Patent ID: 12195257

DETAILED DESCRIPTION

A pouch configured to contain hydrogen-infused water is provided. The pouch includes a frangible seal formed from ultrasonic welding. The frangible seal is disposed between the contents of the pouch and the fitment. As such, the frangible seal is added after the contents of the pouch have been added. The frangible seal is positioned just above the added fluid of the container so as to minimize the amount of oxygen that can enter the pouch and contact the hydrogen water and also to prevent the water from coming into contact with the fitment and cap where the hydrogen can escape due to the fitment and cap having no barrier properties.

The frangible seal is formed through the use of a horn and anvil, where the pouch is placed on the anvil and the horn is pressed by an ultrasonic welding machine into the pouch. The size and the thickness of the frangible seal is adjustable. The frangible seal is formed by tilting the pouch at an angle such that an upper portion of the pouch is higher than a lower portion with respect to the anvil, applying a pressure to pouch and ultrasonic welding the frangible seal into the pouch. The frangible seal seals off an opening to the pouch so to prevent oxygen trapped in the opening during the manufacturing and/or filling process from contacting the hydrogen-infused water. The frangible seal is configured to burst under a pressure provided by a user, thereby allowing the user to access the hydrogen-infused water.

As used herein, “frangible seal” means a seal formed between layers of a pouch that is intended to rupture, at a given pressure, by merely applying a pressure via a human hand onto the seal. That is, a peel strength of the frangible seal is significantly less than that of the peripheral seal. As such, a bond of a frangible seal may not be solid between the different layers of the pouch to provide for a weakness to rupture. In some embodiments described herein, the peel strength of the frangible seal is between 0.945 and 1.155 pounds per square inch of force to rupture the seal. This is at least 9-12 times less pressure required than the pressure required to rupture the peripheral seal, as discussed herein.

As used herein, “peripheral seal” means a permanent bond between layers of the pouch that is not intended to rupture. A peripheral seal is a fixed barrier and has a peel strength significantly greater than that of the frangible seal. As such the bond of the peripheral seal is solid between the different layers to form a barrier, or permanent seal between the layers. That is, the peel strength of the peripheral seal is limited only by the burst properties of the materials used to form the peripheral seal. In some embodiments described herein, the peel strength of the peripheral seal is in a range between 9.18 and 11.22 pounds per square inch of force to rupture the peripheral seal. This is at least 9-12 times greater pressure required than the pressure required to rupture the frangible seal, as discussed herein.

Now referring toFIGS.1-4, a flexible pouch10is schematically depicted. It should be appreciated that in some embodiments, the flexible pouch10may be a stand-up flexible pouch, as depicted inFIGS.1-4. In other embodiments, the flexible pouch10may be any type of pouch that is adapted to contain a fluid. As such, the pouch illustrated inFIGS.1-4is non-limiting. The flexible pouch10includes a front panel12and a rear panel14. The front panel12and the rear panel14are sealed to one another via various peripheral seals16,18,20, to form a compartment22. That is, the various peripheral seals16,18,20, seal around the each peripheral edge of the flexible pouch10such that the various peripheral seals16,18,20permanently bonds the front panel12and the rear panel14to one another to form the compartment22.

In some embodiments, the various peripheral seals16,18,20may be a single permanent peripheral seal. Further, in some embodiments, each of the various peripheral seals16,18,20may be formed by heat sealing. In other embodiments, the various peripheral seals16,18,20are formed by other methods appreciated by those skilled in the art. The compartment22may be adapted to contain, or hold, a gas, solid and/or liquid. For example, the compartment22may be adapted to contain, or hold a fluid, such as hydrogenated water.

A fitment24with a body25is provided along an upper edge28of the flexible pouch10. In some embodiments, the fitment24may be centered along the upper edge28. In other embodiments, the fitment24may be positioned anywhere along the upper edge28of the flexible pouch10. The fitment24includes a center portion30, or passage. The center portion30includes an opening32aat one end and a spout27at the other end. The opening32ais positioned within the flexible pouch10while the spout27is at the opposite end of the body25and out of the flexible pouch10at the spout27. The spout includes an opening32b. The center portion30extends within a gap of the peripheral seal20along the upper edge28. As such, the gap may form a canoe shape that bows outwardly a portion of the front and rear panels12,14created by the fitment24positioned between the front and rear panels12,14through the gap.

The fitment24, the front and rear panels12,14are sealed together via a top seal23. The top seal23seals the front and rear panels12,14together and the fitment24therebetween thereby eliminating the gap. In some embodiments, the top seal23is formed via ultrasonic welding techniques. In other embodiments, the top seal23is formed via traditional heat bonding methods.

The opening32aand the spout27are covered by a cap26when the cap26is secured onto the body25of the fitment24. The cap26is removable to provide access to the spout27and the opening32a, which in turn provides access to the contents of the compartment22. In some embodiments, the cap26may be provided with a childproof or tamperproof feature to prevent ready access to or tampering of the product.

The opening32bis positioned within the compartment22below the top seal23such that the opening32band a portion of the center portion30are in communication with the fluid held within the compartment22. The center portion30of the fitment24extends through the top seal23and is adapted as an entry and/or exit for the gas, solid and/or liquid held in the compartment22of the flexible pouch10.

The fitment24further includes a pair of wings34extending outwardly from an outer surface36of the center portion30. A proximate end38aof the pair of wings34extends from below the upper edge28and the wings extend downwardly towards the compartment22. In some embodiments, a distal end38bof pair of wings34terminates before the opening32band the compartment22. In other embodiments, the distal end38bof pair of wings34terminates at the opening32band the compartment22.

In embodiments, a bottom gusset46may positioned between a bottom edge portion48aof the front panel12and a bottom edge portion48bof the rear panel14such that a stable base for the flexible pouch10is provided. That is, the bottom gusset46may be attached to the bottom edge portions48a,48bwith a bottom portion50sealed to the bottom edge portions48a,48bsuch that the flexible pouch10can stand or remain upright as depicted inFIGS.1-4.

Further, a pair of side gussets52may be formed and positioned between the bottom gusset48and the top seal23. Each of the pair of side gussets52may be positioned between an upper edge portion54aand the bottom edge portion48aof the front panel12and an upper edge portion54band the bottom edge portion48bof the rear panel14. That is, a side panel56of each of the pair of side gussets52may be attached to the upper edge portion54aand the bottom edge portion48aof the front panel12and the upper edge portion54band the bottom edge portion48bof the rear panel14, as best shown inFIG.4.

A frangible seal40is positioned between the compartment22and the top seal23. As such, in some embodiments, a portion of the frangible seal40abuts the top seal23and a portion of the frangible seal40extends into the compartment22. In other embodiments, a portion of the frangible seal40extends into the top seal23. The frangible seal40joins the front and rear panels12,14and is adapted, in an unbroken state, to prevent hydrogen from the liquid held within the compartment22to escape through the center portion30and ultimately through the cap26. When the user wants to drink the fluid held within the compartment22, the frangible seal40is broken, or ruptured, by squeezing or applying a predetermined pressure onto the flexible pouch10to break or rupture the frangible seal40.

In some embodiments, the frangible seal40is a V-shape. In this embodiment, each of a pair of terminating ends42of the V-shape are positioned to abut the top seal23and an inverse apex44of the V-shape is positioned within the compartment22. In other embodiments, the frangible seal40may be square shaped, semicircular shaped, rectangular shape, and the like. In these embodiments, the terminating ends of the different shapes are positioned within or to abut the top seal23and portions of the shape are positioned within the compartment22.

It should be appreciated that the terminating ends42of the frangible seal40are spaced apart and extend into or abut with the top seal23. Further, the frangible seal40may be formed around and under each one of the pair of wings to encapsulate the opening32band to separate the compartment22from the spout27. That is, the frangible seal40and the top seal23surround, or form a complete seal with one terminating end42under one of the pair of wings34and the other terminating end42positioned in a portion of the top seal23under the other one of the pair of wings34to separate the spout27from the contents in the compartment22. The angle of the V-shape may be obtuse, acute, or a reflex angle. It should be appreciated that the shape of the frangible seal40may assist in localizing the stress of the flexible pouch10when squeezed, such that the different shapes of the frangible seal40require less pressure to burst, or rupture, the frangible seal40.

It should be understood that in some embodiments, the fitment24is not required and that the frangible seal40may extend to cover the gap as discussed above. That is, the frangible seal40may extend between a peripheral seal, two peripheral seals, and the like, such that the frangible seal40may be a breakable seal between the compartment and the gap of the peripheral seal(s).

The front and rear panels12,14are formed from a film laminate including a layer of aluminum or silicon oxide. The film laminate, in some embodiments, may be PET/AL/NY/LLDPE; PETALOx/NY/LLDPE; or PETSiOx/NY/LLDPE. Further, varying thickness of the film may be used. For example, a PET film layer may have a thickness of 12 microns, a center aluminum layer having a thickness of 9 microns and an inner layer of S-LLDPE that has a thickness of 150 microns may be used. Such an arrangement provides an airtight seal to preserve the longevity of the fluid within the compartment22. Further, the outer layer of PET may be satisfactory for printing labeling information and warning information, the middle aluminum layer may provide an airtight seal for the flexible pouch10, and the inner layer of S-LLDPE may melt to form an adhesive for bonding the front and rear panels12,14of the flexible pouch together around the peripheral seals16,18,20, to seal the fitment24or closures in place, and for forming of the frangible seal40using ultrasonic welding techniques, as discussed in greater detail herein. Further, it should be understood that film laminates provide or inherently include barrier properties to prevent hydrogen from escaping through the pouch.

The film laminate may be formed into a pouch having three sides on a conventional pouch making machine. The fitment may be heat sealed or ultra-sonically welded along the upper edge28of the flexible pouch10to form the top seal23. The flexible pouch10is then filled with the fluid into the compartment22and the cap26is secured onto the fitment to seal the center portion30and the spout27.

Now referring toFIG.5, the frangible seal40is formed via ultrasonic welding. It should be understood that ultrasonic welding is effective through liquids, such as water, unlike traditional heat seal methods. An additional benefit of ultrasonic welding is that it can weld any potential pouch material, such as PET/AL/NY/LLDPE; PETALOx/NY/LLDPE; PETSiOx/NY/LLDPE, and the like. These laminates beneficially have barrier properties preventing hydrogen from escaping through the pouch.

The ultrasonic welder system100includes an ultrasonic welding machine101, which further includes a horn102that moves relative to the ultrasonic welding machine101, a base104, an anvil108, a guide110, and a finger member112. The ultrasonic welding machine101may be any ultrasonic welding system machine. Further, the time of welding, the amplitude control, the frequency, hold time, and the like are all customizable based on the type of pouch, pouch material, contents, frangible seal shape, and the like.

The horn102includes a distal end116that is moved between an engaged positon and a disengaged positon with respect to the flexible pouch10. The distal end116of the horn102includes a shape118to form the shape of the frangible seal40, as discussed in greater detail herein. In the engaged position, the shape118of the distal end116of the horn102is in contact with the desired portion of the flexible pouch10to add the frangible seal40, as best shown inFIG.5. In this position, the horn102ultrasonically welds in the frangible seal40, as discussed in greater detail herein. In the disengaged positon, the shape118of the distal end116of the horn102is not in contact with the flexible pouch10.

The base104includes an upper surface106and may be positioned to be a separate component from the ultrasonic welding machine101. The upper surface106may be angled with respect to horizontal, indicated by the arrow A1inFIG.5. The anvil108is mounted to the upper surface106. In some embodiments, the angle of the upper surface106and the anvil108is 45 degrees. In other embodiments, the angle of the upper surface106and the anvil108is less than or greater than 45 degrees. The angle of the upper surface106relative to the base104is to position the flexible pouch10at an angle to permit oxygen and other containments that may have entered the compartment22during the manufacturing and/or filling process to escape, as discussed in greater detail herein.

In some embodiments, the anvil108includes a complementary shape114. The complementary shape114is complementary to the shape118positioned on the distal end116of the horn102. As such, the complementary shape114may extend outwardly from the anvil108. The size and shape of both the shape118of the horn102and the complementary shape114, and the operating parameters of the ultrasonic welding machine101may vary the size and thickness of the frangible seal40, as discussed in greater detail herein. Further, it should be understood that each of the shapes of the frangible seal40may have a corresponding shaped anvil and horn. That is, a plurality of shapes are envisioned for the frangible seal and thus each of these shapes may have a corresponding shaped anvil and horn to form the shape.

Further the upper surface106and/or the anvil108includes the guide110for positioning or holding the flexible pouch10onto the upper surface106of the base104. The guide110may be adapted to positively locate the flexible pouch10against the upper surface106and ultimately properly position the pouch against the complementary shape of the anvil108.

For example, a portion of the fitment24may be received within the guide110to hold the flexible pouch10in place. As such, it should be understood that the guide110assists in repeatability and in quality of the frangible seal40formation. In some embodiments, a finger member112is positioned to move between a contact and non-contact position (to and away) with respect to the flexible pouch10such that in the contact position, as best shown inFIG.5, the finger member112is in contact with a lower portion of the flexible pouch10(e.g., towards the bottom seal50) to apply a pressure to the lower portion of the flexible pouch10and the contents within the compartment22. In the non-contact position, the finger member112is not in contact with the flexible pouch10. In other embodiments, the finger member112may not be automated and may be a user's hand or finger that applies a pressure on the lower portion of the flexible pouch10.

Still referring toFIG.5, the frangible seal40is formed through the use of a vibration applied to the flexible pouch10through the horn102and the anvil108when the flexible pouch10is positioned at an angle on the anvil108. The ultrasonic welding machine101operates on a plurality of frequencies. In some embodiments, the frequency is between 20 kHz and 40 kHz. In other embodiments, the frequency is less than 20 kHz and/or greater than 40 kHz. Further, a plurality of parameters may be used to form the frangible seal40. For example, a weld time, a hold time, a delay time and an amplitude setting for different frequencies.

Now referring toFIG.6, a flowchart of an illustrative method600for forming the frangible seal on the flexible pouch is illustrated. Although the steps associated with the blocks ofFIG.6will be described as being separate tasks, in other embodiments, the blocks may be combined or omitted. Further, in other embodiments, the steps may be performed in a different order. The filled flexible pouch is not limiting and the method600described herein may be used in any container that uses flexible panels, overlaying two portions. It is particularly advantageous for a container that already contains a fluid because the method600for forming the frangible seal may be formed through the fluid or liquid within the container.

At block605, an anvil is mounted at an angle. In some embodiments, the angle may 45 degrees. In other embodiments, the angle may be between 20 degrees and 45 degrees. In yet other embodiments, the angle may be greater than 45 degrees. At block610, a filled flexible pouch is placed onto the anvil. The fitment and/or portions of the fitment may be located with the guide to positively locate the flexible pouch with respect to the anvil. Further, the fitment is positioned above the bottom edge in a vertical direction. In some embodiments, the rear panel of the pouch is positioned to be in contact with the anvil while the front panel is positioned to be in contact with the horn. In other embodiments, the front panel of the pouch is positioned to be in contact with the anvil while the rear panel is positioned to be in contact with the horn

At block615, a lower portion of the pouch is pressed on. This may be via the finger member or via a user's hand. That is, the finger member is moved from the non-contact position into the contact position. It should be appreciated that the pressure applied to the lower portion of the pouch may be anywhere below the area where the frangible seal is going to be placed in the vertical direction. It should be understood that the tilting of the pouch and applying a pressure to the pouch moves or drives liquid to the top of the pouch, at the fitment, such that any residual gas within the pouch, such as oxygen, is driven into the fitment, out of the compartment, and remains trapped there once the frangible seal is formed.

At block620, the horn is pressed onto the pouch on a side opposite of the anvil. That is, the horn is moved from the disengaged position into the engaged position. It should be appreciated that the time that the horn is in contact with the pouch may vary, the time between pulses, and the like, may all be varied. In some embodiments, at block625, a gas, such as nitrogen, is injected into the pouch. This step reduces the amount of oxygen that is sealed within the pouch, which prevents the infused hydrogen from combining with oxygen. At block630, a seal is formed ultrasonically using a frequency at the horn for a predetermined period of time. It should be appreciated that a frequency, a weld time, a hold time, and an amplitude may all influence the forming of the frangible seal.

It should be appreciated that ultrasonic welding creates a preferred seal compared to heat sealing as heat sealing over a liquid requires additional heat to counteract cooling caused by the liquid. As such, using ultrasonic welding eliminates this issue. Further, it should be appreciated that this disclosed methods prevents the hydrogen infused in the water from mixing with oxygen in the pouch, thereby increasing the shelf life of the hydrogen-infused water by maintaining a high concentration of hydrogen.

In operation, when the pouch is ready for use by the consumer, the frangible seal is ruptured by the consumer by applying a pressure directly to the frangible seal to promote rupturing of the seal or the contents are squeezed against the seal to rupture the frangible seal. The fitment is then opened and the contents are ready to be consumed by the consumer. The inner frangible seal prevents the hydrogenated water from reaching the fitment and cap where the hydrogen in the water can escape through the fitment and cap that both have very little barrier properties. The inner frangible seal also prevents oxygen from reaching the contents and thereby diffusing the contents.

Example Section

TABLE 1AmplitudeWeld TimeHold TimeDelay TimeSettingResult0.10-0.06 s0.80-0.30 s0.20-0.50 s35%-44%Formation ofsatisfactoryfrangible sealLess than 0.06 s0.80-0.30 s0.20-0.50 s35%-44%frangible seal tooweak to hold hydrogenMore than 0.100.80-0.30 s0.20-0.50 s35%-44%frangible seal toostrong to rupture0.10-0.06 sLess than 0.30 s0.20-0.50 s35%-44%frangible seal tooweak to hold hydrogen0.10-0.06 sMore than 0.80 s0.20-0.50 s35%-44%frangible seal toostrong to rupture0.10-0.06 s0.80-0.30 s0.20-0.50 sLess than 35%frangible seal tooweak to hold hydrogen0.10-0.06 s0.80-0.30 s0.20-0.50 sMore than 44%frangible seal toostrong to rupture

Table 1 above illustrates the testing parameters that were used with a 20 kHz frequency ultrasonic welding machine and anvil as described above with respect toFIG.5. The weld time is the amount of time that the ultrasonic welding machine is welding. The hold time is the duration for which pressure is maintained to ensure proper bonding of the parts. The hold time deactivates ultrasonic. The delay time deactivates the solenoid valve drive circuits and waits for the after burst time to expire. The amplitude percentage is a measure of how far a component's face moves during ultrasonic vibration.

As illustrated in Table 1, in one example, at a 20 kHz frequency, the formation of the frangible seal40with a desired pressure range for rupturing the frangible seal40while also providing a strength to prevent the hydrogen within the compartment22from escaping is a weld time between 0.10-0.06 seconds, a hold time between time 0.80-0.30 seconds, a delay time between 0.20-0.50 seconds and an amplitude setting between 35%-44%. At these parameters, an example frangible seal may be formed that requires an approximately range between 0.945 and 1.155 pounds per square inch of force to rupture the frangible seal. This range also allows the frangible seal to retain the hydrogen within the fluid of the flexible pouch. It should be appreciated that this is non-limiting and that different values may be used at different frequencies to achieve the desired results with respect to the frangible seal40.

As illustrated in table 1, when the weld time is less than 0.06 seconds, the frangible seal is not strong enough to retain the hydrogen within the compartment of the flexible pouch and/or the frangible seal ruptures too easily, such as during transportation. On the other hand, when the weld time is greater than 0.10 seconds, the frangible seal is too strong to rupture and may have similar characteristics to the peripheral seals. Likewise, when the hold time is less than 0.30 seconds, the frangible seal is not strong enough to retain the hydrogen within the compartment of the flexible pouch and/or the frangible seal ruptures too easily, such as during transportation. On the other hand, when the hold time is greater than 0.80 seconds, the frangible seal is too strong to rupture and may have similar characteristics to the peripheral seals. Similarly, when the amplitude percentage is less than 35%, the frangible seal is not strong enough to retain the hydrogen within the compartment of the flexible pouch and/or the frangible seal ruptures too easily, such as during transportation. On the other hand, when the amplitude percentage is greater than 44%, the frangible seal is too strong to rupture and may have similar characteristics to the peripheral seals.

While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.