Patent Document

CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Application Ser. No. 62/238,494, filed Oct. 7, 2015, entitled “System for Forming Packages From Film Material,” and U.S. application for patent Ser. No. 15/004,409, filed Jan. 22, 2016 entitled System for Forming Packages from Film Material, the contents of which are hereby incorporated by reference herein as if fully set forth. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates generally to a package forming system and, more particularly, to a system utilizing a rotary drum to thermoform pouches from a continuous web and a method of forming and filling the pouches. 
       BACKGROUND 
       [0003]    Machines or systems are known for forming pouches or packages from two continuous webs in which a first or base stock film is thermoformed to define a pocket that may be filled to some extent with one or more products or materials and subsequently closed by a second or lid stock film. 
         [0004]    To form the pouches, the base stock film is fed from a supply roll and heated to a temperature sufficient to allow thermoforming. The heated film is continuously wrapped or routed around a base forming drum or roller having a plurality of cavities along an outer surface thereof and a vacuum is applied within each cavity to pull a portion of the heated film into each cavity to form a plurality of base stock pockets as the film is fed and the drum rotated. After the base stock pockets are formed and as the base stock film is continuing to be fed and the drum rotated, each of the base stock pockets may be filled with one or more desired products or materials while the pocket is still positioned within its cavity on the drum. 
         [0005]    As the base stock film is being fed from its supply roll, the lid stock film is fed from a supply roll towards the base forming drum and into contact with the base stock film to seal each base stock pocket after the pocket has been filled to a desired level. To do so, any combination of heat, pressure, and/or a solvent may be applied to either or both of the base stock film and the lid stock film before or as the two films are brought together to continuously seal each pocket and form each sealed pouch or package. The combined base stock and lid stock films are subsequently cut to separate the individual pouches. An example of a machine and a process for forming the pouches is described further in U.S. Pat. No. 3,218,776, which is incorporated herein by reference. 
         [0006]    When forming pouches or packages that contain multiple materials that are to be separated (e.g., a powder and a liquid), the systems used to form the pouches may utilize three or more continuous webs. In one known system for forming pouches from three continuous webs, the base stock film is drawn from a supply roll and wrapped around or engages a heated roller and then around a base forming drum and drawn into cavities to form the pockets as described above. As the base stock film and base forming drum continue to be rotated, one or more desired first products or materials may be dispensed into the pockets formed within the cavities of the base forming drum. 
         [0007]    As the pockets in the base stock film are being formed and filled, lid base stock film is drawn from a supply roll and wrapped around or engages a heated roller where the film is heated to a temperature sufficient to allow thermoforming. The heated lid base stock film is wrapped or routed around a lid forming drum or roller having a plurality of cavities along an outer surface thereof and a vacuum is applied within each cavity to pull a portion of the heated film into each cavity to define the pockets as the film is fed and the drum rotated. As the lid base stock film and lid forming drum continue to be rotated, one or more desired second products or materials may be dispensed into the pockets formed within the cavities of the lid forming drum. 
         [0008]    As the pockets in the lid base stock film are being formed and filled, lid closing stock film is fed from a supply roll towards the lid base stock film to seal each pocket of the lid base stock after the pocket has been filled to a desired level. To do so, any combination of heat, pressure, and/or a solvent may be applied to either or both of the lid base stock film and the lid closing stock film before or as the two films are brought together to continuously seal each pocket and form a sealed lid sub-package or structure having products or materials sealed between the layers of film that form the lid sub-package. 
         [0009]    The sealed lid sub-package is then routed towards the base stock forming drum and the base stock film. As described above, any combination of heat, pressure, and/or a solvent may be applied to either or both of the base stock film and the sealed lid sub-package before or as the two structures are brought together to continuously seal each base stock pocket with the lid sub-package and form a sealed pouch having multiple products or materials sealed therein. The combined base stock and lid sub-packages are then cut to separate the individual pouches. 
         [0010]    In another known system, pouches may be formed from four continuous webs. In doing so, the system is similar to that described above that uses three continuous webs but includes an additional continuous web that is applied to seal the base stock pockets before securing together the base sub-packages and the lid sub-packages. More specifically, base stock pockets are formed and filled as described above. An additional sealing film is secured to the base stock film using a combination of heat, pressure and/or solvent to seal the base stock pockets and form base sub-packages. After the lid sub-packages are formed as described above, the base sub-packages and the lid sub-packages are secured together to form the sealed pouches having different products or materials sealed therein. In one embodiment, the base sub-packages and the lid sub-packages may be secured together using a combination of heat, pressure and/or solvent. In another embodiment, the base sub-packages and the lid sub-packages may be secured together using an adhesive. After securing together the base sub-packages and the lid sub-packages, the webs forming the pouches may be cut to separate the individual pouches. 
       SUMMARY 
       [0011]    An apparatus for forming sealed pouches comprising: a rotatable base forming drum having an outer surface with a plurality of base tooling cavities in the outer surface; a base stock supply mechanism for feeding a base stock film of material along a base stock path, a portion of the base stock path extending along the outer surface of the base forming drum; a system for displacing the base stock film into the base tooling cavities to form a pocket of base stock film material within each base tooling cavity; a material feed mechanism for feeding at least one material into each pocket of the base stock film; a rotatable lid forming drum having an outer surface with a plurality of lid tooling cavities in the outer surface; a lid stock supply mechanism for feeding a lid stock film of material along a lid stock path, a portion of the lid stock path extending along the outer surface of the lid forming drum; a system for displacing the lid stock film into the lid tooling cavities to form a lid recess of lid stock web material within each lid tooling cavity; a material feed mechanism for feeding a material into each lid recess of the lid stock film; and mechanism bringing the base stock film and lid stock film into contact under pressure. In one form, the material fed into the lid recesses is a hardenable material and cooling is used to cool the lid recesses. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a schematic illustration of a pouch forming apparatus in which the principles disclosed herein may be used; 
           [0013]      FIG. 2  is an enlarged, fragmented view of a portion of the lid forming drum of  FIG. 1  and systems associated therewith; 
           [0014]      FIG. 3  is an enlarged, fragmented view similar to  FIG. 2  but illustrating a second embodiment of a cooling system associated with the lid forming drum; 
           [0015]      FIG. 4  is perspective view of a pouch that may be formed with the apparatus of  FIG. 1 ; 
           [0016]      FIG. 5  is an end view of the pouch of  FIG. 4 ; 
           [0017]      FIG. 6  is a schematic illustration of an alternate embodiment of systems associated with the lid forming drum of  FIG. 1 ; and 
           [0018]      FIG. 7  is an enlarged, fragmented view of a second embodiment of the lid forming drum of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0019]      FIGS. 4-5  depict a pouch or package  100  formed from two continuous webs of material. The pouch  100  includes a base  90  including pocket  101  formed from a base stock film or web of material  70 . As depicted, the pocket  101  includes four sidewalls  102  that extend downward from flange  103  and are interconnected by lower surface  104 . The pouch  100  is sealed by a cover or lid  110  formed from a lid stock film or web of material  75 . As depicted, the lid includes a pair of relatively small recesses  111  that extend upward from a flange  112  of the lid. It should be noted, however, that the lid  110  may have one or more recesses  111  and the recesses may be of identical or different sizes and shapes and are oriented to overlie the pocket  101  with flanges  103  and  112  sealed together to form pouch  100 . 
         [0020]    In some instances, such as when the pouches  100  are utilized for cleaning products, the film may be formed of a soluble material such as a water soluble film. In one example, the film may be formed of a polyvinyl alcohol material. Other materials are contemplated. Pocket  101  and recesses  111  may be filled with any desired products and/or materials. As depicted in  FIGS. 4-5 , pocket  101  may be filled with a powder material  105  such as a detergent and the recesses  111  may be filled with a paste or a wax-like hardenable material  113  such as another detergent, a liquid, or any other suitable material. 
         [0021]      FIG. 1  is a schematic representation of a pouch forming apparatus or system  10  for forming a plurality of the pouches  100  depicted in  FIGS. 4-5 . Pouch forming apparatus  10  is generally similar to that disclosed in aforementioned U.S. Pat. No. 3,218,776. In this regard, it includes a first section  20  for forming and filling the base stock film  70  and a second section  40  for forming and filling the lid stock film  75 . The first section  20  includes a rotatable base forming drum  21 , a heater system  25 , a supply roll  30  of material that is the base stock film  70 , and a product feed mechanism  31 . 
         [0022]    The base forming drum  21  includes a plurality of base tooling cavities  22  extending inwardly along the outer surface  23  of the drum. To increase the efficiency of the system  10 , the base forming drum  21  may include a three-dimensional array of cavities  22  around the outer surface  23  so each manufacturing step operates relative to a plurality of horizontally aligned (into the page in  FIG. 1 ) cavities  22 . 
         [0023]    A vacuum system indicated generally at  35 , including conduits  36 , seen in  FIG. 1 , are operatively connected to each cavity  22  to create a vacuum to draw a portion of the base stock film  70  into the cavity to form one of the pockets  101 . Such a vacuum system is well known in the art as seen, for example, in U.S. Pat. No. 3,218,776. A drive system (not shown) is operatively connected to the base forming drum  21  to rotate the drum continuously or intermittently, as desired in direction “A.” 
         [0024]    The heater system  25  is depicted as a rotatable base stock heater roller  26  positioned adjacent the base forming drum  21  and includes an internal heater to heat the base stock film  70  prior to it contacting the base forming drum and being drawn into cavity  22  to form the pocket  101 . In one embodiment, the heater system  25  may be configured as a cartridge-type heater within the base stock heater roller  26  but other types of heaters, either internal or external to a roller, may be used if desired. For example, in another embodiment, a radiant-type heater external to a roller may be used. 
         [0025]    A product feed mechanism  31  is positioned generally adjacent the upper section  24  of the base forming drum  21  to supply one or more products and/or materials into each pocket  101  as the pocket together with base stock film  70  move along with the upper surface of the rotatable drum  21 . The product feed mechanism  31  may be fixed and the base forming drum  21  may be either intermittently stopped or rotated slowly as the material is fed into pockets  101 . In other instances, the product feed mechanism  31  may include a drive mechanism (not shown) to permit the product feed mechanism to move with the pockets  101  as the pockets move during rotation of the base forming drum  21 . The product feed mechanism  31  may be configured to feed any type, number or combination of products and/or materials including a solid, a powder, a liquid including paste or wax-type products, pills, tablets, or even other pouched products. 
         [0026]    The second section  40  includes a rotatable lid forming drum  41 , a heater system  45 , a supply roll of continuous web material that forms the lid stock film  75 , a lid stock product feed mechanism  51 , and a lid stock wetting system  60 . The lid forming drum  41  includes a plurality of lid tooling cavities  42  extending inwardly along the outer surface  43  of the lid forming drum. As with the cavities  22  of base forming drum  21 , the cavities  42  of lid forming drum  41  may be configured as a three-dimensional array upon the outer surface  43  of the lid forming drum. 
         [0027]    A vacuum system generally similar to the vacuum system  35  of the base forming drum  21  indicated generally at  65  is operatively connected to each of the cavities  42  of the lid forming drum to create a vacuum within each cavity to draw a portion of the lid stock film  75  into the cavities  42  to form one or more lid recesses  110 . Conduits  66  of the vacuum system  65  are depicted schematically in  FIGS. 1, 2 and 3 . A drive system (not shown) is operatively connected to the lid forming drum  41  to rotate the drum continuously or intermittently, as desired in direction “B.” 
         [0028]    The heater system  45  is depicted in  FIG. 1  as a rotatable lid stock heater roller  46  and is positioned adjacent the lid forming drum  41  and includes an internal heater to heat the lid stock film  75  prior to it contacting the lid forming drum. The heater system  45  may be of any type and, as with the heater system  25  associated with base forming drum  21 , the heater system  45  associated with lid forming drum  41  may be internal or external to roller  46 . 
         [0029]    A lid stock product feed mechanism  51  is positioned generally adjacent the upper section  44  of the lid forming drum  41  to supply one or more products or materials into each lid recess  111  as the recesses together with lid stock film  75  move along with the upper surface of the rotatable drum  41 . As depicted, the lid stock product feed mechanism  51  is fixed but it may include a drive mechanism (not shown) to permit the lid stock product feed mechanism to move with the lid recesses  111  as the recesses move along with the lid forming drum  41 . It is contemplated that the lid stock product feed mechanism  51  may be configured as a hardenable material feed mechanism to feed any type of product or material in the form of a hardenable material such as a liquid, a paste or a wax-like material that hardens or solidifies after delivery. However, it may also be configured to deliver other materials such as solid objects, or the like that need not change phase. 
         [0030]    Lid stock wetting system  60  is positioned adjacent the lid forming drum  41  at a position after (i.e., downstream from) the lid stock product feed mechanism  51  and before the lid stock film  75  seals the base stock film  70  at the base forming drum  21 . The lid stock wetting system  60  may apply a solvent to the lid stock film  75  to increase its tackiness to assist in adhering the lid stock film  75  to the base stock film  70 . To do so, the solvent may be provided through a wetting system or reservoir  62  to a wetting roller  61  that engages the lid stock film  75 . In an embodiment in which the base stock film  70  and lid stock film  75  are formed of a polyvinyl alcohol material, the solvent for the lid stock wetting system  60  may be water. 
         [0031]    In an alternate embodiment depicted in  FIG. 6 , a lid stock wetting system  160  may be provided before or upstream of the lid stock product feed mechanism  51 . The lid stock wetting system  160  includes a wetting roller  161  that applies a solvent to the lid stock film  75  upstream of the lid stock product feed mechanism  51 . Such a configuration may be desirable or advantageous in situations in which the material delivered into to the lid recesses  111  of the lid stock film  75  extends above the surface or plane of the lid stock film. By wetting the lid stock film  75  before the material is inserted into the recesses  111 , the material will not contaminate the wetting roller  161 . In other words, in the embodiment depicted in  FIG. 1 , if the material within the recesses  111  extends above or is near the plane of the lid stock film  75  (i.e., the outer surface  43  of the lid forming drum  41 ), it may contact, and contaminate, the wetting roller  61 . 
         [0032]    As seen in  FIG. 6 , in some instances, it may be difficult or undesirable to position the wetting system or reservoir  162  immediately adjacent the wetting roller  161 . In such case, the wetting system or reservoir  162  may be spaced from the wetting roller  161  and the solvent applied to a preliminary or transfer wetting roller  163  that engages the wetting roller  161  to transfer the solvent thereto. 
         [0033]    Returning to the embodiment illustrated in  FIG. 1 , the base forming drum  21  and the lid forming drum  41  are positioned adjacent each other so that after forming and filling each of the pockets  101  in base stock film  70  and lid recesses  111  the lid stock film  75  with the desired products and/or materials, the two films may be secured together to form the pouches  100 . Accordingly, one or both of the base forming drum  21  and the lid forming drum  41  may be resiliently mounted to permit relative movement between the two drums in order to apply pressure to the combined base stock film  70  and lid stock film  75  to secure the two films together at the portions defining flanges  103  and  112  of pouches  100 . In another embodiment, a separate roller or rollers could be used to apply the required pressure to secure the two films together. In still another embodiment, one or both of the base forming drum  21  and the lid forming drum  41  may have a resilient coating or material on the outer surface thereof. 
         [0034]    A slitting knife  15  may be positioned after or downstream from the location at which the base stock film  70  and the lid stock film  75  are secured together to slit the combined films in a circumferential direction along the outer surface of base forming drum  21  to create a plurality of circumferential strips that each include a plurality of pouches  100 . A rotary knife  16  may be positioned after or downstream from the slitting knife  15  to cut the combined films laterally relative to the direction of rotation of the base forming drum  21  to cut the combined films into the individual pouches  100 . The individual pouches  100  are discharged onto a conveyor  17  for subsequent processing. 
         [0035]    Optionally, when a hardenable material is delivered to the lid recesses, a cooling system indicated generally at  55  may be associated with the lid forming drum  41  to cool portions of the drum or a portion of a product or material in the lid recesses  111  formed in the lid stock film  75  within the drum cavities. In one embodiment depicted in  FIG. 2 , the cooling system  55  may include a liquid system that internally directs a liquid through conduits  56  within the lid forming drum  41  to each of the cavities  42  of the drum to cool all or a portion of the surface (e.g., a lower surface) of the cavity. In another embodiment, the cooling system  55  may include an air or pneumatic system (or a combination of the two) that internally directs a gas through conduits  56  within the lid forming drum  41  to each of the cavities  42  of the drum to cool all or a portion of the surface of the cavity. The location and number of conduits  56  may be dependent upon the material and the temperature of the lid stock film  75 , the temperature of the cavities  42  of the lid forming drum  41 , the amount of cooling desired, the rate at which the lid forming drum is rotated, and the flow rate and type of medium (i.e., the fluid) being used as a cooling agent. 
         [0036]    Referring to  FIG. 3 , still another embodiment is depicted in which, the cooling system  55  may include an external air or pneumatic system (or a combination of the two) that directs a gas from outside the lid forming drum  41  through external conduits  57  towards or into each of the lid recesses  111  in the film  75  within cavities  42  of the drum. The gas cools all or a portion of the lid stock film  75 , for example, the formed lid recesses  111  of the lid stock film, and/or any material placed within the recesses of the lid stock film. In this embodiment, the internal conduits  56  may be omitted from the lid forming drum  41  and the cooling system  55  configured to utilize the external conduits  57  without the internal conduits. Also, depending on the material delivered to the lid recesses  111  in the lid forming film, it may be that no cooling of the material in the lid recesses is necessary. For example, such would be the case if a solid object were placed in lid recesses  111  by the lid stock product feed mechanisms  51 . 
         [0037]    In instances where cooling is employed, if desired, the outer surface  43  of lid forming drum  41  may include an insulative material  47  thereon as depicted in  FIG. 7 . The insulative material may be any desired material including rubber, silicone, foam, and the like. If the insulative material  47  is a resilient material, it may function as the resilient coating or material referred to above that operates to assist in applying the desired pressure between the base forming drum  21  and the lid forming drum  41 . The insulative material  47  extends along the outer surface  43  and includes openings that correspond to and are aligned with the cavities  42  along the outer surface of the lid forming drum  41 . 
         [0038]    The insulative material  47  operates to insulate the lid stock film  75  from the lid forming drum  41  except within the cavities  42 . More specifically, as the heated lid stock film  75  meets the lid forming drum  41 , it contacts the insulative material  47  along the outer surface  43  of the lid forming drum rather than contacting the outer surface itself. Upon applying a vacuum through conduits  66  of vacuum system  65 , the heated lid stock film  75  is drawn into the cavities  42 . Once the lid stock film  75  contacts the cooled cavities  42 , the portions of the film that are drawn into the cavities  42  to define the lid recesses are cooled. The portions of the lid stock film  75  that form flanges  112  contact the insulative material  47  outside of the cavities  42  and are not cooled by the cooling system  55  due to the insulative properties of the insulative material  47 . This aids in adhering the films  70  and  75  together to form pouches  100 . 
         [0039]    If desired, in some instances, an insulative material (not shown) may be applied to the outer surface  23  of the base forming drum  21 . The insulative material may be similar or identical to insulative material  47  described above that may be applied to the lid forming drum  41 . 
         [0040]    Turning again to  FIG. 1 , in operation, a base stock film  70  such as a polyvinyl alcohol film is fed from supply roll  30  and passes around a portion of rotatable base stock heater roller  26  and is heated to a temperature sufficient to allow thermoforming. In one example, the temperature may be approximately 160° F. but other temperatures may be utilized depending upon the material of the base stock film  70 , the desired manufacturing characteristics, and the performance of the apparatus  10 . The heated base stock film  70  is routed around the base forming drum  21  and a vacuum applied to each cavity  22  pulls a portion of the heated film  70  into each cavity  22  to form the base stock pockets  101  of the pouches  100 . As the base forming drum  21  and the base stock film  70  are rotated, the product feed mechanism  31  operates to fill each base stock pocket  101  to a desired level with one or more products or materials such as powdered detergent or other material. 
         [0041]    As the pockets  101  in the base stock film  70  are being formed and filled, the lid stock film  75  is fed from supply roll  50  and passes around a portion of rotatable lid stock heater roller  46  and is heated to a temperature sufficient to allow thermoforming. As with the example described above with respect to the base stock film  70 , the lid stock film  75  may be heated to a temperature of approximately 160° F. though other temperatures may be used. The heated lid stock film  75  is routed around the lid forming drum  41  and a vacuum applied to each cavity  42  pulls a portion of the heated lid stock film  75  into each cavity to form the lid recesses  111  of the pouches  100 . 
         [0042]    As the lid forming drum  41  and the lid stock film  75  are rotated, the lid stock product feed mechanism  51  operates to deliver material to each lid stock recess  111  to a desired level. The material may be a hardenable material such as a wax- or paste-like detergent in the form of a heated liquid or other suitable material. The cooling system  55 , if employed, is operative to cool the hardenable material within the lid stock recesses  111  sufficiently so that the lid stock film  75  may be further processed without movement of the liquid material within the recesses. 
         [0043]    In the example in which the cooling system  55  is internally located within the lid forming drum  41 , the lid cooling system is operative to cool the heated lid stock film  75  and the material within the recesses  111  as desired. In the example in which the cooling system  55  is located externally from the lid forming drum  41 , the cooling system may direct air or another gas towards the material within the lid recesses  111  to provide cooling. In one example, the liquid material may be sufficiently cooled if a somewhat solidified layer or surface film has been formed about its outer surface such that it adheres to itself to form a unitary element around the liquid interior. It does not flow out of the lid recesses as the lid stock film rotates around the lid forming drum  41 . In addition, such as when a solid material is delivered to the recesses  111 , it may be desirable for the material within the recesses  111  to be sufficiently cool so that it does not react with the material within the pocket  101  as the base stock film  70  and the lid stock film  75  are brought together during the sealing process described. Depending on the material delivered to the lid recesses  111  or the properties of that material, it may not be necessary to include cooling of the lid stock drum  41  or the lid stock film  75  in the process of completing filled pouches  100 . 
         [0044]    After the lid recesses  111  in the lid stock film  75  have been filled, the lid stock film may be wetted by the lid stock wetting system  60 . In doing so, water or another solvent may be applied to the lid stock film  75  so that the film becomes sufficiently tacky to assist in securing the lid stock film  75  to the base stock film  70  along the portions defining flanges  103  and  112 . 
         [0045]    The base forming drum  21  and the lid forming drum  41  are positioned in close proximity to apply pressure and force the base stock film  70  and the lid stock film  75  into contact with sufficient pressure to cause the two films to bond together at flanges  103  and  112  to seal the pockets  101  and form the pouches  100 . The combined base stock film  70  and lid stock film  75  continues to travel around the base forming drum  21  until reaching the slitting knife  15  and the rotary knife  16  which cut the combined films into the individual pouches  100 . The individual pouches  100  may then be discharged along conveyor  17  for further processing. 
         [0046]    Although the lid  110  is depicted with two distinct lid recesses  111  that include material therein, the lid may include any number of recesses with material therein including one or more. 
         [0047]    It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated. 
         [0048]    Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. 
         [0049]    Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Technology Category: 7