U.S. patent application number 11/358522 was filed with the patent office on 2006-06-29 for vertical stand-up pouch with integrated reclose strip.
Invention is credited to Martin Bernhard Dierl, Jay Edward Gehring, Anthony Robert Knoerzer, Garrett William Kohl, Steven Kenneth Tucker.
Application Number | 20060140514 11/358522 |
Document ID | / |
Family ID | 28039796 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060140514 |
Kind Code |
A1 |
Dierl; Martin Bernhard ; et
al. |
June 29, 2006 |
Vertical stand-up pouch with integrated reclose strip
Abstract
A vertical stand-up pouch or flexible package having an
integrated reclose strip, and method for manufacturing same,
constructed by modification to existing vertical form and fill
packaging machines. The modified machine includes a crease-forming
mechanism and an apparatus for applying a reclose strip to the
sheet of material. The apparatus for applying a reclose strip is
incorporated into the mechanism which supplies the continuous sheet
of packaging material to the vertical form, fill, and seal machine.
The invention involves producing a vertical stand-up pouch having
an integrated reclose strip from a single sheet of packaging film
by creating a vertical crease along one edge of a packaging film
tube prior to forming a transverse seal on the tube. Said vertical
crease is formed using a stationary tucker bar positioned outside
the packaging film tube and between two forming plates positioned
inside the packaging film tube. The reclose strip is attached along
the longitudinal axis of the sheet of packaging material prior to
forming the sheet into a tube in the conventional manner. The
reclose strip includes a peel strip which is removable to allow the
package, when opened, to be folded down and sealed against an
adhesive which will be exposed upon the removal of the peel strip.
In a preferred embodiment, the reclose strip comprises a length of
two-sided adhesive tape.
Inventors: |
Dierl; Martin Bernhard;
(Allen, TX) ; Gehring; Jay Edward; (Frisco,
TX) ; Knoerzer; Anthony Robert; (Plano, TX) ;
Kohl; Garrett William; (Allen, TX) ; Tucker; Steven
Kenneth; (Hurst, TX) |
Correspondence
Address: |
CARSTENS & CAHOON, LLP
P O BOX 802334
DALLAS
TX
75380
US
|
Family ID: |
28039796 |
Appl. No.: |
11/358522 |
Filed: |
February 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10696982 |
Oct 30, 2003 |
7032362 |
|
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11358522 |
Feb 21, 2006 |
|
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|
10100370 |
Mar 18, 2002 |
6722106 |
|
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10696982 |
Oct 30, 2003 |
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Current U.S.
Class: |
383/62 ; 383/104;
383/89 |
Current CPC
Class: |
B65B 9/2042 20130101;
B65B 9/20 20130101; B65B 9/213 20130101; B65B 9/22 20130101; B65B
61/188 20130101; B65D 75/008 20130101; B65D 33/1691 20130101 |
Class at
Publication: |
383/062 ;
383/104; 383/089 |
International
Class: |
B65D 33/16 20060101
B65D033/16; B65D 33/30 20060101 B65D033/30; B65D 30/16 20060101
B65D030/16 |
Claims
1. A flexible reclosable stand-up package formed on a form, fill,
and seal packaging machine from a continuous sheet of packaging
film, said package comprising after formation: a package body
having a top end, a bottom end, a front wall, and a back wall
disposed between two vertical edge seals, said walls formed from a
segment of said sheet of packaging film and having a longitudinal
formation axis extending between said vertical edge seals, said
bottom end having a crease formed in the packaging material, said
film joined to itself at said vertical edge seals and at a back
seal extending along said back wall between said vertical seals,
said top end, bottom end, crease and back seal being generally
parallel with said longitudinal formation axis; and a reclose strip
attached to an exterior surface of said back wall and extending
between said vertical edge seals, said strip being generally
parallel with said longitudinal formation axis and spaced from said
top end a distance sufficiently great as to allow the package to be
manually folded in a direction from the top toward the strip before
the fold engages the strip.
2. The flexible reclosable stand-up package of claim 1, wherein
said sheet of packaging film includes a graphics layer which is
oriented for viewing by a consumer when said package is stood on
its bottom end.
3. The flexible reclosable stand-up package of claim 1, wherein
said reclose strip comprises a two-sided length of tape with a
first side bonded to said exterior surface of said back wall by a
first pressure sensitive adhesive of some strength and a second
side of said tape being coated with a second pressure sensitive
adhesive having a strength less than the strength of the first
adhesive and having the characteristics of bonding to both the tape
and the exterior surface of the package and in tension, releasing
the package material before releasing the tape such that the second
adhesive will remain on the tape when the surface of the package
material separates from the second adhesive.
4. The flexible reclosable stand-up package of claim 3, wherein
said reclose strip further comprises a peel strip attached to and
covering the second adhesive, the second adhesive having the
characteristic when in tension of releasing the peel strip prior to
releasing the tape.
5-8. (canceled)
9. A vertical flexible reclosable stand-up package formed by a
method comprising the steps of: a) advancing a continuous sheet of
packaging film towards said vertical form, fill, and seal machine,
wherein said packaging film has lettering oriented perpendicular to
the direction of travel of said film; b) attaching a length of
reclose strip to a surface of said advancing sheet of packaging
film along the longitudinal axis of said sheet of packaging film,
said reclose strip having an adhesive layer facing away from said
surface; c) feeding said packaging film into said vertical form,
fill, and seal machine; d) forming said packaging film into a tube
on said vertical form, fill, and seal machine and forming a
longitudinal seal, wherein said surface of packaging film having
said reclose strip attached thereto is situated on the exterior of
said tube; e) forming a vertical crease in said tube of packaging
film prior to sealing said tube traversely; f) forming a first
traverse seal on said tube, said first traverse seal sealing all
layers of said tube together, wherein said first traverse seal
includes a portion of said vertical crease; g) dropping a product
into the partially formed package created by steps a) through f);
h) forming a second traverse seal on said tube, said second
traverse seal sealing all layers of said tube together, wherein
said second traverse seal includes a portion of said vertical
crease; and i) severing said package from said tube at said second
traverse seal; wherein said vertical crease is heat-sealed only at
said first and second traverse seals.
10. A vertical form, fill, and seal machine for making a flexible
stand-up package having a reclose strip incorporated therein,
comprising: a) a mechanism for supplying and advancing a continuous
sheet of packaging film towards said vertical form, fill, and seal
machine, wherein said packaging film has graphics oriented
perpendicular to the direction of travel of said film; b) an
apparatus for attaching a length of reclose strip to a surface of
said advancing sheet of packaging film along a longitudinal axis of
said sheet of packaging film; c) a former section for receiving and
forming said sheet of packaging film into a tubular shape about a
forming/fill tube such that said surface to which the reclose strip
is attached is on the exterior of said tubular shape, said
forming/fill tube having an entrance portion above said former
section and an exit portion below said former section; d) a heat
seal mechanism for forming a back seal on said tubular shape
thereby creating a film tube; e) an apparatus for imparting a
crease in said film tube; and f) a pair of heat sealing jaws for
imparting a traverse seal on said film tube, wherein said sealing
jaws include a cutting mechanism for severing said package from
said tube.
11. The vertical form, fill, and seal machine of claim 10, wherein
said attaching apparatus is integral to said supplying and
advancing mechanism.
12. The vertical form, fill, and seal machine of claim 10, wherein
said length of reclose strip comprises a composite structure which
includes a two-sided tape having a first side coated with a first
pressure sensitive adhesive of some strength and a second side
being coated with a second pressure sensitive adhesive and covered
by a peel strip, said first pressure sensitive adhesive having a
bonding strength greater than that of said second pressure
sensitive adhesive, said second adhesive having the characteristic
when in tension, of releasing the peel strip prior to releasing the
tape.
13. The vertical form, fill, and seal machine of claim 12, wherein
said second pressure sensitive adhesive has the characteristics of
bonding to both the tape and the surface of said sheet of packaging
film and in tension, and releasing the packaging film before
releasing the tape such that the second adhesive will remain on the
tape when the surface of the packaging film separates from the
second adhesive.
14. The vertical form, fill, and seal machine of claim 10, wherein
said attachment apparatus comprises a mechanism for feeding said
length of reclose strip adjacent to said surface of said sheet of
packaging film as it is advancing, and for positioning and adhering
said length of reclose strip to said surface.
15. The vertical form, fill, and seal machine of claim 14, wherein
said attachment apparatus comprises a pivoting arm assembly which
includes a roller guide mechanism which receives the length of
reclose strip from a supply spool and directs it to a stationary
bar guide assembly, said bar guide assembly positioning said length
of reclose strip a lateral distance across the traverse of said
advancing sheet of packaging film and an application roller for
bringing said length of reclose strip into contact with said sheet
of packaging film.
16. The vertical form, fill, and seal machine of claim 15, wherein
said pivoting arm assembly further includes a weight assembly.
17. The vertical form, fill, and seal machine of claim 15, wherein
said roller guide mechanism is pivotally attached to said pivoting
arm assembly.
18. The vertical form, fill, and seal machine of claim 15, wherein
said bar guide assembly may be adjusted to increase or decrease the
lateral distance said length of reclose strip is positioned across
the traverse of said advancing sheet of packaging material.
19. The vertical form, fill, and seal machine of claim 10, wherein
said crease imparting apparatus comprises two forming plates
attached to and extending below said forming/fill tube, at least
one tension bar attached to and extending below said forming tube
at a location approximately opposite from said forming plates; and
at least one stationary tucker bar positioned between said forming
plates.
20. The vertical form, fill, and seal machine of claim 19, wherein
said crease imparting apparatus further comprises a mechanism for
blowing a pressurized gas against said packaging film, wherein said
gas is blown against the exterior surface of said tube of packaging
film at a point between said forming plates, wherein said mechanism
for blowing a pressurized gas comprises gas ports in said tucker
bar in communication with a pressurized gas source.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 10/100,370, filed on Mar. 18, 2002, the
technical disclosure of which is hereby incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to a vertical stand-up pouch
having an integrated reclose strip constructed using a modified
vertical form and fill packaging machine, and the method for making
same, that provides for a single piece construction of a vertical
stand-up bag suitable for retail snack food distribution. The
invention allows for use of existing film converter and packaging
technology to produce a stand-up package for moisture sensitive
food products or the like with minimal increased costs and minimal
modification. The resulting stand-up package may be opened, a part
of the contents removed and the package resealed to prevent
premature deterioration of the quality of the contents because of
exposure to moisture in the air.
[0004] 2. Description of Related Art
[0005] Vertical form, fill, and seal packaging machines are
commonly used in the snack food industry for forming, filling, and
sealing bags of chips and other like products. Such packaging
machines take a packaging film from a sheet roll and forms the film
into a vertical tube around a product delivery cylinder. The
vertical tube is vertically sealed along its length to form a back
seal. The machine applies a pair of heat-sealing jaws or facings
against the tube to form a transverse seal. This transverse seal
acts as the top seal on the bag below and the bottom seal on the
package being filled and formed above. The product to be packaged,
such as potato chips, is dropped through the product delivery
cylinder and formed tube and is held within the tube above the
bottom transverse seal. After the package has been filled, the film
tube is pushed downward to draw out another package length. A
transverse seal is formed above the product, thus sealing it within
the film tube and forming a package of product. The package below
said transverse seal is separated from the rest of the film tube by
cutting across the sealed area.
[0006] The packaging film used in such process is typically a
composite polymer material produced by a film converter. For
example, one prior art composite film used for packaging potato
chips and like products is illustrated in FIG. 1, which is a
schematic of a cross-section of the film illustrating each
individual substantive layer. FIG. 1 shows a sealable inside, or
product side, layer 16 which typically comprises metalized oriented
polypropylene ("OPP") or metalized polyethylene terephtalate
("PET"). This is followed by a laminate layer 14, typically a
polyethylene extrusion, and an ink or graphics layer 12. The ink
layer 12 is typically used for the presentation of graphics that
can be viewed through a transparent outside layer 10, which layer
10 is typically OPP or PET.
[0007] The prior art film composition shown in FIG. 1 is ideally
suited for use on vertical form and fill machines for the packaging
of food products. The metalized inside layer 16, which is usually
metalized with a thin layer of aluminum, provides excellent barrier
properties. The use of OPP or PET for the outside layer 10 and the
inside layer 16 further makes it possible to heat seal any surface
of the film to any other surface in forming either the transverse
seals or back seal of a package.
[0008] Typical back seals formed using the film composition shown
in FIG. 1 are illustrated in FIGS. 2a and 2b. FIG. 2a is a
schematic of a "lap seal" embodiment of a back seal being formed on
a tube of film. FIG. 2b illustrates a "fin seal" embodiment of a
back seal being formed on a tube of film.
[0009] With reference to FIG. 2a, a portion of the inside metalized
layer 26 is mated with a portion of the outside layer 20 in the
area indicated by the arrows to form a lap seal. The seal in this
area is accomplished by applying heat and pressure to the film in
such area. The lap seal design shown in FIG. 2a insures that the
product to be placed inside the formed package will be protected
from the ink layer by the metalized inside layer 26.
[0010] The fin seal variation shown in FIG. 2b also provides that
the product to be placed in the formed package will be protected
from the ink layer by the metalized inside layer 26. Again, the
outside layer 20 does not contact any product. In the embodiment
shown in FIG. 2b, however, the inside layer 26 is folded over and
then sealed on itself in the area indicated by the arrows. Again,
this seal is accomplished by the application of heat and pressure
to the film in the area illustrated.
[0011] Regardless of whether a lap seal or fin seal is used for
constructing a standard package using a vertical form, fill, and
seal packaging machine, the end result is a package as shown in
FIG. 3a with horizontally oriented top and bottom transverse seals
31, 33. Such package is referred to in the art as a "vertical flex
bag" or "pillow pouch," and is commonly used for packaging snack
foods such as potato chips, tortilla chips, and other various
sheeted and extruded products. The back seal discussed with
reference to FIGS. 2a and 2b runs vertically along the bag and is
typically centered on the back of the package shown in FIG. 3a,
thus not visible in FIG. 3a. Because of the narrow, single edge
base on the package shown in FIG. 3a formed by the bottom
transverse seal 33, such prior art packages are not particularly
stable when standing on one end. This shortcoming has been
addressed in the packaging industry by the development of a
horizontal stand-up pouch such as the embodiment illustrated in
FIGS. 4a, 4b, and 4c. As can be seen by reference to said Figures,
such a horizontal stand-up pouch has a relatively broad and flat
base 47 having two contact edges. This allows for the pouch to rest
on this base 47 in a vertical presentation. Manufacture of such
horizontal stand-up pouches, however, does not involve the use of
standard vertical form, fill, and seal machines but, rather,
involves an expensive and relatively slow 3-piece construction
using a pouch form, fill, and seal machine.
[0012] Referring to FIGS. 4b and 4c, the horizontal stand-up pouch
of the prior art is constructed of three separate pieces of film
that are mated together, namely, a front sheet 41, a rear sheet 43,
and a base sheet 45. The front sheet 41 and rear sheet 43 are
sealed against each other around their edges, typically by heat
sealing. The base sheet 45 is, however, first secured along its
outer edges to the outer edges of the bottom of the front sheet 41
and rear sheet 43, as is best illustrated in FIG. 4c. Likewise, the
mating of the base sheet 45 to the front sheet 41 and the rear
sheet 43 is also accomplished typically by a heat seal. The
requirement that such horizontal stand-up pouch be constructed of
three pieces results in a package that is significantly more
expensive to construct than a standard form, fill, and seal
vertical flex bag.
[0013] Further disadvantages of using horizontal stand-up pouches
include the initial capital expense of the horizontal stand-up
pouch machines, the additional gas flush volume required during
packaging as compared to a vertical flex bag, increased down time
to change the bag size, slower bag forming speed, and a decreased
bag size range. For example, a Polaris model vertical form, fill,
and seal machine manufactured by Klick Lock Woodman of Georgia,
USA, with a volume capacity of 60-100 bags per minute costs in the
range of $75,000.00 per machine. A typical horizontal stand-up
pouch manufacturing machine manufactured by Roberts Packaging of
Battle Creek, Mich., with a bag capacity of 40-60 bags per minute
typically costs $500,000.00. The film cost for a standard vertical
form, fill, and seal package is approximately $0.04 per bag with a
comparable horizontal stand-up pouch costing roughly twice as much.
Horizontal stand-up pouches further require more than twice the
oxygen or nitrogen gas flush. Changing the bag size on a horizontal
stand-up pouch further takes in excess of two hours, typically,
while a vertical form and fill machine bag size can be changed in a
matter of minutes. Also, the typical bag size range on a horizontal
stand-up pouch machine is from 4 oz. to 10 oz., while a vertical
form and fill machine can typically make bags in the size range of
1 oz. to 24 oz.
[0014] One advantage of a horizontal stand-up pouch machine over a
vertical form, fill, and seal machine, however, is the relatively
simple additional step of adding a reclosable seal or a zipper seal
at the top of the bag for reclosing of the bag. Vertical form,
fill, and seal machines typically require substantial modification
and/or the use of reclosable or zipper seals premounted on the film
oriented horizontally to the seal facings used to seal the
horizontal transverse seals.
[0015] For example, U.S. Pat. No. 4,584,201 to Boston discloses a
system for applying a segment of seal strip to the external surface
of a bag manufactured using a vertical form, fill, and seal
machine, such that, when it is desired, the bag may be closed
(i.e., resealed) after it has been opened. According to the Boston
'201 disclosure, the seal strip includes a peel strip which is
removable to allow the package, when opened, to be folded down and
sealed against an adhesive which will be exposed upon the removal
of the peel strip. In accordance with the Boston '201 disclosure,
the bag is typically folded a plurality of times in the direction
of the seal strip and the external surface of the bag is applied to
an exposed adhesive on the seal strip and thereby the bag is
resealed for storage of the contents. However, the Boston '201
invention necessitate the precise placement of discrete segments of
seal strip across the traverse of the sheet of packaging material
such that the applied seal strip is positioned parallel to the top
traverse seal on the resulting bag and perpendicular to the
vertical back seal. While effective, the Boston '201 system is
unduly complex. Moreover, the Boston '201 system is only directed
at and adapted for the production of conventional vertical flex
bags or pillow pouches.
[0016] An alternative approach taken in the prior art to producing
a bag with more of a stand-up presentation is the construction of a
flat bottom bag such as illustrated in FIG. 3b. Such a bag is
constructed in a method very similar to that described above with
regard to prior art pillow pouches. However, in order to form the
vertical gussets 37 on either side of the bag, the vertical form,
fill, and seal machine must be substantially modified by the
addition of two movable devices on opposite sides of the sealing
carriage that move in and out to make contact with the packaging
film tube in order to form the tuck that becomes the gussets 37
shown in FIG. 3b. Specifically, when a tube is pushed down to form
the next bag, two triangular shaped devices are moved horizontally
towards the packaging film tube until two vertical tucks are formed
on the packaging film tube above the transverse seals by virtue of
contact with these moving triangular shaped devices. While the two
triangular shaped devices are thus in contact with the packaging
tube, the bottom transverse seal is formed. The package is
constructed with an outer layer 30 that is non-sealable, such as
paper. This causes the formation of a V-shaped gusset 37 along each
vertical edge of the package when the transverse seals 31, 33 are
formed. While the triangular shaped devices are still in contact
with the tube of packaging material, the product is dropped through
the forming tube into the tube of packaging film that is sealed at
one end by virtue of the lower transverse seal 33. The triangular
shaped devices are then removed from contact with the tube of
packaging film and the film is pushed down for the formation of the
next package. The process is repeated such that the lower
transverse seal 33 of the package above and upper transverse seal
31 of the package below are then formed. This transverse seal is
then cut, thereby releasing a formed and filled package from the
machine having the distinctive vertical gussets 37 shown in FIG.
3b.
[0017] The prior art method described above forms a package with a
relatively broad base due to the V-shaped vertical gussets 37.
Consequently, it is commonly referred to in the art as a flat
bottom bag. Such flat bottom bag is advantageous over the
previously described horizontal stand-up pouch in that it is formed
on a vertical form, fill, and seal machine, albeit with major
modifications. However, the prior art method of making a flat
bottom bag has a number of significant drawbacks. For example, the
capital expense for modifying the vertical form, fill, and seal
machine to include the moving triangular-shaped devices is
approximately $30,000.00 per machine. The changeover time to
convert a vertical form, fill, and seal machine from a standard
pillow pouch configuration to a stand-up bag configuration can be
substantial, and generally in the neighborhood of one-quarter man
hours. The addition of all of the moving parts required for the
triangular-shaped devices to move in and out of position during
each package formation cycle also adds complexity to the vertical
form, fill, and seal machine, inevitably resulting in maintenance
issues. Importantly, the vertical form, fill, and seal machine
modified to include the moving triangular-shaped devices is
significantly slower than a vertical form, fill, and seal machine
without such devices because of these moving components that form
the vertical gussets. For example, in the formation of a six inch
by nine inch bag, the maximum run speed for a modified vertical
form, fill, and seal machine using the triangular-shaped moving
devices is in the range of 15 to 20 bags per minute. A standard
vertical form, fill, and seal machine without such modification can
construct a similarly sized pillow pouch at the rate of
approximately 40 bags per minute.
[0018] Consequently, a need exists for a method to form a stand-up
pouch, similar in appearance and functionality to the prior art
horizontal stand-up pouches, using vertical form, fill, and seal
machine technology and a single sheet of packaging film. Moreover,
a need also exists for a simpler method of incorporating a
reclosable strip into such a formed stand-up pouch using the
vertical form, fill, and seal machine technology. This method
should allow for reduced film cost per bag as compared to
horizontal stand-up pouches, ease in size change, little capital
outlay, and the ability to easily add a zipper seal to the bags,
all while maintaining bag forming speeds typical of vertical form,
fill, and seal machine pillow pouch production. Such method should
ideally produce a vertical stand-up pouch having an integrated
reclose strip, and constructed of material commonly used to form
standard vertical flex bags.
SUMMARY OF THE INVENTION
[0019] The proposed invention involves producing a vertical
stand-up pouch or package having an integrated reclose strip, and
constructed of a single sheet of packaging material using a
slightly modified vertical form, fill, and seal machine. The
modified machine includes a crease-forming mechanism and an
apparatus for applying a reclose strip to the sheet of material.
The crease-forming mechanism includes a tension bar and forming
plates located below the forming tube and a stationary but
adjustable tucker mechanism mounted to the frame of the machine
which, when positioned between the two forming plates, creates a
vertical tuck along the length of the package while it is being
formed. The apparatus for applying a reclose strip is incorporated
into the mechanism which supplies the continuous sheet of packaging
material to the vertical form, fill, and seal machine. The reclose
strip is attached along the longitudinal axis of the sheet of
packaging material prior to forming the sheet into, a tube in the
conventional manner. The reclose strip includes a peel strip which
is removable to allow the package, when opened, to be folded down
and sealed against an adhesive which will be exposed upon the
removal of the peel strip. In a preferred embodiment, the reclose
strip comprises a length of two-sided adhesive tape.
[0020] The graphics on the packages are oriented 90.degree. from a
standard presentation such that the tuck forms the bottom of the
package. The reclose strip can be easily added to the manufacture
of such a vertical stand-up package since the reclose strip, which
is attached along the longitudinal axis of the sheet of packaging
material, can accompany the single sheet of packaging film through
a vertical form, fill, and seal machine in the conventional manner.
The transverse seals on the formed package are therefore oriented
vertically and the reclose strip is oriented horizontally when the
package is placed on display. Thus, when opened, the top of the
package can be double folded and pressed against the exposed
adhesive strip thereby providing a reclosable seal feature.
[0021] The method disclosed and the package formed as a consequence
is a substantial improvement over prior art horizontal stand-up
pouches or packages and flat bottom bags. The method works on
existing vertical form, fill, and seal machines requiring very
little modification. There are no substantial moving parts or jaw
carriage modifications involved with the crease-forming mechanism.
Moreover, the apparatus for applying the reclose strip may be
easily incorporated into the supply mechanism that supplies the
continuous sheet of packaging material to the vertical form, fill,
and seal machine.
[0022] The modified vertical form, fill, and seal machines can also
be easily converted back to a conventional pillow pouch
configuration by selectively disengaging the crease-forming
mechanism and discontinuing the supply of reclose strip. The same
metalized or clear laminations used as materials in pillow pouches
can also be used with the invention therefore saving in per bag
cost. The invention allows for the formation of bags that emulate a
horizontal stand-up pouch using a completely different method that
takes advantage of the economics of vertical form and fill machine
technology.
[0023] The above as well as additional features and advantages of
the present invention will become apparent in the following written
detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself,
however, as well as a preferred mode of use, further objectives and
advantages thereof, will be best understood by reference to the
following detailed description of illustrative embodiments when
read in conjunction with the accompanying drawings, wherein:
[0025] FIG. 1 is a schematic cross-section views of prior art
packaging films;
[0026] FIG. 2a is a schematic cross-section view of a tube of
packaging film illustrating the formation of a prior art lap
seal;
[0027] FIG. 2b is a schematic cross-section of a tube of packaging
film illustrating the formation of a prior art fin seal;
[0028] FIG. 3a is a perspective view of a prior art vertical flex
bag;
[0029] FIG. 3b is a perspective view of a prior art flat bottom
bag;
[0030] FIGS. 4a, 4b, and 4c are perspective views in elevation of a
prior art horizontal stand-up pouch;
[0031] FIG. 5 is a schematic cross-section of a tube of packaging
film formed by the present invention methods;
[0032] FIG. 6 is a perspective view of the tucker mechanism,
forming plates, and tension bar in elevation of the present
invention in relation to a forming tube and sealing jaws of a
vertical form and fill machine;
[0033] FIGS. 7a and 7b are perspective views of the vertical
stand-up bag of the present invention;
[0034] FIG. 8 is a perspective view of one embodiment of the tucker
mechanism of the present invention;
[0035] FIG. 9 is a simplified perspective view of a form, fill, and
seal machine adapted to manufacture a stand-up package having an
integrated reclose strip in accordance with the present
invention;
[0036] FIG. 10 is a perspective view of the apparatus for applying
the reclose strip incorporated into the supply mechanism of the
form, fill, and seal machine shown in FIG. 9;
[0037] FIG. 11 is a schematic elevation view of the apparatus for
applying the reclose strip shown in FIG. 10;
[0038] FIG. 12 is an enlarged overhead view of a portion of the
apparatus for applying the reclose strip shown in FIG. 10;
[0039] FIGS. 13a and 13b are perspective views of the vertical
stand-up bag or package having an integrated reclose strip of the
present invention;
[0040] FIG. 13c is a perspective view of the vertical stand-up
package having an integrated reclose strip shown in FIGS. 13a and
13b that has been opened and subsequently folded over to reseal the
top in accordance with the present invention; and
[0041] FIG. 13d is a fragmentary sectional view taken along line
13d-13d of FIG. 13a.
[0042] Where used in the various figures of the drawing, the same
numerals designate the same or similar parts. Furthermore, when the
terms "top," "bottom," "first," "second," "upper," "lower,"
"height," "width," "length," "end," "side," "horizontal,"
"vertical," and similar terms are used herein, it should be
understood that these terms have reference only to the structure
shown in the drawing and are utilized only to facilitate describing
the invention.
[0043] All figures are drawn for ease of explanation of the basic
teachings of the present invention only; the extensions of the
figures with respect to number, position, relationship, and
dimensions of the parts to form the preferred embodiment will be
explained or will be within the skill of the art after the
following teachings of the present invention have been read and
understood. Further, the exact dimensions and dimensional
proportions to conform to specific force, weight, strength, and
similar requirements will likewise be within the skill of the art
after the following teachings of the present invention have been
read and understood.
DETAILED DESCRIPTION
[0044] FIGS. 5 and 6 illustrate the basic components used with the
method of the proposed invention. The same reference numbers are
used to identify the same corresponding elements throughout all
drawings unless otherwise noted. FIG. 5 is a schematic
cross-section of a tube of packaging material (film) formed by the
present invention method. The tube of packaging film shown in FIG.
5 is illustrated as a cross-sectional area immediately below the
forming tube 101 of FIG. 6. The tube of packaging film comprises an
outer layer 116 and an inner layer 110, and can comprise material
typically used in the field of art for making a standard vertical
flex bag, such as discussed in relation to FIG. 1. The tube in FIG.
5 has been formed by sealing one sheet of film with a vertical back
seal, as previously described with regard to discussions of prior
art vertical form and fill machine methods.
[0045] FIG. 6 shows a forming tube 101 typical in most respects to
those used with prior art vertical form, fill, and seal machines.
This forming tube 101 can be a cylinder, have a rectangular cross
section, or any number of shapes, but is preferably cylindrical as
illustrated. The film illustrated in FIG. 5 is initially formed
around the forming tube 101 of FIG. 6. This forming tube 101 is
shown in elevation but would normally be integrally attached to the
vertical form, fill, and seal machine. Also shown in FIG. 6 are a
pair of prior art sealing jaws 108 likewise illustrated in
elevation. Not shown in FIG. 6 is the sealing jaw carriage on which
such sealing jaws 108 would be mounted below the forming tube
101.
[0046] As previously described, the practice in the prior art in
the manufacture of a vertical flex bag involves feeding a
continuous packaging film directed around the forming tube 101. A
back seal is formed on a single layer of film in order to create a
tube of film around the forming tube 101. The seal jaws 108 close
on the thus formed tube of packaging film, thereby forming a bottom
transverse seal. Product is then dropped through the forming tube
101 into the tube of packaging film. The tube is then driven
downward by friction against rotating belts (not shown), and the
seal jaws 108 are used to form another transverse seal above the
level of the product found inside the tube. This seal is
subsequently cut horizontally such that a top transverse seal is
formed at the top of the filled bag below and a bottom transverse
seal is formed on the tube of packaging film above. The packaging
film during the prior art operation described above is oriented
perpendicular to the longitudinal translation of the film so as to
be readable by an operator of the machine as the film travels down
the forming tube 101. This orientation provides graphics 39 on the
formed prior art bag that are readable by a consumer when the
formed bag is placed on a retail display shelf while resting on its
bottom transverse seal 33 as seen in FIG. 3a. As will be described
in further detail below, the orientation of the graphics on the
film packaging for Applicants' invention is 90.degree. off of the
prior art orientation, such that the graphics appear sideways as
viewed by the operator of the vertical form and fill machine as the
film is pulled down the forming tube 101 of FIG. 6. In other words,
the graphics on the packaging film are oriented perpendicular to
the direction of film travel.
[0047] The invention adds three basic components to a prior art
vertical form, fill, and seal machine. Two forming plates 104 and
one tension bar 102 are used to hold the packaging film tube in
tension from inside the tube, as indicated by the arrows
illustrated on FIG. 5. As shown in FIG. 6, the forming plates 104
and tension bar 102 can be attached directly to the forming tube
101 or, alternatively, to any supporting structure on the vertical
form, fill, and seal machine, as long as the forming plates 104 and
tension bar 102 are positioned within the tube of packaging
material, below the bottom of the forming tube 101, and above the
heat sealing jaws 108.
[0048] Tension is applied on the outside of the film and in the
opposite direction of the tension provided by the forming plates
104 by a fixed or stationary tucker mechanism 106, alternatively
referred to herein as a tucker bar 106, positioned between said
forming plates 104. The tucker bar 106 is preferably attached to
the sealing carriage for the vertical form, fill, and seal machine
and is adjustable along all three axes (in/out, up/down, and
front/back). Alternatively, the tucker bar 106 can be attached to
the frame of the vertical form, fill, and seal machine or any other
point that can supports its function outside the film tube. These
adjustments in all three axes allow for the tucker bar 106 to be
easily moved out of the way to convert the vertical form and fill
machine back to standard operation and is accomplished, in the
embodiment shown in FIG. 6, by a tension screw 162 that can lock
the tucker bar 106 in place when tightened. While the tucker bar
106 is adjustable, unlike in the prior art, it is fixed or
stationary during operation. Therefore, the present invention is a
substantial improvement over the art in that there are no moving
parts to the tucker mechanism during bag making. This improvement
is what Applicants intend to describe when referring to the tucker
bar 106 as "stationary" or "fixed." Because of this stationary
tucker bar feature, bag making speeds can match typical pillow
pouch manufacturing rates.
[0049] When moved forward into position (i.e., toward the forming
plates 104), the tucker bar 106 provides a crease or fold in the
tube of the packaging film between the two forming plates 104. This
crease is formed prior to formation of the transverse seal by the
seal jaws 108. Consequently, once the transverse seal is formed,
the crease becomes an integral feature of one side of the package.
The vertical form and fill machine thereafter operates basically as
previously described in the prior art, with the sealing jaws 108
forming a lower transverse seal, product being introduced through
the forming tube 101 into the sealed tube of packaging film (which
now has a crease on one side), and the upper transverse seal being
formed, thereby completing the package. The major differences
between a prior art package and Applicants' package, however, are
that a crease is formed on one side (which later becomes the bottom
of the formed package) using the fixed mechanism described and that
the graphics on the packaging film used by the invention are
oriented such that when the formed package is stood onto the end
with the crease, the graphics are readable by a consumer.
[0050] An example of the formed package of the instant invention is
shown in FIGS. 7a and 7b, which show the outside layer of the
packaging film 116 with the graphics 179 oriented as previously
described. As can be seen from FIGS. 7a and 7b, the construction of
the invention's vertical stand-up pouch shares characteristics with
the prior art vertical flex bags shown in FIG. 3a. However, the
transverse seals 131, 133 of the vertical stand-up bag of the
invention are oriented vertically once the bag stands up on one
end, as shown in FIG. 7b. FIG. 7a shows the crease 176 that was
formed by the tucker bar 106 and forming plates 104 discussed in
relation to FIGS. 5 and 6.
[0051] Returning to FIG. 6, another optional feature that can be
incorporated into this invention is the use of a diversion plate
160 within the forming tube 101. This diversion plate 160, in the
embodiment illustrated, is a flat plate welded vertically inside
the forming tube 101 that extends from the bottom of the forming
tube 101 to some distance above (for example, at least two or three
inches) the bottom of the forming tube 101, where it then is sealed
against the inside of the forming tube 101.
[0052] The diversion plate 160 in a preferred embodiment
accomplishes two functions. First, the diversion plate 160 keeps
product that is dropped down the forming tube 101 away from the
area where the crease is being formed on the tube of packaging
film. Second, the diversion plate 160, can be used as a channel for
a gas or nitrogen flush. In such instance, the diversion plate 160
at some point above the bottom of the forming tube 101 seals at the
top of the plate 160 against the forming tube 101. Below such seal
(not shown) an orifice can be drilled into the forming tube 101 in
order to provide gas communication between an exterior gas (for
example, nitrogen or oxygen) source and the cavity formed between
the diversion plate 160 and the interior of the forming tube 101.
The diversion plate 160 as shown in FIG. 6 is a flat plate, but it
should be understood that it can be of any variety of shapes, for
example, having a curved surface, provided that it accomplishes the
functionality of diverting the product away from the area where the
tuck is formed on the tube of film.
[0053] By using the diversion plate 160 as a channel for the gas
flush, the present invention eliminates the need for a separate gas
tube to be placed inside the forming tube 101 that normally
accomplishes the same function in the prior art. The added benefit
of providing a relatively large volume channel formed by the
diversion plate 160 and the interior of the forming tube 101 is
that a relatively large volume of flushing gas can be introduced
into a filled and partially formed package at a significantly lower
gas velocity compared to prior art gas tubes. This allows for the
filling of packages using this embodiment of the present invention
that may contain low weight product that might otherwise be blown
back into the forming tube by prior art flushing tubes.
[0054] FIG. 8 illustrates a preferred embodiment of the tucker bar
106. This embodiment of the tucker bar 106 comprises a head 180
attached to a support 182. Drilled within the support 182 and head
180 is a gas channel 184 shown in phantom on FIG. 8. This gas
channel 184 provides a gas communication from an exterior gas
source (not shown) through the support 182, through the head 180,
and out three orifices 186. The gas channel 184 allows for a
metered burst of pressurized gas (typically air) that helps keep
the tuck illustrated in FIG. 5 taut throughout the forming and
sealing operation without the necessity of moving the tucker bar in
and out during bag formation. It should be noted that during
operation (bag making) the tucker bar 106 is always stationary. It
should further be noted that the head 180 necessarily cannot extend
along the entire length of the crease formed by the tucker bar 106
and forming plates 104. Further, it should be understood that when
the sealing jaws 108 close onto the tube of film, the lateral
dimensions of the tube of film change. All of these facts are
compensated for by the use of the pressurized air bursting from the
orifices 186. The pressurized air keeps an even amount of pressure
on the tuck as it is being formed in the various stages of the
forming and sealing process. The air burst can be continuous, but
is preferably metered to start as the film for the next bag is
being pulled down through the completion of the transverse
seal.
[0055] The head 180 can comprise any non-stick material but is
preferably a fluoropolymer, such as Teflon.RTM.. In an alternative
embodiment, the tucker bar 106 can comprise one integral piece of
metal with the head portion 180 being coated with a fluoropolymer.
The curved contact area of the head 180 allows for the continuous
formation of the tuck illustrated in FIG. 5 without tearing the
packaging film as it is pushed down below the forming tube. While
shown with three orifices 186, the head 180 can comprise any number
of orifices from one on.
[0056] To further compensate for the change in the width of the
film tube as the transverse seal is formed by the seal jaws 108 of
FIG. 6, it should be noted that the tension bar 102 bends outwardly
away from the center of said tube of film along the length of the
tension bar 102 and the forming plates 104 are hinged by a
horizontal hinge 105. If the tension bar 102 is designed otherwise
(e.g., strictly vertical) excess slack occurs in the area of the
film tube near the transverse seal. The forming plates 104 comprise
horizontal hinges 105 that allow the forming plates to fold inward
(i.e., toward each other) slightly while the lower transverse seal
is formed. Otherwise, the tube of packaging film would be ripped by
the tips of the forming plates 104 during this step.
[0057] The present invention offers an economic method of producing
a stand-up pouch with numerous advantages over prior art horizontal
stand-up pouches and methods for making them. Examples of these
advantages are illustrated in Table 1 below. TABLE-US-00001 TABLE 1
Commercially Available Applicants' Horizontal Stand- Vertical
Stand-Up Current Up Pouches Bag Machine Type Standard Vertical FFS
Pouch Form, Fill, Seal Standard Vertical FFS Machine Cost
$75,000.00 $500,000.00 $75,000.00 Film Cost $0.04/bag $0.08/bag
$0.04/bag Gas Flush Less than 2% O.sub.2 Only to 5% O.sub.2 Less
than 2% O.sub.2 Size Change Easy, change former 2 hours Easy,
change former Format Change Flex Bag Only Stand-Up Pouch Only Both,
simple change Continuous Feed No Yes Yes Zipper Option Bag Size
Range in (Width/Height) (Width/Height) (Width/Height) Inches 5/5
through 14/24 5/5 through 10/12 5/5 through 24/11
[0058] Referring now to FIG. 9, in another embodiment the present
invention further includes an apparatus and method for producing a
stand-up package having a reclose strip incorporated therein. The
apparatus for applying the reclose strip is incorporated into the
supply mechanism 200 that supplies a continuous sheet of packaging
material or film 120 to the vertical form, fill, and seal machine
100.
[0059] As shown in FIG. 9, the vertical form, fill, and seal
machine 100 includes a forming/fill tube 91 and a former section 92
around which a sheet of packaging material 120 is directed and
formed into a tubular shape in the conventional manner. While the
forming/fill tube 91 illustrated in FIG. 9 is shown as having a
rectangular cross-sectional shape, it is understood 10 that the
cross-sectional shape of the forming/fill tube 91 may be any of
various other shapes, such as circular, oval, or square. The
forming/fill tube 91 illustrated in FIG. 9 may also have a
diversion plate 160, as previously described, incorporated
therein.
[0060] As will be subsequently explained in greater detail, the
supply mechanism 200 includes an apparatus incorporated therein,
which attaches a length of reclose strip 140 to the underside of
the sheet of packaging material 120 such that when the sheet of
packaging material 120 is supplied to the vertical form, fill, and
seal machine 100 and formed into a tubular shape in the
conventional manner, the reclose strip 140 is positioned along a
longitudinal axis on the outer surface of the formed tube 120A.
[0061] Referring now to FIGS. 10 and 11, an embodiment of the
supply mechanism 200 depicted in FIG. 9 is shown that includes an
apparatus for applying a length of reclose strip 140 to the sheet
of packaging material or film 120 being supplied to the vertical
form, fill, and seal machine 100. The supply mechanism 200 includes
a mechanism for unrolling a sheet of packaging material 120 from a
supply spool 220 so as to direct a continuous sheet towards the
vertical form, fill, and seal machine 100.
[0062] For example, in accordance with the conventional art, the
supply mechanism 200 may comprise a horizontal spindle 210 and a
series of rollers 212, 214. The supply spool 220 is placed on the
spindle 210 and a sheet of packaging material 120 is unrolled and
fed through the series of rollers 212, 214 in the direction of
arrows a, b, and c. The rollers 212, 214 control the speed,
direction, and tension of the continuous sheet of packaging
material 120 directed to the towards the vertical form, fill, and
seal machine 100. For example, roller 214 might be a powered roller
which advances the sheet of packaging material 120 off the supply
spool 220 while rollers 212 might be idler rollers, which support,
smooth or direct the sheet of packaging material 120 during its
course of travel through the supply mechanism 200 and control the
tension imparted to the sheet of packaging material 120 as it is
directed towards the vertical form, fill, and seal machine 100. In
another embodiment, both the spindle 210 and roller 214 might be a
powered rollers which advance the sheet of packaging material 120
off the supple spool 220 in a synchronized manner.
[0063] Of particular note, the supply mechanism 200 of the present
invention also includes an apparatus for applying a length of
reclose strip 140 to the sheet of packaging material or film 120.
As shown in the Figures, the apparatus includes a spool arbor 204
onto which a spool 240 of reclose strip 140 is attached, and a
pivoting arm assembly 230, which directs and applies the reclose
strip 140 onto the sheet of packaging material 120. As shown in the
embodiment illustrated in the Figures, the spool arbor 204 and
pivoting arm assembly 230 are positioned and supported by a support
bracket 202, which is integrally attached to the supply mechanism
200.
[0064] The pivoting arm assembly 230 comprises a pivot arm 232
pivotally attached to the support bracket 202 by a pivot pin 234.
The pivot arm 232 is free to rotate about the pivot pin 234 in the
directions shown by the arrows in FIG. 10. The pivoting arm
assembly 230 further includes an accessory plate 232a attached to
the pivot arm 232 and an application roller 236 located at the
distal end of the pivot arm 232. The accessory plate 232a includes
a roller guide mechanism 250, a strip bar guide 256, an extension
bar 254, and a weight assembly 238 attached thereon.
[0065] In accordance with the present invention, a length of
reclose strip 140 is played out from spool 240 and applied, by
means of the pivoting arm assembly 230, to the outer peripheral
surface of the sheet of packaging material 120 being advanced from
the supply spool 220 as described previously. The length of reclose
strip 140 from spool 240 is threaded through a roller guide
mechanism 250 and a bar guide 256 extending from accessory plate
232a, so as to position align, and apply the length of reclose
strip 140 to the sheet of packaging material 120 being advanced
from the supply spool 220. The application roller 236 located at
the distal end of the pivot arm 232 further presses the length of
reclose strip 140 onto the sheet of packaging material 120 ensuring
a good bonding between the reclose strip 140 and the packaging
material 120. A weight assembly 238 may be attached to accessory
plate 232a to increase the force applied by the application roller
236 upon the reclose strip 140 and the sheet of packaging material
120 as well as stabilize the entire pivoting arm assembly 230.
[0066] While the spool 240 of reclose strip 140 utilized in the
present invention could theoretically be a single wound spool, as
shown in the Figures and particularly in FIG. 12, a preferred
embodiment of the present invention includes a spool 240 comprised
of layer of multiple windings of reclose strip 140 arranged
generally adjacent to one another as illustrated. As the length of
reclose strip 140 is unwound from the spool 240, it oscillates back
and forth across the width of the spool as illustrated in phantom
and by the arrows.
[0067] In order to smoothly accommodate the gentle oscillation of
the unwinding reclose strip 140, the roller guide mechanism 250 is
fitted with a guide frame 252, which is pivotally attached to the
an stationary extension bar 254, extending from the accessory plate
232a, which in turn is attached to the pivot arm 232. The roller
guide mechanism 250 may comprise a cylinder having flange elements
on the outer edges that channel the lateral edges of the length of
reclose strip 140. Thus, the roller guide mechanism 250 is
automatically aligned with the relative angle of the length of
reclose strip 140 unwinding from the spool 240 thereby smoothly
guiding the length of reclose strip 140 along to the bar guide 256,
which aligns the length of reclose strip 140 with the sheet of
packaging material 120.
[0068] As shown particularly in FIGS. 10 and 12, the pivoting arm
assembly 230 may be quickly modified to change the placement of the
length of reclose strip 140 on the sheet of packaging material 120.
For example, the stationary extension bar 254 can be lengthened or
shortened, thereby adjusting the lateral placement of the length of
reclose strip 140 on the sheet of packaging material 120.
[0069] Once attached to the sheet of packaging material 120, the
length of reclose strip 140 is, thereafter, continually and
automatically unwound from spool 240 and applied to the sheet of
packaging material 120 by the periodic advance of the sheet of
packaging material 120 from the supply spool 220 of the supply
mechanism 200 as described previously. Thus, as shown in the
Figures, the length of reclose strip 140 is attached to the
underside of the sheet of packaging material 120 such that when the
sheet of packaging material 120 is supplied by the supply mechanism
200 of the present invention to the vertical form, fill, and seal
machine 100 and formed into a tubular shape in the conventional
manner, the reclose strip 140 is positioned along a longitudinal
axis on the outer surface of the formed tube 120A.
[0070] With reference once again to FIG. 9, the tubular shaped
packaging film 120 is driven downward by an advancing mechanism
(e.g., friction against rotating belts 93, 94), whereupon a heat
seal bar 95 reciprocates into contact with the tubular shaped
packaging film 120 imparting a vertical back seal 130 and forming a
tube 120A. In accordance with the embodiment of the present
invention illustrated in FIG. 9, the reciprocating heat seal bar 95
reciprocates consecutively with the advancing means. That is to
say, the advancing means advances a specific length of the tubular
shaped packaging film 120 and stops; whereupon the back heat seal
bar 95 reciprocates imparting a vertical back seal 130. Thus, as
the formed tube 120A is advanced down the forming/fill tube 91, the
length of reclose strip 140 attached to the exterior of the formed
tube 120A is also advanced.
[0071] Also shown in FIG. 9 are a pair of prior art sealing jaws
108 illustrated in elevation. Not shown in FIG. 9 is the sealing
jaw carriage on which such sealing jaws 108 would be mounted below
the forming/fill tube 91.
[0072] At the bottom of the forming/fill tube 91, a crease-forming
mechanism, as previously described, comprised of two forming plates
104, a fixed or stationary tucker mechanism 106, and a tension bar
102, is installed which modifies the standard vertical form, fill,
and seal machine 100 so as to produce a stand-up packages. As with
previous embodiments, the forming plates 104 can swing towards each
other by rotating about a hinge 105. This arrangement allows for
the forming plates 104 to rotate towards one another and avoid
ripping of the packaging film 120 when transverse seals are being
formed below the forming plates 104 by the transverse seal jaws 108
as shown in FIG. 9.
[0073] As in previously described embodiments, the two forming
plates 104 and the tension bar 102 are used to hold the formed tube
120A in tension from inside of the tube 120A. Tension is applied on
the exterior surface of the formed tube 120A and in the opposite
direction of the tension provided by the forming plates 104 by the
tucker mechanism 106, alternatively referred to herein as a tucker
bar 106, positioned between said forming plates 104. The tucker bar
106 is preferably attached to the sealing carriage for the vertical
form, fill, and seal machine 100 and is adjustable along all three
axes (in/out, up/down, and front/back).
[0074] Alternatively, the tucker bar 106 can be attached to the
frame of the vertical form, fill, and seal machine 100 or any other
point that can supports its function outside the film tube 120A.
These adjustments in all three axes allow for the tucker bar 106 to
be easily moved out of the way to convert the vertical form and
fill machine 100 back to standard operation and is accomplished, in
the embodiment shown in FIG. 9, by a tension screw 162 that can
lock the tucker bar 106 in place when tightened. While the tucker
bar 106 is adjustable, unlike in the prior art, it is fixed or
stationary during operation.
[0075] When moved forward into position (i.e., toward the forming
plates 104), the tucker bar 106 provides a crease or fold in the
tube of the packaging film between the two forming plates 104. This
crease is formed prior to formation of the transverse seal by the
seal jaws 108. Consequently, once the transverse seal is formed,
the crease becomes an integral feature of one side of the
package.
[0076] As with previous described embodiments of the invention, the
forming/fill tube 91 illustrated in FIG. 9 may also incorporate a
diverter plate mechanism, like the one previously described and
shown in FIG. 6, to keep product away from the vertical gusset
areas.
[0077] The vertical form, fill, and seal machine 100 of the present
invention shown in FIG. 9, thereafter operates basically as
previously described in the prior art, with the sealing jaws 108
forming a lower transverse seal, product being introduced through
the forming/fill tube 91 into the sealed tube 120A of packaging
film (which now has a crease on one side and a length of reclose
strip attached), and the upper transverse seal being formed,
thereby completing the package.
[0078] This seal is subsequently cut horizontally across the
traverse such that a top transverse seal is formed at the top of
the filled bag below and a bottom transverse seal is formed on the
tube of packaging film above. As previously describe, the packaging
film during the prior art operation is typically oriented
perpendicular to the longitudinal translation of the film so as to
be readable by an operator of the machine as the film travels down
the forming tube 91. Thus, as shown in FIG. 3a, this orientation
provides graphics 39 on the formed prior art bag that are readable
by a consumer when the formed bag is placed on a retail display
shelf while resting on its bottom transverse seal 33. Conversely,
in accordance with the present invention, the orientation of the
graphics on the film packaging is 90.degree. off of the typical
prior art orientation, such that the graphics appear sideways as
viewed by the operator of the vertical form, fill, and seal machine
as the film is pulled down the forming tube 91 of FIG. 9.
[0079] An example of the resulting formed package of the instant
invention is shown in FIGS. 13a-13c, which show the outside layer
of the packaging film 116 with the graphics 179 oriented as
previously described. As can be seen from FIGS. 13a and 13b, the
construction of the invention's vertical stand-up pouch shares
characteristics with the prior art vertical flex bags shown in FIG.
3a. However, the transverse seals 131, 133 of the vertical stand-up
bag of the invention are oriented vertically and the vertical back
seal 130 is oriented horizontally once the bag stands up on one
end, as shown in FIG. 13b. FIG. 13a shows the crease 176 that is
formed by the tucker bar 106 and forming plates 104 and a segment
length of reclose strip 140 positioned and applied on the package
exterior as previously discussed in relation to FIGS. 9-12.
[0080] The reclose strip 140 used in the present invention may be
of any conventional construction. For example, as shown in FIG.
13d, in one embodiment the reclose strip 140 may comprise a
composite of several layers of material applied to the exterior
surface of the package constructed of the sheet of packaging
material or film 120. An adhesive 148 bonds a layer of tape 146 to
the packaging material 120. On the side of the tape remote from the
packaging material 120 is a second adhesive 144 which has a bonding
strength of less than the first adhesive 148. The reason for this
is simple. It is desired that the reclose strip 140 remain bonded
to the external surface of the packaging material 120. Therefore,
the bonding strength of the adhesive 148 must be greater than that
of 144. Otherwise, the reclose strip 140 would peel off of the
package when it adhered to a second surface. Because the adhesive
144 is of less peel strength than the adhesive 148, a peel strip
142 is bonded to the adhesive 144 and serves the purpose of
preventing premature bonding of the reclose strip 140 to undesired
surfaces.
[0081] In typical use, the resulting vertical stand-up pouch or
package having an integrated reclose strip shown in FIGS. 13a and
13b is opened by cutting or tearing the top portion 118 of the
package to provide an opening allowing the user to retrieve the
contents of the package or a part thereof. Oftentimes, not all the
contents of a package is consumed at one time and thus the desire
to close and reseal the package is achieved where the package is
manufactured according to the above discussed procedure. As shown
in FIG. 13d, the package may be opened to remove part of the
contents and resealed to prevent moisture from causing premature
deterioration of the contents; the peel strip 142 has been stripped
away from the adhesive 144 and two or more folds are made in the
top portion 118 of the package in a direction toward the reclose
strip 140. The folded portion of the package which previously
represented the side of the package away from the reclose strip 140
is adhered to the reclose strip 140 and thereby the package may be
returned to a storage compartment for subsequent retrieval and
consumption.
[0082] While the reclose strip 140 is functional anyplace on the
package, it is desirable that the reclose strip 140 be applied on
the upper half of the resulting package and preferably a position
about one-third of the way down from the top portion 118 of the
resulting package. Placing the reclose strip 140 on the lower half
of the bag could cause the user to crush the contents remaining in
the bag when it is resealed. However, the exact location of the
reclose strip 140 depends upon the goods being packaged.
[0083] Thus, as shown by comparing FIGS. 3a-3c with FIGS. 13a-13c,
the major differences between a prior art package and this
embodiment of Applicants' package are that a crease 176 is formed
on one side (which later becomes the bottom of the formed package)
using the fixed mechanism described, that a length of reclose strip
140 is attached to the exterior of the formed package using the
apparatus incorporated into the supply mechanism 200 described, and
that the graphics on the packaging film used by the invention are
oriented such that when the formed package is stood onto its end
with the creased end generally at the bottom, the graphics are
readable by a consumer and the integrated reclose strip is oriented
generally parallel to the top of the package.
[0084] As noted previously, the added ability to attach the length
of reclose strip 140 to a package available on Applicants'
invention, is not available using current vertical form, fill, and
seal machine technology. This is due, in part, to the orientation
of the film graphics used on the packaging film of the present
invention. Since the graphics are oriented 90.degree. from the
prior art, a length of reclose strip 140 can be run longitudinally
along the forming tube adjacent with the packaging film as it is
being formed into a tube and subsequent package. This is not
possible with the prior art, because such orientation of a vertical
length of reclose strip would place such a strip in a vertical
orientation once the package is formed and stood up for display
[0085] The invention is further an improvement over methods for
manufacturing prior art flat bottom bags. Since the tucker
mechanism of Applicants' invention is stationary during bag
formation, the present invention eliminates the need for moving
parts that push against the film tube for the formation of a
gusset. This elimination of moving parts allows for increased bag
production rates, significantly lower changeover times to pillow
pouch production, and significantly fewer maintenance issues.
[0086] While the invention has been particularly shown and
described with reference to a preferred embodiment, it will be
understood by those skilled in the art that various changes in form
and detail may be made therein without departing from the spirit
and scope of the invention.
* * * * *