U.S. patent application number 10/980633 was filed with the patent office on 2005-03-31 for methods of making slide-zippered reclosable packages on horizontal form-fill-seal machines.
This patent application is currently assigned to ILLINOIS TOOL WORKS INC.. Invention is credited to Ausnit, Steve, Crevier, Donald L., Johnson, Joel, Malin, Art, Matthews, David J., McMahon, Michael J..
Application Number | 20050069659 10/980633 |
Document ID | / |
Family ID | 23231052 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050069659 |
Kind Code |
A1 |
McMahon, Michael J. ; et
al. |
March 31, 2005 |
Methods of making slide-zippered reclosable packages on horizontal
form-fill-seal machines
Abstract
Methods of making slide-zippered reclosable packages are
provided. In one embodiment, a pair of opposing film extensions are
provided on each package between which a zipper and slider are
attached. In another embodiment, sliders are inserted on to
zippered packages output from a form-fill-seal machine or the like.
In yet another embodiment, during package formation a reclosable
zipper is sealed to each package and then a slider is inserted on
to the zipper. In yet another embodiment, during package formation
a reclosable zipper is sealed to each package and a slider is
inserted on to each zipper, either before or after zipper
sealing.
Inventors: |
McMahon, Michael J.;
(Palatine, IL) ; Malin, Art; (Northbrook, IL)
; Ausnit, Steve; (New York, NY) ; Crevier, Donald
L.; (Essex, IL) ; Johnson, Joel; (Stockbridge,
GA) ; Matthews, David J.; (Gilman, IL) |
Correspondence
Address: |
PITNEY HARDIN LLP
7 TIMES SQUARE
NEW YORK
NY
10036-7311
US
|
Assignee: |
ILLINOIS TOOL WORKS INC.
|
Family ID: |
23231052 |
Appl. No.: |
10/980633 |
Filed: |
November 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10980633 |
Nov 3, 2004 |
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09915103 |
Jul 25, 2001 |
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09915103 |
Jul 25, 2001 |
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09631179 |
Aug 2, 2000 |
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6810639 |
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09631179 |
Aug 2, 2000 |
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09316866 |
May 21, 1999 |
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6138439 |
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Current U.S.
Class: |
428/34.2 |
Current CPC
Class: |
B31B 50/81 20170801;
B31B 70/8132 20170801; Y10T 428/1303 20150115; B65B 9/04 20130101;
Y10T 24/45168 20150115; B65B 9/093 20130101; B65B 43/50 20130101;
B65B 61/188 20130101 |
Class at
Publication: |
428/034.2 |
International
Class: |
B65D 001/00 |
Claims
1-33. (canceled)
34. A web structure for use in a form-fill-seal machine,
comprising: a web extending between a pair of free longitudinal
edges; a zipper arrangement including a zipper and a plurality of
sliders, said sliders being mounted to said zipper at spaced
locations, said zipper being secured to said web, said zipper being
generally parallel to and located away from said longitudinal
edges.
35. The web structure of claim 34, wherein said web is folded and
includes a pair of opposing panels joined along a fold, said
opposing panels including said respective longitudinal edges
opposite said fold, said zipper being generally parallel to and
near said fold.
36. The web structure of claim 35, wherein said folded web includes
spaced side seals generally transverse to said fold and joining
said opposing panels.
37. The web structure of claim 34, wherein said zipper includes
first and second opposing profiles releasably engageable to each
other and a first fin extending downward from said first
profile.
38. The web structure of claim 37, wherein said zipper includes a
second fin extending downward from said second profile.
39. A web structure for use in a form-fill-seal machine,
comprising: a web extending between a pair of free longitudinal
edges, said web having a c-fold located opposite of said pair of
free longitudinal edges; and a zipper arrangement including a
zipper and a plurality of sliders, said sliders being mounted to
said zipper at spaced locations, said zipper being secured to said
web, said zipper being located near the c-fold of the web.
40. The web structure of claim 39, wherein said zipper is generally
parallel to said c-fold.
41. The web structure of claim 39, wherein said zipper is located
at said c-fold of the web.
42. The web structure of claim 39, wherein said web further
includes a pair of opposing panels joined along said c-fold, said
opposing panels including the respective longitudinal edges
opposite said c-fold.
43. The web structure of claim 42, wherein said web includes spaced
side seals generally transverse to said c-fold and joining said
opposing panels.
44. The web structure of claim 39, wherein said zipper includes
first and second opposing profiles releasably engageable to each
other and a first fin extending downward from said first
profile.
45. The web structure of claim 44, wherein said zipper includes a
second fin extending downward from said second profile.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of reclosable
packaging. More particularly, the present invention relates to
methods of making reclosable packages having slide zippers on
horizontal form-fill-seal (HFFS) machines.
[0003] 2. Description of the Prior Art
[0004] Methods of making reclosable packages on various types of
HFFS machines are well-known in the reclosable packaging art, such
as that disclosed in U.S. Pat. No. 4,876,842. Slide zippers, i.e.,
plastic zippers opened and closed by a slider, are likewise
well-known in the reclosable packaging art. Examples of several
types of slide zippers can be found in U.S. Pat. Nos. 5,007,143,
5,008,971, 5,131,121 and 5,664,299.
[0005] The reclosable packaging art, however, is virtually, if not
totally, silent as it relates to the manufacture of slide-zippered
packages on HFFS machines. Because of the facility which is
provided by slide zippers to consumers of reclosable packages and
because of the large volume of reclosable packages made on HFFS
machines today, it is highly desirable and advantageous to combine
the two technologies so that slide-zippered reclosable packages can
be made on HFFS machines.
SUMMARY OF THE INVENTION
[0006] Accordingly, the object of the present invention is to
provide methods of making slide-zippered reclosable packages on
HFFS machines.
[0007] According to a first embodiment of the present invention, a
chain of packages is formed, filled and sealed on an HFFS machine
or the like. A pair of opposing film extensions are provided on
each package. As the chain of packages is indexed forwardly, a
reclosable zipper is inserted between the film extensions of the
leading package and sealed thereto. A slider is then inserted on to
the reclosable zipper of the leading package and the completed
leading package is cut from the chain.
[0008] According to a second embodiment of the present invention,
packages having reclosable zippers are output from an HFFS machine
or the like, either individually or in a chain. A slider is then
inserted on to the zipper of each package in turn.
[0009] According to a third embodiment of the present invention,
packages are formed, filled and sealed on an HFFS machine or the
like. During package formation, a reclosable zipper is sealed to
each package and then a slider is inserted on to the zipper.
[0010] According to a fourth embodiment of the present invention,
packages are formed, filled and sealed on a horizontal
form-vertical fill-seal (HVFS) machine or the like. During package
formation, a reclosable zipper is sealed to each package and a
slider is inserted on to each zipper, either before or after zipper
sealing.
[0011] The present invention will now be described in detail, with
frequent reference being made to the drawings identified below in
which the same numerals represent the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the accompanying drawings:
[0013] FIG. 1 shows packages being made on an HFFS machine in
accordance with a first embodiment of the present invention;
[0014] FIG. 2 is a perspective view of a package made on the HFFS
machine of FIG. 1 prior to attaching the zipper;
[0015] FIG. 3 is a cross-sectional view of the HFFS machine of FIG.
1 at the slider insertion point;
[0016] FIG. 4 is a cross-sectional view of a first variation of the
HFFS machine of FIG. 1;
[0017] FIG. 5 shows sliders being inserted on a chain of packages
in accordance with a second embodiment of the present
invention;
[0018] FIG. 6 shows sliders being inserted on to individual
packages in accordance with a variation of the second embodiment of
the present invention;
[0019] FIG. 7 shows packages being made on an HFFS machine in
accordance with a third embodiment of the present invention;
[0020] FIG. 7a is a cross-sectional view of the HFFS machine of
FIG. 7 at the first zipper sealing station;
[0021] FIG. 8 is a cross-sectional view of the HFFS machine of FIG.
7;
[0022] FIG. 9 is a cross-sectional view of a package made on the
HFFS machine of FIG. 7;
[0023] FIG. 10 shows packages being made on an HFFS machine in
accordance with a variation of the third embodiment of the present
invention;
[0024] FIG. 11 is a cross-sectional view of packages being made on
the HFFS machine of FIG. 10;
[0025] FIG. 12 shows packages being made on an HFVS machine in
accordance with a fourth embodiment of the present invention;
[0026] FIG. 13 shows packages being made on an HFVS machine in
accordance with a first variation of the fourth embodiment of the
present invention;
[0027] FIG. 14 shows packages being made on an HFVS machine in
accordance with a second variation of the fourth embodiment of the
present invention;
[0028] FIG. 15 is a cross-sectional view of reclosable zipper being
sealed to one package side in the HFVS machine of FIG. 14;
[0029] FIG. 16 is a cross-sectional view of a package prior to
being filled on the HFVS machine of FIG. 14;
[0030] FIG. 17 is a cross-sectional view of a tamper evident sealed
being placed on a package made on the HFVS machine of FIG. 14;
[0031] FIG. 18 shows packages being made on an HFVS machine in
accordance with a third variation of the fourth embodiment of the
present invention; and
[0032] FIG. 19 is a cross-sectional view of a package being formed
on the HFVS machine of FIG. 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] In accordance with a first embodiment of the present
invention, FIG. 1 shows how slide-zippered packages can be made on
a typical thermoform HFFS machine 10. Forming film 12 is indexed
off a coil 14 of the same in a package forming direction.
Downstream of the forming film coil 14 at a forming station 15 the
forming film 12 is thermoformed, using techniques well-known to
those of ordinary skill in the reclosable packaging art, into a
chain 13 of advancing box-like bottom portions or trays 16 of what
will ultimately be completed packages. Product may then be loaded
into the bottom portions 16 at a loading station 17 if desired.
After optional product loading, top film 18 is indexed off a coil
20 of the same in the package forming direction, laid over the
advancing bottom portions 16 and perimeterly sealed thereto at four
locations 22, 24, 26, 28 at a sealing station 21 to form a sealed
package 29, as shown in FIG. 2. The seal at the package opening 22
takes the form of a peel seal so that the consumer can easily gain
access to the contents of the package.
[0034] As shown in FIG. 2, which is a perspective view of a sealed
package 29 formed on the thermoform HFFS machine of FIG. 1 prior to
zipper and slider insertion, the bottom portion 16 and top film 18
are each provided with film extensions 30, 32 which extend beyond
the peel seal 22 on one side of the package 29. The film extensions
30, 32 are not sealed to each other and may readily be spread apart
from each other.
[0035] After the top film 18 is sealed to the bottom portion 16 at
the sealing station 21, the package chain 13 enters a zipper and
slider insertion and attaching station 34. At this station 34 the
film extensions 30, 32 of the leading package are spread apart from
each other and interlocked reclosable zipper 36 supplied from a
coil 38 of the same is fed between the film extensions 30, 32, as
shown in FIG. 3, which is a cross-sectional view of the package
chain and zipper and slider insertion and attaching station 34. The
zipper is comprised of two interlocking closure elements 39, 41 and
flanges 40, 42 extending therefrom which are sealed to the film
extensions 30, 32, such as by a pair of seal bars (not shown).
After the zipper 36 is thus sealed to the film extensions of the
leading package, the zipper 36 is stomped at each end of the
package by a stomping apparatus (not shown) to provide end stops
for the slider and to ensure that the ends of the zipper 36 do not
come apart during use.
[0036] A slider 44 is then removed from a coil 46 thereof and
inserted on to the zipper 36 by a slider insertion apparatus (not
shown). The slider and zipper are designed such that the slider
will open the zipper as the slider is moved along the zipper in an
opening direction towards an opening end of the zipper and close
the zipper as the slider is moved along the zipper in a closing
direction towards a closing end of the zipper. It is preferable
during slider insertion that the slider be inserted at the closing
end of the zipper since the zipper is initially interlocked. The
slider will thus be positioned for normal functioning. If the
slider is inserted at a location other than at the closing end, it
will be necessary to actuate the slider by moving it to the closing
end, after which the slider will be in position for normal
functioning. Such actuation may be done on the HFFS machine, or it
may be done by the initial package user.
[0037] After slider insertion, the leading package is cross-cut
from the remainder of the chain 13 by any one of many commonly
known cutting apparatuses (not shown) to remove a completed package
48 having a slide zipper.
[0038] In practice, the package chain 13 may be a single chain as
shown in FIG. 3, or, alternatively, may be a multiple chain, such
as the double chain 50 shown in cross-section in FIG. 4. In the
case of a double chain, where two packages are joined side by side,
the process of making the packages is virtually identical to that
described above, except that the zippers and sliders are attached
to the opposite sides 47, 49 of the package chain simultaneously,
as shown in FIG. 4, thus requiring two zipper and slider insertion
and attaching stations 34. Additionally, a second cut is needed in
the machine direction along the central axis 51 of the chain to
remove the side-by-side packages from one another.
[0039] The foregoing embodiment of the present invention is not
limited to practice on thermoform HFFS machines, but may be
practiced on any type of package making machine where the packages
are formed with film extensions 30, 32 of the type discussed
above.
[0040] FIGS. 5 and 6 depict a second embodiment of the present
invention. Zippered packages 52, either in a chain 54 as shown in
FIG. 5 or individually as shown in FIG. 6, are output from an HFFS
machine (not shown), or any other type of bag making machine. In
the case of FIG. 5, the package chain 54 is indexed into a slider
insertion station 56. At the slider insertion station 56 or at an
earlier station, the ends of the zipper 36 on the leading package
in the chain 54 are stomped as discussed above. Then, a slider 44
is removed from the slider coil 46 and inserted on to the zipper
36. Finally, a completed package 58 have a slide zipper is
cross-cut from the chain by a cutting apparatus (not shown).
[0041] In the case of FIG. 6, the packages 52 are individual and
not chained together. The individual packages 52 are transported
one by one into the slider insertion station 56 by a conveyor belt
60 or the like, where the ends of the zipper 36 on the leading
package are stomped (unless the stomping was done during package
formation) and a slider 44 is removed from the slider coil 46 and
inserted on to the zipper 36 to provide a completed slide-zippered
package 58.
[0042] In accordance with a third embodiment of the present
invention, FIG. 7 shows a thermoform HFFS machine 62 configured to
make slide-zippered packages. As in FIG. 1, the forming film 12 is
indexed off a coil 14 of the same. Downstream of the forming film
coil 14 at a forming station 15 the forming film 12 is thermoformed
into a chain 13 of box-like bottom portions or trays 16 of what
will ultimately be completed packages. Product may then be loaded
into the bottom portions 16 at the loading station 17 if desired.
Each bottoms portion 16 is provided with a lip 64 on one side
thereof, as shown in FIG. 8, which is a cross-sectional view of the
chain 13. After optional product loading, the reclosable zipper 36
is indexed off a coil 38 of the same and laid over the lips 64 of
the bottom portions 16. The lower zipper flange 42 is then sealed
to the lips 64 by a sealing mechanism, such as a heater bar 63, at
a sealing station 68. The heater bar 63 is positioned below the
lips 64, as shown in FIG. 7a, which is a cross-sectional view of
zipper attachment to the package lips. Also shown in FIG. 7a is an
insulating and guide plate 67 positioned between the zipper
flanges. The insulating and guide plate 67 provides a surface for
the heater bar to react against and removes any danger of sealing
through the zipper flanges, thereby eliminating the need for
accurate heat control. The insulating and guide plate 67 also
serves to guide and position the zipper onto the package lips to
ensure accurate sealing.
[0043] A slider 44 is then removed from the slider coil 46 and
inserted on to the zipper 36 of the instant bottom portion 16 at an
insertion station 70. After slider insertion, the ends of the
zipper are stomped. Alternatively, the zipper ends could have been
stomped together earlier, either on the machine or pre-stomped
prior to winding on the supply coil, and the zipper indexed to the
bottom portion. The top film 18 is then indexed off the top film
coil 20, laid over the formed bottoms 16 and the attached zipper 36
and sealed to the formed bottoms 16 and the upper flange 40 of the
zipper 36 around the perimeter of the package at a second sealing
station 72. As discussed above, the seal at the mouth of the
package may take the form of a peel seal to provide easy access to
the contents of the package. Optionally, the top film 18, if it is
long enough, may be heat tacked to the bottom portion 16 over the
zipper 36 to provide a tamper evident seal 65, as shown in FIG. 9.
In the final step, the completed packages 48 are cross-cut from the
chain at a cutting station 74. If a double chain is used, as shown
in FIG. 8, then the side-by-side packages must also be cut from
each other in the machine direction.
[0044] When making packages using multiple package chains, it is
not necessary that the zippers and sliders be applied to opposite
sides 47, 49 of the package chain, as shown in FIGS. 4 and 8.
Rather, it is also possible to apply the zippers and sliders to the
same sides of the packages. For example, a triple package chain is
shown in FIGS. 10 and 11. In this case the top film 18 is
pre-perforated so that it can be split into three sections and laid
over each of the bottom portions 16. This splitting is achieved by
a separator assembly 78 having three L-shaped separator plates 78a,
78b, 78c. As the top film 18 is indexed off its roll 20, the
vertical portions of the separator plates 78a, 78b, 78c split the
pre-perforated top film 18 into three portions 18a, 18b, 18c and
guide the three top film portions as they are laid over their
corresponding bottom portions 16. Additionally, the horizontal
portions of the separator plates interact with the sealing
mechanism to ensure that there is no seal through, eliminating the
need for accurate heat control.
[0045] As indicated above, the present invention is not limited to
thermoform HFFS machines, but may be practiced on any type of HFFS
machine and on any type of bag making machine for that matter. FIG.
12 shows how slide-zippered packages can be made on a horizontal
form-vertical fill-seal machine (HFVS) 80 in accordance with a
fourth embodiment of the present invention.
[0046] Package film 82 is paid off a roll 84 of the same.
Downstream a pull roller 98 is provided for driving the film 82
through the machine. A folder plow 86 positioned downstream of the
film roll 84 folds the package film 82 about a bottom crease 83 to
form opposing package walls 116, 118. Interlocked reclosable zipper
36 is then paid off a roll 38 of the same and fed between the
advancing package walls. Sliders 44 are inserted on to the
reclosable zipper 36 prior to the folder plow 86 at package width
intervals at what will be the closing end of the zipper by a slider
insertion mechanism at the slider insertion station 88. The sliders
44 are supplied from the slider coil 46.
[0047] At a first sealing station 90, the zipper flanges 40, 42 are
sealed to the opposing package walls. Then at stomping stations 92,
the ends of the zipper 36 for a given package are stomped. At a
second sealing station 94, the folded film and zipper are
cross-sealed to form discrete packages.
[0048] Because the zippers are closed, it is necessary to open the
zippers in order to fill the packages. This is achieved at a slider
opening station 96, where the slider is held in position as the
zipper and film are advanced when the pull rollers 98 are
activated. As the zipper moves through the slider, it is opened.
Alternatively, the slider itself may be moved. Then, at a cutting
station 100 the individual packages 102 are cut from one another.
The separated packages 102 are then taken to the filling station
104 where they are filled. Filling may occur by means of a filling
turret 106 or the packages may be filled in-line, both of which
techniques are well-known to those of ordinary skill in the art.
After a package is filled, the slider 44 is moved backed to the
closing end of the zipper. Finally, a tamper evident 108 seal may
optionally be provided above the zipper 36. Completed
slide-zippered packages 110 are then output from the machine.
[0049] A first variation of the fourth embodiment is shown in FIG.
13. As is clear from FIG. 13, the sliders are attached downstream
of the folder plow 86, rather than upstream of the folder plow 86.
Additionally, the sliders 44 are attached to the zippers 36 at
their opening ends, rather than at their closing ends as above.
Thus, in order to open the zippers for package filling the zippers
must be forced open from the outside of the packages, rather than
by using the sliders. This opening action is carried out at an
opening station 97 by a suitable mechanism provided for the
specific zipper construction. After filling at the filling station
104, the slider is moved to the closing end of the zipper.
[0050] A second variation of the fourth embodiment of the present
invention is shown in FIG. 14. Under certain circumstances it may
be desirable to eliminate the step of opening the zipper for
filling. This can be done by sealing one zipper flange to one side
of the folded film at the first sealing station 90 prior to
filling, as shown in FIG. 15, rather than sealing both flanges to
the film as done previously.
[0051] As shown in FIG. 15, one flange 40 of the zipper is sealed
to one wall 116 of the folded film 82 a distance below the top 120.
The film 82 protrudes above the zipper to form a pair of opposing
ears 122. To ensure that the zipper flanges 40, 42 do not seal to
each other or the other side of the package at the first sealing
station 90, a J-shaped insulator plate 124 is inserted between the
zipper flanges 40, 42 and between the unsealed zipper flange 42 and
the other package wall 118, as shown in FIG. 15. In addition, one
of the seal bars 112 is kept hot and the other 114 is deactivated.
Then, at the second sealing station 94, the packages are
cross-sealed from the bottom of the film 92 up to but not including
the zipper. When it comes time to fill the bag at the filling
station 104, the zipper is bent to one side, as shown in FIG. 16.
In this manner, filing may proceed unobstructed, and there is no
danger of contaminating the zipper. After filling, the unsealed
zipper flange 42 is sealed to the other side of the package and the
ears 122 are sealed to each other by a pair of seal bars 126 with a
perforation seal and a peel seal above the zipper 36, as shown in
FIG. 17. At the same time the ends of the zipper are cross-sealed
together and end stops for the slider are created. The above
indicated zipper cross-seals extend below the zipper flanges into
the package side seals, but not above and beyond the zipper
profiles.
[0052] A third variation of the fourth embodiment of the present
invention is shown in FIG. 18. In this variation, the zipper 36 and
slider 44 are attached to the bottom 128 of the package, rather
than at the top 120. As the film 82 is fed over the folder plow 86,
a perforator 130 perforates the film 82 below the slider 44 to form
a pair of perforations 132 (alternatively, a single perforation
132a may be provided). The zipper is then sealed to the bottom of
the package by sealing the zipper flanges to the film beyond the
perforation lines, as shown in FIG. 19. A peel seal 136 may be
provided between the zipper flanges in order to maintain the
integrity of the packages.
[0053] The packages are completed as discussed above, except that
they are filled from the opposing end to which the zipper has been
attached. Further, if a bottom gusset is required a V shaped film
can be introduced between the package walls 116 and 118 and sealed
into place. During use, the packages are inverted so that the
zipper and slider are at the top and the perforated portion 134 is
torn away from the package to gain access to the slider.
[0054] Thus, in the foregoing manner the object of the present
invention is achieved.. Modifications to the above would be obvious
to those of ordinary skill in the art, but would not bring the
invention so modified beyond the scope of the appended claims.
* * * * *