BACKGROUND OF THE INVENTION
This present invention generally relates to reclosable plastic bags, and a method of their manufacture that is more efficient and economical than conventional methods and devices, and in particular to reclosable bags which can be torn open to access their content.
Current reclosable bags have been designed in to provide ease of use for users. However, there are shortcomings in the currently available reclosable bags. As an example, consider prior art U.S. Pat. No. 6,030,122 to Ramsey et al (“Ramsey '122 patent”). A particular problem with the Ramsey '122 technique is that a greater amount of force is required to open the reclosable fasteners from outside the bag than the amount of force required to tear open the bag from the middle. Such disproportionate amount of force may damage the reclosable bag or even the contents of the reclosable bag when a user opens the bag.
Consider further, U.S. Pat. No. 5,461,845 to Yeager (“Yeager '845 patent”). There are at least two definitive shortcomings with the technology described therein. The first shortcoming relates to the problem of having to open the zipper completely from the front panel of the finished bag. Users of reclosable bags and packaging are accustomed to opening the profiled fastener from the “top” of the package, and not from the front panel of the package. Hence, the user will have to become accustomed to an unfamiliar or uncomfortable manner in which to open a bag.
The second shortcoming is more serious, and relates to the requirement of opening the package from the front panel thereof. If the package is to be opened from the front panel, a cut or perforation must be made before the fastener is applied. This cut, or perforation, is generally shaped like an “oval” with opening “tabs” for gaining access to the fastener. Since the fastener, most likely, is not closed at the ends of the fastener, the possibility of contamination exists.
The most expedient and economical way to make the package is to create the cut, or perforation, in one operation, just upstream of the fastener strip application. This operation, in its simplest form, will leave openings for potential contamination to pass through the cut or perforated front panel opening. To overcome this contamination potential, users of this method add a great deal more cost and complexity to create a sealed, sealable “patch”, or some other means of eliminating this contamination risk. The same problem occurs, if the package must be hermetically sealed.
Hence, there exists a need to solve the problems in the art that are articulated above.
SUMMARY OF THE INVENTION
Accordingly, among other advantages, the reclosable bag described herein overcomes the shortcomings of the prior art by providing a reclosable back-seam bag that provides a hermetic seal by sealing a bag body with a top seal, a bottom seal, a back seam seal, and a plurality of seals sealing a reclosable fastener with flanges to a front wall and, in some cases, to a back wall of the bag body. In another embodiment, a reclosable bag can be configured as a side-seam bag having one web of film folded along a longitudinal fold to form two half webs of film, and having top edges of each of the two half webs of film sealed together to form a side seam. In another embodiment, the reclosable bag is configured as having two webs of film that are sealed together along respective edges of the two webs of film to form four side seams, each of the two webs of film having an inside surface, and the back wall having two sides, each side being defined between each of the four side seams and a respective one of the two webs of film.
The reclosable bag includes a reclosable fastener assembly that includes two ends, a first continuous elongated profile strip and a second continuous elongated profile strip. The first continuous elongated profile strip and the second continuous elongated profile strip provide a seal upon interconnection thereof.
A seal is provided at each end of the reclosable fastener assembly. The reclosable bag is further provided with a first continuous elongated profile strip that has a front wall connecting flange and a gripping flange. Both the front wall connecting flange and the gripping flange have a width greater than a width of the first continuous elongated profile strip to assist in positioning and sealing of the reclosable fastener to web stock. The front wall-connecting flange is sealed to the front wall of the bag.
A frangible access that is substantially parallel to the reclosable fastener assembly may be provided through the front wall of the bag by means of one or more score lines. Upon opening, the frangible access exposes the reclosable fastener assembly. The frangible access may be disposed on the front wall or the back wall of the bag body adjacent the reclosable fastener assembly and above the bottom seal.
In one example, a reclosable back-seam bag includes a gripping flange that includes a continuous rib disposed at a distal end of the gripping flange and/or a plurality of continuous, substantially parallel ribs disposed on the gripping flange. The ribs and the gripping flange provide a user with ease of opening of the reclosable fastener once the frangible access has been opened.
In another example, a method of making a reclosable back-seam bag. The method includes the steps of providing a rectangular sheet of polymeric material having an inside surface. A predetermined length of a reclosable fastener including two ends, and a first continuous elongated profile strip interlocked with a second continuous elongated profile strip is provided, and a front wall connecting flange of the reclosable fastener is connected to the inside surface of the rectangular sheet.
The method includes the step of forming a bag body having a front wall and a back wall. The back wall is formed by folding the rectangular sheet of film along two longitudinal folds, and overlapping and sealing edges of the rectangular sheet.
The method further includes joining the front wall to the back wall at a bottom seal, and connecting a back wall connecting flange to the inside surface of the rectangular sheet and the back wall of the bag at a back wall connecting seal. A frangible access substantially parallel to the reclosable fastener being disposed on the front wall of the bag body adjacent the reclosable fastener and below the back wall connecting seal is provided for exposing the reclosable fastener. The method also includes providing a top seal above the frangible access.
In another example, a first continuous elongated profile strip having a male interlocking profile includes at least one male interlocking member. Also provided is a second continuous elongated profile strip having a female interlocking profile that includes at least one female interlocking member. The first continuous elongated profile strip can be releasably connected to the second continuous elongated profile strip by engaging the male interlocking member with the female interlocking member. However, in a preferred embodiment, the male interlocking member is provided in an open disengaged position in the bag when the bag is sealed. Thus, the bag may be easily opened by pinching the front and back walls of the bag and separating the walls until the top seal is ruptured or peeled open. The open configuration of the fasteners facilitates such opening. Subsequently, easy access is permitted from either the top of the bag, or from rupturing the frangible access portion located above the bottom seal, and then, separating the fastener profile.
The features described below, other than those specifically set forth above, will become apparent in the detailed description of the preferred embodiments set forth below and in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an embodiment of a front plan view of a reclosable bag;
FIG. 2 is an embodiment of a back plan view of the reclosable bag;
FIG. 3 is an embodiment of a side cross sectional view of the reclosable bag of FIG. 1;
FIG. 4 is an embodiment of a side cross sectional view of the reclosable bag through a side seal of the bag;
FIG. 5 is a perspective view of a rectangular sheet of film having a plurality of reclosable fastener assemblies thereon prior to a form, fill and seal operation;
FIG. 6 illustrates an embodiment of the reclosable bag having the reclosable fastener assembly include a first continuous elongated profile strip;
FIG. 7 illustrates an embodiment of the reclosable bag having the reclosable fastener assembly include a second continuous elongated profile strip;
FIGS. 8A-8D illustrate another embodiment of the reclosable bag in which the reclosable fastener assembly may include two ends, a first continuous elongated profile strip having a front wall connecting flange and a second continuous elongated profile strip having a back wall connecting flange, the flanges respectively extending upward, downward or both on the walls of the bag;
FIG. 9 illustrates a plurality of reclosable fastener assemblies that each include a male part and a female part;
FIG. 10 illustrates another embodiment of the reclosable bag having a frangible access portion to access the contents of the reclosable bag;
FIGS. 11A-11C illustrate different views of an embodiment of a two-flanged reclosable bag;
FIGS. 12A-12C illustrate different views of an embodiment of a three-flanged reclosable bag;
FIGS. 13A-13C illustrate different views of an embodiment of a four-flanged reclosable bag having tack-down seals;
FIGS. 14A-14C illustrate different views of an embodiment of a four-flanged reclosable bag having peelable adhesives or co-extruded beads;
FIGS. 15A-15C illustrate different views of an embodiment of a four-flanged reclosable bag having a frangible membrane that at least a pair of the four flanges.
FIG. 16 illustrates another embodiment of a side view of a four-flanged reclosable bag in which the male interlocking member is provided in an open disengaged position when the top seal of the bag remains sealed.
FIG. 17 illustrates an exemplary machine that can be used to manufacture a reclosable back-seam bag.
FIGS. 18A-18C illustrate different views of an embodiment of a four-flanged reclosable bag having a flange overlap configured with overlap seals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a front plan view of reclosable back-seam bag 100. Reclosable back-seam bag 100 includes a bag body 102. Bag body 102 (FIGS. 1-4) can include a top seal 104 and a bottom seal 106, and a front wall 108 and a back wall 110. Front wall 108 (FIGS. 1, 3 and 4) may be joined to the back wall 110 at the top seal 104 and the bottom seal 106 (FIGS. 1-4). It is appreciated that bag body 102 can be formed on conventional form fill and seal machines known in the art. In another embodiment, a reclosable bag can be configured as a side-seam bag having one web of film folded along a longitudinal fold to form two half webs of film, and having top edges of each of the two half webs of film sealed together to form a side seam. In another embodiment, the reclosable bag is configured as having two webs of film that are sealed together along respective edges of the two webs of film to form four side seams, each of the two webs of film having an inside surface, and the back wall having two sides, each side being defined between each of the four side seams and a respective one of the two webs of film.
Bag 100 includes reclosable fastener assembly 130 (FIGS. 1-3). Reclosable fastener assembly 130 includes two ends 132, 134. Between ends 132, 134, a first continuous elongated profile strip 136 may be releasably interlocked with a second continuous elongated profile strip 138. It is appreciated that first continuous elongated profile 136 and the second continuous elongated profile 138 have protruding male and female members (not shown) which when interlocked provide an airtight and watertight seal.
Any of the seals described herein can be made by a variety of devices including heat sealers, ultrasonic sealers, and other devices known in the art. The seals also may be made with an adhesive.
A continuous airtight and/or watertight lower seal 146 is disposed along the length L of the reclosable fastener assembly 130 and may be positioned below the profile strips 136, 138. It is appreciated that seal 146 is placed such that seal 146 connects the reclosable fastener assembly 130 to the front wall 108 prior to rectangular sheet of film 112 being formed into a tubular structure precursor of bag body 102. That is, seal 146 may connect reclosable fastener assembly 130 to rectangular sheet of film 112 while the sheet of film is still in a substantially flat state (FIG. 5).
A continuous airtight and/or watertight upper seal 148 along the length L of the reclosable fastener assembly is positioned above the profile strips 136, 138. The upper seal 148 connects the reclosable fastener to back wall 110. Upper seal 148 may be made after the bag body 102 is substantially complete, e.g. after the bag body 102 has been substantially completed on a form fill and seal machine. This may be accomplished by sealing jaws on the form fill and seal machine.
In an embodiment, reclosable back-seam bag 100 may include a first continuous elongated profile strip 136 that has a front wall connecting flange 140 and a gripping flange 142 (FIG. 3). Both the front wall connecting flange 140 and the gripping flange 142 may have widths W′, W′″″ greater than a width W″ of the first continuous elongated profile strip 136. It is appreciated that by providing flanges 140, 144, the problems associated with sealing an irregularly shaped surface, e.g. a zipper profile, to a smooth surface are eliminated. The flange 140 and flange 144 provide a substantially smooth, planar and uniform surface to which to seal the inside surface 124 of rectangular sheet of film 112 thereto.
By way of example, front wall connecting flange 140 can be sealed to front wall 108 at inside surface 124′. Similarly, second continuous elongated profile strip 138 has a back wall-connecting flange 144. The back wall connecting flange 144 has a width W′″ greater than a width W″ of the second continuous elongated profile strip 138, and in a variant a width greater than gripping flange 142. Back wall connecting flange 140 is sealed to back wall 110 at back wall connecting seal 148.
To improve the appearance and air and watertightness of bag 100, the length L of the reclosable fastener assembly 130 is preferably configured to be less than the width W of back wall 110 (FIG. 2).
In another embodiment, reclosable back seam bag 100 includes a frangible access 154 (FIGS. 1-4). Access 154 can take many forms including a score line or a plurality of perforations. Access 154 can be substantially parallel to the reclosable fastener assembly 130. Removal of access 154 exposes the releasable fastener assembly 130 and provides access to the gripping flange 142, and profile strips 136, 138. In an embodiment, the frangible access 154 may be disposed both on the front wall 108 and on the back wall 110 of the bag body 102 adjacent the reclosable fastener assembly 130 and above the upper seal 148 (FIGS. 1 and 2). In an embodiment, frangible access 154 may include a plurality of perforations 156 (FIGS. 1, 3 and 4).
Back wall 110 of bag body 102 may be formed from rectangular sheet of film 112 (FIG. 5) on a conventional form, fill and seal machine. The form fill and seal machine can be a vertical form, fill and seal machine. Film 112 can be made from any suitable material but is preferably made from a polymeric material. Film 112 can be folded along two longitudinal folds 114, 116, as the film passes through the form fill and seal machine. The vertical edges 118, 120 (FIG. 1) are overlapped and sealed as is conventional to form back seam 122. Back wall 110 has two sides 126, 128 (FIG. 2). Each side 126, 128 is defined between back seam 122 and a respective one of the longitudinal folds 114, 116.
In one embodiment, the back wall 110 can be formed from one web of film folded along a longitudinal fold to form two half webs of film. The top edges of each of the two half webs of film can then be sealed together to form a side seam. In this embodiment, the back wall 110 has two sides, each side being defined between the side seam and a respective one of the longitudinal folds. Further, in this embodiment, the front wall connecting flange 146 may be connected to the inside surface of one web of film and the front wall 108 of the bag body 102 at a front wall seal 146. In this embodiment, the front wall seal 146 may be substantially parallel to the top seal 104 and spaced between the bottom seal 106 and the profile strips 136, 138. Also the back wall connecting flange 144 can be connected to the inside surface of the one web of film and the back wall at a back wall connecting seal such that the back wall connecting seal is spaced between the profile strips and the top seal 104. In this embodiment, a side seal can be disposed at each end of the reclosable fastener such that the side seal connects an end of the reclosable fastener to the inside surface of the one web of film inwardly of the longitudinal folds of the bag body to thereby prevent air or liquids from entering or leaving the bag through the ends of the reclosable fastener.
In another embodiment, the back wall 110 can be formed from two webs of film that are sealed together along respective edges of the two webs of film to form four side seams. Each of the two webs of film has an inside surface. The back wall 110 has two sides, each side being defined between each of the four side seams and a respective one of the two webs of film. In this embodiment, the front wall connecting flange 146 may be being connected to said inside surface of each of the two webs of film and the front wall 108 of the bag body 102 at a front wall seal 146. In this embodiment, the front wall seal 146 may be substantially parallel to the top seal 104 and spaced between the bottom seal 106 and the profile strips 136, 138. Also the back wall connecting flange 144 can be connected to the inside surface of each of the two webs of film and the back wall at a back wall connecting seal, such that the back wall connecting seal is spaced between the profile strips and the top seal 104. In this embodiment, a side seal can be disposed at each end of the reclosable fastener such that the side seal connects an end of the reclosable fastener to the inside surface of each of the two webs of film inwardly of the bag body thereby preventing air or liquids from entering or leaving the bag through the ends of the reclosable fastener.
Reclosable fastener 130 includes two ends 132, 134, a first continuous elongated profile strip 136 and a second continuous elongated profile strip 138. The first continuous elongated profile strip 136 may be releasably connected to the second continuous elongated profile strip 138. Strip 136 is matable to strip 138, and either strip 136 or strip 138 can be complementary male and female strips as required. More of the features of strips 136 and 138 are described later below.
In an embodiment, first continuous elongated profile strip 136 can be configured with a front wall connecting flange 140 and a gripping flange 142. Front wall connecting flange 140 may be heat sealed or ultrasonically sealed to rectangular sheet of film 112 while film 112 can be in a substantially flat state (FIG. 5). The sealing of front wall connecting flange 146 to film 112 occurs prior to the formation of a tube (not shown) from film 112 on a conventional form fill and seal machine. It is further appreciated that strips 136, 138 are interlocked at the time flange 146 is sealed to film 112 (FIG. 5). In particular, front wall connecting flange 146 is connected to the inside surface 124 of the rectangular sheet of film 112 and the front wall 108 of the bag body 102 at a front wall seal 146. Front wall seal 146 may be substantially parallel to top seal 104 and spaced between the bottom seal 106 and the profile strips 136, 138.
Both front wall connecting flange 140 and gripping flange 142 have widths W″″, W″″ greater than a width W″ of the first continuous elongated profile strip 136. Second continuous elongated profile strip 138 may include a back wall-connecting flange 144. In an embodiment, width W′ of gripping flange 142 is about 0.8 centimeters, and width W″ of strip 136 is about 0.3 centimeters. Back wall connecting flange 144 has a width W′″ greater than a width W″ of second continuous elongated profile strip 138. Width W′″ of flange 144 is about 1.7 centimeters in a embodiment, and W″ is about 0.3 centimeters. Gripping flange 142 may allow for a user to easily open the interlocked strips 136, 138, by grasping flange 142 and back wall connecting flange 144 and separating the flanges 142, 144. Width W″″ of the gripping flange 142 may be substantially less than width W′″ of the back wall connecting flange 144. It is appreciated that the use of these widths facilitates the placement of back wall connecting seal 148 such that the gripping flange 142 does not interfere with the sealing process.
To aid in the formation of the airtight and/or watertight seals used in the present invention, it is appreciated that the length L of the reclosable fastener 130 is less than the combined lengths of the two sides 126, 128 that form the back panel of bag body 102. In an embodiment, length L is about 21.5 centimeters.
Back wall connecting flange 144 can be connected to the inside surface 124 of the rectangular sheet of film 112 and the back wall 110 at a back wall connecting seal 148. Back wall connecting seal 148 may be spaced between profile strips 136, 138, and the top seal 104. In an embodiment of bag 100, bag 100 has the various seals placed as follows: Top seal 104 is disposed approximately 3 millimeters from the top of bag 100; Frangible access 154 is disposed about 4 millimeters below top seal 104; Back wall connecting seal 148 is disposed about 5 millimeters below frangible access 154; Profiles 136, 138 are disposed about 1.3 centimeters below back wall connecting seal 148; Front wall connecting flange 140 is disposed about 7 millimeters below profiles 136, 138; and, Bottom seal 106 is disposed about 30 centimeters below front wall connecting flange 140.
Side seals 150, 152 are placed at each end of the reclosable fastener assembly 130. Side seals 150, 152 provide an airtight and/or watertight seal between the inside surface 124 of film 112 and reclosable fastener assembly 130. Prior to the sealing of front wall connecting flange 140 to front wall 108, the ends 132, 134 of reclosable fastener 130 can be splotched. Splotching of reclosable fastener ends 132, 134 creates substantially flattened ends 162, 164 which facilitate the formation of the airtight and/or watertight seals of the invention.
A frangible access 154 can be cut between back wall connecting seal 148 and top seal 104 with a standard perforating die, and the like, access 154 is substantially parallel to the reclosable fastener 130 and exposes reclosable fastener 130 to a user. Frangible access 154 may be disposed on the front wall 108 and on the back wall 110 of the bag body 102 adjacent reclosable fastener 130 and above back wall connecting seal 148. It is appreciated that upon opening of frangible access 154, both front wall 108 and back wall 110 of bag 100 are severed. In an embodiment, frangible access 154 may comprise a plurality of perforations 156.
In an embodiment, first continuous elongated profile strip 136 and the second continuous elongated profile strip 138 each have respective back portions 158, 160 thereof (FIG. 3). By providing the seals 146, 148 as illustrated in the figures, first continuous elongated profile strip back portion 158 can move in relation to the inside surface 124′ of the rectangular sheet of film 112. It is further appreciated that the seal placement permits second continuous elongated profile strip back portion 160 to move in relation to the inside surface 124 of the rectangular sheet of film 112.
Gripping flange 142 may include a continuous rib 166 disposed at a distal end 168 of the gripping flange 142. Gripping flange 142 can also include a plurality of continuous, substantially parallel ribs 170 disposed on the gripping flange 142.
Reclosable fastener assembly 130 can be manufactured in different forms. As an example, gripping flange 142 and front wall connecting flange 140 can be made from a single, extruded, flexible polymeric material. That is, gripping flange 142 and connecting flange 140 and profile strip 136 are extruded and form a continuous member. Similarly, second continuous profile strip 138 and the back wall-connecting flange 144 may be formed from an extruded, flexible polymeric material, and can be extruded such that they form a single continuous member. Back wall connecting flange 144 and front wall connecting flange 140 can be of a sufficient thickness to seal to the respective walls that they connect to, yet of a sufficient thickness not to seal to the inside surface 124 of walls 108, 110 that they are not to seal to when a predetermined amount of heat, pressure and dwell time are applied. A sufficient thickness is empirically determined depending on the type of film 112 used and the type of polymeric material used for profile strips 136,138, and flanges 140, 144.
In an embodiment, gripping flange 142 and the bag wall-connecting flange are made from a single web. First continuous profile strip 136 may be sealed to the web with an airtight and/or watertight seal (not shown). Similarly, strip 138 can be sealed to a second web.
A method of making a reclosable back-seam bag 100 is also provided herein. A rectangular sheet of polymeric material 112 having an inside surface 124 is provided in a substantially flat state (FIG. 5). A predetermined length L of a reclosable fastener 130 including two ends 132, 134, a first continuous elongated profile strip 136 and a second continuous elongated profile strip 138 is cut from a longer length (e.g., a continuous roll of interlocked fastener assemblies). First continuous elongated profile strip 136 is releasably connected to second continuous elongated profile strip 138. For each length L of fastener 130, ends 132 and 134 are splotched so that they are substantially flattened.
The reclosable fastener 130 may be moved onto film 112 transverse to the length of the film 112 in one embodiment, or longitudinally across the length of the film 112 in another embodiment. Front wall connecting flange 140 is sealed with an airtight and/or watertight seal to the inside surface 124′ of the rectangular sheet of film 112 such that it is approximately centered thereon in relation to the width of the sheet of film 112. Bag body 102 can be formed on a conventional form, fill, and seal machine. Bag body 102 can be formed into a tube (not shown) such that a front wall 108 and a back wall 110 are formed. Back wall 110 is formed by folding the rectangular sheet of film 112 along two longitudinal folds 114, 116, and overlapping and sealing edges 118, 120 of the rectangular sheet of film 112. Back wall 110 has two sides 126, 128. Each side 126, 128 is defined between back seam 122 and a respective one of the longitudinal folds 114, 116. After the film is formed into a tube (not shown), front wall 108 is joined to the back wall 110 at a bottom seal 106. Bottom seal 106 can be made in conventional heat sealing jaws (not shown).
Back wall connecting flange 144 may be connected (e.g. by heat sealing) to the inside surface 124 of rectangular sheet 112 at what is now the back wall 110 of bag body 102 at back wall connecting seal 148.
The frangible access 154 can be configured substantially parallel to the reclosable fastener 130 for exposing releasable fastener 130. Access 154 is formed with a conventional perforating die, and is disposed on front wall 108 and on back wall 110 of the bag body 102 adjacent the reclosable fastener assembly 130 and above the back wall connecting seal 148.
The method then includes providing top seal 104 above the frangible access 154. Properly feeding, locating and sealing reclosable fastener 130 at predetermined locations on rectangular sheet of film 112 readily are important aspects of the method (FIG. 5). Rectangular sheet of film 112 may have marks 3 or other machine readable indicia thereon to permit an electric eye or other sensor to read the marks or indicia so that proper registration and alignment of the reclosable fastener 130 is obtained with the bag body. Machines commercially available from Z-Patch, Inc. of Carbondale, Ill. are reliable and capable of repeatedly performing the steps referred to in the method described above with high throughput and with low cycle times. The film as shown in FIG. 5 made by the Z-Patch machine is then fed into a form fill seal machine (not shown), having sealing heads adapted to make seals 104, 106, 150, 152, 122, and other seals referred to herein. The manner in which reclosable fastener 130 is fed and positioned for sealing onto rectangular sheet of film 112 is critical in order to achieve repeatability.
Reclosable fastener 130, which is generally about 3.5 centimeters wide, in one variant of the invention, is delivered in a cross web, stretched position, assuring squareness for positioning onto rectangular sheet of film 112. It is appreciated that the width and length of fastener 130 can be such that it accommodates the size of the bag body. The front wall seal 146 may be transverse to film 112.
FIG. 6 illustrates an embodiment of the reclosable bag having the reclosable fastener assembly 130 include the first continuous elongated profile strip 136. In this embodiment, the first continuous elongated profile strip 136 may be flat. The first continuous elongated profile strip 136 may also be manufactured from polyethylene. In this embodiment, as illustrated in FIG. 6, the first continuous elongated profile strip 136 may include a first rib 630, second rib 634 and third rib 638. The first rib 630, second rib 634 and third rib 638 can be in a location offset from the center of the first continuous elongated profile strip 136, thereby defining a profile adherence surface 642 between ribs 630, 634, 638 and the front wall 108 to which the first continuous elongated profile strip 136 attaches. The first rib 630, second rib 634 and third rib 638 of the first continuous elongated profile strip 136 extend the length, L, of the front wall 108.
FIG. 7 illustrates an embodiment of the reclosable bag having the reclosable fastener assembly 130 include the second continuous elongated profile strip 138. In this embodiment, the second continuous elongated profile strip 138 may be flat. The second continuous elongated profile strip 138 may also be manufactured from polyethylene. Therefore, the second continuous elongated profile strip 138 can be manufactured from the same material and with the same dimensions as the first continuous elongated profile strip 136. In this embodiment, As depicted in FIG. 7, the second continuous elongated profile strip 138 may include a first rib 750, second rib 754 and third rib 758. The first rib 750, second rib 754 and third rib 758 along an edge of the second profile strip 138, thereby defining a profile adherence surface 746 between ribs 750, 754, 758 and the back wall 110 to which the second continuous elongated profile strip 138 attaches. The first rib 750, second rib 754 and third rib 758 of the second continuous elongated profile strip 138 extend the length, L, of the back wall 110. The ribs 630, 634, 638 associated with the first continuous elongated profile strip 136 can interlock with the ribs 750, 754, 758 associated with the second continuous elongated profile strip 138, causing the reclosable back-seam bag 100 to close. The reclosable back-seam bag 100 (FIGS. 1-3) can be then be opened by grasping the gripping flange 142 and back wall connecting flange 144, and then applying a force that facilitates separating the flanges 142 and 144.
FIG. 8A illustrates another embodiment of the reclosable bag in which the reclosable fastener assembly 130 may include two ends, a first continuous elongated profile strip 136 having a front wall connecting flange 140 and a second continuous elongated profile strip 138 having a back wall connecting flange 144. The first continuous elongated profile strip 136 may be configured with a male interlocking profile 802 that may be extruded with at least one male interlocking member 804. The second continuous elongated profile strip 138 may be configured with a female interlocking profile 806 having at least one female interlocking member 808. The first continuous elongated profile strip 136 may be releasably connected to the second continuous elongated profile strip 138 by engaging the male interlocking member 804 with the female interlocking member 808. The male interlocking member 804 can be configured to enable the male interlocking profile 802 to be separated from the female interlocking profile 806 with a substantially equal opening force when being separated in a direction toward the top seal as when separating the male interlocking profile from the female interlocking profile in a direction toward the bottom seal. This causes a differential opening force, applied to the inside and/or outside the reclosable back-seam bag, to remain balanced.
In a preferred embodiment, when the reclosable back-seam bag 100 is desired to be opened, a user may pinch the front wall 108 and the back wall 110 using fingers of opposite hands, and then, open the bag 100 by pulling the pinched front wall 108 and back wall 110 apart from one another. Such mechanism may be referred to as “pinch-'n-pull”. The separation (i.e., pulling apart) of the front wall 108 from the back wall 110 allows the open male and female interlocking members 804, 808 to easily disengage from one another so that separation of the front wall 108 from the back wall 106 can cause the top seal 104 to separate from within as desired by a user.
It is contemplated that different configurations of the front wall connecting flange 140 associated with the first continuous elongated profile strip 136 and the back wall connecting flange 144 associated with the second continuous elongated profile strip 138 can be utilized to facilitate this pinch-'n-pull mechanism. As an example, in one embodiment (see FIG. 8A), the front wall connecting flange 140 may be configured to have a height substantially similar to the height of the back wall connecting flange 144. In another embodiment (see FIG. 8B), back wall connecting flange 144 may be configured with an additional back wall connecting flange 844 so that the combined height of the flanges 144 and 844 is greater than the height of the front wall connecting flange 140. In another embodiment (see FIG. 8C), the front wall connecting flange 140 may be configured with an additional front wall connecting flange 840 so that the combined height of the front wall connecting flange 140 and the additional front wall connecting flange 840 is greater than the height of the back wall connecting flange 144. In yet another embodiment (see FIG. 8D), both the front wall connecting flange 140 and the back wall connecting flange 144 may be, respectively, configured with an additional front wall connecting flange 840 and an additional back wall connecting flange 844. Such a configuration as depicted in FIG. 8D can result in the combined heights of flanges 144 and 844 being substantially similar to the combined heights of flanges 140 and 840. Thus, FIGS. 8A-8D illustrate embodiments of the reclosable bag in which the reclosable fastener assembly may include two ends, a first continuous elongated profile strip having a front wall connecting flange and a second continuous elongated profile strip having a back wall connecting flange, the flanges respectively extending upward, downward or both on the walls of the bag.
FIG. 9 illustrates a plurality of reclosable fastener assemblies that each include a male part and a female part. Each reclosable fastener assembly 130 may include fasteners 928 that comprise a male part 962 and a female part 964, parts 962 and 964 being joined to each other as clearly seen in FIG. 9. The distal ends of each fastener 928 can be flattened so as to permit the fasteners 928 to be free and separate from another adjacent fastener 928. This “free and separate” relationship between adjacent ones of the fasteners 928 can be indicated by reference numeral 970. However, it is to be understood that adjacent fasteners can also be attached to each other, continuously or by spot tacking, dependent on actual operating conditions. Such a structure is considered to be within the scope of this invention.
FIG. 10 illustrates another embodiment of the reclosable bag having a frangible access portion to access the contents of the reclosable bag. In this embodiment, the frangible access portion 154 is substantially parallel to the reclosable fastener assembly 130 and may be provided through the front wall of the reclosable bag by means of one or more score lines. The frangible access portion 154 is disposed within the bag body 102 adjacent to the reclosable fastener assembly 130. In this embodiment, the top seal 104 is provided above the frangible access portion 154, and a bottom seal 106 is provided below the frangible access portion 154. Such frangible access portion 154 may also be disposed below the back wall connecting seal 148. Upon tear opening, peel opening, or opening by delamination, the frangible access portion 154 can expose the reclosable fastener assembly 130 from which a user can then gain access to the contents of the bag 102. The frangible access portion 154 may also be formed with a conventional perforating die, and can be disposed on front wall 108 of the bag body 102 adjacent the reclosable fastener assembly 130 and above the continuous airtight and/or watertight lower seal 146. The continuous airtight and/or watertight lower seal 146 is disposed along the length of the reclosable fastener assembly 130 and may be positioned below the first continuous profile strip 136 and the second continuous profile strip 138 (not shown). It is recognized that the characteristics of the first continuous profile strip 136 and the second continuous profile strip 138 associated with the reclosable fastener assembly 130 may include the features described above with respect to the earlier described figures. It is appreciated that seal 146 may be placed such that seal 146 connects the reclosable fastener assembly 130 to the front wall 108.
FIG. 11A illustrates an embodiment of a two-flanged reclosable bag having a re-sealable first zipper patch 1106 that includes a first zipper flange front wall seal 1102 and a first zipper flange back wall seal 1104 (see FIG. 11B). The re-sealable first zipper patch 1106 may be affixed on the front wall 108. The first zipper flange front wall seal 1102 can then be made on the first zipper patch 1106 on the open web of film. The first zipper flange back wall seal 1104 can be made on a second zipper patch 1140, while the tube of film is being formed into a bag. Of course, the first zipper patch 1106 and the second zipper patch 1140 can be interchanged such that the second zipper patch 1140 and its associated configurations can appear on the front wall 108, while the first zipper patch 1106 and its associated configurations can appear on the back wall 110. The reclosable bag also incorporates a zipper profile 1108, which may include a male interlocking profile 1120 and a female interlocking profile 1130 (see FIG. 11C). The male interlocking profile 1120 may be attached to the back wall of the reclosable bag via the second zipper patch 1140. The male interlocking profile 1120 may have a cross section in the shape of an arrowhead. The female interlocking profile 1130 may be attached to the front wall 108 via the first zipper patch 1106, and adjacent to the male interlocking profile 1120. FIG. 11B illustrates the reclosable bag 100 in a closed position, wherein the female interlocking profile 1130 may be configured with two curved members so as to form a channel in between the curved members such that the male interlocking member can be snappingly engaged to join male and female interlocking profiles 1120, 1130 respectively together to close the reclosable bag 100. FIG. 11C shows the reclosable bag 100 in an open position, wherein the male interlocking member 1120 can be separated from the female interlocking profile 1130 with a substantially equal opening force when being separated in a direction toward the top seal as when separating the male interlocking profile from the female interlocking profile in a direction toward the bottom seal. The configuration of the first zipper flange front wall seal 1102 and the first zipper flange back wall seal 1104 causes a differential opening force, that is applied to the inside and/or outside the reclosable back-seam bag, to remain balanced. Therefore, when the reclosable back-seam bag is desired to be opened, a user may pinch the front wall 108 and the back wall 110 using fingers of opposite hands, and then, open the bag 100 by pulling the pinched front wall 108 and back wall 110 apart from one another. Such mechanism may be referred to as “pinch-'n-pull”. The separation (i.e., pulling apart) of the front wall 108 from the back wall 110 allows the interlocked male and female interlocking profile 1120, 1130 to disengage from one another. Further separation of the front wall 108 from the back wall 110 can cause the top seal 104 to separate from within as desired by a user. The top seal may be configured to include a peelable seal such that the peelable seal can be peeled off when the bag is desired to be opened. In this or other embodiments, the top seal 104 can be torn opened, peeled opened, or delaminated so as to open the reclosable bag.
In an embodiment, the top seal 104 can be configured with an airtight and watertight seal that may be provided along an interconnection of a length of the first zipper patch 1106 and the second zipper patch 1140, and disposed in a location above the first zipper flange front wall seal 1102 and the first zipper flange back wall seal 1104. In this embodiment, the bag, first zipper patch and second patch can comprise a polyethylene material. In another embodiment, the top seal 104 can be configured with a permeable seal that may be provided along an interconnection of a length of the first zipper patch 1106 and the second zipper patch 1140. The permeable seal may be disposed in a location above the first zipper flange front wall seal 1102 and the first zipper flange back wall seal 1104. In this embodiment, the bag 100, first zipper patch 1106 and second zipper patch 1140 can be comprise a polypropylene material.
The reclosable bag can also include a frangible access portion 154 for exposing the contents of the reclosable bag. In this embodiment, the frangible access portion 154 is substantially parallel to the first zipper patch 1106 and may be provided through the front wall 108 of the reclosable bag by means of perforations. The reclosable bag can also contain one or more score lines 158 that may be disposed in on the front wall 108 and parallel to the frangible access portion 154 and the first zipper patch 1106. The frangible access portion 154 is disposed on the front wall 108 between a lower portion of the top seal 104 and the upper portion of the first zipper patch 1106. Upon tear opening, the frangible access portion 154 can then expose the contents of the bag 102.
FIGS. 12A-12C illustrates an embodiment of a front view of a three-flanged reclosable bag having a first zipper flange front wall seal 1102, a second zipper flange front wall seal 1202 attached to the re-sealable first zipper patch 1106, and an first zipper flange back wall seal 1104 attached to a back wall zipper patch. The second zipper flange front wall seal 1202 provides additional support to the re-sealable first zipper patch 1106 such that when a user desires to open the reclosable bag, by pulling a pinched front wall 108 apart from the back wall 110, an equal opening force may be exerted from the to the reclosable as well as to the user. As with FIGS. 11A-11C above, the first zipper flange front wall seals 1102 and the second zipper flange front wall seal 1202 are made on the first zipper patch 1106 on open web. As illustrated in FIG. 12B, the first zipper flange back wall seal 1104 can be made on a second zipper patch 1140. FIG. 12B also illustrates a side view profile of the reclosable bag when closed, wherein the curved members of the female interlocking profile 1130 are configured to form a channel such that the male interlocking member 1120 can be snappingly engaged to join the male and female interlocking profiles 1120, 1130 respectively together. FIG. 12C illustrates a side view profile of the reclosable bag when opened, wherein the male interlocking member 1120 can be separated from the female interlocking profile 1130 with a substantially equal opening force when being separated in a direction toward the top seal as when separating the male interlocking profile from the female interlocking profile in a direction toward the bottom seal. The second zipper flange front wall seal 1202 provides additional support to the re-sealable first zipper patch 1106 for attachment to the reclosable bag so as to cause a differential opening force, applied to the inside and/or outside the reclosable back-seam bag, to remain balanced. The other features of the reclosable bag 100 have been previously described in FIGS. 11A-11C.
FIGS. 13A-13C illustrates an embodiment of different views of a four-flanged reclosable bag having a first zipper flange front wall seal 1102 and a second zipper flange front wall seal 1202 attached to the re-sealable first zipper patch 1106, as well as a first zipper flange back wall seal 1104 and a second zipper flange back wall seal 1304. In this embodiment, as illustrated in FIG. 13A, front wall tack-down seals may 1360 be provided on the first zipper patch 1106 on open web (or during a zipper extrusion process). A corresponding number of back wall tack-down seals 1370 are provided as well as on the second zipper patch 1140. The tack-down seals may be configured as a light continuous seal that may be provided on the first zipper patch 1106 and the second zipper patch 1140. The front wall tack-down seals 1360 are configured to maintain the second zipper flange back wall seal 1304 in a close relationship to the second zipper flange front wall seal 1202, so as to prevent the zipper profile 1108 from jamming a bag making machine during manufacture. Such jamming can occur during, for example, a manufacture process that can involve movement of a web through the reclosable bag, over forming collar and down a fill tube. FIG. 13B shows the front wall tack-down seals 1360 and the back wall tack-down seals 1370 in close proximity to one another when the reclosable bag is closed. Such engagement of the front wall tack-down seals 1360 and the back wall tack-down seals 1370 may be facilitated due to the configurations of each of these tack-down seals. The tack-down seals serve to maintain the second zipper flange back wall seal 1304 in a close proximity to the second zipper flange front wall seal 1202 such that the first zipper patch 1106 and the second zipper patch 1140 are prevented from jamming a bag making machine during manufacture. As an example, the front wall tack-down seals 1360 can be configured to have a female profile configuration while the back wall tack-down seals 1370 can be configured to have a male profile configuration. Therefore, when the bag is closed, the front wall tack-down seals 1360 and the back wall tack-down seals 1370 can serve to maintain the second zipper flange back wall seal 1304 in a close proximity to the second zipper flange front wall seal 1202. FIG. 13C illustrates a side view profile of the reclosable bag when opened, wherein the male interlocking member 1120 can be separated from the female interlocking profile 1130 with a substantially equal opening force when being separated in a direction toward the top seal 104 as when separating the male interlocking profile from the female interlocking profile in a direction toward the bottom seal. The four flanges (i.e., first zipper flange front wall seal 1102, second zipper flange front wall seal 1202, first zipper flange back wall seal 1104, and second zipper flange back wall seal 1304) combine to provide additional support to the reclosable bag so as to cause a differential opening force, applied to the inside and/or outside the reclosable back-seam bag, to remain balanced. The other features of the reclosable bag 100 have been previously described in FIGS. 11A-11C.
FIGS. 14A-14C illustrates another embodiment of the reclosable bag that includes a flange-to-flange peelable adhesive or co-extruded bead attached to the re-sealable first zipper patch 1106. The embodiment described in FIGS. 13A-13C is similar to this embodiment illustrated in FIGS. 14A-14C except that the tack seals of FIGS. 13A-13C are replaced with flange-to-flange peelable adhesive or co-extruded bead 1460. The flange-to-flange peelable adhesive or co-extruded bead 1460 are configured to maintain the second zipper flange back wall seal 1304 in a close relationship to the second zipper flange front wall seal 1202, so as to prevent the first zipper patch 1106 and the second zipper patch 1140 from jamming a bag making machine during manufacture. Such jamming can occur during, for example, a manufacture process that can involve movement of a web through the reclosable bag, over forming collar and down a fill tube. The other features of the reclosable bag 100 have been previously described in FIGS. 11A-11C.
In another embodiment, either tack seals (FIGS. 13A-13C) or the flange-to-flange peelable adhesive or co-extruded bead 1460 of FIGS. 14A-14C can be replaced with a frangible membrane that connects the front wall flanges with the back wall flanges. Such frangible membrane 1560, as illustrated in FIG. 15, also serve to maintain the second zipper flange back wall seal 1304 in a close relationship to the second zipper flange front wall seal 1202, so as to prevent the first zipper patch 1106 and the second zipper patch 1140 from jamming a bag making machine during manufacture. Such jamming can occur during, for example, a manufacture process that can involve movement of a web through the reclosable bag, over forming collar and down a fill tube. The other features of the reclosable bag 100 have been previously described in FIGS. 11A-11C.
FIG. 16 illustrates another embodiment of a side view of a four-flanged (1102, 1104, 1202, 1304) reclosable bag in which the male interlocking member is provided in an open disengaged position when the top seal of the bag remains sealed. In this embodiment, the male interlocking member 1120 is disengaged from the female interlocking member 1130, while the top seal 104 remains sealed. The bag may be easily opened by pinching the front and back walls 108, 110 of the bag 100 and simultaneously separating the walls until the top seal 104 is ruptured or peeled open. The open configuration of the fastener profile (i.e., the male and female interlocking members 1120, 1130) facilitates such opening. The lengths of each of the first zipper patch 1106 and the second zipper patch 1140 may each be disposed to be shorter in length than the width of the bag. Subsequently, easy access is permitted from either the top of the bag, or from rupturing the frangible access portion 154 (not shown), and then, separating the fastener profile. It is contemplated that this configuration can be applicable for two-flanged and three-flanged reclosable bags as well. Further details of each of the four flanges 1102, 1104, 1202, 1304 and other features of the reclosable bag have been previously described.
FIGS. 18A-18C illustrate different views of an embodiment of a four-flanged reclosable bag having a flange overlap configured with overlap seals. In this embodiment, as shown in FIGS. 18A and 18B for example, overlap seals 1860 may be provided on a flange overlap 1870, which can then be connected to at least one of the first zipper patch 1106 and/or the second zipper patch 1140 on open web (or during a zipper extrusion process), when the reclosable bag is in a closed position. As illustrated in FIG. 18B, when the reclosable bag is in a closed position, the overlap seals 1860 can be constructed and arranged to maintain the second zipper flange back wall seal 1304 in a close relationship to the second zipper flange front wall seal 1202, so as to prevent the zipper profile 1108 from jamming a bag making machine during manufacture. Such jamming can occur during, for example, a manufacture process that can involve movement of a web through the reclosable bag, over forming collar and down a fill tube. The overlap seals 1860 may be configured to break open relatively easily when the bag 100 is opened by a user. In an embodiment, such overlap seals 1860 can be configured as at least one of tack-down seals, peelable adhesives, light continuous seal, and/or frangible membrane that may be provided on the first zipper patch 1106 and/or the second zipper patch 1140. FIG. 18C illustrates a side view profile of the reclosable bag when opened, wherein the male interlocking member 1120 can be separated from the female interlocking profile 1130 with a substantially equal opening force when being separated in a direction toward the top seal 104 as when separating the male interlocking profile from the female interlocking profile in a direction toward the bottom seal. In this embodiment, first zipper flange front wall seal 1102 and second zipper flange front wall seal 1202 are attached to the re-sealable first zipper patch 1106, and first zipper flange back wall seal 1104 and a second zipper flange back wall seal 1304 are attached to the second zipper patch 1140. Each of the four flanges (i.e., first zipper flange front wall seal 1102, second zipper flange front wall seal 1202, first zipper flange back wall seal 1104, and second zipper flange back wall seal 1304) as well as the flange overlap 1870 combine to provide additional support to the reclosable bag so as to cause a differential opening force, applied to the inside and/or outside the reclosable back-seam bag, to remain balanced. The other features of the reclosable bag 100 have been previously described in FIGS. 11A-11C.
FIG. 17 illustrates an exemplary machine that can be used to manufacture a reclosable back-seam bag described herein. Such reclosable back-seam bag machine may be configured by supplying a desired web material, whether single ply or laminated, to a form, fill and seal machine 1700. Such machines are well known in the art and may include a combination bag forming and filling nozzle cylinder 1729 that can be adapted to receive products to be filled into the formed bags from a hopper 1730. Bag making web 1731, which may carry the reclosable fastener or zipper means 1727, can extend across the formation axis of the web at suitable longitudinal spaced intervals along the web, and may be guided by means of guide roller 1732 to the cylindrical outer surface of the cylinder 1729.
At the cylinder 1729, a folding or wrapping arm device 1733 guides and wraps the web 1731 about the cylinder 1729 with the longitudinal margins of the web brought together into a longitudinal, laminar closure fin assembly 1734. Sealing of the fin assembly 1734 into a closure seam may be achieved by means of a pair of vertical sealing bars 1735 which are movable into clamping and sealing engagement with the closure fin assembly 1734, as indicated by the solid directional arrows 1737. Such vertical sealing bars may be configured with a sinusoidal wave seal (e.g., a sine wave seal 1750) that may serve to maintain the seals. The bars 1735 are then separable as indicated by the dashed arrows 1738 to release the heat sealed seam section of fin 1734 of the now closed bag forming tube of the web material.
The longitudinally sealed tube is advanced by bag length increments. Such advancement is achieved by means of a pair of horizontal, parallel bag end sealing bars 1739, which operate by clampingly engaging the bag web tube below the end of the cylindrical forming and filling nozzle member 1729 for simultaneously sealing the top end of a filled bag section 1720 and the bottom end of the next succeeding bag section. Such horizontal sealing bars 1739 may be configured with a sine wave seal 1750 that may serve to maintain the seals. The sealing bars 1739 may be configured to grip the bag web tube, and then move downwardly by a bag section length as indicated by the directional arrow 1740, so as to pull and advance the entire bag making tube one bag increment downwardly. As this occurs, the next succeeding bag can be filled with product that may be dropped down the cylinder 1729 from the hopper 1730. As the sealing and pull down bars 1739 reach the lower end of their sealing and pulldown stroke, a severance means such as a cutoff bar 1741 can cut midway across the seal 1742 that has been effected by the bars 1739, thus releasing the previously filled bags 1720 which may then be handled as desired, such as to be packed for market. Having completed its downstroke, the sealing bar and cutoff device 1739, 1741 may return as indicated by the dashed directional arrow 1743 to its starting position adjacent to the lower end of the cylinder 1729. It will be understood, of course, that operation of the vertical sealing bars 1735, and the horizontal sealing and pulldown bars 1739 are operated in coordinated cyclical relation, as is well known in the art for form, fill and seal machines of this type.
While this disclosure includes particular examples, it is to be understood that the disclosure is not so limited. Numerous modifications, changes, variations, substitutions, and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present disclosure upon a study of the drawings, the specification, and the following claims.
Patent Application
20110235951
