Contoured pouch with pourable spout, and apparatus and process for producing same

Abstract

The present invention relates to sealed pouches, and apparatus and processes for producing the same. The pouch includes contoured first and second lateral edges, with each lateral edge having concave and convex surfaces. The concave surface of the first lateral edge is substantially opposite the convex surface of the second lateral edge and the convex surface of the first lateral edge is substantially opposite the concave surface of the second lateral edge. Accordingly, a distance between the first and second lateral edges is substantially the same for all elevations of the pouch.

What is claimed is:  
     
         1 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; each of the first and the second lateral edges comprising a concave surface and a convex surface, wherein the concave surface of the first lateral edge is substantially opposite the convex surface of the second lateral edge and the convex surface of the first lateral edge is substantially opposite the concave surface of the second lateral edge.  
     
     
         2 . The pouch of    claim 1    wherein at least one of the first and the second lateral edges is substantially S-shaped.  
     
     
         3 . The pouch of    claim 1    wherein each of the first and the second lateral edges comprises at least one rectilinear portion.  
     
     
         4 . The pouch of    claim 3    wherein said at least one rectilinear portion of each of the first and the second lateral edges is positioned near a top of the pouch.  
     
     
         5 . The pouch of    claim 3    wherein said at least one rectilinear portion of each of the first and the second lateral edges is positioned near a bottom of the pouch.  
     
     
         6 . The pouch of    claim 1    wherein each of the first and the second lateral edges comprises a first rectilinear portion and a second rectilinear portion, the first rectilinear portion of each lateral edge being positioned near a top of the pouch and the second rectilinear portion of each lateral edge being positioned near a bottom of the pouch.  
     
     
         7 . The pouch of    claim 1    comprising a base for supporting the pouch in an upright position.  
     
     
         8 . The pouch of    claim 7    wherein the base comprises a curved section.  
     
     
         9 . The pouch of    claim 1    comprising a pour spout defined by a channel in a sealed edge of the pouch communicating with the inner cavity of the pouch.  
     
     
         10 . The pouch of    claim 9    wherein the channel defines a drinking straw.  
     
     
         11 . The pouch of    claim 9    wherein the pour spout comprises a first sealed edge portion, a slit positioned in the first sealed edge portion, and a second sealed edge portion having a ribbed section and a non-ribbed section, the non-ribbed section of the second sealed edge portion being substantially opposite the slit.  
     
     
         12 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; and a pour spout defined by a channel in a sealed edge of the pouch communicating with the inner cavity of the pouch; wherein each of the first and the second lateral edges comprises a concave surface, a convex surface, and at least one rectilinear portion positioned near a bottom of the pouch, and wherein the concave surface of the first lateral edge is substantially opposite the convex surface of the second lateral edge and the convex surface of the first lateral edge is substantially opposite the concave surface of the second lateral edge.  
     
     
         13 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; the first lateral edge comprising a concave surface and the second lateral edge comprising a convex surface, wherein the concave surface of the first lateral edge is substantially opposite the convex surface of the second lateral edge.  
     
     
         14 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; each of the first and the second lateral edges comprising a non-rectilinear portion, wherein a distance between the first and the second lateral edges is substantially the same for all elevations of the pouch.  
     
     
         15 . The pouch of    claim 14    wherein at least one of the first and the second lateral edges is substantially S-shaped.  
     
     
         16 . The pouch of    claim 14    wherein each of the first and the second lateral edges comprises at least one rectilinear portion.  
     
     
         17 . The pouch of    claim 16    wherein said at least one rectilinear portion of each of the first and the second lateral edges is positioned near a top of the pouch.  
     
     
         18 . The pouch of    claim 16    wherein said at least one rectilinear portion of each of the first and the second lateral edges is positioned near a bottom of the pouch.  
     
     
         19 . The pouch of    claim 14    wherein each of the first and the second lateral edges comprises a first rectilinear portion and a second rectilinear portion, the first rectilinear portion of each lateral edge being positioned near a top of the pouch and the second rectilinear portion of each lateral edge being positioned near a bottom of the pouch.  
     
     
         20 . The pouch of    claim 14    comprising a base for supporting the pouch in an upright position.  
     
     
         21 . The pouch of    claim 20    wherein the base comprises a curved section.  
     
     
         22 . The pouch of    claim 14    comprising a pour spout defined by a channel in a sealed edge of the pouch communicating with the inner cavity of the pouch.  
     
     
         23 . The pouch of    claim 22    wherein the channel defines a drinking straw.  
     
     
         24 . The pouch of    claim 22    wherein the pour spout comprises a first sealed edge portion, a slit positioned in the first sealed edge portion, and a second sealed edge portion having a ribbed section and a non-ribbed section, the non-ribbed section of the second sealed edge portion being substantially opposite the slit.  
     
     
         25 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; and a pour spout defined by a channel in a sealed edge of the pouch communicating with the inner cavity of the pouch; wherein each of the first and the second lateral edges comprises a non-rectilinear portion and at least one rectilinear portion positioned near a bottom of the pouch, and wherein a distance between the first and the second lateral edges is substantially the same for all elevations of the pouch.  
     
     
         26 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; a first sealed edge portion; a slit positioned in the first sealed edge portion; and a second sealed edge portion having a ribbed section and a non-ribbed section, the non-ribbed section of the second sealed edge portion being substantially opposite the slit.  
     
     
         27 . The pouch of    claim 26    wherein the slit comprises a notched section.  
     
     
         28 . A pouch comprising opposing flexible panels having first and second lateral edges, a bottom edge, and a top edge, at least the first lateral edge and the second lateral edge being sealed, defining an inner cavity; a first sealed edge portion; a second sealed edge portion adjoining the first sealed edge portion to form a corner; a sealed section extending generally between the first sealed edge portion and the second sealed edge portion to define an opening; and a slit formed in the first sealed edge portion at a position intermediate the sealed section and the corner such that the distance between the first edge portion at the location of the slit to the second edge portion is not substantially less than the size of the opening.  
     
     
         29 . An apparatus for forming a pouch comprising: 
 a. a pouch forming component for assembling the pouch from at least one web of pouch-forming material;    b. a bottom sealing component for sealing a bottom edge of the pouch;    c. a top sealing component for sealing a top edge of the pouch;    d. an end sealing component for sealing a lateral edge of the pouch to provide a lateral edge having a concave portion and a convex portion;    e. a filling component for filling the pouch with a fill material; and    f. a cutting component for cutting the lateral edge along the concave and convex portions.    
     
     
         30 . The apparatus of    claim 29    wherein the pouch forming component forms a pouch having a front panel, a rear panel, and a base from a single web of pouch-forming material.  
     
     
         31 . The apparatus of    claim 30    wherein the pouch-forming component forms the base as a gusset positioned between the front panel and the rear panel of the pouch.  
     
     
         32 . The apparatus of    claim 29    wherein the top sealing component comprises a pour spout forming section for forming a pour spout near the top edge of the pouch.  
     
     
         33 . The apparatus of    claim 32    wherein the top sealing component comprises a slit forming component.  
     
     
         34 . The apparatus of    claim 32    wherein the top sealing component comprises a notch forming component.  
     
     
         35 . The apparatus of    claim 29    wherein the end sealing component comprises a rib forming portion for forming the lateral edge with a ribbed section.  
     
     
         36 . The apparatus of    claim 35    wherein the rib forming portion is positioned along the end sealing component such that the ribbed section of the lateral edge terminates at a preselected distance from the top edge of the pouch.  
     
     
         37 . The apparatus of    claim 29    wherein the cutting component comprises a cutting knife having a concave cutting surface and a convex cutting surface.  
     
     
         38 . A process for forming a pouch comprising: 
 a. assembling the pouch from at least one web of pouch-forming material;    b. sealing a bottom edge of the pouch;    c. sealing a top edge of the pouch;    d. sealing a first Lateral edge of the pouch to provide a lateral edge having a concave portion and a convex portion;    e. filling the pouch with a fill material;    f. sealing a second lateral edge of the pouch to provide a lateral edge having a concave portion and a convex portion; and    g. cutting the second lateral edge along the concave and convex portions.    
     
     
         39 . An apparatus for forming a pouch comprising: 
 a. a pouch forming component for assembling the pouch from at least one web of pouch-forming material;    b. a bottom sealing component for sealing a bottom edge of the pouch;    c. a top sealing component for sealing a top edge of the pouch;    d. an end sealing component for sealing a lateral edge of the pouch to provide a substantially S-shaped lateral edge;    e. a filling component for filling the pouch with a fill material; and    f. a cutting component for cutting along the substantially S-shaped lateral edge.    
     
     
         40 . The apparatus of    claim 39    wherein the pouch forming component forms a pouch having a front panel, a rear panel, and a base from a single web of pouch-forming material.  
     
     
         41 . The apparatus of    claim 40    wherein the pouch-forming component forms the base as a gusset positioned between the front panel and the rear panel of the pouch.  
     
     
         42 . The apparatus of    claim 39    wherein the top sealing component comprises a pour spout forming section for forming a pour spout near the top edge of the pouch.  
     
     
         43 . The apparatus of    claim 42    wherein the top sealing component comprises a slit forming component.  
     
     
         44 . The apparatus of    claim 42    wherein the top sealing component comprises a notch forming component.  
     
     
         45 . The apparatus of    claim 39    wherein the end sealing component comprises a rib forming portion for forming the lateral edge with a ribbed section.  
     
     
         46 . The apparatus of    claim 45    wherein the rib forming portion is positioned along the end sealing component such that the ribbed section of the lateral edge terminates at a preselected distance from the top edge of the pouch.  
     
     
         47 . The apparatus of    claim 39    wherein the cutting component comprises a cutting knife having a substantially S-shaped cutting surface.  
     
     
         48 . A process for forming a pouch comprising: 
 a. assembling the pouch from at least one web of pouch-forming material;    b. sealing a bottom edge of the pouch;    c. sealing a top edge of the pouch;    d. sealing a first lateral edge of the pouch to provide a substantially S-shaped lateral edge;    e. filling the pouch with a fill material;    f. sealing a second lateral edge of the pouch to provide a substantially S-shaped lateral edge; and    g. cutting along the substantially S-shaped second lateral edge.    
     
     
         49 . The process of    claim 48    wherein the filling and second lateral edge sealing steps occur simultaneously.