body <NUM> is formed from a flexible material such that pouch <NUM> is a flexible or squeezable container. In this embodiment, front wall <NUM> is attached to rear wall <NUM> by one or more seals or attachments formed between the peripheral sections of front wall <NUM> and the opposing peripheral sections of rear wall <NUM>. Specifically, pouch <NUM> includes a left lateral heat seal <NUM>, a right lateral heat seal <NUM> and an upper heat seal <NUM>. Left lateral heat seal <NUM> couples the left lateral edge of front wall <NUM> to the left lateral edge of rear wall <NUM>. Right lateral heat seal <NUM> couples the right lateral edge of front wall <NUM> to the right lateral edge of rear wall <NUM>. Upper heat seal <NUM> couples the upper edge of front wall <NUM> to the upper edge of rear wall <NUM>. Thus, as shown, left lateral heat seal <NUM> defines the left lateral edge of pouch <NUM>, right lateral heat seal <NUM> defines the right lateral edge of pouch <NUM>, and upper heat seal <NUM> defines the upper edge of pouch <NUM>. As shown in more detail below, upper heat seal <NUM> is formed following filling of the container through an open upper end.

In one embodiment, heat seals <NUM>, <NUM> and <NUM> are seals formed by melting together an adhesive layer located on the inner surfaces of front wall <NUM> and/or rear wall <NUM>. In one embodiment, heat seals <NUM>, <NUM> and <NUM> are formed by melting together a thermoplastic material. In other embodiments, other types of seals may be used. In one embodiment, seals <NUM>, <NUM> and <NUM> may be formed by ultrasonic welding, and in another embodiment, seals <NUM>, <NUM> and <NUM> may be formed from a pressure sensitive adhesive.

In the embodiment shown, body <NUM> of pouch <NUM> is formed from a folded, single contiguous sheet of flexible material. In this embodiment, pouch <NUM> includes a folded edge <NUM>, shown located at lower end <NUM>. Front wall <NUM> and rear wall <NUM> are located on opposite sides of folded edge <NUM>, and the material of body <NUM> is folded along folded edge <NUM> such that the inner surfaces front wall <NUM> and rear wall <NUM> face each other and may be coupled together. In another embodiment, front wall <NUM> and rear wall <NUM> are formed from separate sheets of material, and in this embodiment, lower end <NUM> includes a seal (e.g., a heat seal, weld, etc.) closing the bottom edge of the pouch in place of folded edge <NUM>.

Pouch <NUM> includes a membrane <NUM> (the upper and lower edges of membrane <NUM> are depicted by the dotted lines in <FIG>), and membrane <NUM> extends between the inner surfaces of front wall <NUM> and rear wall <NUM>. Pouch <NUM> includes a contents holding portion <NUM> located above membrane <NUM> and a dispensing spout <NUM> located below membrane <NUM>. As explained in more detail below, portion <NUM> includes an inner cavity or chamber above membrane <NUM> that holds the contents of the container prior to rupture of membrane <NUM>, and membrane <NUM> is a continuous single portion of material that holds the container contents within the contents chamber of pouch <NUM> prior to rupture of the membrane.

Dispensing spout <NUM> is located below membrane <NUM> and extends generally from membrane <NUM> to folded edge <NUM>. Dispensing spout <NUM> generally defines a dispensing passage that provides a pathway for fluid to flow out of pouch <NUM> following rupture of membrane <NUM> and creation of an opening or aperture in spout <NUM>. In this embodiment, because folded edge <NUM> provides for a continuous portion of material, folded edge <NUM> acts as a seal along the distal end of spout <NUM>. In one embodiment, spout <NUM> includes a frangible tear line <NUM> located adjacent to folded edge <NUM> (e.g., tear line is located closer to folded edge <NUM> than membrane <NUM>). Tear line <NUM> provides a weakened area to facilitate the removal of the portion of spout <NUM> between tear line <NUM> and folded edge <NUM> to create the opening in spout <NUM>.

Referring to <FIG>, in another embodiment, pouch <NUM> may include an elongated dispensing spout <NUM>. Spout <NUM> is configured to facilitate dispensing of fluid into certain containers that may be difficult to fill using a shortened spout <NUM>. For example, spout <NUM> may be placed into a container having a small filling opening (e.g., a motor oil filler oil, the opening of refillable spray bottle, etc.) allowing the fluid from pouch <NUM> to be filled directly into the container without the need for a funnel or other filling device. Spout <NUM> may be different lengths and widths to suit different applications. In one embodiment, the length of spout <NUM> (e.g., the distance between membrane <NUM> and folded edge <NUM>, the distance between membrane <NUM> and tear line <NUM>) may be greater than <NUM>% of the total length of pouch <NUM>, and in another embodiment, the length of spout <NUM> may be greater than <NUM>% of the total length of pouch <NUM>. In another embodiment, the length of spout <NUM> may be between <NUM>% and <NUM>% of the total length of pouch <NUM>. Similarly, the width of spout <NUM> may be narrower that the width of the pouch <NUM> at upper heat seal <NUM>. This configuration provides a spout which is more useable for small openings without limiting the width of the pouch <NUM> at the contents holding position and thus provides a narrow spout without limiting the corresponding volume of pouch <NUM>. In one embodiment, the width of spout <NUM> is less than <NUM>% of the width of pouch <NUM> at upper heat seal <NUM>, and in another embodiment, the width of spout <NUM> is less than <NUM>% of the width of pouch <NUM> at upper heat seal <NUM>.

Referring to <FIG>, a side elevation view of pouch <NUM> is shown according to an exemplary embodiment. In the embodiment shown, the peripheral edge of the portion of pouch <NUM> between membrane <NUM> and the upper edge at upper heat seal <NUM> is a substantially rectangular section. Dispensing spout <NUM> includes a tapered section that tapers inward toward the longitudinal axis of pouch <NUM> as the dispensing spout <NUM> extends towards folded edge <NUM> and away from upper heat seal <NUM>. In other embodiments, pouch <NUM> may be formed such that its peripheral edge has other shapes, for example, triangles, squares, circles, ovals, etc..

Referring to <FIG>, a cross-section view of pouch <NUM> taken along line <NUM>-<NUM> in <FIG>, is shown according to an exemplary embodiment. Front wall <NUM> includes an inner surface <NUM>, and rear wall <NUM> includes an inner surface <NUM>. Inner surface <NUM> and inner surface <NUM> define the interior cavity <NUM>. Membrane <NUM> separates interior cavity <NUM> into a contents chamber <NUM> and a dispensing passage <NUM>. In the embodiment shown, liquid contents <NUM> are located in contents chamber <NUM>, and membrane <NUM> provides a barrier maintaining contents <NUM> within contents chamber <NUM> prior to the rupture of membrane <NUM>.

As shown in <FIG>, when viewed perpendicular to the longitudinal axis of pouch <NUM>, membrane <NUM> is substantially U-shaped having a front wall <NUM> and rear wall <NUM>. A front heat seal <NUM> attaches the front surface of membrane front wall <NUM> to inner surface <NUM> of body front wall <NUM>, and a rear heat seal <NUM> attaches a rear surface of membrane rear wall <NUM> to inner surface <NUM> of body rear wall <NUM>. Front heat seal <NUM> and rear heat seal <NUM> extend the width of pouch <NUM> between lateral heat seals <NUM> and <NUM>, as shown by the dotted line representation of front heat seal <NUM> shown in <FIG>. The material of membrane <NUM>, front heat seal <NUM> and rear heat seal <NUM> are fluid tight such that liquid contents <NUM> are maintained in contents chamber <NUM>. While seals <NUM> and <NUM> are shown in the exemplary embodiments as heat seals, other sealing and attachment arrangements may be used between membrane <NUM> and outer body <NUM>. For example, pressure sensitive adhesive or ultrasonic welds may be used to provide fluid tight seal and attachment between membrane <NUM> and the inner surface of body <NUM>.

Liquid contents <NUM> may be a wide variety of materials that are suitable to be contained within a dispensing pouch such as pouch <NUM>. For example, in one embodiment, liquid contents <NUM> is a single use amount of a ready to use liquid. In one embodiment, liquid contents <NUM> may be a ready to use cleaning solution, stain remover, a personal care product (e.g., shampoo, hand lotion, antibacterial lotion, hand soap, etc.), automotive fluid (e.g., motor oil, coolant, gasoline additive, windshield washer fluid, etc.), etc. In another embodiment, liquid contents <NUM> is a single use amount of a concentrate solution. In various embodiments, the concentrate may be a cleaning concentrate or a drink concentrate. In other embodiments, liquid contents <NUM> may be any other suitable concentrate material, for example, pesticide concentrates, herbicide concentrates, fertilizer concentrates, automotive fluid concentrates, pharmaceutical concentrates, medical solution concentrates, nutritional supplement concentrates, etc. In these embodiments, the user will dispense the concentrate from pouch <NUM> into a suitable container, and will add a the proper amount of diluting agent (e.g., water, saline, etc.) to prepare a mixture at the desired concentration level. In one embodiment, pouch <NUM> is a small size for easy carrying in a bag or pocket.

Referring to <FIG>, a cross-sectional view of pouch <NUM> taken along line 5A-5A in <FIG>, is shown according to an exemplary embodiment. While front heat seal <NUM> and rear heat seal <NUM> provide for the fluid tight bond that extends laterally along the inner surface of body <NUM> across the width of pouch <NUM>, a fluid tight seal between membrane <NUM> and body <NUM> is also provided along the left and right lateral edge of pouch <NUM>. In the embodiment shown in <FIG>, the left and right lateral portions of membrane <NUM> are positioned between front wall <NUM> and rear wall <NUM> of body <NUM> within the left and right lateral heat seals <NUM> and <NUM>. Thus, at the position of membrane <NUM> within the lateral heat seals <NUM> and <NUM>, the inner surface <NUM> of body front wall <NUM> is attached to the outer surface of membrane front wall <NUM>, the inner surface of membrane front wall <NUM> is attached to the inner surface of membrane rear wall <NUM>, and the outer surface of membrane rear wall <NUM> is attached to the inner surface <NUM> of body rear wall <NUM>.

Referring to <FIG>, a cross-sectional view of pouch <NUM> taken along line 5B-5B in <FIG>, is shown according to an exemplary embodiment. <FIG> shows left lateral heat seal <NUM> and right lateral heat seal <NUM> at an exemplary position that does not include membrane <NUM>. In this embodiment, the inner surface <NUM> of body front wall <NUM> is attached to inner surface <NUM> of body rear wall <NUM> within heat seals <NUM> and <NUM>. The upper heat seal <NUM> shown in <FIG> is also formed from an attachment between the inner surface <NUM> and inner surface <NUM>.

Referring to <FIG>, a detailed view of rear wall <NUM> and membrane <NUM> at rear heat seal <NUM> is shown according to an exemplary embodiment. In the embodiment shown, container body <NUM> and thus, rear body wall <NUM> is made from a sheet of multilayer material and membrane <NUM> is made from a single layer or monolayer material. In one such embodiment, the material of container body <NUM> includes an inner adhesive layer <NUM>. Inner adhesive layer <NUM> bonds to the material of membrane <NUM> to form heat seals <NUM> and <NUM> and to provide the sealing within the portions of lateral heat seals <NUM> and <NUM> shown in <FIG>. Inner adhesive layer <NUM> also bonds with itself to form lateral heat seals <NUM> and <NUM> and upper heat seal <NUM> in those places without membrane <NUM> (see <FIG>).

In one embodiment, the material of the outer container body <NUM> is formed from a multilayer supported film material. In one such embodiment, the inner adhesive layer <NUM> is a heat sensitive adhesive, for example a thermoplastic, and at least one of the other outer layers is a strengthened supporting material. In one embodiment, at least one of the outer layers is a foil material, and in another embodiment, at least one of the outer layers is a nylon material. In one such embodiment, membrane <NUM> is made from a sheet of polymer monolayer material that bonds with the heat sensitive adhesive. For example, in one embodiment, membrane <NUM> is made from a thermoplastic material that melts to form a fluid tight seal with the thermoplastic of inner adhesive layer. In one embodiment, inner adhesive layer <NUM> and membrane <NUM> are made from the same thermoplastic material. For example, inner adhesive layer <NUM> and membrane <NUM> may both be a polyethylene material. In other embodiments, inner adhesive layer <NUM> and membrane <NUM> are other suitable thermoplastic materials such as polypropylene, polyvinylchloride, etc..

Referring to <FIG>, dispensing of contents from container <NUM> is shown according to an exemplary embodiment. Referring to <FIG>, a dispensing opening <NUM> is created along dispensing passage <NUM>. In the embodiment shown, dispensing opening <NUM> is created by tearing folded edge <NUM> along tear line <NUM> to remove folded edge <NUM> from body <NUM>. In other embodiments, dispensing opening <NUM> may be created in other ways. For example, in one embodiment, body <NUM> does not include tear line <NUM> and dispensing opening <NUM> may be created by cutting folded edge <NUM> from body <NUM>. In another embodiment, dispensing opening <NUM> may be a preformed opening closed by a closure, for example, a peelable foil closure that is removed prior to dispensing. The sealed end of dispensing passage <NUM> provided by folded edge <NUM> (or one of the other sealing mechanisms) provides a backup seal that maintains the contents of pouch <NUM> with container body <NUM>, even if membrane <NUM> were to rupture inadvertently prior to intended use. Thus, folded edge <NUM> may act to limit the chance of spilling if membrane <NUM> were to be ruptured unintentionally.

After dispensing opening <NUM> is formed, membrane <NUM> is ruptured to release contents <NUM> from contents chamber <NUM> into passage <NUM> to allow for contents <NUM> to be dispensed through opening <NUM>. To rupture membrane <NUM>, pressure within contents chamber <NUM> is increased such that the pressure is greater than a rupture threshold of membrane <NUM>. As shown in <FIG>, the flexible material of body <NUM> allows an inwardly directed force F to be applied to the outer surfaces of front wall <NUM> and rear wall <NUM> resulting in an increase in pressure within contents chamber <NUM>. In one embodiment, pouch <NUM> is sized to fit within the user's hand or between the user's fingers such that force F is representative of the user squeezing pouch <NUM>. As shown in <FIG>, when the pressure within contents chamber <NUM> exceeds the rupture threshold of membrane <NUM>, membrane <NUM> ruptures or breaks at a position between heat seals <NUM> and <NUM> to create a membrane breach <NUM>. When membrane <NUM> ruptures, bonds within the material of membrane <NUM> break or separate from itself resulting in the creation of the dispensing opening. When membrane <NUM> ruptures, contents chamber <NUM> is placed in fluid communication with dispensing passage <NUM>, allowing contents <NUM> to flow from contents chamber <NUM>, through membrane breach <NUM> into dispensing passage <NUM> and then through dispensing opening <NUM>.

In various embodiments, the materials of body <NUM> and membrane <NUM> and the structure of the heat seals of pouch <NUM> are selected such that membrane <NUM> is the portion of pouch <NUM> that ruptures or fails upon the increase of pressure within contents chamber <NUM>. In one such embodiment, the material of body <NUM> is stronger than the material of membrane <NUM> such that when the rupture threshold of membrane <NUM> is reached, membrane <NUM> ruptures but body <NUM> remains intact. Further, the heat seals <NUM>, <NUM>, <NUM>, <NUM> and <NUM> are structured to remain sealed when the rupture threshold of membrane <NUM> is reached. These configurations help to provide for controlled dispensing by ensuring that membrane <NUM> breaks while the heat seals and the outer body of pouch <NUM> remain intact. In various embodiments, the melt temperature used to make a seal relates to the strength of seal. Accordingly, in various embodiments, the melt temperature used to form heat seals <NUM> and <NUM> is substantially the same as or similar to the melt temperature used to make heat seals <NUM>, <NUM>, and <NUM>. Using as substantially similar melt temperature for all of the heat seals of pouch <NUM> helps to ensure that none of the heat seals are weaker than the other heat seals, and thus, helps to ensure that membrane <NUM> is the portion that ruptures upon increase in pressure. In one embodiment, the melt temperature used to make the heat seals is between <NUM> and <NUM> / <NUM> and <NUM> degrees Fahrenheit, is more specifically between <NUM> and <NUM> / <NUM> and <NUM> degrees Fahrenheit, and specifically is about <NUM> / <NUM> degrees Fahrenheit.

In various embodiments, body <NUM> and membrane <NUM> may be each formed such that membrane <NUM> has a rupture stress (i.e., the stress at which the material ruptures) that is less than the rupture stress of body <NUM>. In one such embodiment, body <NUM> and membrane <NUM> may be each formed from different materials, such that the rupture stress of membrane <NUM> is less than the rupture stress of body <NUM>, to provide for differential failure upon squeezing discussed above. For example, in one embodiment, membrane <NUM> is made from a first type of material and body <NUM> is made from a second type of material, and the rupture stress of the first type of material is less than the rupture stress of the second type of material. In addition, the rupture stress of membrane <NUM> is also less than the rupture stress of the heat seals of pouch <NUM>. In another embodiment, membrane <NUM> and body <NUM> may be formed from the same type of material (e.g., both are monolayers of the same type of thermoplastic) but with different thicknesses such that membrane <NUM> has a rupture stress less than the rupture stress of body <NUM>. Further, in various embodiments, the squeeze to dispense operation of pouch <NUM> may facilitate dispensing without spilling as compared to pouring from standard rigid wall containers or to dispensing from a package without internal membrane <NUM>.

In various embodiments, the rupture stress of membrane <NUM> is selected to be rupturable by application of manual force. In such embodiments, the rupture stress of membrane <NUM> is between <NUM> Pa / <NUM> psi and <NUM> Pa / <NUM> psi specifically is between <NUM> Pa / <NUM> psi and <NUM> Pa / <NUM> psi, and more specifically is between <NUM> Pa / <NUM> psi and <NUM> Pa / <NUM> psi. In one specific embodiment, the rupture stress of membrane <NUM> is about <NUM> Pa / <NUM> psi. In various embodiments, membrane <NUM> having rupture stresses discussed in this paragraph is formed from a polymeric material, as discussed above, and in one embodiment, is polyethylene. In such embodiments, the rupture stress of body <NUM> may be greater than <NUM> Pa / <NUM> psi, may be greater than <NUM> Pa / <NUM> psi and may be greater than <NUM> Pa / <NUM> psi.

In other embodiments, pouch <NUM> is designed such that membrane <NUM> is ruptured by application of force by a device, machine or vice, and in such embodiments, the rupture stress of membrane <NUM> may be greater than a rupture stress that can be ruptured by application of manual force. In such embodiments, pouch <NUM> may be configured to hold various contents (e.g., chemicals, cleaning agents, lubricants, motor oil, etc.) that are typically used in conjunction with a machine or device such that rupture of membrane <NUM> within the machine or device is desirable to dispense the contents into the device for use. For example, in one embodiment, pouch <NUM> is configured to be ruptured within the mop wringer of a mop bucket. In such embodiments, the rupture stress of membrane <NUM> is greater than <NUM> Pa / <NUM> psi, and specifically is greater than <NUM> Pa / <NUM> psi.

In various embodiments, membrane <NUM> is formed from a material having a thickness between <NUM> / <NUM> mil and <NUM> / <NUM> mil, specifically between <NUM> / <NUM> mil and <NUM> / <NUM> mil, and more specifically between <NUM> / <NUM> mil and <NUM> / <NUM> mil. In one specific embodiment, membrane <NUM> is formed from a material having a thickness of about <NUM> / <NUM> mil. In one specific embodiment, membrane <NUM> is formed from a material having a thickness of about <NUM> / <NUM> mil having a rupture stress of about <NUM> Pa / <NUM> psi. In various embodiments, membrane <NUM> having thickness discussed in this paragraph is formed from a polymeric material, as discussed above, and in one embodiment, is polyethylene.

Referring to <FIG>, manufacture of pouch <NUM> is shown according to an exemplary embodiment. As shown in <FIG>, a first sheet of material <NUM> is provided from which outer container body <NUM> is made, and a second sheet of material <NUM> is provided from which membrane <NUM> is made. Sheet <NUM> is folded into a substantially U-shaped configuration such that sheet <NUM> has a front portion <NUM>, a rear portion <NUM> and a folded edge <NUM> that provides the folded transition from front portion <NUM> to rear portion <NUM>. As shown in <FIG>, a section of front portion <NUM> becomes front wall <NUM> of pouch <NUM>, a section of rear portion <NUM> becomes rear wall <NUM> of pouch <NUM>, and a section of folded edge <NUM> becomes folded edge <NUM> of pouch <NUM>.

Sheet <NUM> is also folded into a substantially U-shaped configuration such that sheet <NUM> has a front portion <NUM>, a rear portion <NUM> and a folded edge <NUM> that provides the folded transition from front portion <NUM> to rear portion <NUM>. As shown in <FIG>, a section of front portion <NUM> becomes front wall <NUM> of membrane <NUM> and a section of rear portion <NUM> becomes rear wall <NUM> of membrane <NUM>. Sheet <NUM> is positioned between front portion <NUM> and rear portion <NUM>, as shown in <FIG>, such that the inner surfaces of front portion <NUM> and rear portion <NUM> of the outer sheet <NUM> face the outer surfaces of front portion <NUM> and rear portion <NUM> of inner membrane material sheet <NUM>.

Referring to <FIG>, formation of heat seals attach membrane material sheet <NUM> to the inner surfaces of body material sheet <NUM> is shown according to an exemplary embodiment. In the embodiment shown, the heat seals coupling membrane material sheet <NUM> to the inner surface of body material sheet <NUM> (e.g., heat seals <NUM> and <NUM>) are formed by heat bars <NUM>. Heat bars <NUM> are heated to the desired melt or weld temperature and contact the outer surface of body material sheet <NUM> such that the inner adhesive layer <NUM> (shown in <FIG>) melts and bonds to the outer surface of membrane material sheet <NUM> forming heat seals <NUM> and <NUM>. An inner supporting member <NUM> may be used to support material sheets <NUM> and <NUM> as heat bars <NUM> press inward during formation of the heat seals.

As shown in <FIG>, following attachment of membrane <NUM> to the inner surface of outer material sheet <NUM>, lateral heat seals <NUM> and <NUM> are formed. Lateral heat seals <NUM> and <NUM> may be formed by contact of heat bars, similar to heat bars <NUM>, vertically to define the lateral edges of pouch <NUM>. As shown in <FIG>, material sheets <NUM> and <NUM> are cut to the left of left lateral heat seal <NUM> and to the right of right lateral heat seal <NUM>. This cutting separates pouch <NUM> from material sheets <NUM> and <NUM>. As shown in <FIG>, upper end <NUM> of pouch <NUM> is initially an open filing end allowing container contents <NUM> to be filled through the open filing end. As shown in <FIG>, following filing of pouch <NUM>, upper end <NUM> is sealed by upper heat seal <NUM>. In various embodiments, the steps shown in <FIG> occur in the order shown. In some embodiments, the process shown in <FIG> repeats sequentially, at different positions along material sheets <NUM> and <NUM>, such that multiple pouches <NUM> are formed from sheets <NUM> and <NUM>. In one embodiment, various heat seal and filling equipment may be configured to create pouch <NUM> as shown in <FIG>.

Referring to <FIG>, formation of pouch <NUM> including elongated spout <NUM> is shown according to an exemplary embodiment. As shown in <FIG>, the lateral heat seals include first and second horizontal heat seals <NUM> and <NUM> that extend inward from lateral heat seals <NUM> and <NUM>, respectively. First and second spout heat seals <NUM> and <NUM> extend along the lateral edges of spout <NUM> downward away from the inner portions of first and second horizontal heat seals <NUM> and <NUM>, respectively. As shown, first and second spout heat seals <NUM> and <NUM> extend the length of spout <NUM> from first and second horizontal heat seals <NUM> and <NUM> to folded edge <NUM>. As shown in <FIG>, following formation of first and second spout heat seals <NUM> and <NUM>, excess portions <NUM> of the material of sheet <NUM> are cut from pouch <NUM> to create elongated spout <NUM> that is narrower than the contents containing portion of pouch <NUM>.

Claim 1:
A heat-sealed squeezable dispensing pouch (<NUM>) comprising:
an outer sheet (<NUM>) having a front wall (<NUM>), a rear wall (<NUM>) and a folded edge (<NUM>) located between the front wall and the rear wall, wherein the outer sheet is folded along the folded edge such that an inner surface (<NUM>) of the front wall faces an inner surface (<NUM>) of the rear wall;
a first heat seal (<NUM>) coupling the inner surface of a peripheral section of the front wall to a peripheral section of the inner surface of the rear wall such that the inner surfaces of the front and rear walls define an interior chamber;
a rupturable inner membrane (<NUM>) formed from a contiguous, single monolayer of thermoplastic material, the rupturable inner membrane located within the interior chamber, wherein the rupturable inner membrane divides the interior chamber into a contents compartment and a dispensing channel, wherein the first heat seal (<NUM>) defines an edge of the contents compartment and the folded edge (<NUM>) defines an edge of the dispensing channel;
a second heat seal (<NUM>) coupling the rupturable inner membrane to the inner surface of the front wall;
a third heat seal (<NUM>) coupling the rupturable inner membrane to the inner surface of the rear wall; and
wherein the second heat seal and the third heat seal are positioned within the interior chamber;
wherein the rupturable inner membrane is configured to break when a pressure within the contents compartment is greater than a rupture threshold, wherein the first, second and third heat seals are configured to remain sealed when the inner membrane breaks.