Flexible container forming apparatus having integrated web surface deformation

A method of forming a film for a container comprising the steps of:

• providing at least one film;
• heating at least a portion of the film against a heated roller;
• forcing the film into contact with an embossing roller, to in turn, continuously deform at least a portion of the surface of the at least one film into a plurality of peaks and valleys;
• accumulating film after the step of surface deforming;
• separating the film from the heated roller in the event that the step of providing the at least one film is stopped;
• reversing the film so that the portion of film that was against the embossing roller is directed backwards so as to be positioned at the heated roller to, in turn, facilitate the reheating of film which had been heated prior to the step of separating but which had not undergone the step of forcing, to in turn, maintain a substantially continuous embossing of peaks and valleys;
• and
• engaging the film with the heated roller when the method is restarted at the location where the embossing ceased on the film, to reheat the location, to in turn, render a substantially continuous embossing of peaks and valleys.

A flexible container forming and filling apparatus which forms a flexible container from at least one film and fills the formed container, the apparatus comprising:

• a flexible container forming assembly including:
• a surface deformation assembly comprising at least one surface deformation subassembly having
• a heating assembly including a heated roller for heating a portion of a film, the heating assembly including means for selectively introducing the film to the heated roller;
• a surface deformation station following the heating assembly configured for plastically deforming at least a portion of the film heated by the heating assembly to form a plurality of valleys and hills on the film, the surface deformation station including means for directing the film in opposing directions therethrough, such that after the operation of the surface deformation assembly is stopped, and prior to restarting thereof, the film heated by the heating assembly but not deformed by the surface deformation station can be rewound to a position at the heating assembly, such that the film is reheated when the surface deformation assembly is restarted, beginning with the region of the film which was previously heated but not deformed by the deformation station prior to stopping;
• a slack accumulation assembly configured for accumulating at least a portion of the film, positioned after the surface deformation station;
• and
• a flexible container sealing assembly;
• a flexible container filling assembly;
• and
• a transfer assembly positioned between the flexible container forming assembly and the flexible container filling assembly, the transfer assembly transferring formed flexible containers from the flexible container forming assembly to the flexible container filling assembly.

A flexible container film forming apparatus which forms film for a flexible container, the apparatus comprising:

• a surface deformation assembly comprising at least one surface deformation subassembly having
• a heating assembly including a heated roller for heating a portion of a film, the heating assembly including means for selectively introducing the film to the heated roller;
• a surface deformation station following the heating assembly configured for plastically deforming at least a portion of the film heated by the heating assembly to form a plurality of valleys and hills on the film, the surface deformation station including means for directing the film in opposing directions therethrough, such that after the operation of the surface deformation assembly is stopped, and prior to restarting thereof, the film heated by the heating assembly but not deformed by the surface deformation station can be rewound to a position at the heating assembly, such that the film is reheated when the surface deformation assembly is restarted, beginning with the region of the film which was previously heated but not deformed by the deformation station prior to stopping;
• a slack accumulation assembly configured for accumulating at least a portion of the film, positioned after the surface deformation station.