ONE-PIECE FITMENT WITH RETAINED, TAMPER-EVIDENT FEATURE FOR FILLING AND DISPENSING FLEXIBLE POUCH OR BAG CONTAINERS

CROSS REFERENCE TO RELATED APPLICATION AND TECHNICAL FIELD

[0001] This application claims priority to United States provisional patent application serial no. 63/343,220 filed on May 18, 2022 and relates generally to welded-in plastic spout dispensers and, more specifically, to a single piece, integrally-molded spout and cap assembly, having retained tamper-evidence.

BACKGROUND

[0002] Flexible containers and pouches are finding increased utility owing to their simple, cost-efficient construction and adaptability to numerous dispensing and manufacturing operations. In particular, the containers and pouches (also referred to as “bags”) can be made from a single or multi-layered sheets of film that bonded or heat sealed together into any number of shapes and configurations. The use of such bags also allows for greater versatility in selection of materials (both on the inner and outer surfaces that are, respectively speaking, in contact with the dispensed fluid and the ambient environment).

[0003] In order to facilitate filling and/or dispensing from such bags, specifically shaped plastic assemblies are provided to serve as a conduit for fluids flowing in and out of the bag. United States Patents 5,823,383; 6,958,033; 7,850,044; 8,075,189; and 10,486,880 provide examples and further explanation of the considerations inherent to these welded-in fitments and pieces. Still other fitments are focused on creation of spouts and in situ dispenser elements, such as United States Patent Publication 2011/0108572 and United States Patents 8,448,820; 8,573,445; and 9,592,944 (although it should be noted that these fitments lack heat dissipating elements and, therefore, are not directly comparable to the previously identified examples). All of the aforementioned patent documents are incorporated by reference in their entirety.

[0004] These fitments penetrate through an aperture or slit formed in one of the layered or single sheets forming the bag. Heat is applied to melt and adhere the layered sheet to the fitment so as to create a heremtic or leak-proof seal. Formations on the inner facing of the fitment may enhance contact, heat conductance, and overall performance of the seal between the bag and the fitment, while a spout or flow channel on the outer facing allows fluid to be dispensed from the bag. It may also be possible to position the fitment between the sheets of the bag or pouch as part of the assembly process for that bag or pouch.

[0005] Conventional fitments, including those shown in the patents above, relied upon a threaded cap to be rotatably attached to the fitment. While this approach is familiar to users, cost effective, and suitable to seal the bag/flow channel, it relies upon a multiplicity of pieces that must be manufactured separately and may be prone to becoming misplaced. The threads also require an elongated axial surface on the outer protruding part of the fitment to allow for rotation and engagement of the parts. To the extent tamper-evident (“TE”) features are desired, such twist caps usually rely upon a frangible ring provided beneath the lower axial edge of the cap. When the cap is initially removed, the ring breaks loose from cap thereby creating a third plastic part.

[0006] Within the packaging industry, considerable attention is now being placed on reduction of loose plastic parts and reliance on designs that are more environmentally sustainable. As such, conventional fitments with multiple pieces are not favored. Further, these designs may rely on separate manufacturing processes for the spout and the cap (and TE features, if present), including the need for separate tooling and possibly even the use of different and potentially incompatible polymers (from a recycling perspective).

[0007] In view of the foregoing, a welded-in, one piece, resealable fitment would be welcome. If such a fitment also had tamper-evidence that did not detach from the fitment itself, it would be viewed even more favorably.

DESCRIPTION OF THE DRAWINGS

[0008] The appended drawings form part of this specification, and any information on/in the drawings is both literally encompassed (i.e., the actual stated values) and relatively encompassed (e.g., ratios for respective dimensions of parts). In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein. Unless otherwise stated, all dimensions in the drawings are with reference to inches, and any printed information on/in the drawings form part of this written disclosure.

[0009] In the drawings and attachments, all of which are incorporated as part of this disclosure:

[0010] Figure 1 A is a side plan view of the various fitments described herein affixed to a bag or pouch, while Figures IB and 1C are, respectively speaking, isolated views of the side and front of the fitment affixed to the bag, similar to the one shown in Fig. 1 A. [0011] Figure 2A is a three dimensional, perspective view and Figure 2B a top plan view, both of the fitment of Fig. 1A in isolation and in its closed and unopened state, so that the tamper evident strip remains in its original form.

[0012] Figure 3A is a three dimensional, perspective view; Figure 3B a top plan view; and Figure 3C a side plan view — all of the fitment of Fig. 1 A in isolation and in its opened and tamper-evidenced state.

[0013] Figures 4A and 4B are comparative cross-sectional side views (as taken along a central diameter, based upon the view in Fig. 3C) of the fitment of Fig. 1 A in isolation in its closed (Fig. 4A) and opened (Fig. 4B) states.

DESCRIPTION OF INVENTION

[0014] Operation of the invention may be better understood by reference to the detailed description, drawings, claims, and abstract — all of which form part of this written disclosure. While specific aspects and embodiments are contemplated, it will be understood that persons of skill in this field will be able to adapt and/or substitute certain teachings without departing from the underlying invention. Consequently, this disclosure should not be read as unduly limiting the inventions).

[0015] As used herein, the words “example” and “exemplary” mean an instance or illustration and, as such, are not intended to indicate a key or preferred aspect or embodiment. The word “or” should be construed as inclusive rather an exclusive, unless context suggests otherwise. For example, the phrase “A employs B or C,” includes any combination or permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0016] Understanding that the invention is particularly useful with elongated containers having a spout that directs fluid flow along an axis, it will be understood that “axial” and “longitudinal” may be used synonymously, with both referring to the direction of fluid out of the spout (in cases where the spout is on the top edge of the container, vertically or at an angle when the spout is affixed to a comer of a directional pour bag — see Fig. 1A). In contrast, “radial” or “transverse” are with reference to the axial or longitudinal direction, meaning an orthogonal relationship. In some contexts, top and bottom may simply refer to the spout as it is pictured and oriented in Figs. 3 A and 3C, with the outlet of the spout corresponding to the top and the inlet (formed within the base) at the bottom.

[0017] The size and spacing of the component presents one of the primary challenges in designing fully functional welded-in fitments. These fitments require an elongated base, sometimes provided with ribs or ridges to dissipate heat experienced by the fitment and the bag when the two are welded together. An aperture is formed through that base and extends upward by way of a cylindrical channel that serves as the spout. However, owing to the tolerances required to fit the spout channel through the aperture in the bag as well as the need to mitigate heat transfer during welding, fitment designs cannot be arbitrarily expanded or significantly altered. In addition, the inclusion of extraneous or excessively large protrusions may increase materials costs.

[0018] These considerations are amplified with respect to tamper-evident features. The conventional approach for TE features between a container neck and cap is to form a single piece cap with a frangible ring. When the cap is initially screwed down onto the fitment spout, the ring flexes outward as it passes over a capture protrusion formed on the spout. That capture protrusion than retains the ring and causes it to break away from the lower extremities of the cap the first time the product is used. Various styles of flip top caps, some with tamper evident features, can be found in International Publication WO 2006/099214 and United States Patents 5,201,440; 5,662,245; 5,755,360; 6,655,553; and 6,848,603.

[0019] This conventional approach involving a detachable cap is easily adapted (and is widely, if not exclusively, used) for welded-in fitments. A cap of the same or a comparatively smaller outer diameter (relative to the base of the spout on the fitment) may be readily incorporated into existing bag designs and production lines. However, particularly for directional pour-formed pouches (in which the spout is positioned in the comer of a flat polygonal shaped container, like the one shown in Fig. 1A), screw-on flip top caps can create obstructions if the cap does not align properly when it is first secured. That is, the direction in which the top pivots must be on the opposite side of the expected pouring direction. This means that fitments lacking an elongated base are not amenable to welded-in attachments for directional pour bags because it is difficult to properly register the threads/positioning of the cap when affixed.

[0020] As such, the conventional approach produces in two separate and fully detached plastic components. Recent legal requirements focused on sustainability call for reduction or elimination of precisely this sort of extraneous plastic waste. As a result, while squeeze pouches with screw-on flip top caps are known (e.g., see United States Patents 9,598,820 and 10,399,750), the inventor is unaware of any welded-in fitment in which an integrated, selfrestrained tamper evident feature has been adapted to a welded-in fitment and particularly for one capable of registering properly for use on directional pour-formed pouches. [0021] The inventor endeavored to address the shortcomings of conventional welded-in spouts, including the elimination of loose plastic waste and providing a reliable, self-aligning flip top cap that will not interfere with pouring/dispensing. The fitment is now formed in a single molding operation, including appropriate tooling to create/impart the features described herein. The resulting single piece welded-in fitment includes a flip top cap, automatic directional alignment for the pivot of the cap, and a tamper-evident strip that remains affixed to the cap while still providing a clear indication the first time the cap is opened/used.

[0022] With further reference to Figs. 1A through 4B (as described above), dispensing system 10 includes a pouch-style container 100 with a welded-in fitment 200. The container 100 may be formed by heat sealing and adhering conforming front and back panels 110, 120. An optional bottom panel 130 — as well as additional panels (not shown) — may be included to impart a specific shape to the container 100. As shown, panels 110, 120 are largely polygonal, while bottom panel 130 has an oval or elliptical shape, although other configurations are possible. In a preferred aspect, the pouch 100 will be configured so that the inventive spout is positioned in a top comer, as shown in Fig. 1 A.

[0023] The sheets 110, 120, 130 are attached by any conventional means. However, as these sheets are being formed into the final, desired container shape, fitment 200 is situated between two adjoining layers. In this manner, the edges of fitment 200 can be integrally formed within the container 100 itself. One configuration of particular interest is to insert the fitment 200 at a comer 102, with the edges of sheets 110, 120 either clipped or folded inward. The fitment 200 itself also possesses certain features to enhance its attachment to the sheets 110, 120, as will be described below. [0024] Heat or adhesive is applied to the joined edges of the sheets 110, 120 and fitment 200 so as to create a fluidic and/or hermetic seal. To further these purposes, the sheets 110, 120 may be made of one or more layers of various polymers, with additional layers (e.g., foil(s)) interposed therebetween. Ultimately, the selection of films is dependent upon the fluids to be provided to the container and the means of sealing the sheets to form the container.

[0025] One of the more salient aspect of the invention relates to the shape and features provided to the fitment 200. Generally speaking, fitment 200 includes three functional aspects: an transverse attachment base 220, a longitudinal conduit 240, and a pivoting cap or closure 260. The tamper evident feature 280 is disposed at the interface between the conduit 240 and the cap 260.

[0026] As noted above, fitment 200 is formed as single unitary piece, with appropriate tooling or post molding operations imparting the necessary features. In this manner, the need for further assembly and sealing of the dispensing system 10 is largely if not completely eliminated. Also, by providing a flip top cap that is automatically registered so as to pivot orthogonally in comparison to the pouring direction (line 4B-4B in Fig. 4B), inspection and/or cameras to verify positioning of the pivot direction of the cap can also be eliminated.

[0027] Polymers that are capable of being recycled and/or post-consumer recyclable materials are preferred candidates for forming the fitment 200. Polypropylene, polyethylene, and other similar grades of plastics could be particularly beneficial.

[0028] In terms of the features, the transverse base 220 has a diamond or wedge-like shape when viewed from the top (see Figs. 2B and 3B). The transverse end points 221, 222 may include fins or a transversely aligned flange. The base 220 increases in width from those two points, preferably in regular and symmetrical manner so as to accommodate the outer diameter of the conduit 240. A series of planar ribs 224 are aligned between the top and bottom base plates 223, 225. The ribs 224 will substantially conform to the shape of the plates 223, 225, and ribs 224 help to create a sealing surface along the longitudinal faces of the base 220, with gaps between the ribs providing means of dissipating heat applied to the sheets 110, 120 when the fitment 200 is welded in place. The flanges 221, 222 may extend between the top and bottom plates 223, 225 to improve the structural integrity and/or further accommodate heat dissipation.

[0029] Conduit 240 includes a hollow tube 242 aligned along axis 4B-4B with an inner diameter that provides passage for fluid. Tube 242 defines a fluid passage or aperture 243 that allows for dispensing when the cap 260 is pivoted to the open position.

[0030] The outer facing in lower portion 244 of the conduit 240 may have a reduced outer diameter to allow for ribs 224 to be partially formed thereon, as well as reduced thickness for heat dissipation. In contrast, the upper portion 246 has an increased wall thickness for structural integrity and to accommodate the cap 260 and tamper evident features 280.

[0031] At the top end 247 of conduit 240, a cylindrical wall 248 extends upward beyond wall portion 246. The cross sectional or transverse shape of wall 248 is configured to cooperate with a similar wall 268 formed on the pivoting head 262 of cap 260. A sloping ledge 249 is disposed adjacent to the wall 248 on the opposite side from where living hinge 270 connects the cap 260 to the conduit 240. Ledge 249 is configured to accommodate the tamper evident 280, including its attachment hinge 290 and release detent 282, along with the release tab 264 formed on the cap head 262 (see Fig. 2A). A bead, sloping section, or other coupling feature 241 that cooperates with wall 268 (or corresponding features formed on its lower edge) may be provided on the inner facing of the upper section 246. [0032] Cap or closure 260 is attached to the conduit 240 by way of a living hinge 270. Hinge 270 is integrally formed as part of the molding process, although it may include multiple bending members 271, 272, 273. In some configurations, members 271, 273 are substantially identical and formed to have a different length in comparison to member 272. This allows for the members 271, 272, 273 to extend and remain in a fully opened position, as shown in Figs. 3A and 3B. The thickness of the hinge 270 is configured to withstand repeated opening and closing without detaching from the conduit 240.

[0033] The cap 260 includes an optional annular skirt 263. Release tab 264 may extend from the wall 286 and/or the skirt 263. When the fitment 200 is first molded, the head 262 is provided in the closed position, but with the tab 263 sandwiched between the ledge surface 249 and the detent 282 on the tamper evident strip 281. Frangible bridges 284 on the strip 281 keep the tamper evident feature 280 secured to the conduit 240 or the wall 248; however, when the cap 260 is pivoted to open the flow passage 243, tab 264 causes the bridges 284 to break away, thereby displacing the strip 281 and providing an indication the first time the cap 260 is opened [0034] A pull tab 286 may be provided at one end of the strip 281 to facilitate or initiate breaking of the bridges 284. In this manner, the strip 281 is pealed away from the fitment 200 (and, more specifically, the conduit 240) so as to allow the tab 264 and the cap head 262 to pivot to the open position.

[0035] A reinforced hinge or attachment section 290 is formed on the strip 281 at the opposite end from the tab 286. Hinge 290 allows the strip to be bent away from the interface of the conduit 240 and cap 260, so that the dispensing channel 243 can be opened or closed as desired without interference from strip 281. In some aspects, hinge 290 allows the strip 281 to fold away from and/or onto the outer facing of the conduit 240. However, the hinge is structurally sufficient to remain affixed to the fitment (possibly by having increased thickness in comparison to the bridges 284), thereby eliminating the creation of unwanted plastic parts.

[0036] In some arrangements, the release tab may be affixed to the conduit and the tamper evident strip to the cap. In this arrangement, the “sandwiched” arrangement of the tab and the tamper evident strip are flipped, so that the ledge abuts the strip and the tab (which remains immovably fixed in place on the conduit) provides resistance to require removal of the strip before the cap can be pivoted to the open position.

[0037] Also, the cap 260 can be configured to pivot open at an orthogonal angle in comparison to the intended positioning of the transverse base 220. That is, the diamond-like shape of the transverse base 220 insures that the base will oriented with a preferred dispensing position, as shown in Figs. 1A through 1C. Thus, the living hinge 270 is formed to open at an angle so that the open position of the cap 260 does not impede the ability to pour or dispense fluid. Preferably, that angle will be oriented at about ninety degrees in comparison to the transverse axis defined by the opposing ends 221, 222 of the base 220. This arrangement eliminates problems encountered when a conventional flip top cap is separately attached, in which case an extra processing step is needed to insure the open position for the pivoting action is not impeded.

[0038] Also disclosed is a spout and dispenser with tamper-evidence and formed as an integral, monolithic piece, all as substantially described, disclosed, or otherwise contemplated herein.

[0039] Further disclosed is a method, system, and combination of the same, all as described, disclosed, or otherwise contemplated herein. [0040] All patents identified in this section are incorporated by reference to provide further details informing aspects of the background and aspects of the invention itself. All components should be made of materials having sufficient flexibility and structural integrity, as well as a chemically inert nature. Certain grades of polypropylene and polyethylene are particularly advantageous, especially in view of the absence of any thermosetting resins and/or different, elastomeric polymer blends. The materials should also be selected for workability, cost, and weight. Common polymers amenable to injection molding, extrusion, or other common forming processes should have particular utility.

[0041] References to coupling in this disclosure are to be understood as encompassing any of the conventional means used in this field. This may take the form of snap- or force fitting of components, although threaded connections, bead-and-groove, and slot-and-flange assemblies could be employed. Adhesive and fasteners could also be used, although such components must be judiciously selected so as to retain the recyclable nature of the assembly.

[0042] In the same manner, engagement may involve coupling or an abutting relationship. These terms, as well as any implicit or explicit reference to coupling, will should be considered in the context in which it is used, and any perceived ambiguity can potentially be resolved by referring to the drawings.

[0043] Although the present embodiments have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the invention is not to be limited to just the embodiments disclosed, and numerous rearrangements, modifications and substitutions are also contemplated. The exemplary embodiment has been described with reference to the preferred embodiments, but further modifications and alterations encompass the preceding detailed description. These modifications and alterations also fall within the scope of the appended claims or the equivalents thereof.