Multi-compartment pouch apparatus and methods of manufacture

A multi-compartment pouch apparatus comprising:

• a pouch portion constructed out of a first sheet and an opposing second sheet of a substantially flat, flexible laminate material secured to one another about a sealed perimeter edge thereof, the first sheet and second sheet of a substantially transparent laminate material cooperating to define a pouch cavity therebetween;
• the laminate material comprising:
• an innermost layer constructed out of a polyethylene material configured for being heat-sealable, biocompatible for food contact, and providing a compliant interface that is capable of being welded reproducibly;
• a second layer, adjacent to the innermost layer, constructed out of a polyamide material configured for providing puncture resistance, tear resistance, and flexural toughness to the laminate material;
• a third layer, adjacent to the second layer, constructed out of an aluminum foil material configured for providing an oxygen barrier and light barrier to the laminate material;
• and
• an outermost layer, adjacent to the third layer, constructed out of a polyethylene terephthalate material configured for providing tensile strength, dimensional stability under heat, and resistance to creep to the laminate material;
• a frangible seal spanning the perimeter edge of the first sheet and second sheet of laminate material so as to divide the pouch cavity into a first compartment and a separate second compartment, the frangible seal formed as a heat seal between the innermost layer of each of the first sheet and second sheet of laminate material, without use of any adhesive materials, such that an interfacial bond between the innermost layer of each of the first sheet and second sheet of laminate material is structurally weaker than a cohesive strength of each innermost layer and of the sealed perimeter edge;
• the first compartment containing a volume of a powdered infant formula along with a volume of nitrogen gas;
• the second compartment containing a volume of water along with a volume of nitrogen gas;
• a spout in fluid communication with the pouch cavity for selectively dispensing the powdered infant formula and water therefrom;
• a cap removably engageable with the spout;
• and
• a storage sleeve within which the pouch portion is temporarily positioned during storage and transport, the storage sleeve constructed out of a substantially opaque material configured for blocking light;
• whereby, during use of the apparatus, upon the pouch portion being removed from the storage sleeve and external manual pressure subsequently being applied to the first compartment or second compartment, the frangible seal separates cleanly and uniformly along a length of the frangible seal, turning the first compartment and second compartment back into the single pouch cavity, and causing the powdered infant formula to mix with the water prior to the cap being removed from the spout, without introducing extraneous materials or residues into the pouch cavity.

A method for manufacturing and filling the multi-compartment pouch apparatus of claim comprising the steps of, with the spout already engaged with the pouch portion, the cap already engaged with the spout, and the frangible seal already dividing the pouch cavity into the first compartment and separate second compartment within the pouch portion:

• positioning the apparatus in a dehumidified environment;
• temporarily inserting a first dispensing nozzle into the perimeter edge of the pouch portion so as to be in fluid communication with the first compartment;
• flushing the first compartment with a volume of nitrogen gas via the first dispensing nozzle so as to purge the first compartment of oxygen and moisture;
• with oxygen and moisture displaced from the first compartment, introducing a predetermined volume of the powdered infant formula into the first compartment via the first dispensing nozzle;
• flushing the first compartment again with a volume of nitrogen gas via the first dispensing nozzle so as to purge the first compartment of oxygen and moisture;
• retracting the first dispensing nozzle from the perimeter edge of the pouch portion;
• sealing the perimeter edge of the pouch portion proximal to the first compartment so as to create a permanent seal between the first sheet and second sheet of laminate material;
• temporarily inserting a second dispensing nozzle into the perimeter edge of the pouch portion so as to be in fluid communication with the second compartment;
• flushing the second compartment with a volume of nitrogen gas via the second dispensing nozzle so as to purge the second compartment of oxygen and moisture;
• with oxygen and moisture displaced from the second compartment, introducing a predetermined volume of water into the second compartment via the second dispensing nozzle;
• flushing the second compartment again with a volume of nitrogen gas via the second dispensing nozzle so as to purge the second compartment of oxygen;
• retracting the second dispensing nozzle from the perimeter edge of the pouch portion;
• sealing the perimeter edge of the pouch portion proximal to the second compartment so as to create a permanent seal between the first sheet and second sheet of laminate material;
• sterilizing an outer surface of the pouch portion;
• inserting the pouch portion into the storage sleeve;
• flushing the storage sleeve with a volume of nitrogen gas so as to purge the storage sleeve of oxygen and moisture;
• and
• sealing the storage sleeve.