Pouch forming mold configuration, and method

1. A mold configuration for forming a pocket in a base film of a pressurized product containment pouch having a base film and a lid film adhered about a perimeter seal seam comprising:

a film support surface;

perimeter edge at said film support surface;

wall surfaces extending inward from said perimeter edge defining a mold cavity;

said wall surfaces including a bottom wall surface and transition wall surfaces extending to said bottom wall surface; and

at least one plateau surface within said mold cavity, inward of said perimeter edge.

2. A mold configuration for forming a pocket in a base film as claimed in claim 1 , wherein said perimeter edge includes sharp corner profile perimeter edge portions defining at least one sharp corner profile; and said wall surfaces include inward edge surfaces that extend between said sharp corner profile perimeter edge portions and said at least one plateau surface of said at least one sharp corner profile.

3. A mold configuration for forming a pocket in a base film as claimed in claim 2 , wherein one of said transition wall surfaces extends between said bottom wall surface and said plateau surface of said at least one sharp corner profile.

4. A mold configuration for forming a pocket in a base film as claimed in claim 3 , wherein said sharp corner profile perimeter edge portions defining said at least one sharp corner profile are straight or slightly curved, and meet at an intersection or vertex.

5. A mold configuration for forming a pocket in a base film as claimed in claim 3 , wherein said perimeter edge includes plural sharp corner profile perimeter edge portions defining plural sharp corner profiles, each said sharp corner profile including a plateau surface inward of said sharp corner profile perimeter edge portions.

6. A mold configuration for forming a pocket in a base film as claimed in claim 5 , wherein inward edge surfaces extend between said sharp corner profile perimeter edge portions and said plateau surfaces of each said sharp corner profiles.

7. A mold configuration for forming a pocket in a base film as claimed in claim 6 , wherein a transition wall surface extends between said bottom wall surface and said plateau surface of each said sharp corner profiles.

8. A mold configuration for forming a pocket in a base film as claimed in claim 7 , wherein said wall surfaces further include side wall surfaces extending inward from said perimeter edge and merging with said transition wall surfaces, and said side wall surfaces, transition wall surfaces and bottom wall surface defining a fill volume sized to receive a delivered product component.

9. A mold configuration for forming a pocket in a base film as claimed in claim 6 , wherein said plateau surfaces are disposed relative to the perimeter edge such as to limit elongation of the base film into the mold configuration from the film support surface to no more than twice its original area.

10. A mold configuration for forming a pocket in a base film as claimed in claim 6 , wherein said sharp corner profiles include sharp corner edge portions defining acute and obtuse angles.

11. A mold configuration for forming a pocket in a base film as claimed in claim 6 , wherein said plateau surface is continuous about said perimeter edge.

12. A mold configuration for forming a pocket in a base film as claimed in claim 7 , wherein said inward edge surfaces of each sharp corner profile are disposed at ninety degrees (90°) to each other.

13. Apparatus for forming a pressurized product containment pouch from a base film and a lid film adhered about a perimeter seal seam comprising:

mechanism including a film support surface having at least one mold configuration therein, for forming a pocket in the base film comprising:

a perimeter edge at said film support surface;

wall surfaces extending inward from said perimeter edge defining a mold cavity;

said wall surfaces including a bottom wall surface and transition wall surfaces;

extending to said bottom wall surface, and

at least one plateau surface within said mold cavity inward of said perimeter edge,

mechanism supplying a base film onto said film support surface;

mechanism applying a vacuum to said mold configuration to cause said base film to form a pocket conforming to the shape of said mold cavity;

mechanism for filling said pocket with at least one product component;

mechanism for adhering a lid film to the base film on said film support surface.

14. The apparatus for forming a pouch from film as claimed in claim 13 , wherein said perimeter edge includes sharp corner profile perimeter edge portions defining at least one sharp corner profile; and said wall surfaces include inward edge surfaces that extend between said sharp corner profile perimeter edge portions and said at least one plateau surface of said at least one sharp corner profile.

15. The apparatus for forming a pouch from film as claimed in claim 14 , wherein one of said transition wall surfaces extends between said bottom wall surface and said plateau surface of said at least one sharp corner profile.

16. The apparatus for forming a pouch from film as claimed in claim 15 , wherein said perimeter edge includes plural sharp corner profile perimeter edge portions defining plural sharp corner profiles, each said sharp corner profile including a plateau surface inward of said sharp corner profile perimeter edge portions.

17. The apparatus for forming a pouch from film as claimed in claim 14 , wherein said mechanism including a film support surface comprises a rotatable base forming drum.

18. A method of forming a pouch having at least one sharp corner profile, using a mold configuration for forming a pocket in a film comprising: a film support surface; a perimeter edge at said film support surface; wall surfaces extending inward of said perimeter edge defining a mold cavity; said wall surfaces including transition wall surfaces extending to a bottom wall surface, and a plateau surface inward of said sharp corner profile perimeter edge portions;

the steps comprising:

supporting a base film on said film support surface overlying said mold configuration;

applying a vacuum to said mold configuration to cause said base film to form a pocket conforming to the shape of said mold configuration;

filling said pocket with at least one product component;

adhering a lid film to said base film laterally of said perimeter edge of said mold configuration.

19. A method of forming a pouch as claimed in claim 18 , wherein:

wherein said plateau surfaces are spaced inward of said film support surface a distance sufficient to prevent adherence of a lid film to a base film overlying said plateau surfaces.

20. A method of forming a pouch as claimed in claim 19 , wherein during said forming step said film overlying said plateau surfaces is stretched less than twice its original area.

21. A method of forming a pressurized product containment pouch having a base film and a lid film adhered about a perimeter seal seam using a mold configuration having

a film support surface;

perimeter edge at said film support surface;

wall surfaces extending inward from said perimeter edge defining a mold cavity;

said wall surfaces including a bottom wall surface and transition wall surfaces extending to said bottom wall surface; and

at least one plateau surface within said mold cavity, inward of said perimeter edge;

the steps comprising:

supporting a base film on said film support surface overlying said mold configuration;

applying a vacuum to said mold configuration to cause said base film to form a pocket conforming to the shape of said mold configuration;

filling said pocket with at least one product component;

adhering a lid film to said base film laterally of said perimeter edge of said mold configuration.

22. A method of forming a pressurized product containment pouch having a base film and a lid film adhered about a perimeter seal seam, as claimed in claim 21 ;

wherein said at least one plateau surface is spaced inward of said film support surface a distance sufficient to prevent adherence of the lid film to the base film overlying said at least one plateau surface.

23. A method of forming a pouch as claimed in claim 22 , wherein during said step of forming said base film, said film overlying said plateau surfaces is stretched less than twice its original area.