Flexible pouch with ergonomic shape and method of forming

Abstract

An ergonomically beneficial flexible 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. The flexible pouch may include 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. For an ergonomic flexible pouch containing a carbonated product, the pressure in the pouch from the carbonated product ergonomically shapes the pouch, such that the front wall and the back wall each have a longitudinally oriented convex shape and the sealed side edge and the smooth side edge each have a longitudinally oriented concave shape.

1 . A flexible pouch with a folded 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 a first side edge and a second side edge extending therebetween said upper edge and said lower edge;    a folded portion in said second side edge that is defined by a fold line extending transversely along the second side edge and spaced a predetermined distance from the outermost portion of said second side edge;    a folded flat seam joining said first side edge and said folded portion in said second side edge to form a body of the pouch, wherein first side edge is positioned over the folded portion in said second side edge, so that an outermost portion of said the first side edge is aligned with the outermost portion of said second side edge, and the folded flat seam lies flat against the body of the pouch; 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 the outermost portion of said second side edge is folded 180 degrees along said fold line, so that the folded portion is adjacent the outer surface of said panel.  
   
   
       3 . The pouch as set forth in  claim 1  wherein said pouch includes a gusset.  
   
   
       4 . The pouch as set forth in  claim 1  wherein said pouch body 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 1  further including a strip of material sealed over said folded 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  further comprising a label disposed over the outer surface of said panel.  
   
   
       8 . An ergonomic flexible pouch for a carbonated product comprising: 
 a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and a first side edge and a second side edge extending therebetween said upper edge and said lower edge;    a side seal joining said first side edge of said panel to said second side edge of said panel to form a body of the pouch having a front wall and a back wall, and a smooth side edge and a sealed side edge;    a first closing seal sealing lower edges of said front wall and said back wall together;    a second closing seal sealing said lower edges of said front wall and said back wall together, wherein said second closing seal is spaced a predetermined distance outboard of the first closing seal, and the carbonated product is trapped between the first closing seal and the second closing seal; and    an opening means disposed between upper edges of said front wall and said back wall, wherein a pressure in the pouch from the carbonated product ergonomically shapes the pouch, such that said front wall and said back wall each have a longitudinally oriented convex shape and said sealed side edge and said smooth side edge each have a longitudinally oriented concave shape.    
   
   
       9 . The pouch as set forth in  claim 8  wherein said side seal includes an inner seal at a low temperature, and an outer seal at a high temperature and spaced a predetermined distance outboard of said inner low temperature seal.  
   
   
       10 . The pouch as set forth in  claim 9  wherein said first seal is a tack seal that tacks the side edges together, and a gas in the pouch is pushed out of the pouch through the side edges before the second high temperature seal is applied.  
   
   
       11 . The pouch as set forth in  claim 9  wherein said side seal is formed using a seal bar having a plasma coating.  
   
   
       12 . The pouch as set forth in  claim 9  wherein said opening means includes a fitment, and a cap removably attached to said fitment.  
   
   
       13 . The pouch as set forth in  claim 9  further comprising a label disposed over said front wall and said back wall of said pouch.  
   
   
       14 . A method of forming and filling an ergonomic flexible pouch with a carbonated product, 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 a first side edge and a second side edge extending therebetween;    aligning the first side edge with the second side edge to form the front wall and back wall of the body of the pouch;    forming a side seal in the aligned first side edge and the second side edge;    sealing an opening means between the upper edges of the front wall and back wall;    opening the pouch;    filling the pouch with the carbonated product;    sealing the lower edges of the front wall and back wall using a first ultrasonic closing seal;    applying a second closing seal that is spaced a predetermined distance outboard of said first ultrasonic closing seal, such that the carbonated product is trapped in the space between said first closing seal and said second closing seal, wherein the pressure in the pouch due to the carbonated product ergonomically shapes the pouch, such that the front wall and back wall each have a longitudinally oriented convex shape and said sealed side edge and said smooth side edge each have a longitudinally oriented concave shape; and    finishing the filled pouch.    
   
   
       15 . The method as set forth in  claim 14  wherein said step of forming the side seal further includes the steps of: 
 applying an inner seal at a low temperature; and    applying an outer seal at a high temperature, wherein the outer seal is spaced apart from the inner seal by a predetermined distance, so that there is an air gap between the inner seal and the outer seal and a gas is pushed out of the pouch through the open edges of the panels.    
   
   
       16 . The method as set forth in  claim 14  wherein said step of forming the side seal includes the step of using a seal bar coated with a plasma material.  
   
   
       17 . The method as set forth in  claim 14  further including the step of applying a sleeve over the outer surface of the panel and heat-shrinking sleeve to the outer surface of the panel.  
   
   
       18 . An ergonomic flexible pouch for a carbonated product comprising: 
 a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and a first side edge and a second side edge extending therebetween said upper edge and said lower edge;    a side seal joining said first side edge of said panel to said second side edge of said panel to form a body of the pouch having a front wall and a back wall, and a smooth side edge and a sealed side edge;    a first closing seal sealing lower edges of said front wall and said back wall together;    a fitment ultrasonically sealed between said upper edges of said front wall and said back wall, wherein said fitment includes a base portion having a vertically oriented wall, a pair of opposed fins extending outwardly from an outer surface of said wall, a lip extending outwardly from an upper edge of said wall, a spout projecting upwardly from the upper edge said wall, and said spout includes a thread encircling said spout with a plurality of vertically oriented vents bisecting said thread;    a replaceable cap secured to said fitment, wherein said cap is a cylindrical member, having a closed and an open end, and an inner surface of said cylindrical member includes a thread with a plurality of vertically oriented vents bisecting said thread, such that said cap vents are disposed between said fitment vents when said cap is secured to said fitment to control a release of pressure from the pouch due to the carbonated product; and    the pressure in the pouch from the carbonated product ergonomically shapes the pouch, such that said front wall and said back wall each have a longitudinally oriented convex shape and said sealed side edge and said smooth side edge each have a longitudinally oriented concave shape.    
   
   
       19 . The ergonomic flexible pouch of  claim 18  wherein said cap includes a detachable collar that remains on the spout when said cap is removed from said spout.  
   
   
       20 . The ergonomic flexible pouch of  claim 18  wherein said fitment has an elongated oval shape.  
   
   
       21 . The ergonomic flexible pouch of  claim 18  wherein said fitment is ultrasonically sealed by applying an ultrasonic seal to the upper edges of said front wall and said back wall, applying a heat seal, and applying a cool seal, so that there are no voids between the fitment and upper edges of said front wall and said back wall.  
   
   
       22 . The pouch as set forth in  claim 18  further comprising a label disposed over the outer surface of said panel.  
   
   
       23 . The pouch as set forth in  claim 18  wherein said side seal includes an inner seal at a low temperature, and an outer seal at a high temperature and spaced a predetermined distance outboard of said inner low temperature seal.  
   
   
       24 . The pouch as set forth in  claim 23  wherein said first seal is a tack seat that tacks the side edges together, and a gas in the pouch is pushed out of the pouch through the side edges before the second high temperature seal is applied.  
   
   
       25 . The pouch as set forth in  claim 18  wherein said side seal is formed using a seal bar having a plasma coating.