Patent Description:
In food service, and in particular in the field of high volume fast food service, it is frequently desired that food be supplemented by condiments such as ketchup, mustard, mayonnaise, and the like. It has recently become customary in retail fast service chain food outlets to use a wide variety of devices to dispense a measured quantity of flowable product. For example, a trigger-activated dispensing gun assembly has commonly been used in "back of the restaurant" operations for discharging one or more condiments or sauces. The gun assembly dispenses a quantity of a condiment with each pull of a gun trigger. The gun assembly includes a cylindrical container that houses the condiment and cooperates with a trigger in a gun to dispense the condiment out of a nozzle. However, the gun, cylindrical container, and nozzle are typically disassembled and/or cleaned each time the container is emptied and/or refilled In addition, the gun assembly typically can be messy, as condiment can drip from the nozzle between uses; conventional systems can be labor intensive; and the container can sometimes become damaged and not insert properly into the gun. <CIT> discloses a package with a tape consisting of two outer layers of polyethylene and an inner layer of low-pressure polyethylene/polybutylene, as peel film. The two outer layers of the tape are welded to the inner layer of the package, while between the two outer layers there is a single type of material, namely that of peel layer. <CIT> discloses a pouch and a base strip including a monolayer or multilayer sealing segment, an intermediate layer comprising PSA, and a monolayer or multilayer backing segment. The base strip comprises a first surface and a second surface. At least the first surface comprises a sealant. In one embodiment, both the first and second surfaces comprise a sealant. Either or both of the sealants of the base strip are an easy open sealant. <CIT> discloses a pouch with a pouring spout.

A package according to the invention is disclosed in any one of the appended claims.

The present invention is illustrated in various embodiments by reference to the following drawing figures wherein:.

"A", "an", and "the" as used herein do not limit to the singular unless expressly so stated. Thus, for example, reference to "a package" can include a plurality of such packages, and so forth.

"Abuse layer" and the like herein refers to an outer film layer and/or an inner film layer, so long as the film layer serves to resist abrasion, puncture, and other potential causes of reduction of package integrity, as well as potential causes of reduction of package appearance quality. Abuse layers can comprise any polymer, so long as the polymer contributes to achieving an integrity goal and/or an appearance goal. In some embodiments, the abuse layer can comprise polyamide, ethylene/propylene copolymer, and/or combinations thereof.

"Antifog" and the like herein refers to an agent that can be incorporated into an outermost film layer, be coated onto an outermost film layer, or migrate from an internal layer to an outermost film layer, with the effect of lowering the seal strength of a seal subsequently made. Suitable antifog agents may fall into classes such as esters of aliphatic alcohols, esters of polyglycol, polyethers, polyhydric alcohols, esters of polyhydric aliphatic alcohols, polyethoxylated aromatic alcohols, nonionic ethoxylates, and hydrophilic fatty acid esters. Useful antifog agents include polyoxyethylene, sorbitan monostearate, polyoxyethylene sorbitan monolaurate, polyoxyethylene monopalmitate, polyoxyethylene sorbitan tristearate, polyoxyethylene sorbitan trioleate, poly(oxypropylene), polyethoxylated fatty alcohols, polyoxyethylated <NUM>-nonylphenol, polyhydric alcohol, propylene diol, propylene triol, and ethylene diol, monoglyceride esters of vegetable oil or animal fat, mono- and/or diglycerides such as glycerol mono- and dioleate, glyceryl stearate, monophenyl polyethoxylate, and sorbitan monolaurate. The antifog agent is incorporated in an amount effective to suitably reduce the seal strength of the film.

"Barrier", "barrier layer", and the like herein refers to the ability of a film or film layer to serve as a barrier to one or more gases. For example, oxygen barrier layers can comprise, but are not limited to, ethylene/vinyl alcohol copolymer, polyvinyl chloride, polyvinylidene chloride, polyamide, polyester, polyacrylonitrile, and the like, as known to those of ordinary skill in the art. In some embodiments, the barrier film or layer has an oxygen transmission rate of no more than <NUM> cc O<NUM>/m<NUM>•day•atm; less than <NUM> cc O<NUM>/m<NUM>•day•atm; less than <NUM> cc O<NUM>/m<NUM>•day•atm; less than <NUM> cc O<NUM>/m<NUM>•day•atm; less than <NUM> cc O<NUM>/m<NUM>•day•atm; or less than <NUM> cc O<NUM>/m<NUM>•day•atm (tested at <NUM>,<NUM> (<NUM> mil) thick and at <NUM> in accordance with ASTM D3985, herein incorporated by reference in its entirety).

"Bulk layer" and the like herein refer to any layer of a film that is present for the purpose of increasing the abuse-resistance, toughness, and/or modulus of a film. In some embodiments, bulk layers can comprise polyolefin, ethylene/alpha-olefin copolymer, ethylene/alpha-olefin copolymer plastomer, low density polyethylene, linear low density polyethylene, and combinations thereof.

"Condiment" and the like herein refers to (but is not limited to) ketchup, mustard, guacamole, sour cream, salsa, nacho cheese, taco sauce, barbecue sauce, tartar sauce, mayonnaise, jams, jellies, spices, and the like. In some embodiments, the term "condiment" can include any and all additives that a user can choose to add to any food item for any purpose, e.g. for organoleptic, processing, or preservative purposes.

"Container" and the like herein refers to tubes, bottles, jars, tubs, cylinders, vessels, flasks, chambers, and the like, whether pliable or rigid.

"Exterior" refers to the outside portion of an article.

"Filled" and the like herein, with respect to a pouch, refer to a pouch that has been filled with a product in a manner consistent with a commercial filling operation. Thus, a pouch may or may not be <NUM>% filled.

"Film" and the like herein refers to a laminate, sheet, web, coating, or the like, that can be used to package a product. The film can be a rigid, semirigid, or flexible product. In some embodiments, the film is produced as a fully coextruded film, i.e., all layers of the film emerging from a single die at the same time. In some embodiments, the film is made using a flat cast film production process or a round cast film production process. Alternatively, the film can be made using a blown film process, double bubble process, triple bubble process, or adhesive or extrusion coating lamination.

"Flexible" and the like herein refer to materials that are pliable and easily deform in the presence of external forces.

"Frangible seal" and the like herein refer to a seal that is sufficiently durable to allow normal handling and storage, but ruptures or substantially ruptures under applied pressure. In some embodiments, suitable frangible seals will have a peel strength of from <NUM> to less than <NUM>/m ( <NUM> to less than <NUM> pounds/inch) as measured by ASTM F88.

"Heat seal" and the like herein refers to any seal of a first region of a film surface to a second region of a film surface, wherein the seal is formed by heating the regions to at least their respective seal initiation temperatures. Heat-sealing is the process of joining two or more thermoplastic films or sheets by heating areas in contact with each other to the temperature at which fusion occurs, usually aided by pressure. In some embodiments, heat-sealing can be inclusive of thermal sealing, melt-bead sealing, impulse sealing, dielectric sealing, and/or ultrasonic sealing. The heating can be performed by any one or more of a wide variety of means, such as (but not limited to) a heated bar, hot wire, hot air, infrared radiation, ultrasonic sealing, and the like.

"Interior" and the like herein refers to the inside portion of an article.

"Label" and the like herein refer to a portion of sheet or film material that can be used to construct a frangible seal in accordance with some embodiments of the present invention.

"Multilayer film" and the like herein refers to a thermoplastic film having one or more layers formed from polymeric or other materials that are bonded together by any conventional or suitable method, including one or more of the following methods: coextrusion, extrusion coating, lamination, vapor deposition coating, solvent coating, emulsion coating, or suspension coating.

"Outlet" and the like herein refer to an aperture, orifice, opening, chute, passage, or similar channel through which a product can exit the disclosed packaging system.

"Panel" and the like herein refer to a wall or major section of a pouch. A first and second panel can be derived from two pieces of film joined together by any suitable means, such as heat sealing. Alternatively, a single web of film can be folded into a tubular configuration, and longitudinally and transversely sealed to create a pouch exhibiting a first and second panel.

"Peelable sealant" and the like herein refers to any suitable polymer or polymer blend that forms at least a part of a film layer or is applied to a film layer, wherein the peelable sealant exhibits a seal strength that is less than the seal strength of the permanent sealant as described herein. In some embodiments, the peelable sealant can comprise a food grade cold seal adhesive.

"Permanent sealant" and the like herein refers to any suitable polymer or polymer blend that forms at least a part of a film layer or is applied to a film layer, wherein the permanent layer exhibits a seal strength that is greater than the seal strength of the peelable sealant as described herein.

"Pouch" and the like herein refers to any of a wide variety of containers known in the art, including (but not limited to) bags, packets, packages, and the like.

"Product" and the like herein refer to any of a wide variety of food or non-food items that can be packaged in the disclosed systems. In some embodiments, the product is a condiment, and/or a flowable product.

"Seal" and the like herein refer to any seal of a first region of a film surface to a second region of a film or substrate surface. In some embodiments, the seal can be formed by heating the regions to at least their respective seal initiation temperatures using a heated bar, hot air, infrared radiation, ultrasonic sealing, and the like. In some embodiments, the seal can be formed by an adhesive. Alternatively or in addition, in some embodiments the seal can be formed using a UV or e-beam curable adhesive seal.

"Seal layer" and the like herein refers to an outermost film layer or layers involved in heat sealing of the film to itself, to another film layer of the same or another film, and/or another article that is not a film. "Outermost" layer herein includes a layer found on the outside of a film, i.e. a layer not bounded on both major surfaces by another film layer. Layers involved in heat sealing can include a second layer, adjacent an outermost layer, that assists in or substantially affects or influences the overall strength of the heat seal. Heat sealing can be performed by any one or more of a wide variety of manners known to those of ordinary skill in art, including using heat seal technique (e.g., melt-bead sealing, thermal sealing, impulse sealing, ultrasonic sealing, hot air, hot wire, infrared radiation, and the like), adhesive sealing, UV-curable adhesive sealing, and the like.

"Tie layer" and the like herein refers to an internal film layer having the primary purpose of adhering two layers to one another. In some embodiments, a tie layer can comprise any nonpolar polymer having a polar group grafted thereon, such that the polymer is capable of covalent bonding to polar polymers such as polyamide and ethylene/vinyl alcohol copolymer. In some embodiments, the tie layers can comprise modified polyolefin, modified ethylene/vinyl acetate copolymer, and/or homogeneous ethylene/alpha-olefin copolymer.

"Transparent" and the like herein refers to the ability of a material to transmit incident light with negligible scattering and little absorption, enabling objects to be seen clearly through the material under typical unaided viewing conditions, i.e. the expected use conditions of the material, as measured in accordance with ASTM D1746.

"Valve" and the like herein refers to any device by which the flow of material can be started, stopped, rerouted or regulated by a movable part that opens, closes, or partially obstructs a passageway through which the material flows. In some embodiments, a suitable valve can comprise any of an umbrella valve, duckbill valve, reed valve, ball valve, flapper valve, poppet valve, Gott valve, check valve, or any suitable combination thereof.

All compositional percentages used herein are presented on a "by weight" basis, unless designated otherwise.

The definitions and disclosure of the present application control over any inconsistent definition or disclosure present in an incorporated reference.

The present invention provides a dispensing system and method for dispensing a product onto one or more areas (one or more spots of mustard dispensed on a hamburger bun, for example). In one embodiment, the dispensing system includes a packaging system <NUM> that cooperates with a dispensing device (such as a dispensing gun <NUM>) to dispense a dose of product.

As illustrated in the Figures, packaging system <NUM> comprises outer container <NUM> with first and second ends <NUM>, <NUM>, and package <NUM> positioned within the container interior <NUM>. Package <NUM> includes a pouch <NUM> that houses product <NUM>, which in some embodiments can be a condiment. Container first end <NUM> accommodates dispensing assembly <NUM>, including a valve housing <NUM> comprising valve <NUM> that enables product <NUM> to exit the package interior, as set forth in more detail herein below. Diffuser <NUM> coordinates with valve housing <NUM> to dispense product <NUM> from one or more product outlets <NUM>. Pusher plate <NUM> is in one embodiment configured on the interior <NUM> of container second end <NUM> and cooperates with a dispensing gun to dispense product <NUM>.

As illustrated in the Figures, packaging system <NUM> comprises container <NUM>, package <NUM>, and dispensing assembly <NUM>. System <NUM> optionally includes diffuser <NUM>, and pusher plate <NUM>. In some embodiments, pusher plate <NUM> does not form part of system <NUM> and is instead included as part of dispensing gun <NUM>.

Several of the figures, including <FIG>, <FIG>, <FIG>, <FIG> and <FIG>, illustrate container <NUM>. Container <NUM> includes tubular sidewall <NUM> with open second end <NUM> sized to house package <NUM> and accommodate pusher plate <NUM> within the interior <NUM> of the container. The container further includes mouth <NUM> positioned at first end <NUM>, through which product <NUM> can be dispensed via valve housing <NUM> and diffuser <NUM>. The container sidewall tapers (with a reduced diameter) into container neck <NUM> at first end <NUM>. In some embodiments, neck <NUM> includes a fastening device <NUM>, such as a screw thread, extending around the neck exterior for engaging dispensing assembly <NUM>, as will be described below. Alternative methods of attaching a dispensing assembly include a location fit, press fit, twist lock, tab, slot, and/or snap fit arrangements.

Container <NUM> can be constructed from any of a variety of rigid or semirigid materials known in the art, e.g. plastic, metal, wood, cardboard, chipboard, stiff paper, foamed plastics, recycled materials, compostable materials, heavy foil, and/or combinations thereof; such as foamed or solid polystyrene, crystallized polystyrene (CPS), polyethylene terephthalate (PET), polypropylene, polyethylene, or combinations thereof. Such materials are typically suitable for forming, yet stiff or rigid enough to resist buckling, folding, crumbling or collapsing due to compression, handling, and shipping.

In some embodiments, container <NUM> can be constructed from a material that provides a barrier to the passage of oxygen, e.g., vinylidene chloride copolymer, nylon, polyethylene terephthalate, ethylene/vinyl alcohol copolymer, and the like. In some embodiments, the material(s) from which the container is constructed can comprise an oxygen scavenging material, e.g. Amisorb®. Alternatively or in addition, container <NUM> can comprise a substantially gas-impermeable sealant film laminated or otherwise bonded to the inner or outer surface thereof. In some embodiments, the material from which the container is made exhibits an oxygen transmission rate of no more than about <NUM> cc/m<NUM>/<NUM> hr. at <NUM>, <NUM>% RH, <NUM> atm (in accordance with ASTM D <NUM>), such as no more than <NUM> cc/m<NUM>/<NUM> hr. at <NUM>, <NUM>% RH, <NUM> atm.

Container <NUM> can be constructed using any conventional process known in the art, such as rotational molding, blow molding, reheat stretch blow molding, injection molding, casting, roll forming, stamping, and the like.

Container <NUM> is not limited to the cylindrical shape illustrated in the figures, and can have a rectangular, triangular, hexagonal, octagonal or square or other cross-sectional shape, including a combination of any of these shapes. The container be formed as any suitable receptacle with an interior <NUM> for housing a pouch, e.g. a carton, can, jar, or bottle, and can have different dimensions and volume capacities.

Optionally, container <NUM> includes one or more vent holes in the upper part of the container, e.g. in the shoulder <NUM> of the container. Such vent holes can expedite manual removal of a spent package from the container interior after product <NUM> has been dispensed. The vent holes are in one embodiment small, round holes of the type shown as <NUM> in <FIG>.

Package <NUM> includes sealed pouch <NUM>, with product <NUM> disposed therein. Pouch <NUM> can be any of a variety of pouches known in the art, including e.g. a stand-up pouch, a gusseted stand-up pouch, a lay-flat pouch, a pouch comprising at least one longitudinal seal, and the like. In some embodiments, pouch <NUM> can comprise a pair of films joined together along a pair of opposing sides and a bottom bridging the sides. Alternatively, in some embodiments, pouch <NUM> can be formed from a single film that has been center folded at one edge, or a pouch that includes one or more lap seals, fin seals, and/or edge seals. In another embodiment, pouch <NUM> can comprise a continuous tubular material with no longitudinal seal, but with transverse seals as disclosed herein. The description of the pouch herein as having "first and second panels" should be understood to describe a pouch that when filled with product and laid on a surface, will display a major first surface, wall or panel, and, on the opposite side of the pouch, a second major surface, wall, or panel.

As illustrated in <FIG>, pouch <NUM> comprises first and second panels <NUM>, <NUM> that are sealed together about the pouch perimeter with perimeter seal <NUM>. Perimeter seal <NUM> can be formed using any suitable method, known and used in the art, including e.g. the use of heat, pressure, adhesive, and/or mechanical closure. As shown, perimeter seal <NUM> does not span top edge <NUM> of pouch spout <NUM>. Rather, in some embodiments, pouch spout <NUM> includes frangible seal <NUM> positioned between the first and second panels <NUM> using a heat seal, ultrasonic seal, static seal, RF seal, adhesive, or a combination thereof. Frangible seals are known to those of ordinary skill in the packaging art. See, for example, <CIT> and <CIT>, the entire disclosures of which are hereby incorporated by reference.

Alternatively, as shown in <FIG>, pouch <NUM> comprises first and second panels <NUM>, <NUM>, a first transverse seal <NUM>, a second transverse seal <NUM>, a first side fold <NUM>, a second side fold <NUM>, a longitudinal seal <NUM>, a first pouch end <NUM>, and a second pouch end <NUM>. According to the invention , frangible seal <NUM> comprises label <NUM>. Particularly, label <NUM> includes permanent sealant <NUM> positioned on first label face <NUM> and peelable sealant <NUM> positioned on second label face <NUM>, as shown in <FIG>. The sealants can comprise part of a film layer, or can be coated, extrusion coated, or applied to the surface of a film using conventional labeling systems known in the art. As depicted in <FIG>, pouch spout <NUM> comprises label <NUM> with permanent sealant <NUM> positioned on one label face, adjacent to second panel <NUM>, and peelable sealant <NUM> positioned on the opposing label face, adjacent to first panel <NUM>. In some embodiments, the label is maintained in proper position using one or more spot seals <NUM>. Label <NUM> can be positioned in any suitable location either fully or partially within pouch spout <NUM>, e.g. adjacent to top edge <NUM>.

Permanent sealant <NUM> can comprise any suitable polymer or polymer blend that makes up at least a portion of a film layer or is applied to a film layer (i.e., a coating). Suitable permanent sealants, for example, can be selected from the group comprising: Ziegler-Natta catalyzed linear low density polyethylenes (such as such as DOWLEX® <NUM>, DOWLEX® <NUM>, and DOWLEX® <NUM>), metallocene-catalyzed LLDPE (such as EXCEED® 4518PA and EXCEED® 3518CB), polyolefin "plastomer" grade polyethylenes with high comonomer (such as Dow AFFINITY® PL <NUM>, Dow AFFINITY® PL <NUM>, Dow AFFINITY® PL <NUM>, EXACT® <NUM>, and EXACT® <NUM>), propylene-ethylene copolymer, LDPE (such as ESCORENE® LD-<NUM>), ionomer resin, such as SURLYN® <NUM>, ethylene/vinyl acetate copolymers, ethylene/methyl (meth)acrylate copolymers, and ethylene/butyl acrylate copolymers. Materials used as permanent sealant <NUM> typically melt with the application of heat and/or pressure to form permanent (non-frangible) seals. Typical seal strengths for the permanent sealant can range from <NUM> pounds/inch to <NUM> pounds/inch in accordance with ASTM F88-<NUM>. In some embodiments, the seal strength of the permanent sealant can be greater than the seal strength of the peelable sealant by a difference of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> per meter (<NUM><NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> pounds per inch).

Peelable sealant <NUM> can comprise any suitable sealant known in the art, e.g. DuPont APPEEL® resins such as those based on EVA, modified EVA, ethylene/acrylate copolymer, or modified ethylene/acrylate copolymer; blends of immiscible polymers, such as polyethylene and polybutylene; polyethylene, such as low density polyethylene and/or EVA copolymers blended with polypropylene, polyethylene blended with polybutene-<NUM>, random propylene/ethylene copolymer blended with polybutene-<NUM>, EVA or LDPE blended with polypropylene, LDPE blended with EVA and polypropylene, to introduce a molecular incompatibility into the sealant layer. It is believed that the molecular incompatibility creates discontinuities that reduce the force necessary to rupture the seal. Alternatively or in addition, the sealant can be printed in a pattern on a surface of the film. Typical seal strengths of peelable sealant <NUM> can in some embodiments be less than about <NUM> pounds/inch in accordance with ASTM F88-<NUM>. A peelable sealant will typically allow the user to open the seal with relatively little effort (e.g. by advancing a pusher plate <NUM> within the container interior). In some cases, peelable sealant <NUM> can peel away from the surface to which it is adhered. Alternatively, a rupture of the sealant (cohesive failure) or breakage of the sealant and delamination along an adjacent layer interface can occur. See, for example, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

After label <NUM> has been positioned fully or partially within spout <NUM>, frangible seal <NUM> can be constructed using the application of heat and/or pressure (i.e., heat sealing). Specifically, the application of heat/pressure activates permanent sealant <NUM> into an adhesive state. As a result, label <NUM> becomes permanently sealed to the adjoining pouch panel (second panel <NUM> in <FIG>). The application of heat and/or pressure further activates peelable sealant <NUM>, resulting in a frangible seal <NUM> positioned between label <NUM> and the adjoining pouch panel (first panel <NUM> in <FIG>). As a result, label <NUM> becomes peelably sealed to first panel <NUM>. The frangible seal can be constructed in any of a variety of patterns, such as straight line, chevron, half moon, and the like, using e.g., targeted application of heat/pressure. in use, after the frangible seal has been constructed, an increase in pouch pressure (such as from the advancement of pusher plate <NUM>) forces peelable sealant <NUM> to separate from the adjacent pouch panel. As a result, product <NUM> is able to flow through the pouch spout <NUM>, as depicted by Arrow "A" in <FIG>. In a not claimed alternative frangile seal <NUM> may be constructed using first and second labels as shown in <FIG> and <FIG>. The two labels include a permanent sealant 51a, 51b respectively positioned on outer label faces <NUM>, adjacent to the pouch panels <NUM>, <NUM>. Either or both of the two labels further comprise peelable sealant 53a, 53b on their respective inner faces <NUM> (i.e., facing each other). After the labels have been positioned fully or partially within spout <NUM>, frangible seal <NUM> can be constructed by heat sealing the labels to the pouch films as described earlier, creating permanent seals between the labels and front and rear panels. An alternative to the use of heat sealing to create a permanent seal, is the use of a permanent adhesive. Heat sealing creates a frangible seal <NUM> between the inner faces of the two labels, as a result of peelable sealant 53a, 53b. In some embodiments, the labels can include spot seals <NUM> to maintain proper positioning in the area outside of the frangible seal. In use, increased pressure within the pouch will rupture frangible seal <NUM>, allowing product to flow between the labels to exit the pouch, as shown by Arrow B in <FIG>.

The disclosed labels and pouch <NUM> can be constructed from any of a wide variety of polymeric materials known in the art, including in some embodiments food safe materials and/or a base film having a food safe material coated thereon. In some embodiments, the label(s) can be a continuous strip of material that spans the entire pouch length in the machine direction, e.g. parallel to the pouch longitudinal seal. In these embodiments, the label(s) can be indexed from a roll and applied (sealed, adhered, or the like) to a pouch. Alternatively, in some embodiments, the label(s) can be an intermittent strip (registered film) positioned in the transverse seal area on one end of pouch <NUM> in the machine direction, i.e., perpendicular to the longitudinal seal. In these embodiments, the label can be indexed from a roll and applied to the middle of the pouch film web. Alternatively, the frangible strip can run continuously in the transverse or other suitable direction. In some embodiments, the label(s) can be constructed from one or more semirigid materials (e.g., EVA sealant/semi-rigid layer/lock down sealant) that can be registered and applied on an end of the pouch parallel to the pouch longitudinal seal. In an alternative embodiment, a food grade cold seal can be used.

A film used to construct the disclosed pouch and/or label(s) can be multilayer or monolayer. Typically, the films employed will have two or more layers to incorporate a variety of properties, such as, for example, sealability, gas impermeability, and toughness into a single film. Thus, in some embodiments, the films can comprise a total of from <NUM> to <NUM> layers, such as from <NUM> to <NUM>, or from <NUM> to <NUM> layers. The films can comprise more than <NUM> layers e.g. in embodiments wherein the films comprise microlayering technology.

The films used to construct pouch <NUM> and/or the disclosed labels(s) can include one or more barrier layers, bulk layers, tie layers, abuse layers, and/or sealant layers, e.g., at least one barrier layer such that the pouch has an oxygen transmission rate of no more than about <NUM> cc/m<NUM>/<NUM> hr. at <NUM>, <NUM>% RH, <NUM> atm (in accordance with ASTM D <NUM>).

The polymer components used to fabricate the films can also comprise appropriate amounts of other additives normally included in such compositions. For example, slip agents (such as talc), antioxidants, fillers, dyes, pigments and dyes, radiation stabilizers, antistatic agents, elastomers, and the like can be added to the disclosed films. See, for example, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>, the disclosures of which are hereby incorporated by reference in their entireties. In some embodiments, pouch <NUM> can be constructed from a food grade material, as would be well known to those of ordinary skill in the art.

The films used to construct pouch <NUM> and the disclosed label(s) can have any total thickness so long as they provide the desired properties for the particular packaging operation in which they are to be used. Nevertheless, in some embodiments the disclosed films have a total thickness of from <NUM>,<NUM> to <NUM> (<NUM> mils to <NUM> mils), such as from <NUM>,<NUM> to <NUM> ( <NUM> mils to <NUM> mils); <NUM> to about <NUM> ( <NUM> mils to about <NUM> mils); and from <NUM> to <NUM>,<NUM> (<NUM> mils to <NUM> mils).

The films can be provided in sheet or film form and can be any of the films commonly used for the disclosed type of packaging, and can be constructed by any suitable process including e.g. coextrusion, lamination, extrusion coating, and combinations thereof. See, for example, <CIT>.

In some embodiments, the films can be transparent (at least in any non-printed regions) such that the packaged product is at least partially visible through the films. The transparency of the films can be at least about any of the following values: <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, and <NUM>%.

In some embodiments the films used to construct pouch <NUM> or label <NUM> can be pigmented, tinted, or printed. Printing can be employed at any time prior to use of the pouch. In some embodiments, pouch <NUM> can be ink jet or thermal transfer printed using a device mounted on a packaging machine that forms and seals the pouch. In some embodiments, printing can include branding, product information, use instructions, and/or a mark that identifies the region of the pouch that is to align with the neck of container <NUM>.

In one embodiment, package <NUM> can be configured to provide a first transverse seal <NUM> that facilitates the insertion of package <NUM> into container <NUM>. Viewing <FIG>, first transverse seal <NUM> can include.

In the embodiment shown in <FIG>, the central seal segment <NUM> comprises two oblique portions 170a and 170b, and a central linear portion, connecting 170a and 170b, disposed substantially perpendicular to the longitudinal axis <NUM> of the pouch. This particular configuration not only facilitates manual loading of package <NUM> into container <NUM>, but also improves the centering of spout <NUM> with relation to neck <NUM> of the container. Centering of spout <NUM> in turns facilitates dispensing of product <NUM> out of the package <NUM> and through the dispensing assembly <NUM>.

Alternatively, central seal segment <NUM> is substantially U-shaped, as shown in <FIG>.

Second transverse seal <NUM> can take the form of first transverse seal <NUM>, as shown for example in <FIG>, but without the presence of a frangible seal <NUM>. Alternatively, second transverse seal <NUM> can take the form of a conventional, linear seal running perpendicular to the longitudinal axis <NUM> of the pouch. These two alternative configurations are related to the design of the seal bars used, the desired look of the pouch, and the internal pouch volume.

In an alternative embodiment, the package can be made with the frangible seal positioned in the machine direction, with waste areas at the side of the package perforated for tear off. The lap seal in this embodiment runs from side to side in the package. In another alternative embodiment, the package can be made without a lap seal, but with a fin seal located at the side of the package.

In some embodiments, in lieu of a frangible seal, the pouch spout can have a tear-off feature, such as a tear notch optionally combined with a line of weakness such as a score area or line of perforations, that enables access to the pouch contents.

In another embodiment, the pouch can have neither a frangible seal nor a tear off feature, and the pouch contents can be accessed by mechanically cutting off a portion of the pouch spout.

<FIG> shows, in an alternative embodiment, a first and second transverse seal <NUM>, <NUM> that each include the contoured seal disclosed herein for the embodiment of <FIG> and <FIG>. A frangible seal <NUM> is thus provided at each of the two ends of the pouch <NUM>. In one embodiment, a single transverse seal bar can, in accordance with the VFFS process disclosed herein, simultaneously produce seals <NUM> and <NUM>. As can be seen in <FIG>, the seal configuration results in a pouch <NUM> that is symmetrical with respect to the central transverse axis of pouch <NUM>. The embodiment of <FIG> provides for a package <NUM> that can be loaded into container <NUM> with either first transverse seal <NUM> or second transverse seal <NUM> facing downstream in the container, while still providing a frangible seal in the downstream portion of the pouch.

In the embodiments disclosed in <FIG>, and <FIG>, production of pouches with a contoured transverse seal in a VFFS process would typically result in the production of scrap as a part of the pouch making process. Although this scrap can be removed during production, it would be beneficial to avoid the necessity of providing for scrap removal, while still gaining the benefit of the contoured spout. This can be achieved by the embodiment of <FIG>, where a pouch <NUM> like that of <FIG> is provided, but which includes skirts 172a,b located on respective sides of the contoured seals <NUM> and <NUM>. These skirts, made during the VFFS process, in effect capture what would otherwise be scrap material by retaining these portions of the pouch material on the finished pouch rather than cutting the material away from the pouch. Scrap removal is thus avoided. Skirts 172a,b can be included in one embodiment at one transverse seal of the pouch <NUM>, or alternatively at both transverse seals of the pouch.

In one embodiment, the embodiment of <FIG> can optionally include slits <NUM>. These slits can be produced during production of the transverse seals, by a suitable cutting device. At point of use, when package <NUM> is loaded in container <NUM>, and the packaging assembly is activated by dispensing gun <NUM>, slits <NUM> allow skirts 172a,b to fold or bend back inside container <NUM>, enhancing the orientation of frangible seal <NUM> with respect to the first end <NUM> of container <NUM>, and dispensing of product <NUM> from package <NUM>. The slits <NUM> as shown in <FIG> extend obliquely from respective ends of skirt 172a,b towards the respective contoured seal <NUM>, <NUM>. Those skilled in the art will appreciate, after a review of this disclosure, that the location, length, shape (linear, curved, etc.), and orientation of slits <NUM> can be selected as needed to optimize the performance of package <NUM>.

System <NUM> can be used to house any of a wide variety of food and non-food products. For example, product <NUM> can include any of a wide variety of condiments, including (but not limited to) mustard, ketchup, salsa, guacamole, cheese sauce, sour cream, taco sauce, mayonnaise, tartar sauce, syrup, gravy, hot fudge, caramel, butterscotch toppings, flowable margarine and butter, horseradish, creamers, cream, yogurt, jelly, peanut butter, and the like. Liquids (such as water, milk, lemonade, and the like) can also be packaged in accordance with the present invention.

<FIG> schematically illustrates a vertical form/fill/seal (VFFS) apparatus that can be used in conjunction with the apparatus and process according to some embodiments of the present invention. VFFS packaging systems are generally well known to those of skill in the art, and described for example in <CIT>), <CIT>), <CIT>), and <CIT>).

Apparatus <NUM> utilizes a lay-flat web <NUM> as a rollstock. Product <NUM> is manually or mechanically supplied to apparatus <NUM> from a source (not illustrated), from which a predetermined quantity of product <NUM> reaches the upper end portion of forming tube <NUM> via a funnel (not shown) or other conventional means. The packages are formed in a lower portion of apparatus <NUM>, and web <NUM> from which the packages are formed is fed from a feed roll or other feeding device over certain forming bars (not illustrated), is wrapped about forming tube <NUM> (sometimes known as a "sailor's collar" or "forming collar") and is provided with a longitudinal fin seal or lap seal <NUM> by longitudinal heat sealing device <NUM>, resulting in the formation of a vertically-oriented folded web in the form of a tube <NUM>.

Transverse heat seal bars <NUM> operate to close and seal horizontally across the lower end of vertically-sealed tube <NUM>, to form a pouch <NUM> which is thereafter immediately packed with product <NUM>. Film drive belts <NUM>, powered and directed by rollers, as illustrated, or by suitable alternative motive means, advance tube <NUM> and pouch <NUM> a predetermined distance, after which seal bars <NUM> close and simultaneously seal horizontally across the lower end of vertically-sealed tube <NUM> and across the upper end of sealed pouch <NUM>, to form a package <NUM> in which a product <NUM> is disposed in sealed pouch <NUM>. The next pouch <NUM>, thereabove, is then filled with a metered quantity of product <NUM>, forwarded, and the packaging cycle is repeated. It is conventional to incorporate with the seal bars <NUM> a cut-off knife (not shown) which operates to sever a lower sealed pouch <NUM> from the bottom of upstream pouch <NUM>.

Lay-flat web <NUM> of <FIG> will in operation typically travel vertically upward from a feed roll to forming tube <NUM>, and then vertically downward for the remaining process steps.

<FIG> illustrate a frangible seal applicator <NUM> that can be used to apply a frangible seal <NUM>, as disclosed herein, in a package.

Applicator <NUM> includes a film strip mandrel /unwind <NUM> for supporting a roll of frangible strip <NUM> and maintaining tension. This part of the applicator is mounted to the VFFS machine in a location that can be accessed for easy loading of the frangible strip <NUM>. Applicator <NUM> also includes an indexer <NUM>, a heat sealer <NUM>, and a slitter <NUM>. Indexer <NUM> feeds a short section of film strip <NUM>, e.g. about one inch in length. Heat sealer <NUM> is then activated, and the film strip <NUM> is tack sealed to film web <NUM> along the film path <NUM> of web <NUM>. This is done so that frangible strip <NUM> will stay in position as web <NUM> is indexed and pull over the forming collar. The result is a film tube with a frangible strip adhered to the inside. Each time apparatus <NUM> indexes, a new label <NUM> will be applied to the film web.

While the heat seal is being made, slitter <NUM> cuts off the small section of film strip <NUM> that was fed through the indexer, effectively creating a label <NUM>. Apparatus <NUM> then indexes, i.e. web <NUM> is advanced, thus pulling the new sealed label <NUM> along with it. After the machine cycle completes, applicator <NUM> indexes, seals, and cuts another label <NUM>.

Applicator <NUM> is mounted to apparatus <NUM> so that the frangible strip <NUM> is positioned in the center of web <NUM>, perpendicular to the web path. Strip <NUM> will be sealed to the surface of web <NUM> that will comprise the interior surface of the finished package <NUM>. Where strip <NUM> meets web <NUM>, the strip will be parallel to web <NUM>.

If the apparatus <NUM> being used is one that makes a fold over seal or a side seal, the location of the strip may be moved from center so that strip <NUM> will be located in the center of the transverse seal, perpendicular to the film path. Alternately, strip <NUM> can be located anywhere along the transverse seal, thus resulting in a frangible seal at any location along the transverse seal. By changing the length of each label <NUM>, the size of the package opening, when product is eventually dispensed, can be changed. Applicator <NUM> is in one embodiment located so that the position of the applied label <NUM> will be a distance from the transverse seal that is a multiple of the finished package length. Because of the location of applicator <NUM>, each label <NUM> sealed into the transverse seal <NUM> of the package. The resulting package <NUM> has a strong seal all around except for the location of label <NUM>.

The invention provides the creation of a weak spot in the package that enables dispensing of a flowable product out of the package in a controlled manner, and as desired, while maintaining a strong, integral package during production, shipping and storage. As an alternative to providing a film strip that can be cut into labels and applied to the film web, alternative methods can be employed for achieving a weak spot in a package, including:.

In one embodiment, strip <NUM> and the resulting individual labels <NUM> are visually colored or patterned in a manner that allows visual verification that each label is positioned correctly in the respective transverse seal, and also for verifying that label <NUM> is not in the second transverse seal of each package.

Packages <NUM> can alternatively be made using horizontal form/fill/seal (HFFS) packaging systems, such as those available from Bossar, KHS-Bartelt, Mespack, Laudenberg, and other suppliers; and can also be made using rotary FFS systems such as those marketed by RA Jones, Cloud, etc..

As illustrated in the drawings, in particular <FIG>, and <FIG>, dispensing assembly <NUM> comprises a valve <NUM>, a valve housing <NUM> that retains the valve, and a connecting portion <NUM> that functionally cooperates with, and is in engagement with container <NUM> (valve <NUM> not shown in <FIG>). In particular, dispensing assembly <NUM> is positioned adjacent to, and connected to container neck <NUM>.

in one embodiment, as shown in <FIG> and <FIG>, the valve housing includes a top face <NUM> and wall <NUM> configured to extend down onto all or part of container neck <NUM>. The valve housing interior can in some embodiments include a fastening device <NUM>, such as inner valve housing threads, for mating with the container screw threads <NUM> positioned around the external circumference of container neck <NUM> (see <FIG>). Alternatively, the valve housing interior can include any other suitable mechanism (such as location fit, press fit, twist lock, tab, slot, and/or snap fit arrangements) to cooperate with the container neck. In some embodiments, the exterior of valve housing body includes a fastening device (such as outer threads <NUM> or a location fit, press fit, twist lock, tab, slot, and/or snap fit arrangement) that allow coupling with diffuser <NUM>, as set forth in more detail herein below.

Valve housing <NUM> includes at least one valve <NUM> through which product <NUM> can be dispensed during use. Valve <NUM> can be of any suitable variety known in the art, and can have (see <FIG>) at least one cut <NUM> to form arms <NUM> that move in response to increased pressure, such as from the advancement of the pusher plate <NUM>, to form at least one passageway <NUM>. Product <NUM> can travel from the interior of package <NUM>, through passageway <NUM> of valve <NUM>, to be dispensed on an item such as a food product, either directly, or indirectly by first entering and then exiting diffuser <NUM>. Once pressure ceases, valve <NUM> closes (i.e., arms <NUM> resume the original closed position of <FIG>) to shut passageway <NUM>. Valve <NUM> may fully close after pressure ceases, or alternatively remain slightly open (i.e., about <NUM>-<NUM>% open), partially open (i.e., about <NUM>-<NUM>% open), or somewhat open (i.e., about <NUM>-<NUM>% open). Valve <NUM> can be constructed in any suitable shape, e.g. circular, square, oval, and the like. Although depicted as X-shaped in the figures, the valve arms can be also be constructed using any suitably shaped cut, e.g. slits, star, etc..

Valve housing <NUM> can be constructed from any suitable rigid or semirigid material known in the art, such as metal, wood, rubber, plastic, and the like; from polyethylene terephthalate, high density polyethylene, low density polyethylene, polyvinyl chloride, polypropylene, polystyrene, polycarbonates, or combinations thereof. Although depicted as circular in shape in the drawings, the valve housing can be formed in any desired shape, e.g. oval, circular, square, rectangular, and the like.

In some embodiments, valve <NUM> can be constructed from an appropriately flexible material, e.g. polymeric, rubber, silicone, polyester, thermoplastic polyester elastomer, and the like, including polymeric films that include these materials. In some embodiments, the materials used to form the valve and the shape of the valve cuts can be selected based on the product viscosity, as would be known to those of ordinary skill in the art. For example, products that include particulates (like tartar sauce) can be used with a flexible valve with large cuts to allow the particulates to pass through.

Valve <NUM> can be of any suitable type, such as an umbrella valve, duckbill valve, reed valve, ball valve, flapper valve, poppet valve, Gott valve, check valve, or any suitable combination thereof.

Valve <NUM> can be retained or seated in the valve housing in any suitable manner. In one embodiment, as shown in <FIG> and <FIG>, a retainer <NUM>, such as a retaining ring, is adapted to secure the valve within the valve housing. A retaining clip, or a flange or flanges molded into the valve housing so as to retain the valve <NUM>, can alternatively be used. In some embodiments, fastening device <NUM> can function as a retainer for the valve.

Valve housing <NUM> can in some embodiments also include a fastening device <NUM> such as external valve housing threads, disposed on the outside surface of wall <NUM>, and adapted to interconnect with a diffuser <NUM> discussed in more detail below.

As illustrated in the drawings, in particular <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, in some embodiments packaging system <NUM> comprises diffuser <NUM> positioned adjacent to and in communication with valve housing <NUM> to facilitate dispensing of product <NUM> from package <NUM>. <FIG> illustrate one embodiment of a suitable diffuser comprising top face <NUM> and wall <NUM> that extends down onto all or part of valve housing <NUM>. The interior of diffuser <NUM> can include a fastening device, such as internal threads <NUM> or a location fit, press fit, twist lock, tab, slot, and/or snap fit arrangement) for engaging external valve housing threads or other fastening device <NUM> of valve housing <NUM>. In one embodiment, the diffuser is connected to the valve housing by a snap fit. This snap fit can be installed on the valve housing so as to render it not removable from the valve housing in normal use, i.e. is permanently installed on the valve housing. This particular feature of the invention can be beneficial when the use includes use of the combined valve housing/diffuser such that when desired, both are discarded as a unit. In some embodiments, the dispensing assembly does not include a diffuser, i.e. the overall packaging assembly, and the overall dispensing system, does not in every instance require a diffuser.

In some embodiments, the diffuser <NUM> can further include one or more conduits (not shown) or the like that extends through the interior of the space defined by the valve housing and the diffuser.

Diffuser <NUM> includes one or more outlets <NUM>, that can be of any suitable size, shape, distribution and number, these choices dictated at least in part by the properties, e.g. viscosity or particulate content of the product being dispensed.

Diffuser <NUM> can be constructed from any suitable material, such as metal, wood, rubber, polyethylene terephthalate, high density polyethylene, low density polyethylene, polyvinyl chloride, polypropylene, polystyrene, polycarbonates, and combinations thereof. Although depicted as circular in shape in the drawings, the diffuser <NUM> and/or outlets <NUM> can be formed in any desired shape known in the art, e.g. oval, circular, square, rectangular, and the like.

In an alternative embodiment (see <FIG>), a dispensing assembly_<NUM> can comprise_one or more valves <NUM>, of any of the types disclosed herein for valve <NUM>, but in which each valve <NUM> is juxtaposed adjacent an outlet <NUM>, analogous to outlets <NUM>, in a diffuser <NUM> analogous to diffuser <NUM> as shown herein. In one embodiment, a single disc <NUM> of a thermoplastic and/or elastomeric material can be installed inside the diffuser <NUM>, with a valve <NUM> positioned in each portion of disc <NUM> that is juxtaposed to and in communication with each respective outlet <NUM>. For example, a diffuser <NUM> with three outlets <NUM>, as shown in <FIG>, can be underlain by a thermoplastic and/or elastomeric disc <NUM> with a reed valve <NUM> positioned in each portion of disc <NUM> that underlies a respective outlet <NUM>. The single disc <NUM> can have a geometry suitable for fitting inside and suitably attaching to the interior (pouch side) of diffuser <NUM>.

Alternatively, an individual disc <NUM> bearing a valve <NUM> can be separately placed adjacent each outlet <NUM>, such that e.g. three individual discs <NUM>, each bearing a valve <NUM>, are present in the embodiment of <FIG>; but such an arrangement may be less convenient and more difficult to install than the embodiment employing a single disc <NUM>.

Diffuser <NUM> with the underlain juxtaposed disc <NUM> bearing valves <NUM> can be connected, integrally or as a discrete, attached component, to a housing <NUM> similar to valve housing <NUM> disclosed herein, but not including a valve. Diffuser <NUM> can be permanently attached to housing <NUM>, or alternatively releasably attached thereto (for example, for purposes of cleaning between uses). Housing <NUM> provides a plenum for product <NUM> flowing out of package <NUM> to be directed to diffuser <NUM> and out through the individual valves <NUM> and outlets <NUM>.

Dispensing assembly <NUM> also includes a connecting portion <NUM>, like connecting portion <NUM>, that functionally cooperates with, and is in engagement with container <NUM>. The housing interior can in some embodiments include a fastening device <NUM>, like device <NUM>, e.g. inner housing threads, for mating with the container screw threads <NUM> positioned around the external circumference of container neck <NUM> (see <FIG>).

In one embodiment, packaging system <NUM> comprises pusher plate <NUM>, configured to cooperate with piston <NUM> of a dispensing gun. The pusher plate is sized and shaped to be closely received within the container interior at second end <NUM> to help ensure that the package <NUM> is fully retained within the container <NUM> during dispensing. In some embodiments, pusher plate <NUM> can be configured to define a mating relationship with the interior surface <NUM> of container <NUM> when in contact. The pusher plate <NUM> is slidable within the interior of the container to ultimately allow product <NUM> to be dispensed from the package. When pressure is exerted on pusher plate <NUM> from a dispensing gun, the pusher plate reacts by slidably moving from container second end <NUM> towards container first end <NUM>. As a result, pouch <NUM> is compressed, thereby increasing pressure on frangible seal <NUM> to dispense product <NUM>.

In some embodiments, pusher plate <NUM> can be slightly undersized in relation to the inner diameter of container <NUM> allowing it (in conjunction with package <NUM>) to wipe product as it transverses the length of the container, pushing toward the outlet. The package binds to the pusher plate <NUM> as it is retracted, thereby permitting easy removal of the used pouch.

Alternatively, the pusher plate can be a component of a dispensing gun instead of, or in addition to, a component of packaging system <NUM>, as described herein.

Suitable materials for use in constructing pusher plate <NUM> include (but are not limited to) plastic, wood, metal, rubber, and the like. In some embodiments, pusher plate <NUM> is configured as part of a dispensing gun. Alternatively, in some embodiments, the pusher plate can be configured as part of packaging system <NUM>.

An alternative embodiment to the pusher plate <NUM> described above, is a segmented pusher plate <NUM> (see <FIG>) that includes in various embodiments an outer plate segment <NUM>, an inner plate segment <NUM>, a biasing member <NUM> such as a spring, an upper plug <NUM>, a lower plug <NUM>, and a retaining pin <NUM> (for simplicity, package <NUM> is not shown in <FIG>, but in practice is present inside container <NUM> as indicated elsewhere in the description and drawings. ) In one embodiment, segmented pusher plate <NUM> has a telescopic coaxial configuration, such that the outer and inner plate segments <NUM> and <NUM> are concentrically arranged, either within a single plane or within two planes. As shown in various embodiments in <FIG>, <FIG>, and <FIG>, pusher plate <NUM> has been advanced to the container first end <NUM>, with the inner plate segment <NUM> in a retracted position. Inner plate segment <NUM> is attached to piston rod <NUM>, and is retained in this retracted position by biasing member <NUM>, such as a mechanical or elastomeric spring.

In practice, at this stage of the dispensing cycle, the package <NUM> inside container <NUM> is nearly completely collapsed, and most of the contained product <NUM> has already been dispensed from the pouch <NUM>.

With further advancement of the pusher plate, by additional force put on piston rod <NUM>, outer plate segment <NUM> remains essentially stationary, but inner plate segment <NUM> advances further, overcoming the biasing action of biasing member <NUM> (e.g. by compressing a spring), to take an extended position, i.e. move further toward or up the container neck <NUM>. <FIG>, and <FIG> show in various embodiments the inner plate segment <NUM> in its extended position. This action results in removal of much of the remaining product <NUM> inside pouch <NUM>. Thus, segmented pusher plate <NUM> in use provides a method of reducing the product <NUM> left in package <NUM> at the completion of a dispensing cycle, this configuration leading to higher dispensing yield, i.e. the percentage of product <NUM> that is dispensed from pouch <NUM>.

In one embodiment (see <FIG>), the shoulder <NUM> of the first end <NUM> of container <NUM> is configured as a flat, circular planar surface (disregarding container neck <NUM>) that is positioned at right angles to the longitudinal axis of container <NUM>, i.e. at right angles to side wall <NUM> of container <NUM>. In certain technologies such as blow-molding and injection-molding, however, a certain "draft", i.e. an amount of taper for molded or cast parts perpendicular to the parting line is necessary. Thus, for example as shown in <FIG>, as well as <FIG>, at least a shallow draft, of e.g. about <NUM> degrees, is included for shoulder <NUM>. For an embodiment where some draft is required for container <NUM>, a discrete shim <NUM> (see e.g. <FIG>) can be separately made and then installed inside container <NUM>, juxtaposed against the interior surface of shoulder <NUM>, in a "donut" fashion, to accommodate the draft on the container by providing a first surface matching the taper of the first end, while providing a second surface with a flat configuration, i.e. a planar surface that is positioned at right angles to the longitudinal axis of container <NUM>. It can be seen that this arrangement will provide a geometry that maximizes the utility of either an unsegmented pusher plate <NUM> or a segmented pusher plate <NUM> by allowing the collapsing pouch <NUM> to operate against a flat surface.

In some embodiments, the segmented pusher p[ate <NUM> can be arranged so that, when inner plate segment <NUM> is in a retracted position, as shown in <FIG>, the downstream surface of inner plate segment <NUM> is not in substantially the same plane as the downstream surface of outer plate segment <NUM>. In other embodiments, the segmented pusher p[ate <NUM> can be arranged so that, when inner plate segment <NUM> is in a retracted position, as shown in <FIG>, the downstream surface of inner plate segment <NUM> is in substantially the same plane as the downstream surface of outer plate segment <NUM>.

Although the segmented pusher plate <NUM> is shown in one embodiment as having an outer plate segment <NUM>, an inner plate segment <NUM>, and a biasing member <NUM>, in yet another alternative embodiment, a segmented pusher plate can comprise more than two segments, for example a multisegmented pusher plate having an outer plate segment, an inner plate segment, and an intermediate plate segment, wherein the intermediate plate segment is disposed between the outer and inner plate segments, and the respective plate segments are concentrically arranged, either within a single plane or within multiple planes. In such an embodiment, a first biasing member can regulate the relative axial movement of the outer and intermediate plate segments, and a second biasing member can regulate the relative axial movement of the intermediate and inner plate segments, in a telescoping coaxial configuration.

Another alternative embodiment to the pusher plate <NUM> described above, is a composite pusher plate <NUM> (see <FIG>) that includes a rigid plate component <NUM>, and an elastomeric plate component <NUM> attached to the rigid plate component. Plate component <NUM> is in one embodiment made from a rigid material such as a metal or metal alloy, or a hard, rigid plastic. It will typically have substantially the same geometry, although not necessarily the same thickness, as pusher plate <NUM> shown e.g. in <FIG> and <FIG>. Plate component <NUM> is in one embodiment made from an elastomeric material that will under load exhibit a certain degree of flexibility, but return to its original position when the load is removed. Plate component <NUM> in one embodiment has a concave configuration on its downstream surface, i.e. on the surface of plate component <NUM> that faces the first end of container <NUM>. This concavity can be in the form of a curved surface, or as shown in <FIG>, in the form of a beveled surface having one or more planar portions, where the depth or thickness of the plate component <NUM> is greater along the outside circumference of the plate component than at its center. Thus, the change in thickness of the plate component, moving from the outside edge of the plate component <NUM> to the radial center of plate component <NUM> can be linear or non-linear. An advantage of the configuration of composite pusher plate <NUM> is to distribute the load forces on package <NUM> such that product <NUM> inside pouch <NUM> will tend to move toward the longitudinal center axis of the dispensing system, that is, towards the pouch spout, to expedite dispensing of product out of the pouch. Rigid plate component <NUM> and an elastomeric plate component <NUM> can be attached to each other by any suitable means, including a mechanical or chemical bond or seal, using for example an adhesive.

In another embodiment, a pusher plate system can be used similar to composite pusher plate <NUM> (see <FIG>) that includes a rigid plate component <NUM>, but in which the elastomeric plate component <NUM> does not have a concave profile, but instead has two major surfaces that are each substantially planar. In one embodiment, the elastomeric plate component <NUM> can have an annular or circumferential bead or protrusion along the outside cylindrical periphery of the component, the bead disposed on the downstream surface of plate component <NUM>, i.e. on the surface of plate component <NUM> that faces the first end of container <NUM>.

In both this and the other described alternative embodiments of a composite pusher plate, the rigid component <NUM> and the elastomeric component <NUM> can be attached at their mating surfaces by any suitable means, including a mechanical means such as an external coaxial screw or bolt that holds the rigid and elastomeric components together, or a chemical bond or seal, or using for example an adhesive.

Also, in both this and the other described alternative embodiments of a composite pusher plate, the rigid component <NUM> and the elastomeric component <NUM> can typically have substantially the same geometry, although not necessarily the same thickness, as pusher plate <NUM> shown e.g. in <FIG> and <FIG>. Alternatively, the elastomeric plate component can have a slightly larger OD (outside diameter) than the rigid plate component.

Yet another alternative embodiment to the pusher plate <NUM> described above, is a segmented composite pusher plate <NUM> (see <FIG>) that includes a rigid plate component comprising an outer rigid plate segment <NUM> and an inner rigid plate segment <NUM>; and an elastomeric plate component <NUM> attached to the rigid plate component. Plate segments <NUM> and <NUM> are in one embodiment made from a rigid material such as a metal or metal alloy, or a hard, rigid plastic. Elastomeric plate component <NUM> is in one embodiment made from an elastomeric material that will under load exhibit a certain degree of flexibility, but return to its original position when the load is removed, and in one embodiment has a concave configuration on its downstream surface, i.e. on the surface of plate component <NUM> that faces the first end of container <NUM>. This concavity can be in the form of a curved surface, or a beveled surface having one or more planar portions, where the depth or thickness of the plate component <NUM> is greater along the outside circumference of the plate component than at its center. In another embodiment, the elastomeric plate component <NUM> can be substantially planar on both major surfaces, and optionally can include a circumferential bead or protrusion as described above on its downstream surface.

Thus, the pusher plate <NUM> of <FIG> is in at least one respect like pusher plate <NUM> of <FIG>, in that the pusher plate has a segmented outer and inner portion. Pusher plate <NUM> of <FIG> is in at least one respect like pusher plate <NUM> of <FIG>, in that the pusher plate has a rigid and an elastomeric portion. One advantage of the embodiment of <FIG> is that no separate biasing member, such as a spring, is needed, since a load force put on piston rod <NUM> pushes inner rigid plate segment <NUM> up against the central portion of elastomeric plate component <NUM>, tending to move plate component <NUM> downstream, assisting in removal of much of the remaining product <NUM> inside pouch <NUM>. The concavity of elastomeric plate component <NUM> can provide the same beneficial effect in distributing the load forces on package <NUM>, as described above for the embodiment of <FIG>. Outer and inner rigid plate segments <NUM> and <NUM> and an elastomeric plate component <NUM> can be attached to each other by any suitable means, including a mechanical or chemical bond or seal, using for example an adhesive; or as shown in <FIG>, by an interlocking joint <NUM> including a groove in each of plate segments <NUM> and <NUM>, and a mating fastener in preselected portions of plate component <NUM>. Of course, the inverse could also accomplish the same attachment, i.e. a groove present in preselected portions of plate component <NUM>, and a mating fastener in each of plate segments <NUM> and <NUM>. In another alternative embodiment, plate segments <NUM> and <NUM>, and an elastomeric plate component <NUM> can be comolded.

The dispensing gun system <NUM> includes a dispensing gun <NUM>, a cylindrical container <NUM>, a cylindrical pusher plate <NUM>, and a package <NUM> disposed within the container.

Dispensing gun <NUM> can comprise any apparatus that comprises a component of the disclosed dispensing system <NUM>, and/or functions in cooperation with the disclosed packaging system <NUM>, to dispense a product; as disclosed for example in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. Dispensing gun <NUM> will typically comprise a mechanical device that can accommodate a packaging system as described herein, and can effect movement of a flowable product, contained in a flexible package, out of the package, through a dispensing valve, and onto an area. As shown in <FIG>, the dispensing gun in one embodiment includes a trigger <NUM> to activate the dispensing system <NUM>; a piston <NUM> to drive pusher plate <NUM> through the container <NUM> and thus push the flexible package <NUM> toward the first end <NUM> of the container; a barrel <NUM> to house packaging system <NUM>; and a wall <NUM> against which the container <NUM> of packaging system <NUM> can abut.

The cylindrical pusher plate <NUM>, is configured, when advanced by the piston into the container, to fit within the container in close proximity to the interior surface of the container. In one embodiment, the space between the annular outside edge of the pusher plate and the interior surface of the container, as the pusher plate passes through the interior of the container, is less than three times the thickness of the film thickness of the package; such as less than two times the film thickness of the package.

As a first step, package <NUM>, including a sealed pouch <NUM> containing product <NUM>, can be inserted into the interior of container <NUM> through second end <NUM> such that the pouch spout <NUM> is positioned in container neck <NUM>, as illustrated in <FIG>. Valve housing <NUM> is then seated flush atop the container mouth <NUM>. In some embodiments, valve housing <NUM> includes interior screw threads <NUM> that align with threads <NUM> on the neck of container <NUM> to allow coupling of the valve housing and the container, as depicted in <FIG> and <FIG>. Diffuser <NUM> can then be releasably or permanently attached to the distal end of the valve housing (the end furthest from the container <NUM>) by aligning the diffuser internal threads <NUM> with the valve housing external threads <NUM>, as shown in <FIG>. Alternatively, diffuser <NUM> can be snap fit in a releasable or permanent arrangement onto valve housing <NUM>. Pusher plate <NUM> (if present as part of the packaging assembly) can then be inserted within the interior of container <NUM> at second end <NUM>, as shown in <FIG>. Alternatively or additionally, the pusher plate can be a component of a dispensing gun as described herein.

It should be appreciated that the methods used to assemble packaging system <NUM> disclosed above are not limited and can performed in any suitable order. In some embodiments, the packaging system can be partially or fully pre-assembled such that a user need not perform all of the steps described herein.

After assembly, packaging system <NUM> can be inserted into a dispensing gun <NUM>, as shown in <FIG>. In some embodiments, dispensing gun <NUM> can be of the type that dispenses a portion of the contents of pouch <NUM> upon each actuation. To this end, dispensing gun <NUM> can include trigger <NUM> that forms part of an actuating structure. Specifically, trigger <NUM> can be coupled to piston <NUM> that is movable within the interior of container <NUM> via contact with pusher plate <NUM>. The actuating structure functions such that upon each movement of trigger <NUM>, the piston <NUM> moves towards first end <NUM> of the container <NUM>, and a bias spring returns the trigger to its original position. In some embodiments, dispensing gun <NUM> includes wall <NUM> that is configured to abut against the front end of system <NUM> (i.e. the first end <NUM> of container <NUM>) so that pressure applied by the trigger <NUM> is effective to dispense product <NUM>. Packaging system <NUM> can be used with any of a variety of dispensing guns known in the art. See, for example, <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

To dispense product <NUM> disposed within pouch <NUM>, a user can initiate trigger <NUM> on the dispensing gun <NUM>. When trigger <NUM> is pulled, piston <NUM> advances pusher plate <NUM> within the interior of container <NUM> toward first end <NUM>. Such movement reduces the volume of pouch <NUM>, thereby collapsing the pouch and increasing the pouch internal pressure. As a result, frangible seal <NUM> ruptures, allowing product <NUM> to exit the pouch through spout <NUM> and passageway <NUM> of valve <NUM> of valve housing <NUM>. Product then passes through diffuser <NUM> and out of system <NUM> through outlets <NUM>. In this way, product can be dispensed in a desired pattern associated with the outlets in the diffuser. For example, a diffuser with three exit outlets <NUM> will allow dispensing of three areas of product. Once the trigger has been pulled, a metered dose of product is dispensed and the diffuser and valve housing prevent any substantial leakage of product.

Piston <NUM> will continue to move towards the second end <NUM> of container <NUM> with continued application of pressure (i.e., each pull of trigger <NUM>), thereby dispensing product <NUM>. When pusher plate <NUM> has reached an abutting position with container shoulders <NUM>, the mating relationship ensures that a maximum amount of product housed within pouch <NUM> has been dispensed. System <NUM> can then be removed from dispensing gun <NUM> and replaced with a new system. As set forth above, in some embodiments, container <NUM>, valve housing <NUM>, diffuser <NUM>, and/or pusher plate <NUM> can be used repeatedly such that only pouch <NUM> is replaced.

In some embodiments, the invention lowers costs associated with materials and assembly and with sufficient ruggedness to survive filling, closing, packing and shipping.

System <NUM> and/or pouch <NUM> can also be economically disposed of after a single use, or after the pouch contents have been dispensed.

The pouch is flexible, reducing storage space needed to house the pouch prior to use. Similarly, the space needed to ship the pouch is less than other alternatives. Further, the flexible pouch requires less space (in trash and in landfills) at the time of disposal.

In addition, pouch <NUM> is constructed to be substantially free of voids and to have suitable mechanical integrity and flexibility. As a result, the pouch can withstand high pressure treatment, such as can be used to reduce unwanted microorganisms in the packaged product.

Claim 1:
A package (<NUM>) including a pouch (<NUM>) comprising:
a) a first and second panel (<NUM>, <NUM>);
b) a frangible seal (<NUM>) positioned between the panels (<NUM>, <NUM>); and
c) a flowable product disposed in the pouch (<NUM>); and
wherein the frangible seal (<NUM>) comprises:
d) a single label (<NUM>) with a first face (<NUM>) and a second face (<NUM>), the first face (<NUM>) comprising a permanent sealant (<NUM>) positioned on said first face (<NUM>) and the second face (<NUM>) comprising a peelable sealant (<NUM>) positioned on said second face (<NUM>)