BACKGROUND OF THE DISCLOSURE

[0001] This application claims priority of U.S. Provisional Application Serial No.

62/490,696, filed on April 27, 2017; U.S. Provisional Application Serial No. 62/490,740, filed on April 27, 2017; and U.S. Provisional Application Serial No. 62/545,229, filed on August 14, 2017, the contents of the disclosure of all of which are incorporated by reference herein for all purposes.

Field of the Disclosure

[0002] The present disclosure relates to the use of a stopper in combination with a valve using a trapped bubble of air, gas or other fluid within a pair of material sheets. The bubble valve contains liquids within flexible packaging, wherein the user can press the air bubble to actuate the zipper or reclosure to open the package.

Description of the Prior Art

[0003] Prior art packaging in the food/beverage, personal care and household care industries is primarily a combination of a rigid bottle or semi-flexible tube with a rigid fitment or cap of varying dispense types. Transition to flexible pouches for the main body of the container has continued to utilize similar, still rigid, fitments. There exists a need within these industries to complete the transition in order to create a fully flexible solution.

[0004] Prior art embodiments of a plastic valve for flexible pouches required many manufacturing steps, material, and time. First, a rectangular pocket of ambient air is trapped between two sheets of plastic film. Then the pocket is repeatedly condensed in footprint by the use of successive heat seals on pouch making equipment. Reduction of the area gradually increases the amount of internal pressure within the formed bubble. There exists a need for a method of manufacturing a bubble in flexible packaging using less manufacturing steps, material, and time.

[0005] The prior art includes U.S. Patent No. 8,613,547 entitled "Packages Having

Bubble-Shaped Closures"; U.S. Patent No. 7,883,268 entitled "Package Having a Fluid Activated Closure"; U.S. Patent No. 7,207,717 entitled "Package Having a Fluid Activated Closure"; U.S. Published Application 2014/0155240 entitled "Stationary Closure Device and Package"; U.S. Published Application 2016/0297571 "Package Valve Closure System and Method"; International Publication No. WO 2016/069883 entitled "Closure for a Recusable Package with an Air Pocket Formed on a Flange"; and European Patent EP 1 812 318 Bl entitled "Package Having a Fluid Actuated Closure,"

[0006] A related application is PCT/US 17/61500 entitled "Bubble Valve for Flexible

Packaging."

OBJECTS AND SUMMARY OF THE DISCLOSURE

[0007] It is therefore an object of the present disclosure to provide improved dispensing valves for flexible packages, particularly fluid-activating closures or dispensing valves.

[0008] This and other objects are attained by providing a pouch or package with a bubble valve including a fluid containment chamber which further includes a fluid reservoir portion and a closure portion in fluid communication with each other through a tortuous flow path. The bubble valve includes gas, liquid or fluid entrapped therewithin. When the gas, liquid or fluid (i.e., enclosed material) is urged or otherwise directed to the fluid reservoir portion away from the closure portion so that the fluid reservoir portion is inflated and the closure portion is deflated, the product flow path of the valve is open thereby allowing the package contents to pass therethrough. However, when the enclosed material within the valve is urged or otherwise directed to the closure portion away from the fluid reservoir portion so that the fluid reservoir portion is deflated and the closure portion is inflated, the closure portion acts as a dam or stopper for the dispensing valve and the product flow path is closed.

[0009] Embodiments may include a valve with a base layer and a channel layer with the fluid containment chamber formed between an interior bubble layer and the channel layer, or a valve with a base layer and a channel layer with the fluid containment chamber formed between two interior bubble layers. Further embodiments include such valves with packages. The bubble valve can be contoured to address specific packaging needs. BRIEF DESCRIPTION OF THE DRAWINGS

[00010] Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawings, wherein:

[00011] Figure 1 is a plan view of a typical package of an embodiment of the present disclosure.

[00012] Figure 2 is a plan view of the neck and valve portions of the typical package of an embodiment of the present disclosure, as shown in Figure 1.

[00013] Figure 3 is a perspective view of an open configuration of an embodiment of a valve of the present disclosure.

[00014] Figure 4 is a side view of an open configuration of an embodiment of a valve of the present disclosure.

[00015] Figure 5 is a perspective view of a closed configuration of an embodiment of a valve of the present disclosure.

[00016] Figure 6 is a side view of a closed configuration of an embodiment of a valve of the present disclosure.

[00017] Figure 7 is a side view of an open configuration of an alternate embodiment of a valve of the present disclosure.

[00018] Figure 8 is a side view of a closed configuration of an alternative embodiment of a valve of the present disclosure.

[00019] Figure 9 is a perspective view of a further alternative embodiment of a valve of the present disclosure.

[00020] Figure 1 OA is a cross-sectional view along plane 10-10 of Figure 9, showing the zipper in a closed configuration.

[00021] Figure 10B is a cross-sectional view along plane 10-10 of Figure 9, showing the zipper in an opening process.

[00022] Figure IOC is a cross-sectional view along plane 10-10 of Figure 9, showing the zipper in an open configuration. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[00023] Referring now to the drawings in detail, wherein like numerals indicate like elements through the several views, one sees that Figures 1 and 2 illustrate an embodiment of a package or pouch 100 utilizing the valve structure 10 (i.e., a bubble valve) of the present disclosure. The illustrated pouch 100 includes a lower enlarged storage volume 102 and an upper neck (or storage access portion) 104, typically formed from first and second coextensive sheets of polymeric material 106, 108 forming first and second panel portions. The interior of upper neck 104 houses the valve structure 10 and farther provides a pathway from the storage volume 102 (typically containing consumer product) to the exterior of the package 100. As shown in Figure 2, first and second side seals 110, 1 12 seal together the edges of first and second polymeric sheets 106, 108 and the edges of the metering valve structure 10. A bottom seal (or fold) 114 joins the lower edges of the first and second polymeric sheets 106, 108 to form the lower boundary of the lower enlarged storage volume 102. At the uppermost portion of upper neck 104, the portions of first and second co-extensive sheets of polymeric material 106, 108 between first and second side seals 1 10, 112 are not sealed together in the area, thereby forming a dispensing mouth 116, with exiting flow controlled by valve structure 10.

[00024] Further, valve structure 10 is illustrated in Figure 2 as including a fluid containment chamber 20 positioned longitudinally along the product flow channel 11 of upper neck 104. The fluid containment chamber 20 includes a fluid reservoir portion 22 and further includes closure portion 26 which extends across the width of product flow channel 11 which leads from the storage volume 102 to mouth 1 16. Fluid reservoir portion 22 is positioned downstream (with respect to flow exiting the mouth 116) of closure portion 26, with both fluid reservoir portion 22 and closure portion 26 being placed within the product flow channel 11. Fluid containment portion 20 includes and enclosed material - for example, but not limited to, air, gas or other fluid - in order to act as a bubble valve and to selectively inflate or expand either fluid reservoir portion 22 or closure portion 26 thereby configuring the valve structure in a respective open or closed configuration.

[00025] As illustrated in Figures 2-6, die fluid reservoir portion 22 includes an enlarged central portion 30, first tapered end 32 and second tapered end 34 resulting in a diamond-shaped configuration. Likewise, the closure portion 26 includes a tapered proximal end 36, in fluid communication with second tapered end 34 of fluid reservoir portion 22, and an enlarged distal end 38 presenting a convex surface 40. The enlarged distal end 38 extends radially outward from the tapered proximal end 36 whereby the convex surface 40 is semicircular and equi-dislant from the tapered proximal end 36. First and second ends 41, 43 of convex surface 40 may be sealed or otherwise attached to respective first and second side seals 110, 1 12 or proximate thereto. Moreover, the fluid communication between tapered proximal end 36 of closure portion 26 and second tapered end 34 of fluid reservoir portion 22 includes a tortuous path which typically requires external pressure to be applied to the fluid reservoir portion 22 or the closure portion 26 to move the fluid or gas between the two portions 22, 26. The resulting shape of some embodiments of the fluid containment chamber 20 is fish-like, with the fluid reservoir portion 22 resembling a body of a fish and the closure portion 26 resembling a tail of fish.

[00026] One sees that this embodiment uses the fluid reservoir portion 22 as a diamond-shaped pillow of air, gas or other fluid as a spherical ball trapped within the fluid containment chamber 20 which may be in the form of a welded pocket in an outer sleeve formed within storage access portion 104. When the user would like to dispense product through the valve 10, the user presses the closure portion 26 so that the air, gas or other fluid flows to and fills the fluid reservoir portion 22 and deflates the closure portion 26 thereby allowing fluid communication to be formed through product flow channel 11 (in the four- layer embodiment illustrated in Figures 4 and 6, formed from upper product flow channel 1 la above the fluid containment chamber 20 and lower product flow channel l ib below the fluid containment chamber 20, as shown in Figure 4) between the storage volume 102 and mouth 116. The thickness of the filled fluid reservoir portion 22, illustrated as "X" in Figure 4, is sufficiently low so as to allow flow through product flow channel 11 (comprised of upper and lower product flow channels 11a and l ib) as shown in Figures 3 and 4. This allows the product contents of storage volume 102, which may be in the form a fluid or semi-fluid, to pass over and under the fluid containment chamber 20 (both fluid reservoir portion 22 and closure portion 26) at a controlled dispensing rate depending upon the contents of the package or pouch 10 and the customer need. When the user desires the package or pouch 10 to be more definitively sealed, such as, but not limited to, travel and carry purposes, the fluid reservoir portion 22 can be squeezed, forcing the air, gas or other fluid through the tortuous path and filling the closure portion 26 as shown in Figures 5 and 6. The closure portion 26 and its convex surface 40 is configured and arranged to inflate so that it is thick and wide thereby creating a dam or stopper in front of the pouch contents within product flow channel 1 1 as shown in Figures 5 and 6. The height of the inflated convex surface 40, shown as "Y" in Figure 6, is typically greater than the height "X" of the inflated fluid reservoir portion 22 shown in Figure 4. That is, the thickness or height "Y" of inflated convex surface 40 is sufficiently high to block flow through channel 1 1 while the thickness or height "X" of the inflated fluid reservoir portion 22 is sufficiently low to allow flow through product flow channel 1 1. Additionally, a crease may form at the base of the wide convex surface 40 thereby causing the pouch 100 to kink when squeezed and enhancing the sealing action further.

[00027] In some embodiments, the valve structure 10 is formed separately from the package or pouch 100 and subsequently welded, sealed or otherwise joined to the pouch 100 in a separate operation. In such embodiments, an area of the valve structure 10 near the convex surface 40 is an attachment section or flanges. The panels 106, 108 of the pouch 100 attach to the valve structure 10 at the attachment section or flanges near the convex surface 40.

[00028] In the four-layer embodiment exemplified in Figures 4 and 6, the fluid containment chamber 20 includes an upper layer 21 and a lower layer 23 ("upper" and "lower" being with respect to the illustrated configuration) of polymeric material, sealed together at the edges thereof, with the air, gas or other fluid trapped therein. The product flow channel 11 is comprised of upper product flow channel 11a above upper layer 21 and is bounded by upper channel layer 106' (which may be the first co-extensive sheet of polymeric material 106 or may be a separate panel segment which is welded, sealed or otherwise joined to first co-extensive sheet of polymeric material 106, as may be done if it is desired to form the valve structure 10 separately, and weld, seal or otherwise join the valve structure 10 to the package or pouch 100 in a subsequent or separate operation) and further comprised of lower product flow channel l ib below lower interior bubble layer 23 and bounded by lower channel layer 108' (which may be the second co-extensive sheet of polymeric material 108 or may be a separate panel segment which is welded, sealed or otherwise joined to second co-extensive sheet of polymeric material 108, as may be done if it is desired to form the valve structure 10 separately, and weld, seal or otherwise join the valve structure 10 to the package or pouch 100 in a subsequent or separate operation). [00029] Alternatively, in the three-layer embodiment of Figures 7 and 8, the lower layer 23 of the fluid containment chamber 20 is formed from lower layer 108' (which, as described above, may be the second co-extensive sheet of polymeric material 108 or may be a separate panel segment) thereby forming a base layer with no lower fluid channel. A single product flow channel 11 is formed above upper layer 21 (or interior bubble layer) of fluid containment chamber 20, bounded by upper channel layer 106' (which, as described above, may be the first co-extensive sheet of polymeric material 106 or may be a separate panel segment) which forms a channel layer.

[00030] In the alternative embodiment of valve structure 10 illustrated in Figures 9 and lOA-C, a reclosure 58, such as, but not limited to, a zipper, is positioned adjacent to and partially over the bulbous opening portion 26' of the fluid containment chamber 20. First and second profiles 60, 62 of reclosure 58 are positioned on an interior of respective first and second co-extensive sheet of polymeric material 106, 108 (or a flange-type structures attached thereto, if the valve structure 10 is assembled separately from the pouch or package 100). The first profile 60 extends over the bulbous opening portion 26* of the fluid containment chamber 20 in a cantilevered configuration and includes a first interlocking element 66 on the rightmost side (from the orientation of Figures 1 OA- IOC), The first interlocking element 66 of first profile 60 interlocks with second interlocking element 68 of second profile 62 in Figure 10A so that the reclosure 58 is in a closed position and first profile 60 is cantilevered over the deflated bulbous opening portion 26' of fluid containment chamber 20. As shown in Figure 10B, to open the reclosure 58, the user presses on fluid reservoir portion 22 of fluid containment chamber 20 so that the inflated bulbous opening portion 26' separates the first and second profiles 60, 62 from each other to achieve the open position of the reclosure 58, with the first and second profiles 60, 62 separated from each other, as shown in Figure IOC. A channel 1 1 is similarly formed between the valve structure 10 and the sheets of polymeric material 106, 108. In such a configuration, the inflation of bulbous opening portion 26' would not impede subsequent flow of product through the valve structure 10.

[0001] A possible method and apparatus for manufacturing the valve structure 10 is described herein. The valve structure 10 may be assembled separately from the pouch or package 100 (i.e., layers 106', 108 ^* are separate from panel portions 106, 108). Additional details can be drawn from related application PCT/US 17/61500, entitled "Bubble Valve for Flexible Packaging." The polymeric or similar sheet material for one or both of the channel layers 106', 108', the lower layer 23, and upper layer 21 are provided by unwinds or spools. The fluid reservoir portion 22 and closure portion 26 are formed by at least one

thermoformer. In the three-layer embodiment (illustrated in Figures 7 and 8), the portions 22, 26 are formed in only the upper layer 21 of film. In the four-layer embodiment (illustrated in Figures 4 and 6), the portions 22, 26 are formed in both the lower layer 23 and upper layer 21 of film.

[0002] In one embodiment, the portions 22, 26 are formed using both vacuum forming and thermoforming processes. The fluid reservoir portion 22 and closure portion 26 man be formed during the same thermoforming step or separate thermoforming steps. The shaping and dimensions of the portions 22, 26 using vacuum forming and/or thermoforming processes can be customized to the specific needs of the product and/or consumer or user requirements. Such specific needs include, for example, but are not limited to, opening force and speed of the valve structure 10, closing (i.e., shut-off) force and speed of the valve 10, and viscosity of contents (if liquid; solid contents are also possible) in a package.

[0003] The polymeric or similar sheet material for the lower layer 23 is sealed to the upper layer 21 by a first ultrasonic sealer (i.e., applying a valve seal). The polymeric or similar sheet material for the exterior layer(s) 106', 108' is sealed to the combination of the layers 21, 23 by a second ultrasonic sealer (i.e., applying a channel seal).

[0004] Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby.