Flexible pouch with flat seam and method of forming

Abstract

A flexible pouch with a flat seam for containing a product and a method of forming the pouch is provided. The pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween. One side edge is positioned over the second edge and sealed to form a flat seam that lies flat against the outer surface of the panel. An upper edge of the pouch includes a first ultrasonic closing seal, and a second seal is positioned above the first closing seal. The pouch also includes opening means integral with the panel for accessing a product contained within the pouch.

1 . A flexible pouch with a flat seam for containing a product, said pouch comprising: 
 a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween, wherein said side edges are joined together by a folded flat seam that lies flat against said outer surface of said panel such that one side edge includes a fold forming an obtuse angle extending transversely along the first side edge and the second side edge includes a fold forming an acute angle extending transversely along the second side edge, and the first side edge is positioned over the second side edge so that the first fold along the first side edge is aligned with the second fold along the second side edge, and a portion of the first side edge extends beyond the second side edge, and the extending first side edge is folded over the second side edge and sealed; and    an opening means integrally formed in said panel for accessing a product contained within the pouch.    
   
   
       2 . The pouch as set forth in  claim 1  wherein said pouch includes a gusset.  
   
   
       3 . The pouch as set forth in  claim 1  wherein said gusset is integrally formed in said panel.  
   
   
       4 . The pouch as set forth in  claim 1  wherein said pouch includes a front wall and a back wall and an insert positioned between said front wall and said back wall.  
   
   
       5 . The pouch as set forth in  claim 4  further including a strip of material sealed over said flat seam.  
   
   
       6 . The pouch as set forth in  claim 1  wherein said opening means includes a fitment and a cap removably attached to said fitment.  
   
   
       7 . The pouch as set forth in  claim 1  wherein a base portion of said removable cap has an oval shape for supporting said cap in an upright position.  
   
   
       8 . A flexible pouch with a flat seam for containing a product, said pouch comprising: 
 a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween, wherein said side edges are joined together by an overlap flat seam that lies flat against said outer surface of said panel such that a first side edge overlaps a second side edge a predetermined amount; and    an opening means integral with said panel for accessing a product contained within the pouch.    
   
   
       9 . The pouch as set forth in  claim 8  wherein said pouch includes a gusset.  
   
   
       10 . The pouch as set forth in  claim 9  wherein said gusset is integrally formed in said panel.  
   
   
       11 . The pouch as set forth in  claim 8  wherein said pouch includes a front wall and a back wall and an insert positioned between said front wall and said back wall.  
   
   
       12 . The pouch as set forth in  claim 8  further including a strip of material sealed over said flat seam.  
   
   
       13 . The pouch as set forth in  claim 8  wherein said opening means includes a fitment and a cap removably attached to said fitment.  
   
   
       14 . The pouch as set froth in  claim 13  wherein a base portion of said removable cap has an oval shape for supporting said cap in an upright position.  
   
   
       15 . The pouch as set forth in  claim 8  wherein said first side edge has a fold extending transversely along the first edge, and the first edge is positioned over the second edge, so that the first fold along the first edge overlaps the second edge a predetermined amount.  
   
   
       16 . A method of forming a flexible pouch with a flat seam on a machine, said method comprising the steps of: 
 forming a body of the pouch from a roll of laminate material, wherein the body of the pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween;    joining together and sealing the side edges of the panel to form a flat seam that lies flat against the outer surface of the pouch;    sealing the lower edge of the panel;    applying an opening means to the panel; and    finishing the pouch.    
   
   
       17 . The method as set forth in  claim 16 , further including the steps of: 
 opening the pouch;    filling the pouch with the product;    carbonating the product;    sealing the upper edge of the pouch using an ultrasonic seal;    applying a second seal above the first ultrasonic seal; and    finishing the filled pouch.    
   
   
       18 . The method as set forth in  claim 17  wherein said step of forming the body of the pouch includes the step of forming a plurality of pouches from the roll of material.  
   
   
       19 . The method as set forth in  claim 18  further includes the step of separating the pouches using a double cut between the pouches.  
   
   
       20 . The method as set forth in  claim 17  further includes the step of pasteurizing the product within the sealed pouch.  
   
   
       21 . The method as set forth in  claim 16  wherein said step of joining together the side edges further includes the steps of: 
 forming a fold having an obtuse angle extending transversely along the first side edge;    forming a fold having an acute angle extending transversely along the second side edge;    positioning the first side edge over the second side edge so that the first fold along the first side edge is aligned with the second fold along the second side edge and a portion of the first side edge extends beyond the second side edge;    folding the extending first side edge over the second side edge; and    sealing the first side edge to the second side edge.    
   
   
       22 . The method as set forth in  claim 16  wherein said step of joining together further includes the steps of: 
 overlapping the first side edge over the second side edge a predetermined amount; and    sealing the first side edge to the second side edge.    
   
   
       23 . The method as set forth in  claim 16  further including the step of positioning a strip of material over the seam and sealing the material strip to the outer surface of the pouch.