REFERENCE TO RELATED APPLICATIONS

[0001] This Application claims the benefit of U.S. Provisional Application 61/353,080 filed on June 9, 2010 and U.S. Provisional Application 61/353,094 filed on June 9, 2010, the disclosures of which are incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

[0002] The invention relates to a flexible pouch. More particularly the invention relates to a flexible pouch having a gusset.

BACKGROUND OF THE INVENTION

[0003] Flexible pouches are formed from sheets of pliable material such as metal laminates.

Flexible pouches include a pouch body having a front portion and a back portion. The pouches may be formed by symmetrically shaped first and second sheets sealed together along the edges.

Alternatively, the sheet may be folded onto itself and sealed along the edges.

[0004] Current pouches may include gussets to help the pouch expand during filling operations and to provide greater storage space for the pouch body. The gussets are formed by a sheet of material, also referenced herein as a gusset sheet, disposed on either the top or bottom portion of the pouch. The gusset sheet may be integrally formed with the either the first or second sheet, or may be introduced as a separate sheet.

[0005] In some instances the gusset may be disposed on both top and bottom portions of the pouch. Preferably the gusset sheet is composed of similar material to that of the pouch body. The gusset sheet includes a fold so as to divide the gusset sheet into a first gusset portion and a second gusset portion. The outer edges of first and second gusset portions are sealed to respective edges of the pouch body. Currently the first and second gusset portions are sealed to respective outer edges of the pouch body along an axis. Accordingly during filling operations the first and second portions of the gusset expand away from each other, opening the gusset along the fold so as to expand the pouch body and accommodate the introduction of beverages.

[0006] It is also known to form handles on a portion of the pouch to facilitate manipulation of the pouch and carrying the pouch. For example, a top portion of the pouch may include apertures configured to receive fingers. These apertures are formed along an extended sealed side edge of respective first and second sheets of the pouch body. The extended sealed side edge is formed by sealing a portion of the first sheet to a corresponding portion of the second sheet. [0007] It is also known to configure flexible pouches to be self standing. In such instances, the bottom of the pouch body is formed with a skirt. The skirt is a panel of material extending along the bottom of the pouch, bounding the bottom surface of the pouch. In some cases, the weight of the pouch may cause the skirt to fold, and thus prevent the pouch from standing up right.

[0008] Another advantage of the flexible pouch is the relatively inexpensive manufacturing cost as compared to other drinking containers such as a relatively rigid plastic or glass bottle. Accordingly it remains desirable to have a flexible pouch configured to contain relatively larger amounts of liquids without significantly increasing manufacturing costs and yet can support the pouch in an upright manner in spite of the added weight of fluids.

[0009] Accordingly it remains desirable to have a pouch with a gusset having a sturdier seam relative to seams currently known and used. Furthermore, it remains desirable to have a pouch with a handle that does not require as much material as the current art. Furthermore, it remains desirable to have a pouch with a skirt sufficiently rigid to help maintain the pouch in an upright manner. Further, it remains desirable to have a pouch with a rigid side edge to help support the pouch in generally rigid upright manner.

SUMMARY OF THE INVENTION

[0010] According to one aspect of the invention a flexible pouch is provided having a gusset. The gusset includes a pair of gusset seals that extends arcuately along the inner wall of the pouch body. The gusset seal binds the gusset to respective front and back portions of the pouch body. The arcuate shaped gusset seals provide a more durable seam than that of the axially sealed gussets of the prior art. The arcuate shaped gusset seals also allow for greater expansion of the gusset relative to the axially sealed gussets of the prior art.

[0011] The flexible pouch may further include a handle formed on one of either the first or second sheet of the pouch body so as to reduce material for making a pouch handle with respect to the pouch handles of the prior art. Thus, manufacturing costs are also reduced relative to pouches having handles of the prior art.

[0012] The flexible pouch may further include a plurality of elongated baffles disposed on the skirt. The elongated baffles are operable to provide support for the weight of a filled flexible pouch so as to help the pouch remain upright when placed on its bottom surface.

[0013] The flexible pouch may further include first and second side seals extending longitudinally along the length of the pouch. The first seal is spaced apart from the second seal so as to form a chamber for containing gases. The chamber extends generally from the top to the bottom of the pouch, and along respective side edges of the pouch body. The gases are disposed within the chamber so as to form a generally rigid pocket of air extending axially along the side edges of the pouch. The elongated rigid pocket of air is operable to provide structural strength to the side edges to help users manipulate the pouch and to further stabilize and maintain the pouch in an upright position

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0015] Figure 1 is a prior art view of a pouch having gussets sealed to the pouch body along an axis;

[0016] Figure 2 is a prior art view of a pouch having seams disposed axially along the sides, top and bottom edges of the pouch body;

[0017] Figure 3 is a front view of a flexible pouch of the present invention having a gusset sealed arcuately along respective first and second sheets of the pouch body;

[0018] Figure 4 is a perspective view of an embodiment of first and second sheets;

[0019] Figure 5 is a perspective view of the pouch of Figure 3 filled with a beverage;

[0020] Figure 6 is a perspective view of the bottom of the pouch showing the sealing bars operable to form baffles along the skirt; and

[0021] Figure 7 is a perspective view of the bottom of the pouch of Figure 3.

DETAILED DESCRIPTION OF THE INVENTION

[0022] Referring to Figure 3, an illustration of a flexible pouch 10 of the present invention is provided. The flexible pouch 10 includes a pouch body 12. The flexible pouch 10 has a front portion 14 opposite a back portion 16, and a pair of side portions 18 separating the front portion 14 from the back portion 16. The side portions 18 are formed by a sheet of material sealed together and form a generally planar surface extending outwardly from the pouch body 12. The pouch body 12 may be formed by a sheet 20 of laminate material folded and sealed so as to form the pouch body 12.

[0023] Alternatively, the pouch body 12 may be formed by a first and second sheet 22, 24 of material. The first sheet 22 generally forms the front portion 14 of the pouch 10 and the second sheet 24 generally forms the back portion 16 of the pouch 10. The first and second sheets 22, 24 have respective outer edges 26 which are sealed to each other so as to form a pouch body 12.

[0024] The pouch 10 includes a gusset 28. The gusset 28 has a gusset sheet 30 having a fold 32. The fold 32 extends generally axially between opposing ends of the gusset sheet 30 and divides the gusset sheet 30 into a first gusset portion 34 and a second gusset portion 36. As shown in Figure 5, the gusset 28 is sealed to the bottom portion 38 of the pouch body 12. Preferably, the gusset 28 is generally circular, or elliptical in shape. The fold 32 generally divides the gusset 28 in half so as to form the first gusset portion 34 and the second gusset portion 36. The outer edges 26 of both the first gusset portion 34 and second gusset portion 36 are sealed to the inner wall surface of the pouch body 12. Specifically, the first gusset portion 34 is sealed to the first sheet 22 and the second gusset portion 36 is sealed to the second sheet 24 so as to form a gusset seal 40, as indicated by the dashed lines in Figure 3.

[0025] The gusset seal 40 extends generally arcuately between opposing side edges 26 of the pouch body 12. More specifically, in instances where the gusset 28 is circular, as shown in Figure 4, the first and second gusset portions 34, 36 are sealed along respective first and second sheets 22, 24 so as to define an arc 44. The arc 44 may be uniform so as to have a predetermined radius "R." The arc 44 begins from respective midportions 46 of the side edges 26 of the pouch body 12 and extends towards the bottom edge 42 of the pouch body 12 so as to form a bottom gusset 48.

[0026] It should be appreciated that the pouch 10 may include a pair of arcs 44 on disposed on a top or bottom corner of the pouch body 12, as shown in Figure 3. Specifically, one of the pair of arcs 44 is opposite the other, and an length of pouch body extends along a general axis between each of the pair of arcs, as shown in Figure 8. Arcs 44 help distribute the load along the entire inner surface of the corner of the pouch 10 so as to help preserve the structural integrity of the pouch body 12. Thus, force from weight being added to the pouch body 12, or pressure is applied to the pouch body 12, is distributed across a greater surface area relative to pouches where such corners are formed with obtuse angles as shown in the prior art Figure.

[0027] With reference now to Figures 3 and 5, a perspective view of a flexible pouch 10 filled with a beverage is provided. As shown, the gusset 28 is expanded, and forms a generally rounded top and bottom surface of the pouch body 12. Further, the front and back portions 14, 16 of the pouch 10 expand outwardly away from each other, and a pair of spaced apart ribs 50 is formed on both the front and back portions 14, 16 of the pouch 10. The ribs 50 extend generally axially from the top to the bottom of the pouch 10 so as to form a generally rectangular shaped body 52, as shown in Figures 3, 5, and 7.

[0028] The ribs 50 may be formed by making a fold along the pouch body 12. The fold extends along the length of the outer surface 42 of the pouch body 12. Preferably, the pouch 10 includes a pair of ribs 50 formed along the outer surface 42 of both the front and back of the pouch 10. The ribs 50 may be formed using a seal bar (not shown). The seal bar is configured to create the fold along the outer surface of the pouch body 16. The seal bar is further operable to apply a pressure seal along the fold. The fold may be heated and cooled so as to form the generally rigid rib 50.

[0029] With reference again to Figure 2, the pouch body 12 may further include a top gusset 54. The top and bottom gussets 54, 48 are generally symmetrical to each other. Accordingly, a discussion of the bottom gusset 48 is sufficient to describe and enable one skilled in the art to make the top gusset 54.

[0030] With reference now to Figure 4, an illustration of an embodiment of first and second sheet 22, 24 is provided. The first and second sheets 22, 24 are generally rectangular. Preferably the first sheet 22 includes a pair of gussets 28 formed along the top and bottom of the sheet 20. The gusset 28 is also rectangular and includes a fold 32. It is anticipated that either the first or second sheet 22, 24 may be cut so as to include a gusset sheet 30. The fold 32 is positioned between the first and second sheets 22, 24 of the pouch body 12. The first gusset portion 34 of each gusset 28 are folded along respective bottom and top edges 26, 42 of the first sheet 22. The distal edges 18a, 36a of each gusset sheet 30 is then aligned with respect to the top and bottom edges of the second sheet 24, wherein the gusset 28 is partially folded along the fold 32. The gusset 28 is then sealed to respective top and bottom portions 38 of the second sheet 24.

[0031] A seal bar (not shown) is fitted between the first and second gusset portions 34, 36 of the gusset 28. The seal bar has an arcuate surface and compresses a portion of respective first and second sheets 22, 24 to the gusset 28 so as to seal the first gusset portion 34 to the first sheet 22 so as to form a first panel of material 56 and the second gusset portion 36 to the second sheet 24 so as to form a second panel of material 58, as shown in Figure 3.

[0032] The gusset seal 40 extends arcuately between respective side edges 26, 42 of the pouch body 12, as shown in Figure 3. The fold 32 lies generally along an axis extending between opposing side edges of the pouch body 12 to help the pouch body 12 expand during filling operations. [0033] The seal bar may include apertures. The apertures are selectively disposed along the seal bar and are operable to form a pocket 62 in respective first and second panels of material 56, 58. The pockets 62 may be configured to hold devices such as radio frequency identifying devices 64 (RFIDs). Other devices may be placed within the pockets 62 formed along the top portion and bottom portion 38 of respective panels of material 56, 58. For instance temperature indicators may be disposed in the pocket 62 so as to inform the user of the temperature of the product.

[0034] With respect to the top gusset 54, the gusset 28 is formed in a like manner as the bottom gusset 48. However, the gusset 28 is formed further away from the top edge of the pouch 10 than the bottom gusset 48 is formed from the bottom edge 42 of the pouch 10. Thus excess material is disposed between the top gusset 54 and the top edge of the pouch body 12. As with the bottom gusset 48, the sealing bar 66 may include apertures so as to form pockets 62 for devices such as RFIDs along the respective first and second sealed sheet portions 60 of the top gusset 54.

[0035] With reference again to Figure 3, the first and second panels of material 56, 58 may further include handle apertures 68. The handle apertures 68 are configured to receive fingers so as to help the consumer carry the filled pouch 10. The first and second sealed sheet portions 60 provide support for the weight of the pouch body 12. It is anticipated that the handle apertures 68 may be formed on the first and second sealed sheets 20 of the bottom portion 38 of the pouch 10 as well.

[0036] With reference now to Figures 5 and 6, the pouch 10 may further include a skirt 70. The skirt 70 is formed along the bottom edge 42 of the pouch body 12. The skirt 70 may be composed of a sheet 20 of laminate material. More specifically, the skirt 70 may include a panel of material extending along the bottom edge 42 of the pouch body 12. The panel of material may include at least one elongated baffle 72. The elongated baffle 72 extends axially along a portion of the length of the skirt 70.

[0037] The skirt 70 further includes an inner surface opposite 74 an outer surface 76. The skirt 70 may include multiple elongated baffles 72 formed on both the inner and outer surfaces 76 of the skirt 70. The elongated baffles 72 are operative to prevent the bottom edge 42 of the pouch body 12 from collapsing inwardly with respect to the center of the pouch body 12. Thus, the skirt 70 remains sufficiently rigid so as to retain its wall shape and support the filled pouch 10 in a generally upright manner when the pouch 10 is placed upon its bottom end. [0038] The baffles 72 may be formed using a pair of sealing bars 66. Each of the sealing bars 66 includes a sealing surface. The sealing surfaces include a teethed edge configured to fittingly engage each other. In operation, heat may be applied to the sealing bars 66. The skirt 70 is placed between each of the sealing bars 66. The sealing bars 66 are pressed towards each other pinching the skirt 70. The skirt 70 is heated and the sealing bars 66 are displaced away from each other, leaving a plurality of baffles 72 formed on the inner and outer surfaces 76 of the skirt 70.

[0039] Each side portion 18 has a predetermined width (W) and extends axially along the respective sides of the pouch 10. The side edges 18 have an outer seal 80a spaced apart an inner seal 80b so as to form a gas pocket 80. The inner seal 80b extends generally longitudinally from the top of the pouch body 12 to the bottom of the pouch body 12. It should be appreciated that the top 11 of the pouch body 12 refers to the portion of the pouch 10 adjacent the handle 68, and the bottom of the pouch body 12 refers to the portion of the pouch 10 adjacent the skirt 70. Preferably the inner seal 80b is a tack seal formed by applying low temperatures to the sheets so as to melt a portion of the respective sheets 22, 24 together. Tack sealing is a sealing method currently known and used in the art. It is known by those skilled in the art that the temperature used for the tack seal is sufficient to melt the sheets 22, 24 together and yet prevent the ketones from entering into the pouch body 12.

[0040] The outer seal 80a is spaced apart from the inner seal 80b. The outer seal 80a may be formed using a high temperature seal technique. High temperature seal techniques are currently known and used in the art, and any such technique is adaptable for use herein. The temperature used in high temperature seal techniques is sufficient to melt the material together to form one body of material. In the instant case, single body of material forms the distal ends of the side portions 18. The singular body of material is then cooled.

[0041] The outer and inner seals 80a, 80b both extend between the top 11 and bottom 13 of the pouch body 12. Gases may be injected into the gas pocket 80. Preferably gases such as carbon dioxide, nitrogen, or oxygen are injected into the pocket 80 so as to fill the pocket 80 with a predetermined pressure sufficient to support the side portions of the pouch body in a relatively upright manner. Upon injection of the gas, the top 11 and the bottom 13 of the pouch 10 may be sealed so as to maintain the predetermined pressure within the pocket 22.

[0042] With reference again to Figures 3 and 7, a pouch 10 with a fitment 17 is provided. As shown, the bottom 13 of the pouch 10 includes a gusset 34 to help the pouch body 16 expand during filling operations. The top 11 and bottom of the pouch 10 are sealed to form a single sealed edge extending axially between opposing side portions 18 of the pouch 10. The gas pocket 80 is filled with gas and has a predetermined pressure operable to support the pouch in a relatively upright manner.

[0043] With reference now to Figure 3, a side view of the formed pouch 10 is provided. The ribs 42 extend generally between the top 20 of the pouch and the gusseted bottom 28 of the pouch 10. The side edge 18 is shown and the gas pocket 30 is also shown extending beyond the outer surface of respective side edges 18. Accordingly the pouch 10 is provided with structure to help maintain the pouch in a generally upright position. More specifically the pair of opposing side pockets 30 help form a rigid outer side edge 18 of the pouch 10 which can be used as a handle 46 for manipulating the pouch and handling the pouch. Additionally the reinforcing ribs 40 form a structural support to maintain the pouch 10 in an upright manner despite the displacement of product in the pouch.

[0044] The invention has been described in an illustrative manner. It is therefore to be understood that the terminology used is intended to be in the nature of words of description rather than limitation. Many modifications and variations of the invention are possible in light of the above teachings without varying from the scope and spirit of the invention described herein.