Not applicable
Not applicable
Not applicable
1. Field of the Invention
The present invention relates to a method of and apparatus for forming closures for reclosable pouches, and more particularly, to an extrusion process and apparatus for forming multiple closure elements.
2. Description of the Background of the Invention
A reclosable thermoplastic pouch includes a closure disposed at a mouth of the bag. Recently, pouches have been developed wherein the closure comprises multiple closure elements. The closure is typically formed by extruding two closure elements connected by an intermediate portion through an aperture of a die plate. An example of one such closure, depicted in
Zieke et al. U.S. Pat. No. 4,741,789 discloses a zipper and a method of extruding the zipper onto a plastic film web. The zipper includes a base member, a single closure member protruding from the base member, and a pair of guide ribs on the base member on opposite sides of the closure member. During formation of the zipper, the web is drawn from a roll over a lamination cylinder, and the base member is extruded onto the web as the web passes over the lamination cylinder. The single closure member and ribs are then extruded onto the base member as the film and base member pass over the lamination cylinder. The single closure member and the two guide ribs are extruded through separate apertures that are vertically spaced from and laterally overlapping each other.
Goulde U.S. Pat. No. 4,835,835 discloses a method of extruding a fastener strip having a plurality of interlocking closure elements. The interlocking elements are connected by a base portion. The closure elements and the base portion are extruded through a single die plate aperture.
DiPietro et al. U.S. Pat. No. 5,411,692 discloses a method of and apparatus for extruding a bag film and a closure profile integrally connected to the bag film. A single die is used for extruding the film and closure profile. The film is extruded through a main plenum and the closure profile is extruded through a channel that is diverted from the main plenum. The channel and the main plenum converge upstream of a die exit port so that the closure profile is reunited with the film prior to exiting the die.
Tomic et al. U.S. Pat. No. 5,425,911 discloses a method of extruding a bag film with an integral closure strip having two interlocking closure elements and a die assembly for use in the method. The film is extruded through a thin outlet port between two opposing die lips in the die assembly. The closure elements are extruded integrally with the film through a set of grooves in one of the die lips.
Plourde U.S. Pat. No. 6,080,252 discloses a method of forming a zipper component for subsequent attachment to a bag wall. A flange is extruded onto a continuous carrier web, and a single profile is extruded onto the flange while the flange is on the carrier web. The resulting component is then cooled and stripped from the carrier web.
In one embodiment of the invention, a method of forming a first closure element and a second closure element on a film web includes the steps of passing a polymer film web having a lateral width adjacent to an extrusion die and extruding the first and second closure elements at the same time directly onto the web. The closure elements are extruded such that the first closure element is laterally spaced from the second closure element on the web. The first closure element is extruded from a first aperture that is spaced from and partially overlaps laterally a second aperture from which the second closure element is extruded.
In another embodiment of the invention, a die plate includes a first aperture through a face of the die plate and a second aperture through the face. The first aperture is shaped for extruding a first closure element onto a polymer web having a lateral width and the second aperture is shaped for extruding a second closure element. The first aperture is spaced from the second aperture on the face and partially overlaps the second aperture in the lateral direction
Referring to
A hybrid integral/post applied process using the apparatus shown in
After the web 62 is pinned to the casting roll 52, the closure elements 28-34 and bead elements 36, 38 are formed onto the edge portions 64a, 64b of the web 62. Preferably, the extrusion dies 58a, 58b receive molten thermoplastic from separate extruders and extrude the male and female closure elements 28, 34 and 30, 32 onto the edge portions 64a and 64b, respectively. Alternatively, the separate extrusion dies 58a, 58b may be replaced by a single extrusion die having two outlets at which the male and female closure elements 28, 34 and 30, 32 are simultaneously extruded onto the edge portions 64a and 64b, respectively. Regardless of which extrusion process is used, the extrusion die 58a includes a first die plate 66a (depicted in detail in
Referring to
Referring to
The size, shape, and relative positions of the apertures 80, 82, 84 and 88, 90, 92 in each die plate 66a and 66b, respectively, are preferably designed, both individually and as a set, in order to provide a balanced flow rate of extrudate through all the apertures in the die plate. If the apertures are not correctly designed, the extrudate may flow through one aperture, or one area of one aperture, more rapidly than through other areas of the apertures, which may cause the final closure elements 28-34 to have incorrect shapes and/or sizes and prevent the closure elements from functioning properly. To initially balance the apertures in a die plate, the layout of the apertures, including the area, shape, and relative positions of the apertures, is varied by trial and error until a layout is achieved that produces acceptable closure elements. After obtaining a balanced layout, changes can be made to an individual aperture by changing the shape in small increments and generally keeping the area of the aperture constant.
Referring to
Referring to
Once the molten thermoplastic from the die plates 66a, 66b has been deposited onto the web 62, coolant is applied to the closure and bead elements 28-38 by cooling apparatus 60a, 60b to bring the temperature thereof below the melting point of the thermoplastic material, thereby forming the elements as quickly as possible. Preferably, the coolant comprises water or any other suitable cooling fluid and the coolant is applied to the material of the closure elements 28-38 only after such material contacts the material of the web 62 so that adhesion thereto is optimized. The web 62 and the closure and bead elements 28-38 are maintained in contact with the temperature-controlled casting roll 52 for a period of time as the roll is rotated so that the web and closure/bead elements are further cooled. The casting roll 52 should be maintained at a temperature below the melting point of the thermoplastic materials forming the web 62 and the closure/bead elements 28-38, typically about 20-80 degrees C.
Referring to
The method disclosed above is not limited to forming an entire pouch, but may be easily adapted if desired, to form zipper tape. In such a case, the closure elements and/or bead elements of the above embodiment can be separately extruded on internal surfaces of flanges to form zipper tape having two closely spaced closure elements. The zipper tape may be subsequently post-applied to film in a bag production process.
Thermoplastic pouches similar to that described above can be produced by any suitable bag-making process, such as a cast post applied process, in which the closure elements are extruded separately from die plates similar to die plates 66a, 66b onto the film web that forms the bag walls. It should also be noted that the extrusion die(s) used to form the closure mechanisms and strip(s) must include a suitable number of die plates to form such structures. In addition, an air nozzle may be provided in association with each female closure element that blows air into the opening of each C-shaped female profile member to open the member as it is being extruded.
The method and apparatus described herein may be used to form the pouch and zipper tape described herein, which advantageously creates a perception of a wide-track feel that guides a user's fingers during closure thereof. The method and apparatus eliminates the need to extrude an interconnecting portion between two (or more) closely spaced closure elements and still form multiple, individual, closely spaced closure elements through a single die plate for subsequent application to a film web.
Numerous modifications will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.
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