U.S. patent application number 10/278461 was filed with the patent office on 2004-04-29 for method of manufacturing tamper evident package.
Invention is credited to Buchman, James E., Melchoir, Greg W..
Application Number | 20040079052 10/278461 |
Document ID | / |
Family ID | 32106549 |
Filed Date | 2004-04-29 |
United States Patent
Application |
20040079052 |
Kind Code |
A1 |
Buchman, James E. ; et
al. |
April 29, 2004 |
Method of manufacturing tamper evident package
Abstract
A method of making a resealable package is provided. The method
comprises providing an assembly that has a header section and a
closure mechanism comprising first and second closure profiles
constructed and arranged to selectively interlock. The method
further includes providing a package comprising first and second
panel sections joined together to define an enclosed region, first
and second opposite side edges, a bottom and a mouth that provides
access to the enclosed region. Finally, the method comprises
attaching the assembly to the package such that the header section
is attached to the closure mechanism at a point between the closure
profiles and the bottom of the package.
Inventors: |
Buchman, James E.;
(Hortonville, WI) ; Melchoir, Greg W.; (Green Bay,
WI) |
Correspondence
Address: |
ECKERT SEAMANS CHERIN & MOLLETT, LLC
ALCOA TECHNICAL CENTER
100 TECHNICAL DRIVE
ALCOA CENTER
PA
15069-0001
US
|
Family ID: |
32106549 |
Appl. No.: |
10/278461 |
Filed: |
October 23, 2002 |
Current U.S.
Class: |
53/412 |
Current CPC
Class: |
B65D 33/2516 20130101;
B31B 70/8132 20170801 |
Class at
Publication: |
053/412 |
International
Class: |
B65B 061/18 |
Claims
What is claimed is:
1. A method of making a resealable package comprising: (a)
providing an assembly comprising: (i) a header section; (ii) a
closure mechanism comprising first and second closure profiles; (1)
the first and second closure profiles constructed and arranged to
selectively interlock; (b) providing a package comprising: (i)
first and second panel sections joined together to define an
enclosed region, first and second opposite side edges, a bottom and
a mouth that provides access to the enclosed region; and (ii)
attaching the assembly to the package such that the header section
is attached to the closure mechanism at a point between the closure
profiles and the bottom of the package.
2. The method of claim 1, wherein the header section comprises two
sides joined together to define first and second mouths, the first
and second mouths being in fluid communication with each other.
3. The method of claim 2, wherein the step of providing the
assembly comprises sealing a portion of the two sides together.
4. The method of claim 3, wherein the seals are formed in a pair of
mirror-image L-shapes.
5. The method of claim 4, wherein the step of providing the
assembly further comprises removing the portions of the header
inside of the L-shaped seals.
6. The method of claim 2, wherein the header section includes a
preferential area of weakness.
7. The method of claim 6, wherein the area of weakness is produced
by scoring the header section.
8. The method of claim 6, wherein the preferential area of weakness
includes at least one notch cut into the header section.
9. The method of claim 2, wherein the two sides are formed by
folding a single sheet of header material in half, and the second
mouth is formed by eliminating a portion of the header material
around the fold.
10. The method of claim 1, wherein step of providing the assembly
comprises sealing the header section to the flanges of the closure
mechanism.
11. The method of claim 10, wherein the step of sealing the header
section comprises (a) separating the first and second closure
profiles; (b) placing a portion of the header section between the
first and second closure profiles; (c) attaching the slider to the
closure mechanism; (d) notching the closure profile at one end, the
notch to be used as a park position for the slider; and (e)
applying a stop seal to at least one end of the closure
mechanism.
12. The method of claim 1, wherein the step of attaching the
assembly to the package comprises heat sealing the closure profiles
to the two opposing panels.
13. The method of claim 12, wherein the step of attaching the
assembly to the package further comprises sealing the sides and
bottom of the two opposing panels together.
14. The method of claim 1, further comprising filling the package
with a product through the first mouth of the header section.
15. The method of claim 1, further comprising sealing the first
mouth of the header section.
16. A header and closure mechanism assembly for use in a resealable
package consisting essentially of: (a) a closure mechanism
comprising first and second closure profiles, the first and second
closure profiles constructed and arranged to selectively interlock;
and (b) a header section comprising two sides joined together
defining first and second mouths, the first and second mouths being
in fluid communication with each other, the header section being
attached to the closure mechanism.
17. The assembly of claim 16, further consisting essentially of a
slider attached to the closure mechanism.
18. The assembly of claim 17, wherein the closure mechanism defines
a notch near one end of the closure mechanism.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a method of
making polymer packages, for example, plastic bags. In particular,
the present invention relates to a method of making a resealable
bag having a tamper-evident structure.
DISCUSSION OF RELATED ART
[0002] Many packaging applications use resealable containers to
store various types of articles and materials. These packages may
be used to store and ship food products, non-food consumer goods,
medical supplies, waste materials, and many other articles.
Resealable packages are convenient in that they can be closed and
resealed after the initial opening to preserve the enclosed
contents. The need to locate a storage container for the unused
portion of the products in the package is thus avoided. As such,
providing products in resealable packages appreciably enhances the
marketability of those products.
[0003] Resealable packages typically utilize a closure mechanism
that is positioned along the mouth of the package. The closure
mechanism often comprises profile elements or closure profiles that
engage one another when pressed together. Resealable packages also
often use a tamper-evident structure to allow consumers to
determine if the package has previously been opened. Typically,
these structures are attached above the closure mechanism, or are
attached on the outside of the package. In those cases, it is
necessary to fill the package prior to attaching or engaging the
tamper-evident structure, or it is necessary to fill the package
from the bottom. The former method is inconvenient, as the package
must be moved to a station to attach the structure while the
package is full of product. The packages that are made using this
method are also susceptible to having product contaminate the
closure mechanism as the package is filled through the top.
[0004] It is therefore desirable to attach the tamper-evident
structure on the inside of the package, so the structure can be
attached prior to filling the package and to protect the closure
mechanism from contamination upon filling the package with
product.
SUMMARY OF THE INVENTION
[0005] In an embodiment of the present invention, a method of
making a resealable package is provided. The method comprises
providing an assembly. The assembly comprises a header section, a
closure mechanism comprising first and second closure profiles
constructed and arranged to selectively interlock. The method
further comprises providing a package comprising first and second
panel sections joined together to define an enclosed region, first
and second opposite side edges, a bottom and a mouth that provides
access to the enclosed region. Finally, the method comprises
attaching the assembly to the package such that the header section
is attached to the closure mechanism at a point between the closure
profiles and the bottom of the package.
[0006] In an alternate embodiment of the present invention, a
header and closure mechanism assembly for use in a resealable
package is provided. The assembly consists of a header section
comprising two sides joined together defining first and second
mouths, the first and second mouths being in fluid communication
with each other; and a closure mechanism comprising first and
second closure profiles, the first and second closure profiles
constructed and arranged to selectively interlock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The various features and benefits of the present invention
are apparent in light of the following detailed description and the
accompanying drawings, in which:
[0008] FIG. 1 is a perspective view of a flexible, resealable
package in accordance with an embodiment of the present
invention.
[0009] FIG. 2 is an elevated, side view of the resealable package
of FIG. 1.
[0010] FIG. 3 is a cross-sectional view of the resealable package
of FIG. 1, taken along line 3-3 of FIG. 2.
[0011] FIG. 4 is a perspective view of a flexible, resealable
package in accordance with an embodiment of the present
invention.
[0012] FIG. 5 is an elevated, side view of a consumer opening the
resealable package of FIG. 4.
[0013] FIG. 6 is an elevated, side view of the resealable package
of FIG. 4 after it has been opened.
[0014] FIG. 7 is an elevated, perspective view of a component used
in constructing the header section and closure mechanism assembly
in accordance with another embodiment of the present invention.
[0015] FIG. 8 is an elevated, perspective view of a component used
in constructing the header section and closure mechanism assembly
in accordance with another embodiment of the present invention.
[0016] FIG. 9a is an elevated, perspective view of a component used
in constructing the header section and closure mechanism assembly
in accordance with another embodiment of the present invention.
[0017] FIG. 9b is an elevated, perspective view of a component used
in constructing the header section and closure mechanism assembly
in accordance with another embodiment of the present invention.
[0018] FIG. 10a is an elevated, perspective view of a component
used in constructing the header section and closure mechanism
assembly in accordance with another embodiment of the present
invention.
[0019] FIG. 10b is an bottom view of the component used in
constructing the header section and closure mechanism illustrated
in FIG. 10a.
[0020] FIG. 11 is an elevated, perspective view of a partially
constructed header section and closure mechanism assembly in
accordance with another embodiment of the present invention.
[0021] FIG. 12 is an elevated, perspective view of a partially
constructed header section and closure mechanism assembly in
accordance with another embodiment of the present invention.
[0022] FIG. 13 is an elevated, perspective view of a partially
constructed header section and closure mechanism assembly in
accordance with another embodiment of the present invention.
[0023] FIG. 14 is an elevated, perspective view of a partially
constructed header section and closure mechanism assembly in
accordance with another embodiment of the present invention.
[0024] FIG. 15 is an elevated, perspective view of a header section
and closure mechanism assembly in accordance with another
embodiment of the present invention.
[0025] FIG. 16 is an elevated, perspective view of a partially
constructed, resealable package in accordance with another
embodiment of the present invention.
[0026] FIG. 17 is an elevated, perspective view of a flexible,
resealable package in accordance with another embodiment of the
present invention.
[0027] FIG. 18a is a largely schematic view of a portion of a
process for constructing a flexible, resealable package in
accordance with another embodiment of the present invention.
[0028] FIG. 18b is a largely schematic view of the remainder of the
process for constructing a flexible, resealable package partially
illustrated in FIG. 18a.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIGS. 1-3 illustrate an example of a resealable, flexible
package 10 having a closure mechanism 20 with first and second
closure profiles 33, 35 and a slider device 30 to open and close
the profiles 33, 35.
[0030] The flexible package 10 includes first and second opposed
panel sections 12, 14 made from a flexible, polymeric film. For
some manufacturing applications, the first and second panel
sections 12, 14 are heat-sealed together along two edges 13, 17 and
meet at a fold line in order to form a three-edged containment
section for a product within the interior of the package 10. The
fold line comprises the bottom edge 15. Alternatively, two separate
panel sections 12, 14 of polymeric film may be used and heat-sealed
together along the two edges 13, 17 and at the bottom 15.
[0031] As illustrated in FIGS. 1-3, the flexible package 10 also
includes a closure mechanism 20 made in accordance with an
embodiment of the present invention. The closure mechanism 20
includes first and second closure profiles 33, 35. The first and
second closure profiles 33, 35 may be of any appropriate design
known in the art. Example closure profiles are disclosed in U.S.
Pat. Nos. 5,983,466, 5,947,603, and 6,217,215.
[0032] A slider device 30 is mounted on the closure mechanism 20 to
facilitate the opening and closing of the closure mechanism 20.
Slider devices and how the function to open and close such
mechanisms, in general, are taught, for example, in U.S. Pat. Nos.
5,063,644, 5,301,394, 5,442,837 and 5,664,229, each of which is
incorporated by reference herein. A preferred slider device is
taught in U.S. Pat. Nos. 6,293,701 and D434,345 which are
incorporated herein by reference, in their entirety.
[0033] Two portions of the closure mechanism 20, one close to the
first side edge 13 and another close to the second side edge 17,
act as slider stop areas. These slider stop areas are preferably
crushed, such as by ultrasonic crushing, shown as crush areas 23,
27 in FIG. 2. The slider stop areas or crush areas 23, 27 securely
seal the first and second closure profiles 33, 35 together to
minimize the chance of the slider device 30 sliding off the side
edges 13, 17 of the package 10. The slider stop areas or crush
areas 23, 27 further minimize the tendency for slider device 30 to
abut against either of the first side edge 13 or the second side
edge 17, and may in fact entirely preclude contact between the
slider device 30 and either side edge 13, 17.
[0034] A notch 21 (shown in FIG. 1) is preferably disposed within
the closure mechanism 20. The notch 21 is designed to provide a
"park place" into which the slider 30 settles when the closure
mechanism 20 is sealed. The notch 21 decreases the chances an
incomplete interlock between the first and second closure profiles
33, 35. Examples of notches are disclosed, for example, in U.S.
Pat. Nos. 5,067,208 and 5,301,395, each of which is incorporated
herein by reference.
[0035] The flexible package 10 also preferably includes a
tamper-evident header section 40 that is attached to the closure
mechanism 20 at the seal 41. The header section 40 comprises two
sides 45, 47 (shown most clearly in FIG. 3) sealed together along
the two edges 46, 48. The two sides 45, 47 define first and second
mouths 42, 44 (shown in FIG. 3). Access to the interior 11 of the
flexible package 10 can be gained through the first and second
mouths 42, 44.
[0036] The header section 40 includes a preferential area of
weakness 38 that extends along a portion of the header section 40.
The preferential area of weakness 38 is included to facilitate
removal of the header section 40 from the package 10. To that end,
the header section 40 may also include a notch 39 (shown in FIG. 2)
at one or both of the intersections of the preferential area of
weakness 38 and the sides 45, 47. The notch 39 acts as a "starter"
for removing the header section 40 from the package 10 by tearing
the header 40 at the preferential area of weakness 38.
[0037] As can be seen best in FIGS. 1 and 3, the header section 40
is preferably attached to the closure mechanism 20 at a point 41
where, when the closure mechanism 20 is attached to the side panels
12, 14, the point 41 is between the closure profiles 33, 35 and the
bottom 15 of the package 10. The header section 40 extends from the
attachment point 41 and between the first and second closure
profiles 33, 35. Preferably, the header section 40 extends well
past the first and second closure profiles 33, 35. In this way,
when package 10 is filled with a product through the mouth 42 of
the header section 40 the first and second closure profiles 33, 35
are protected from contamination by the product.
[0038] After a product has been placed in the interior 11 of the
package 10, the mouth 42 of the header section 40 is sealed, as
illustrated in FIG. 4. This creates a tamper-evident seal 44 along
the length of the header section 40. In order to gain access to the
product once the package 10 has been filled and sealed, the
consumer simply removes the header section 40, as illustrated in
FIG. 5. For example, the header section 40 may be removed by
tearing, starting at the notch 39, along the preferential area of
weakness 38. Once the header section 40 is removed, the closure
mechanism 20 may be sealed (or re-sealed) by sliding the slider 30
along the length of the package 10, as shown in FIG. 6.
[0039] FIGS. 7-17 illustrate a method of manufacturing the package
10 in accordance with an embodiment of the present invention. FIG.
7 shows the first and second header sides 45, 47 joined together at
the header bottom, 43. The first and second header sides 45, 47 may
be provided as separate sheets that are sealed together at the
bottom 43. Preferably, however, the first and second header sides
45, 47 are formed by providing a single sheet of material that is
then folded in half at the bottom 43.
[0040] Once the two header sides 45, 47 are formed, the
preferential area of weakness, 38 is formed on the header sides 45,
47, as shown in FIG. 8. The preferential area of weakness 38 is
provided by scoring the header sides 45, 47, in a manner that is
known in the art. The header sides 45, 47 may be scored
individually, but are preferably scored simultaneously.
Alternatively, a single sheet of material may be provided that is
pre-scored prior to folding the sheet.
[0041] As shown in FIG. 9, the header sides 45, 47 are sealed
together at the seals 48a, 46a. The seals 48a, 46a are preferably
formed by heat sealing or by other means such as compression,
ultrasonic welding, vibration welding or adhesives. The seals 48a,
46a eventually comprise the header edges 48, 46, as shown in FIG.
1. In the preferred embodiment shown in FIG. 9, the seals 48a, 46a
are L-shaped, with the bottom edge of the seal aligned with the
preferential area of weakness 38. This allows for the starter notch
39 to be formed in later steps at the corner of the L (as shown in
FIG. 10). While the seals 48a, 46a in this embodiment are L-shaped,
the seals may also be C-shaped, or any other appropriate shape
known in the art. It is noted that sealing the header sides 45, 47
together defines the header mouth 42. Mouth 44 is created by
eliminating a portion of the bottom 43, as illustrated in FIG. 9a.
The portion that is eliminated creates the mouth 44, that is in
fluid communication with the mouth 42, as illustrated in FIG. 10b.
The portion eliminated to create the mouth 44 may be removed by any
appropriate means known in the art, for example, by punching out or
cutting out the desired portion. The formation of the seals 48a,
46a results in the formation of a header section 40 having a mouth
44 that is smaller relative to the mouth 42.
[0042] In order to transform the seals 48a, 46a to the sides 48,
46, respectively, the sections 48b, 46b inside of the L-shaped
seals 48a, 46a are removed, as illustrated in FIG. 10a. The
sections 48b, 46b may be removed by any suitable means known in the
art. Preferably, sections 48b, 46b are removed by use of a
punch-out apparatus. After sections 48b, 46b are removed, the
header section is notched at the corners of the L-shaped seals 48a,
46a. The notches 39a, 39b are aligned with the preferential area of
weakness 38. The notches 39a, 39b may preferably act as starters
for removing the header section 40 at the preferential area of
weakness 38 when it is desirable to open the package 10 for the
first time. The header section may contain no notches, one of the
notches 39a, 39b or both of the notches 39a, 39b.
[0043] After the header section 40 is completed, it is placed
between the first and second closure profiles 33, 35 as illustrated
if FIG. 11. If the first and second closure profiles 33, 35 are
provided in an engaged state, they must first be separated. Once
they are separated, the header section 40 is placed between the
first and second closure profiles 33, 35. The header section 40 is
positioned such that the preferential area of weakness 38 is
disposed beneath the interlocking closure members (as shown in FIG.
3). By "beneath" it is meant that the preferential area of weakness
is placed in a position that will be between the interlocking
closure members and the bottom 15 of the package 10, once the
closure mechanism 20 is attached to the side panels 12, 14 of the
package 10. When the header section 40 is properly positioned
between the first and second closure profiles 33, 35, it is
attached to the first and second closure profiles 33, 35, as
illustrated in FIG. 12. Preferably, the header section 40 is
attached to the first and second closure profiles 33, 35 by heat
sealing.
[0044] As is shown in FIGS. 13-15, the slider 30 is placed on the
closure mechanism 20. The slider 30 may be placed on the closure
mechanism 20 by several means, examples of which are discussed
below. Preferably closure mechanism 20 is also notched, to provide
the notch 21 as a "resting place" for the slider 30 when the slider
30 is moved into the fully closed positioned. Spot seals 23, 27 may
also be provided on the ends of the closure mechanism 20. The spot
seals 23, 27 are provided to help prevent the slider 30 from
sliding off of the closure mechanism 20 and to halt the travel of
the slider 30. This completes the construction of assembly 70.
[0045] FIGS. 16-17 illustrate the steps of positioning the assembly
between the side panels 12, 14 of the package 10, and attaching the
side panels 12, 14 of the package 10 to the assembly 70. Once the
assembly 70 is attached to the side panels 12, 14 of the package
10, the side panels 12, 14 are sealed together at edges 13, 17 to
complete construction of the package 10.
[0046] With reference to FIGS. 16-17, as well as FIG. 3, in order
to fill the package 10, the mouth 42 is opened and product is
dispensed through mouth 42, through the mouth 44, and into the
interior 11 of the package 10. The header section, because it is
joined to the closure mechanism 20 beneath the interlocking closure
members and passes between those interlocking closure members,
protects the interlocking closure members from the possibility of
contamination by product as the package 10 is being filled. The
mouth 42 of the header section 40 is then sealed to form a
tamper-evident structure.
[0047] FIGS. 18a and 18b illustrate one embodiment of a continuous
process for producing the resealable package 10 of the present
invention. The process starts with a spool 100 of pre-folded header
material. The material is unrolled from spool 100 and fed past
score line applicator 102 which applies the preferential area of
weakness 38. Alternatively, the spool 100 of pre-folded header
material my have been pre-scored. The header material continues
in-line to sealing station 104, where the L-shaped seals 48a, 46a
are formed, for example, by heat sealing.
[0048] After the L-shaped seals 48a, 46a are formed, the material
inside the L is punched out at punching station 106. The header
material then passes over the spool 108 of closure profiles 33, 35.
The header material is inserted between the closure profiles 33,
35, as described above. Once the header material is between the
closure profiles 33, 35, the header material and closure profiles
33, 35 pass through the slider application station 110. The slider
application station 110 applies the slider 30 to the closure
mechanism 20 through the use of a vibratory feeder, applies the
stop seals 23, 27, and punches the notch 21 in the closure profiles
33, 35 as described in U.S. patent application Ser. No. 09/649,557,
filed Aug. 28, 2000, the entire contents of which are hereby
incorporated by reference.
[0049] Once the header assembly 70 is complete, it passes to a
typical horizontal form fill and seal machine, as shown in FIG.
18b. The material comprising the side panels 12, 14 of resealable
package 10 is provided on roll 150. The material is unwound and
passes over folding board 145 to form the two side panels 12, 14.
In this embodiment, there is a slot 146 in the folding board 145
through which the header assembly 70 passes. This positions the
header assembly 70 between the side panels 12, 14. The side panels
12, 14 are then heat sealed to the closure profiles 33, 35.
Alternatively, the header assembly 70 travels over the upper edge
of the film after it travels over the folding board 145 instead of
passing through the slot 146 in the folding board 145, thus being
positioned between the side panels 12, 14. Other embodiments may
include utilizing a tube or guide mechanism to position the header
assembly 70 between the side panels 12, 14.
[0050] The continuous line of packages continues to sealing bars
112 that seal the sides 13, 17 of the package 10. The packages then
pass under hopper 114 that contains the product to be placed in
package 10. As the packages pass under the hopper 114, product
passes through the mouth 42 and the mouth 44 of the header section
40 and into the interior 11 of the package 10. The mouth 42 is then
sealed by sealing bars 116 to form the tamper-evident structure.
Finally, the continuous line of packages is separated into
individual packages by cutting knife 118.
[0051] It should be understood that other methods of attaching the
header assembly 70 to the side panels 12, 14 may be used. The
header assembly 70 may be incorporated into other package
manufacturing processes known in the art, such as a horizontal-form
vertical-fill-seal method, a pre-made pouch method, and a fill seal
method.
[0052] While specific embodiments and methods for practicing this
invention have been described in detail, those skilled in the art
will recognize various manifestations and details that could be
developed in light of the overall teachings herein. Accordingly,
the particular mechanisms disclosed are meant to be illustrative
only and not to limit the scope of the invention which is to be
given the full breadth of the following claims and any and all
embodiments thereof.
* * * * *