CA2273266C

CA2273266C - Fastener tape material, bag utilizing fastener tape material, and method of manufacture thereof

Info

Publication number: CA2273266C
Application number: CA002273266A
Authority: CA
Inventors: James R. Johnson
Original assignee: Illinois Tool Works Inc
Current assignee: Illinois Tool Works Inc
Priority date: 1996-07-24
Filing date: 1997-07-24
Publication date: 2005-02-15
Anticipated expiration: 2017-07-24
Also published as: US6350340B1; AU3738997A; US6152601A; US6662843B1; DE69736672D1; ATE339300T1; EP0928244B9; EP0928244A4; WO1998003328A1; CA2273266A1; EP0928244A1; US6509080B1; US6116314A; EP0928244B1; US6251209B1; DE69736672T2; US6321423B1

Abstract

The present invention includes methods, an apparatus and a system in which reclosable bags and components thereof are formed. The reclosable bags (2001) are made from base web material that has transversely applied fastener tape segments thereon. The web material is used in a vertical form, fill and seal bag forming method. The method includes the steps of supplying a continuous strip of tape, having male and female fasteners profiler across the web for sealing thereon. In one embodiment a continuous strip of barrier material, and a continuous strip of fastener having first and second interlocked fastener profile strips are positioned on the continuous strip of tape; and secured thereon, the barrier tape is folded to obtain a fold and two opposing barrier tape fastener strip connecting portions; and, the fold is slit to form two separate continuous strips of barrier material strips and two continuous strips of tape. In another embodiment a coating is applied to the tape itself to prevent sealing of the folded slit tape to itself. The resulting tape and fastener are cut (220) and portioned properly on the web by the unique vacuum belt system of the present invention and by the interconnected tape drive, web drive and the connection to the form fill seal machine.

Description

AN IMPROVED FASTENER ASSEMBLY, FASTENER TAPE MATERIAL, BAG
UTILIZING FASTENER TAPE MATERIAL, AND METHOD OF
MANUFACTURE THEREOF
BACKGROUND OF THE INVENTION
This invention relates generally to reclosable plastic bags and in particular to fastener assemblies for such bags, tape having reclosable fasteners thereon used in the manufacture of reclosable plastic bags, the web that the bags are made from, methods related to their manufacture and an apparatus for manufacturing reclosable bags that is more efficient and economical than conventional methods and devices.
While most packaging is done with polyethylene sheeting, or multilayer sheeting that includes a polyethylene layer, there are problems in sealing reclosable profiles to the such sheeting due to the thickness of the profiles, or the thickness of flange material that may be integral with the profile. Sealing is even more difficult when the sealant layer of the bag walls is something other than polyethylene, such as oriented polypropylene, for example, used in potato chip bags. An additional problem is to manufacture reclosable bags which would remain closed until opened by the user. The present invention provides apparati, methods and materials for sealing profiles to sheeting and for making bags in an efficient and practical manner.
Prior art such as U.S. Patent No. 4,909,017, McMahon disclose the delivery CA 02273266 1999-OS-27 ~ ~ ~ I 3 0 2 ~P~US 2 I J U L 1998

2 of a fair of interlocked, profiled fasteners transversely across a web of film, to be used in forming a plurality of bags. However, the McMahon disclosure is non-enabling in that fastener strips cannot be delivered as described therein.
Also, the strip material shown, if sealed in the center, would be unstable due to the rib and groove design, which would rock. Similarly, the strip material is naturally curled from extrusion and distorted from being wound onto a spool.
There are at least two other major shortcomings of the McMahon '017 patent.
The first shortcoming involves the impossibility of making commercially acceptable seals of the bag walls to the backside of each fastener in the bagger sealing jaws.
The second shortcoming involves the window of registration required to seal the backside of the fastener to a finished bag wall during bagger cross sealing;
known form fill seal and equipment cannot repeat the film draw down with the required accuracy.
Specifically, the McMahon '017 patent describes a pressure bar seal in the ~_.~i 15 bagger sealing jaws that seals the outer bag material precisely to the backside of the fastener profile. Yet, it has been discovered, as indicated in Applicant's specification, that a pressure bar seal requires a stable and flat surface to properly seal. The irregular shape of the McMahon fastener profile makes this impossible.
One requires heat, dwell time, and pressure to effect a commercially acceptable seal.
Due to the irregular shape of the profile, it is impossible to get enough stable pressure to accomplish a commercially acceptable seal. The surface moves and gives unpredictably. If enough heat and pressure are applied for a sufficient dwell time to mash the base of the profile flat enough to seal, the profile hooks are softened and CA 02273266 1999-OS-27 , ~ 7 ~ I 3 0 2 ~
(j~ 2 ~ ~UL 1998

3 deformed, making it impossible to repeatedly use the completed bag for opening and reclosing. In addition, no bagger can draw with the accuracy the McMahon '017 patent requires, to place the second seal, in register, on the back side of the fastener profiles.
In U.S. Patent No. 4,528,224, it has been known to manufacture reclosable fastener assembly in which a pair or even several pairs of male and female profiles interlock. In U.S Patent No. 4,528,224 by inventor Steven Ausnit, such a pair fastener has shown. In Figure two of Osnet, a pair of such profiles have flanges which extend between them. However, the flanges are the same thickness as the entire based of the profiles. Similarly, in U.S. Patent No. 4,264,288, Sandborn, a pair of fastener profiles has flanges extended there between. However, in both cases the fastener profiles are not sufficiently separate so that the flanges extending between them are not relatively ragged but are flexible and are not supportive by the fastener profiles themselves. In U.S. Patent No. 5,509,734 again, pairs of fastener profiles are shown. However, in the '734 patent, a wedge is located between the fastener r_. .
profiles.
U.S. Patent No. 4,993,844 discloses a complimentary interlock strip extruded with and mounted on strips of plastic material. Similarly, U.S. Patent No. 5, 071,689, discloses strips of extruded plastic zipper sections. However, none of the foresaid patents discloses sealing of reclosable fastener assembly to tape strips of tape are in return are sealed to or webs of bag making materials.
PCT application number 97/06062, published February 20, 1997 discloses a zipper film and bag in which a reclosable bag has a reclosable refastener assembly t

4 connected to a single wall of the bag in which the film of the bag has a reclosable fastener connected to one side thereof which does not require attachment to any other portion of the film when making the bag. This differs from the present invention in which the fasteners attached to both walls of the bag, either directly or intermediate tape material.
SUMMARY OF THE INVENTION
Accordingly, the present invention seeks to overcome the shortcomings of the prior art by providing a fastener assembly which is easier to seal to flerible film than prior art fasteners. Further, the invention seeks to provide a fastener assembly in which thickened sealing bridges are positioned between a pair of profiles, as to facilitate sealing. Still further the invention seeks to provide a fastener assembly having opposing dual profile closure elements in which one of the male profiles has a layer head or barb, the other male profile, thereby making that side of the fastener assembly (the consumer side) harder to open so as to prevent product from inadvertently forcing the bag open.
Further still the invention seeks to utilize fastener profile mounted on tape in the bag forming process, thus sealing two flat, substantially parallel surfaces together. As a result, there is no irregular surface that is sealed to attach the fastener to the front panel, or to carry the fastener through the bagger and down the form, fill and seal tube or to seal the back-seamed side of the package.
Yet further the invention seeks to solve the shortcomings of the art through the use of fastener tape to which the fastener assembly is attached as to provide a thin substantially flat surface which is sealed to the bag wall(s).
The invention also seeks to treat the inside surface of the area to prevent area from being sealed together during the process described below, to allow zipper and bag S
opening from this area.
Another aspect of the invention seeks to provide an automatic contamination-free package by sealing the fastener completely inside the package. In this variant, the top seal of the package must be cut off to allow the customer/user to get to the opening tabs of the fastener.
An additional aspect of the invention seeks to provide a method of making a reclosable bag having a body with top and bottom ends and opposing walls in a vertical, form, fill and seal machine that includes the steps of forming the bag walls from web material having a longitudinal back seal extending between the top and bottom ends of the bag body and transversely securing across the longitudinal back seal a tape having a flanged, interlocked fastener strip thereon. The tape is substantially wider than the width of the interlocked fastener strip attached to the flange.
Further the invention seeks not to contact or deform the interlocked fastener strip during the sealing process.
Still further the invention seeks to create a commercially-acceptable seal across the longitudinal back seal of a bag while providing greater tolerance for deviations in bagger web draw.
The tape is sized and dimensioned to provide a larger window of registration than that required to seal the backside of a conventional fastener onto a finished bag wall, whether it is a back or front panel wall, directly onto the backside of the fastener during bagger cross sealing. The tape is also sized and dimensioned to provide repeatable sealing of the tape to the bag wall during the transverse bagger cross sealing process while allowing for variances and deviations in bagger web draw.
Yet further the invention seeks to provide an improved vertical, form, fill and seal process that includes transversely sealing a non-profiled, stable and substantially flat surfaced appendage or flange having a profiled, interlocked, reclosable fastener strip connected thereto across the longitudinally extending back seal of a bag during bagger cross sealing. It is appreciated that the transverse sealing across the non-profiled, stable and substantially flat surfaced appendage permits one to seal the appendage to bag material with an effective heat, dwell time and pressure to effect a commercially acceptable seal without the surface moving and giving unpredictably. It is also appreciated that greater, pressure and dwell can be applied to mash the shape flat enough to seal, while simultaneously preventing the profiled fastener from softening and deforming making it possible to repeatedly use the completed bag for opening and reclosing.
The system method and tape assembly described above is extremely versatile.
The tape or flange is substantially thin allowing its use with a greater variety of bag walls materials, regardless of the base web thickness. The tape or flange, since it is ribless and thin, blends the cross seals better, from tape plus bag wall thickness to bag wall thickness only and results in continuous seals, sealed in the bagger sealing jaws.
Further, the assembly described above is constructed to be readily, transversely "pulled" across a web of material and the assembly method and system can be used with any appropriate tape base material. The invention described above can be used on laminate bag wall base web material, e.g. snack food bag wall and base web material where a user does not want to change their present structure/bag wall material, which does not easily seal to LDPE (Low Density Polyethylene) material.
The invention in one broad aspect of particular interest herein is an apparatus for dispensing, applying and sealing individual sections of thermoplastic tape having at least one fastener profile attached thereto, the tape being sealed across a portion of a web of thermoplastic material. The apparatus comprises means for dispensing the tape and fastener profile, a tape applicator apparatus and means for delivering tensioned tape and fastener profile from the tape dispensing means.
The means for delivering comprises a tape registration assembly for adjusting the position of the tape and fastener profile and a tape drive assembly for advancing the tape and fastener profile. A tape cutter assembly is provided for cutting the tape and fastener profile into individual sections of a preselected length. Vacuum belt means is provided for advancing the section of tape and fastener profile into a position across the web of thermoplastic material. A tape sealing mechanism applies pressure and heat to the tape section on the web for a specified dwell time and there is means for sequentially advancing the web.
Another aspect of the invention pertains to a method of sealing individual sections of thermoplastic tape across a portion of a web of thermoplastic material comprising the steps of dispensing the tape a desired distance, cutting the tape to a desired length of the individual sections of said tape, grasping the end of the individual section through the use of a vacuum, sequentially applying vacuum to the length of the individual section of tape and simultaneously advancing the individual section of tape over the web, pressing the individual section of tape to the web and heat sealing the individual section of tape to the web.
The aspects and features of the present invention, other than those specifically set forth above, will become apparent in the detailed description of the invention set forth below and in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of the system for performing the processes of the present invention;
FIG. 2 is a schematic representation of a sub-assembly of an apparatus used in the system of FIG. 1;
FIG. 3 is a flow chart of a routine of the present invention;
FIG. 4 is a perspective view of the tape of FIG. 6 being ultrasonically staked to the web;
FIG. 5 is a perspective view of a web of the present invention;
FIG. 6 is a side cross sectional view of a tape of the present invention;
FIG. 7 is a side cross sectional view of a flange of the fastener of the present invention;
FIG. 8 is a side cross sectional view of a variant of a flange of the present invention of FIG. 7;

CA 02273266 1999-OS-27 . z _ ~_T~$ 9 7 ~ I 3 ~ 2 8 s FIG. 9 is a side cross sectional view of a flange of the present invention;
FIG. 10 is a side cross sectional view of an assembled bag of the present invention;
FIG. 11 is a front plan view of the bag of FIG. 10;
FIG. 12 is a side cross sectional mew of a variant of the bag of the invention and sealing bars;
FIG. 13 is a side cross sectional view of a flange of the invention;
FIG. 14 is a side cross sectional view of the bag material and a flange of the invention;
FIG. 15 is a side cross sectional view of a bag of the invention having the tape of FIG. 14;
FIG. 16 is an exploded side cross sectional view of an upper portion of a bag of the present invention having a fastener tape connected thereto in which the fastener is in an open position;
f"~ ; 15 FIG. 17 is a top plan view of a web having fastener tape segments thereon;
FIG. 18 is a side cross sectional view of a portion of the web having fastener tape segments of FIG. 17;
FIG. 19 is a top plan view of the bag including the portion of the bag shown in FIG. 16;
FIG. 20 is a side perspective view of the fastener tape dispensing assembly of the present invention;
FIG. 20-A is a side view, partially broken away. of the fastener tape dispensing assembly of the present invention;
. . ....._ CA 02273266 1999-OS-27 ~ 7 / 13 0 2 8 FIG. 20-B is a side view, partially broken away, of the fastener tape dispensing assembly of FIG 20.
FIG. 21 is rear perspective view of the fastener tape dispensing assembly of FIG. 20;
FIG. 22 is a side perspective view illustrating an ultrasonic sealing horn and cutter and the fastener tape dispensing assembly of FIG. 20;
FIG. 23 is a rear perspective view illustrating the ultrasonic sealing horn and cutter of FIG. 22;
FIG. 24 is a rear perspective view illustrating a zipper spool drive and the fastener tape dispensing assembly of FIG. 22;
FIG. 25 is a side perspective view of a web material dispensing assembly of the form fill seal machine of the present invention and a roll of web material;
FIG. 26 is a rear perspective view of a web material dispensing assembly of FIG. 25;
FIG. 27 is a front perspective view of the vacuum belt and sealing bar assembly of the present invention;
FIG. 28 is a front perspective view of the vacuum belt and sealing bar assembly of FIG. 27 and the web having fastener tape segments of FIG. 17;
FIG. 29 is a side perspective view of two sets of dancer rollers through which the web having fastener tape segments of FIG. 17 is fed through the present invention;
FIG. 30 is a perspective view of the web having fastener tape segments of FIG. 17 as it moves over a forming collar of a form fill seal machine;
~m CA 02273266 1999-OS-27 ~~ ", ~ ~ 13 0 2 g IP~~~ 2 1 J U L 1998 to _ FIG. 31 is a side perspective view of the forming collar of FIG. 30;
FIG. 32 is a front view of a form fill seal machine;
FIG. 33 is a close up view of sealing bars and a cutting knife of FIG. 32;
FIG. 34 is a top plan view of laminate material used in the manufacture of fastener tape;
FIG. 35 is a side cross-sectional view of an interior cap sealed to a base web of a partially processed fastener tape assembly;
' FIG. 36 is a side cross-sectional view of the partially processed fastener tape assembly of FIG. 35 after a folding operation;
FIG. 37 is a side cross sectional view of the partially processed fastener tape assembly of FIG. 36 having a fastener sealed to the sealant layer of the base web;
FIG. 38 is a side cross sectional view of the partially processed fastener tape assembly of FIG. 36 having a fastener sealed to the interior cap at ends thereof;
FIG. 39 is a side cross sectional view of a variant of FIG. 37 having a sealed ~°' ~ '~ 15 header portion thereof;
s,._..~
FIG. 39a is a top plan view of a reclosable bag utilizing the web of FIG. 35;
FIG. 40 shows a variant of the top of the bag of FIG. 19 in which gripping flanges are provided above an adhesive seal sealing the bag wall together;
FIG. 41 is a diagram of an apparatus for forming the fastener tape illustrated in FIG. 20, 21 and 23;
FIG. 42 is a side cross sectional view of a variant of the fastener tape described herein having a non-sealing nitrocellulose coating thereon; and, FIG. 43 illustrates a top plan view of a variant of a top portion of a reclosable bag of the invention.
~ I302v IPE~j~ 2 1 ~ U L 1998 FIG. 44 is a front elevational view of the improved reclosable plastic bag of the present invention;
FIG. 45 illustrates a perspective sectional view of an improved reclosable plastic bag of the present invention of FIG. 44;
FIG. 46 is a perspective view of a vertical bag forming, filling and sealing apparatus for manufacturing bags of the present invention;
FIG. 47 is a perspective view of a roll of web of the present invention;
FIG. 48 is a side cross-sectional view of an optional reclosable flange of the present invention;
FIG. 49 is a partial side cross-sectional view of the recloseable flange of FIG.
48 connected to a web wall;
FIG. 50 is a partial side cross-sectional view of an optional recloseable tape of FIG. 51 in an assembled bag of the present invention;
FIG. 51 is a side cross-sectional view of an optional recloseable tape of the present invention;
FIG. 52 is a partial side cross-sectional view of the recloseable tape of FIG.
51 connected to a web wall;
FIG. 53 is a partial side cross-sectional view of the recloseable flange of FIG.
48 in an assembled bag of the present invention;
FIG. 54 is a side view of a variant of the flange of FIG. 48;
FIG. 55 is a side cross sectional view of the flange of FIG. 54 in an assembled bag of the invention;

CA 02273266 1999-OS-27 p~T~S 9 7 ~ I 3 0 2 IP~'~~~ 2 ~ JUL 199 FIG. 56 is a perspective view of an apparatus to manufacture web material that is used with the vertical bag forming, filling and sealing apparatus of FIG. 46;
and, FIG. 57 is a side cross sectional view of the bag of FIG. 53 upon severance of the top portion thereof.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic representation of a system 120 for practicing the present invention, which relates generally to reclosable plastic bags, and more particularly to the sealing of reclosable fastener mounted on tape to a web, used in making reclosable bags on a form/fill/seal machine. System 120 is capable of repeatedly performing the steps required for the manufacture of such bags with high throughput and with low cycle times.
The proper feeding, locating and sealing of tape 100 at predetermined locations on base web 110 are important aspects of system 120. The manner in which tape 100 is fed, and positioned for sealing onto base web 110 is critical to achieving accurate secure sealing of tape 100 to web 110. To this end, base web 110 is indexed at indexing station 130, via servo motor 140. Servo motor 140 has control over acceleration, speed and deceleration of web 110.
As shown in FIG. 4, in an alternative embodiment, the movement of web 110 in the direction of the arrow 112 in FIG. 1 creates air movement over web 110 affecting anything that is attempted to be passed over it, such as tape 100.
The -.......err w.

tendency is to pull the leading edge of tape 100 in the direction of the movement of base web 110. Tape 100, which is generally about 1" to 2-3/4" wide, effectively floats on current of air 180 (not shown). At the end of the tape delivery 190, tape 100 is in a stretched position 320 across web 110, assuring squareness for positioning onto base web 110. By "pinning" or staking tape 100 at a stretched corner, then pinning or staking it at a corner at the opposite end of tape 100, sealing can be accomplished with tape 100 square and in register with base web 110. Seal 114 is transverse to web 110 and parallel to the fastener that is attached to tape 110.
It has been determined that the following sequence of steps rapidly and accurately feeds, locates, cuts and seals tape 100 onto web 110.
1. A signal to index base web 110 and index tape 100 is given, controlled by the level of take up dancer 520.
2. A servomotor 469 drives the tape 100 forward via the nip drive 470 of Tape Drive Assembly (D-23587) 2107.
3. The leading edge 110A of the tape 100 is driven into the vacuum belt 2132 in Vacuum Drive Assembly (D23625) 2167. Vacuum openings 2049A in the belt 2132 attach to the skirt area 100A of Tape 100, above the zipper 980. The Vacuum belt 2132 is driven slightly faster than nip drive roller surfaces 2113-17 and carries the leading edge 110A of the tape 100 to its farthermost position in a stretched manner.
4. After driving the tape 100 the distance desired, the Tape Cutter Assembly (C 23095) 2109 is activated to clamp and cut tape 100.

5. As the cutter 2109 clears to return to its uppermost position, the leading edge 110A of the next piece of tape 110 is lifted clear of the cutting slot 2109A

to avoid a potential jam on the next feed cycle and so as to be aimed properly for transference to the vacuum belt 2132. Concurrently the cutting ledge 2109B
moves clear to allow the trailing edge of the tape piece just cut to lay flat for sealing.

6. The tape 100 is sealed to the base web 100 via the sealing bar 2159 which is part of vacuum drive assembly 2167. The sealing bar 2159 clears, (is raised) and the cycle is ready to be repeated. The trailing edge 110B of the piece of tape 100 just attached to the base web 110 does not interfere with the lifted leading edge 110A
of the tape 100 on next feed cycle, due to the leading edge 110A feeding over the trailing edge 110B and being pulled away in a transverse direction.

7. The vacuum belt 2132 remains constantly on, rather than cycling on and off, thereby preventing delays in building up vacuum strength after being shut down. This occurs because the seal strength of the bond between the tape 100 and base web 110 is strong enough to allow separation of the tape skirt flange 1070 from the vacuum belt 2132 when the base web 110 indexes.
In an alternative embodiment, it has been determined that the following sequence of steps rapidly and accurately feeds, positions and seals tape 100 onto web 110:
1. Tape 100 is driven forward using a set of grooved rubber nip rollers 150 connected to stepping motor 160 at stepping station 170.
ZO 2. Tape 100 is carried transversely across web 110 with a curtain or stream 180 of air directed above and below tape 100 from air supply 105, so as to eliminate the influence of base web 110, which is moving concurrently beneath tape 100 and at a right angle thereto.

CA 02273266 1999-OS-27 p~T~~ 9 7 i 13 0 2 g IPE,4/(~~ 2 I ~UL 1998 is - 3. Air curtain 180 is stopped at delivery end station 190, and concurrently loop side corner 200 of tape 100 is pinned to base web 110 (FIG. lA) before the tape 100 is cut off at cutting station 210 (FIG. 4).
4. Tape 100 is pinned at opposite end 230 (FIG. 4) as cut 220 is being made and tape 100 is held in position to be sealed at positioning station 240 by pinning devices 260.
5. Single lip 250 is sealed to base web 110 with a sealing device, namely fastener segment attachment assembly 2101, while pinning device 260 continues to hold severed tape piece 270 (FIGS. 4) in position, substantially square with base web 110.
6. Tape 100 is continuously held by pinning devices 260 while the seal bar 21s9 (FIG. 33) lifts away from the sealing position, effectively allowing the sealing bar 21s9 (FIG. 33) to strip away from the seal.
7. Pinning devices 260 (FIG 4) is released. Pinning devices 260 includes pneumatically operated rubber boots 310, which are generally about 1 " square.
Another aspect of the invention, as seen in Figure 1, provides for an attachment of tape applicator 420 to a winder 600 (not shown). This allows bagger 410 to function with pre-applied tape. There exists substantial demand for zippered roll stock 630 with tape 100 already sealed onto base web 2164 to be run on separate baggers. This approach to zippered packaging is not a replacement for in-line capability, but can be used as another option.
As seen in Figure 4, the invention also provides an apparatus 1140 and method for forming and driving web 340 (web 110 having tape 100 sealed thereto) . ..f i~ ~' ~~S
~:~,~.~IUS ~ I ~ ~ ! ''-' ~ , downwardly along the outside of tube 350 (which is part of a vertical form, fill and seal machine), making back seal 360 and making cross seals 370, 380. Each end 230, 235 of the severed tape piece 270 (FIG. 5) must be sealed in some manner, or the severed tape piece 270 will, simply, separate at its first opening and realignment will be very difficult. To solve this problem, the ends 230, 235 of our zipper tape piece are "staked" ultrasonically.
As seen in Figure 1, the invention ftirther provides a device 400 for coordinating bagger 410 and tape applicator 420. It is important to coordinate the operations of bagger 410 and the operations of tape applicator 420, because uniform web tension must be maintained between these operations, or web tracking will be lost.
As partially illustrated in FIG. 1 and 2, assembly 430 is responsive to device 400 and delivers uniformly tensioned web 440 to bagger 410, takes up the material being fed by the tape applicator 420, and simultaneously maintains proper tension.
The three sections of assembly 430 are: 1. a spring loaded three loop dancer ...
' with a photo sensor 460 which reads the position of the dancer 490 and, when ready, starts the cycle of tape 100 application; 2. a nip drive 470, for feeding the tape 100 (FIG. 29) and; 3. a second three loop dancer 2136 (as shown in FIG. 29) between the nip drive 470 and the bagger 410 (FIG. 1) which controls the nip drive 470.
Indexing of the bagger 410 and indexing of the tape applicator 420 are independent. Bagger 410 indexes, causing the three loop dancer 490 to rise. A
proximity switch (not shown) and a cam cause nip drive 470 (FIG. 2) to pull material 440, thereby lowering arm 520 on the dancer 490. When additional material 440 is P~T/US 9 7 ~ I 3 0 2 g ~~~ 2 1 JUL 1998 pulled through the nip 470, the upstream dancer arm 520 rises causing coils 510 in springs 521 to stretch under tension. Photo sensor 460 then sees flag 570 on arm 550 of the dancer 490, which causes tape applicator 420 to index. The coils 521, which are under tension, pull arm 520 down to receive material 340 being indexed into three loop assembly 490. The process is then continually repeated. As light a tension as possible is used on the spring 521 so that little resistance to the movement of the tape 100 is applied, thereby reducing the tension on the tape 110 and resistance to the inertia of the tape 100 moving forward. As a result positioning of the tape 100 is more accurate throughout the system.
FIG. 3 illustrates a tape applicator program 580 that executes the following steps of the routine: 1. -- Base web 110 indexes to eye spot 590, via servo motor 140; 2. -- Tape 100 is fed, via stepping motor 160; 3. -- Vacuum belt 2132 carries tape 100 for positioning. 4. -- Tape 100 is cut, and sealed to base web 110.
5. --Seal 280 is actuated to seal tape 100 to base web 110.
System 120 described above optionally feeds a winder 600 (not shown), as well as bagger 410 with, practically, no modifications. In these cases, the equipment may be used by a company packing product or a film converter . This approach allows any converter to provide a customer-packer with preapplied zippered mll stock 630, enabling the converter to obtain base web business he would not ordinarily get.
Similarly the packer can run preapplied zippered roll stock 630 on multiple bagging machines without having to provide tape applicator machine 420.
The invention also provides for methods of treating the internal loop or flap area 1060 of tape 100 to create a non-sealing characteristic thereon as illustrated in r FIGS. 6 and 7. The inside surface of the loop or flap area 1060 of the tape 100 material is treated to make it not seal in bagger 410 (FIG. 1) during the jaw sealing process 1260.
There are several ways in which this is accomplished, including electronic surface (corona-style) treatment, application of non-sealable printing materials, lamination or sealing of a barrier (non-sealable) strip application onto tape 100 material between zipper halves 720 and 730, or insertion of a barrier (non-sealable) strip 740 into loop (flap) area 1060, as seen in (FIG. 6).
In one variant, as seen in FIG. 9, the invention includes frangible opening 750, used when the product packaged does not require hermetic seals, such as IQF
(instant quick freeze) vegetables and/or fruits. For items not requiring hermetic seals, such as IQF vegetables, where holes are punched to get air out of the bag and release COZ, frangible opening 750 is desirable as opposed to cutting a top seal 830 (FIGS.
10, 11 and 12) off with scissors.
As illustrated in FIGS. 9 - 11, opening is created during tape 100 manufacturing. Top end 760 is slit open during manufacturing. The tape material 100 is constructed from a single-layer of polyethylene with additives such as ethylene vinyl acetate to facilitate sealing. The application of tape 100 results in a finished package 1 as depicted in FIG. 10. The perforating operation to create frangible opening 750 (FIG.
9) is incorporated into the sealing jaws 1260 (FIG. 12) of the bagger 410 (FIG. 1), which also seals the cross web tape loop 880 (FIG. 13) the top seal 830 (FIG. 10) and bottom sealer 832 (FIG. 11) of the bag 1.
As illustrated in FIGS. 9 -13, flanges 770 and 780 having fastener profiles PCT/US 9 7 ~ 13 0 2 8 IPE~/~S 2 1 ~ U L 1998 and 730 thereon are sealed to the inside walls 810 and 820. Flanges 770 and 780 are sealed to walls 930 and 940 below top seal 830 at seals 790 and 800. Frangible opening 750 (FIG. 9) is disposed below top seal 830 and above flange 780 (FIG.
10).
The invention further includes a process to make pre-applied zippered tape roll stock 630 (FIG. 5). The tape 100 material is optionally applied in-line with the customer's product bagging machines. Preapplied zippered roll stock 630 may also be provided by adding a winder 600 to the tape applicator 420 system 120.
The invention also includes variants for "chip" industry applications. The invention includes an "easy opening" feature for plastic bags. As shown in FIG. 12, chip bag 840 carries very thin sealant layer 850, commonly about 2/ 10 of a millimeter in thickness. Chip bag 840 includes a reclosable strip 860 just below separable opening portion 870. Separation of the walls of opening portion 870 exposes reclosable opening flanges 770 and 780 to the environment if the tape loop 760 (FIG. 9) is slit apart during its manufacture. FIG. 12 also illustrates the location of sealing bars 2159. Sealing bars 2159 seal at least a flat, unprofiled portion of flanges 770 and 780 to the bag 840 walls.
In a preferred embodiment, tape loop 880 is slit open during manufacturing.
Inside surfaces 890 and 900 on flanges 770 and 780 (FIG. 13) are treated to be unsealable.
Chip bag 840 is manufactured using the following steps: As depicted in FIG.
10, outside surfaces 910 and 920 of tape assembly 950 are sealed to chip bag inside wall surfaces 930 and 940, respectively. Outside surfaces 910 and 920 on flanges 770 and 780 (FIG. 12) include a laminate surface sealant compatible with inside bag CA 02273266 1999-OS-27 ~ 7 ~ 1 3 p 2 8 ~P~U~ 2 ~ ~UL 1998 surfaces 930 and 940 (FIG. 12).
Profiled reclosable strip 860 is provided, (FIG. 12), having zipper halves 720 and 730 between flanges 770 and 780 in an interlocked arrangement. Top seal FIG. 10 is formed from the same material used to make the easy open chip bag 5 (FIG.12). Bottom seal 832 (not shown) is formed concurrently.
In the case where packaging material 960, e.g. web stock, has a "different"
sealant layer 970 from zipper 980, a coextruded or laminate, tape material 1010 is applied to material 960 (FIGS. 14-15). The fastener side 1005 contains a compatible LDPE (low density polyethylene) surface 1000 and the opposite side 1020 is layered 10 with material 1030 that is compatible with the sealant layer 970 of the packaging material 960, such as a potato chip bag 840. Opposite side 1020 is compatible with sealant layer 970 of packaging material 960. Inside surface 1000 is constructed for easy sealing to zipper 980. The inside loop area 1060 is treated after zipper 980 is sealed in so that loop area 1060 cannot be sealed to itself. The outside surface 1030 15 remains sealable and compatible with the inside surface of packages, to effect the desired seal to the package. "Cut here" instructions or other indicia are provided so that the user can expose fastener 980 upon severance along the indicated lines (FIG.
15).
In yet another aspect, the invention provides an apparatus 1140 to make 20 reclosable tape 1010 (FIG. 14) or flange zipper material 950 (FIG. 13) and wind it into rolls. In one variant, tape 1010 has a tape portion 1090 of about 3/4" of an inch in length and a tape portion 1100 about 1-1/4" in length which is treated to be non-sealable. Tape 1010 is formed from about 3 millimeter stock. In another variant, lP~~!(~!~' ~ ~_ '! t ~' -~
flange-1110 is manufactured (FIG. 9). Flange 1110 has flange portion 1120 which is about 3/4" in length, and a second flange portion 1125 that is about 1-1/4"
in length. The inside high flange area portion 1130 is treated to be non-sealable.
Either tape 1010 is affixed to the fastener profiles and processed as described herein.
As shown in FIG. 1, apparatus 420 is provided, for indexing sealing tape 100 or flange 1110 to web 110. Apparatus 420 is located behind (or upstream) of form, fill, seal bagger 410. Apparatus 420 unwinds reclosable tape 100 or flange material 1070, indexes, punch holes, and indexes tape 100 again to a location centered above the backside 1160 of the intended front panel 1170 of base web material 2154 (cross web) and cuts tape 100 or flange 1110 to a length that is just shy of the width W of front panel 1170 of the intended bag 1 (FIG. 1).
Concurrent with the steps described above, the apparatus 1140 feeds (indexes) base web 110 to a position that allows registration of the tape 100 or flange 1110 to just below the intended top portion 1090 FIG. 14 of the finished bag 1. The next step of the method involves sealing as much of the lower flange area 1200 (FIGS. 6 ' . ' and 7) and the side of the loop 1202 adjacent to the inside surface of the front panel area 1170 to the inside surface 1220 of web 110 as is practical. Step three of the method is to provide web 110, now called web 340 to bagger 410. In bagger 410, in addition to making the normal cross sealing and cutting operations, the sealing bars 2159 are modified to seal the opposite side of the loop (or flange) areas 770, (optionally 780), to bag wall 2004 and 2028 having longitudinal seal 1267 thereon (FIG. 1). It is appreciated that the width of tape 1010 or flange 770 permits wall sections 775 and 785 to be sealed to front panel 1170 and back panel 1265 of bag 1 ~P~~ 2 I J U L 1998 relatively effortlessly, since substantially smooth, parallel, and unprofiled wall sections 775 and 785, and front panel 1170 and back panel 1265 are sealed together as illustrated in FIG. 16, utilizing sealing mechanism 1260.
As illustrated in FIGS. 14 and 15, the invention includes a tape 1010 for S attachment to a web. The tape 1010 includes a zipper compatible inside portion 1000 for connection of zipper 980 to the zipper compatible, inside portion 1000, and an outside portion 1030 compatible with sealant layer 970 of packaging material 960 for ~., ,_ connection of outside portion 1030 to sealant layer 970. In one variant the zipper compatible inside portion 1000 and the outside portion 1030 are incompatible.
The zipper compatible inside portion 1000 is compatible with low density polyethylene compatible. The inside loop surface 1060 is treated so as to be incompatible, i.e.
virtually non-sealable during the sealing process.
In a variant, a simplified method of manufacturing the tape 1010 described above is provided that includes the step of coextruding a first base tape 2210 material to obtain zipper compatible inside surface portion 1000 and a second base tape - material to obtain outside surface portion 1030. Optionally, the method includes the step of fusing the zipper compatible inside portion 1000 to the outside portion 1030 to obtain a laminate structure (Fig. 14). As shown in Fig. 5, the invention includes a web 440 for making reclosable bags 2001 comprising the tape 1010 on flange described hereto.
FIG. 16 illustrates an exploded cross section of a portion of reclosable bag 2001 of FIG. 19. Reclosable bag 2001 has a bag body 2003 with bag top end 2000 (FIGS. 16 and 19) and bottom end 2059. Bag 2001 has bottom seal 2060 and back CA 02273266 1999-OS-27 p~T~S 9 7 ~ I 3 0 2 g fPEA/US 2 1 ~UL 1998 seal 2062, and confronting bag walls 2004 and 2028. Reclosable bag 2001 includes fastener tape segment 2047 (FIGS. 16-19) sealed to confronting bag walls 2004 and 2028 at seals 2002, 2008, and 2030 in the finished bag 2001. Reclosable bag optionally includes indicia 2054 indicating where bag 2001 should be cut to provide a user access to interlocked fastener strip assembly 2048. It is appreciated that bag 2001 can be used in many applications including, but not limited to, snack bag applications.
Fastener tape segment (2047) has an interlocked fastener strip assembly 2048 including fastener profile strips 2012 and 2022. Strips 2012 and 2022 are not sealed to confronting bag walls 2004 and 2028. Fastener strip 2012 is sealed to film strip 2006 at continuous seal 2010, and complimentary strip 2022 is sealed to film strip 2026 at continuous seal 2024. Film strip 2006 is sealed to bag wall 2004 at continuous seal 2002, and film strip 2026 is sealed to bag wall 2028 at seals continuous seals 2008, and 2030. Barrier material strips 2014 and 2020 are interposed between film snips 2006 and 2026. It is appreciated that, as shown in ' FIG. 16, fastener 2012 is sealed to wall 2004 only at seal 2002 and sealed to strip 2026 at seals 2038 and 2044. Thus, a portion of strip 2004 and fastener 2012 are free to move relative to wall 2004. Barrier material strip 2014 is sealed to film strip 2006 at seals 2016 and 2050. Barrier material strip 2020 is sealed to film strip 2026 at continuous seals 2018 and 2052. Barrier material strips 2014 and 2020 are made from material that is not capable of sealing to itself at temperatures at which film strips 2006 and 2026 would seal to bag walls 2004 and 2028. It is appreciated that seals 2002, 2008, 2010, 2016, 2018, 2024, 2030 can be made by conventional . , methods known in the art.
PCT/US 9 7 i I 3 0 2 8 IPE'v~~ 2 I J U L '998 It is understood that reclosable bag 2001 is generally formed in a form, fill and seal machine (as shown in FIG. 1), in which (as seen in FIGS. 16-19) walls 2004, and 2028 are formed from a base web 2032 having a longitudinal direction of flow in the bag formation process as indicated by arrow 2045 (FIG. 17). Base web 2032 is joined to itself at back seal 2062 (FIG. 19) that extends between bag top end 2058 and bottom end 2059 along one side of bag body 2003.
As shown in FIG. 18, fastener strips 2012 and 2022 are formed from continuous one-piece extruded resiliently flexible plastic profiled reciosable fastener strip material. Fastener strips 2012 and 2022 are also sealed one to another at seals 2038, and 2044 (FIG. 17) so that the strips are in alignment with one another and interlocked together. It is appreciated that provision of seals 2038, 2044, in combination with the other seals herein, provide a hermetic seal so that the only access to the interior of bag 2001 is provided upon releaseably disengaging fasteners 2012 and 2022. FIG. 17 illustrates base web 2032 for making a plurality of reclosable bags 2001. Base web 2032 is formed from conventional materials used in the snack bag and plastic bag industries such as poiyethylene, paper/poly/foil/poly laminates, propylene, and other laminated and coated material. The base web 2032, is utilized in the method and apparatus 1140 described herein, and in FIGS. 20-33.
Base web 2032 is an elongated roll of film having a longitudinal direction of formation indicated by arrow 2045. Base web 2032 has secured thereto a fastener tape segment 2047 at transverse fastener tape segment seal 2036. In a preferred embodiment, seal 2036 extends continuously from fastener tape segment end 2043 to IPE~4/US 2 I ~ U L 199 fastener tape segment end 2045. In an alternate embodiment, seal 2036 includes a plurality of spot seals for securing strip portion 2046 of fastener tape segment 2047 to base web 2032. It is appreciated that securing strip portion 2046 is sized and dimensioned to provide a large vertical sealing area in which transverse fastener tape 5 segment seal 2036 can be disposed. Seal 2036 can be placed at any location in portion 2046. Seal 2036 can also include spot seals at any location in the sealing area. Hence, optional film lip 2034 (FIGS. 16-18) located below transverse fastener tape segment seal 2036 can be of varying height, but is preferably about an eight of an inch in height. In another variant, optional film lip 2034 is omitted.
10 Non-barrier containing upper portion 2040 (FIG. 17) of film strips 2006 and 2026 (FIG. 16) has an optional gap between the bottom edges 2041 and 2043 of barrier material 2014 and 2020 and fasteners 2012 and 2022. Barrier containing upper portion 2042 (FIG. 17) includes the portions of film strips 2006 and 2026 upon which barrier material 2014 and 2020 are disposed.
15 As shown in FIG. 17, secured to web material 2032 at bag length intervals L
are a plurality of fastener tape segments 2047, sealed along the length of web and extending lengthwise across about less than half the width of web 2032.
The fastener tape segments 2047 are oriented substantially perpendicularly to the direction of formation of the bag 2001, and are located near the ends 2063 and 2065 of the 20 bags into which web material 2032 is formed.
It is appreciated that fastener tape segment 2047 and the securing thereof to web 2032 prior to the formation of bag body 2003 in a form fill seal machine has a number of benefits. First, it is not necessary to directly seal the narrow individual fasteners 2012 and 2022 to the web. Sealing bars 2159 of sealing bar assembly 2167 (FIG. 20b) seal securing strip portion 2046 to web material 2032 at seal 2036 FIG. 18. Further, as the web material 2032 (having fastener tape segment thereon), travels in the direction of arrow 2045 onto the forming collar 2140 of a form fill seal machine 2138 (FIGS. 30 - 31), there is a minimal risk that fasteners 2012 and 2022 (FIG. 18) will come apart when the web material is being processed.
Further, seals 2038 and 2044 FIG. 17 secure fasteners 2012 and 2022 to each other, to prevent undesirable movement of one fastener in relation to another. Seals 2038 and 2044 also improve overall rigidity of segment 2047 and maintain fasteners 2012 and 2022 in alignment with one another during the bag formation process. It is appreciated that fastener tape segment 2047 may also function as an air foil as the current of air flows over the tape segment 100A in a direction opposite that indicated by arrow 2045.
Various types of barrier material can be used herein. However, the barrier material strips 2018 and 2020 do not seal one to another during the bag formation process, but readily seal to film strips 2006 and 2026 (FIG. 16).
FIGS. 20 - 33 show an apparatus 1140 for manufacturing and sealing tape 2047 to base web 2179 and then using a form fill seal machine 2138 for making bag 2001 of the present invention. The form fill seal machine 2138 includes a zipper tape feed 2199 portion as shown in FIGS. 20 - 24. The zipper tape feed 20 portion 2199 includes tension arm 2100 (FIGS. 20 - 24) for tensioning finished fastener tape 2240 (from which segments 2047 are formed) and for signaling fastener spool drive 2114 (FIG. 20 - 24) to rotate spool 2108. Fastener tape 2240 unwinds from zipper spool 2108 (FIGS. 20 - 24) and advances over roller 2070 and under a roller PcrNS 9 7 ~ 13 0 2 8 I~~U~ 2 1 JUL 1998 on floating arm 2106 (FIGS. 20, 21, 22, and 23) connected to film synchronizer (FIG. 20), and over roller 2174. Fastener tape 2240 then passes under ultrasonic sealing horn 2102 (FIGS. 20, 20A, 22, 23, and 24) where seals 2038, and 2044 are formed, through tape registration assembly 2105, and into tape drive assembly 2107.
S Tape registration assembly 2105, in combination with tape drive assembly advances tape 100 sequentially into tape cutter assembly 2109. Proper tension is maintained by rollers 2111, 2113 and 2115 (FIG. 20A) in tape registration assembly 2105, which adjusts tension based on the position of three loop dancer 490, and activation by photo sensor 460 (Fig. 1). Tape drive assembly 2107 includes nip drive 470 for feeding tape 100, as required into tape cutter assembly 2109. Nip drive assembly 470 includes rollers 2111A, 2113A and 2115A for advancing tape 100.
When cutting die plate actuator 2117 pushes die plate 2119 forward under tape 100, Cutter blade 2121 then cuts downwardly through tape 100 by means of an air piston 2123 and shaft 2125 having blade 2121 attached to the distal end 2127 thereof.
After full extension of shaft 2125, cutter blade 2121 is retracted, as is die plate 2119. A
stripper 2129 helps strip tape 100 from blade 2121 and in fact urges tape segment 100A into tape sealer vacuum assembly 2131. Thus, fastener tape 2240 is cut into predetermined sections the length of segment 2047. It is preferred that segments 2047 be about less than half of the width of base web 2179. The control synchronizer 2110 (FIG. 23) synchronizes the feeding of fastener tape 2240 with the feeding of base web 2179 (FIG. 25) so that segments 2047 can be properly processed as described and sealed to base web 2179. The various operations are actuated by air pressure controls 2104 (FIGS. 20, 21, and 22).

Segment 2047 is next fed into fastener segment attachment assembly 2101 (FIG. 28). Fastener segment attachment assembly 2101 secures segment 2047 to ~a~e web 2179 and forms seal 2036. Base web 2179 advances into machine 2138 under the control of film speed quantity control 2116 (FIGS. 25 and 26). Base web 2179 is mounted on web spool drive 2118 (FIG. 25) that includes positioning shaft 2120 (FIG.
26). Base web 2179 travels through dancer rollers 2126 (FIG. 26) prior to arrival at fastener segment attachment assembly 2101 at the rear 2122 thereof.
Segment 2047 is properly positioned and sealed on base web 2179 with a vacuum belt and sealing bar assembly 2131 (FIGS. 20B, 26 and 27) having a front portion 2124 and rear portion 2122. The assembly 430 forms seal 2036 and positions segment 2047 on base web 2179 at an appropriate location. FIG. 26 illustrates the rear portion 2122 of vacuum belt 2132 and sealing bar assembly 2131. FIG.
27 illustrates that front portion 2124 of vacuum belt 2132 and sealing bar assembly. FIG. 28 illustrates vacuum belt 2132 and sealing bar assembly front portion 2124 including a belt drive 2169 for vacuum heft 2132 (FIG. 28) and vacuum belt 2132 (FIG. 28) which advances segment 2047 and properly positions segment 2047 on base web 2179. Four vacuum zones 2049, 2051, 2053 and 2055 in vacuum manifold 2056 maintain tight control of segment 2047 and then in turn reverse air pressure and force segment 2047 fixedly against web 2179. Vacuum belt 2132 and sealing bar assembly 2131 include a horizontal sealing bar 2059, a tape support shelf 2161 and a sealing bed 2162. Sealing bar 2059 includes a heating element 2165 and is mounted on a sealing bar press assembly 2167 which forces sealing bar 2059 downward against tape segment 100A for sealing to base web 2047. Vacuum belt CA 02273266 1999-OS-27 p~Tj~S 9 7 ~ 13 0 2 8 ~~~~ 2 1 JUL 1998 assembly 2131 also includes a belt drive 2169 which advances tape segment 100A
(2047) into the desired position over base web 2179. Prior to sealing, tight control of positioning of tape segment 100A is maintained by manifolds 2049, 2051, and 2055, as is the vacuum belt 2132 is advanced, controlled by tape registration S assembly 2105 and tape drive assembly 2107.
As shown in FIG. 20-A, a roller drive 2130 for vacuum belts 2132 is shown.
Roller drive 2130 comprises a servo motor 469 contained in container 2130A
having a drive shaft 2130B. Shaft 2130B has a sprocket at 2130C on the distal end thereof.
A rubber belt 2130D is disposed around sprocket 2130C and extends to a hub on nip roller 2115. Hub 2115A has a similar sprocket 2115B so that as shaft rotates it causes rotation of shaft 2130B. When rubber belt 2130D is driven it causes rotation of nip roller 2115. At the same time nip roller 2115 has a double hub 2115C so that a second belt 2130E extends therefrom over idle roller 2130F and drive roller 21306 on vacuum belt assembly 2130. It should be noted in this regard that idle roller 2130F could be a drive roller for use in a mechanically powered cutter assembly (not shown), replacing air piston 2123 (FIG 20-A), if desired. Belts are again driven by hub 2115A, which drives belt 2130E which is mounted on sprocket 2130H, thereby causing rotation of drive shaft 21306. Thus, tape 100 is incrementally advanced by nip rollers 2113 and 2115, under cutter blades 2121, then stopped at the appropriate distance. Cutter blade 2121 then is pushed downwardly by air piston 2123 as is clamp 2121A. Clamp 2121A also forces spring loaded stripper 2109A downwardly and out of the way of cutting blade 2121. After cutting blade 2121 has cut tape segment 100A, air piston 2123 is reversed so that shaft 2125 ~~lfi is pulled upwardly, thereby releasing clamp 2121A and spring loaded stripper 2109A.
Servo motor 469 then is actuated causing rotation of hubs 21306, 2115A and 2130B so as to cause advancement of nip roller 2115 and vacuum belt 2132. Vacuum belt then picks up the leading edge 110A of cut tape segment 100A and advances it over web 5 110, (FIG. 1) where heat sealing is applied as shown in FIG. 20A. It should be noted that the spring loaded stripper 2109, when it moves upwardly causes the leading edge 110A of tape segment 100A to spring upward against vacuum belt 2132 so as to facilitate advancement of tape segment 100A and prevent jamming of the segment 100A in the slot 2109B in retractable die plate 2119 (FIG. 20A). Further shown in (FIG. 20A) is a ledge 10 2171, which prevents the movement of web 110 below vacuum belt 2132 from causing displacement of tape segment 100A on vacuum belt 2132, as advancing tape segment 100A into position over web 110. The ledge 2171 is constructed of DELRINT"' brand thermoplastic elastomer so as to provide a slick surface and to eliminate static electricity created by the movement of web 110 approximate thereto. Alternatively, other materials 15 such as TEFLONT'~' (polyethylene-terephthalate) could be used.
After the segment 2047 is sealed to base web 2179, rubber nip roller 2128 (FIGS. 27 and 28) advances the base web 2179 having segment 2047 forward. The base web 2179 having segment 2047 is then fed through form fill seal machine 2138 dancer rolls 2136 (FIG. 29) into the form fill seal portion of machine 20 (FIG. 32). The base web 2179 having segment 2047 sealed thereon is fed over forming collar 2140 (FIG. 32) and filling tube 2142 (FIGS. 30 - 31) by the belts 2181 and 2183 shown in FIGS. 32. Back seal 2062 is then formed. Sealing bar 2159 and cutting t~ ~: ~ ~ 9 ., ~ ;t n " ..
I~ r~ ~~~n knife assembly 2144 (FIG. 33) form seals 2056, 2058, and 2060 simultaneously and sever the finished bag. Although it cannot be seen in FIG. 33, sealing bar includes two sets of sealing bars 2056' and 2058' . Seal bar 2056 forms seal 2056.
Seal bar 2058' forms seal 2058. Seal bar 2060' forms seal 2060. Knife 2144 cuts S the partially formed bag between seal bars 2058' and 2060' . It is appreciated that this method of forming seals 2058 and 2060 with sealing jaws 2058' and 2060' provides a benefit. Seal 2058 having a width W at top portion 2000 is generally narrower than seal 2060 having a width W' . This facilitates opening of the top end of bag 2001 by providing a weaker seal at the top end of bag 2001 than at the bottom end of the bag while simultaneously providing a hermetic seal of the top end of the bag and a stronger lower seal at the lower end of the bag. Hence, it is appreciated that the invention provides for a bag 2001 that requires a differential opening force to open the top end of the bag versus the bottom end of the bag.
FIGS. 35-38 illustrate a bag and method of forming a bag in a horizontal form fill seal machine 2138. A web of thermoplastic material which is preferably about 1 mil thick and is a laminate material is formed and wound on standard 3 or 6 inch cores to be used as interior end cap 2146. Interior end cap 2146 goes through an operation in which perforations 2150 are formed thereon as indicated in FIG.
34.
The laminate material from which interior end cap 2146 is formed is a non-stretchy base thermoplastic material such as polypropylene with a thin sealant layer 2562 on one side thereof, or on each side thereof. The preferred width of the finished roll of interior end cap 2146 is about three and one half inches or less. The web material is perforated in the web direction as shown in FIG. 34.
~a~.ii~.-a~r~

PCTIUS 9 7 ~ I 3 0 2 8 ~~U~ 2 1 JUL 19x8 A modified applicator system 120 for connecting interior cap/web assembly 2148, (preferably an AMI-RD machine manufactured by AMI REC-PRO), is used for the application of interior cap 2146 and webless fastener 2152 (FIGS. 37-39) to base web 2154 (FIGS. 36-38) for the manufacture of bags. The method of making the bags includes the steps of sealing interior cap 2146 onto base web 2154 to obtain interior cap/web assembly 2148, center folding the interior cap/web assembly to obtain folded base web 2156 (FIGS. 36-38), introducing webless fastener 2226, 2152 between the opposing walls 2567 of the folded base web 2156 (FIGS. 36-38), and sealing fastener 2152 to opposing walls 2567. Fastener 2152 and header (FIG. 39) are sealed at the same station. Alternatively, instead of opening the web, the folded base web 2156 may be turned and delivered in line to a horizontal "shred"
machine (not shown), at the height desired. As shown in FIGS. 37 and 38, fastener 2152 can be sealed at the ends of interior cap 2158 (FIG. 37) or to a sealant layer of base web 2156 (FIGS. 35 and 37) at fastener seals 2162 and 2164 (FIG. 39).
Header seals 2166 (FIG. 39) and fastener seals 2162 and 2164 can be formed simultaneously or at different stations. The web is delivered, in-line and upright, to a horizontal machine.
The finished package is substantially flat and neat, improving package appearance, and overall quality. The function of opening the package is also improved since the package is opened via a tear notch along the perforations 2150.
Then, when header 3014 is completely torn off by the user, the opening tabs are completely intact and parallel. Since the package is more uniform, opening and reclosing the bag is made easier using the reclosable fastener 2152. The machinery PCTI_US 9 7 ~ 13 0 2 8 IPE~4/I;ju~ 2 I ~ U L 19 Q

for making the above referenced invention is a continuous motion operation that require less maintenance and results in more reliable operation than existing intermittent motion machines.
Optionally, base web 2154 includes perforations 2151 that are complementary to and aligned with perforations 2150 of interior cap 2146. It is appreciated that perforations 2150 and 2151 FIG. 39A allow a user to readily open the bag formed with these elements, and easily access the bag. Perforations 2150, 2151 are preferably located between centerfold 2269 and fastener assembly 2152. In an alternate embodiment, perforations 2150 may be omitted.
FIG. 39a is a top plan view of a reclosable bag 3060 made from the web of FIG. 35. Bag 3060 includes a header 3014, a bottom seal 3100, and side seals 3070, and 3080 forming bag body. Fastener assembly 2152 is positioned below perforations 2150 and 2151 so that when header 3014 is removed, a tear forms along perforations 2150 and 2151, providing access to reclosable fastener assembly 2152.
FIG. 40 illustrates a variant of the top portion of bag 2001 that includes ..
means for easy access to fasteners 2012 and 2022. The top end of bag 2001 includes adhesive layer 2168, (FIG. 40), above fastener segment 2047 but below bag wall e~s 3042 and 3044. This adhesive layer 2168 is applied using conventional adhesives that are readily separated by the mechanical opening force generated by a user's fingers. This adhesive layer 2168 hermetically holds together and seals walls 2004 and 2028 during shipment and storage of bag 2001. Adhesive layer 2168 can be applied to web 2032 before the web moves onto the forming collar 2140.
Opening of the bag 2001 to access interlocked fasteners 2012 and 2022 is facilitated CA 02273266 1999-OS-27 ~~~~ 9 7 ~ 13 0 2 ~
~~~ 2 1 JUL 1998 by prevision of bag wall pull flanges 2170 and 2172 (FIG. 40) which are formed from bag walls, 2004 and 2028. It is also contemplated that the inside and/or outside surfaces 3046, 3048, 3050, and 3052 of bag wall pull flanges 2170 and 2172 can be textured, ribbed or grooved to improve gripping thereof by a user and opening of the bag top can be facilitated.
FIG. 41 illustrates an apparatus 2200 for forming fastener tape 2240.
Apparatus 2200 is used to make fastener tape 2240 described herein using the methods described herein. Base tape 2206 is fed from roll of tape material 2202 onto dancer rollers 2208. Barrier material 2210 is fed from roll of barrier material 2204 onto dancer rollers 2212. Barrier material 2210 and base tape 2206 are aligned, and positioned with respect to each other. In one variant the center of barrier material 2210 is aligned with the center of base tape 2206. In another variant, the barrier material 2210 is positioned on base tape 2206 to provide for unsealed portion 2046, (not shown). Barrier material 2210 and base tape 2206 are sealed to each other and advanced by belts 2214 and 2216. Sealing bars 2218 and 2220 seal barrier material 2210 to base tape 2206 at seals 2016, 2050, 2018 and 2052 to obtain a sealed barrier/base material assembly 3017. The seals may be continuous or periodic.
Sealed barrierlbase material assembly 3017 is next folded at fold station 2222. The barrier material 2210 is directed to the inside of the assembly 3017 and the base tape 2210 material is directed to the outside of the assembly 3017. Webless fastener 2226 is fed from roll of webless fastener 2228 and aligned and positioned on base tape 2210 material as shown in the figures herein. Optionally base tape 2210 material 2206 may be fed by roller 2224. Belts 2230 and 2232 advance the materials and PCT/~$ 97~I3028 ~~ 2 1 JUL 1998 sealing bars 2234 and 2236 seal the webless fastener 2226 (interlocked profiles 2012, 2022) to assembly 3017. The fold formed at fold station 2222 is slit at slitting station 2238 to provide the finished fastener tape 2240, which may then be rolled into a roll of finished fastener tape 2242, or used immediately. Preferably, the base tape 5 material 2206 is about 3.5 inches wide while the barrier material strip 2210 is about 2 inches wide.
A method of making tape 2240 having reclosable fasteners 2226 thereon is provided. The method comprises the steps of supplying a continuous strip of tape 2206, a continuous strip of barrier material 2210, and a continuous strip of fastener 10 2226 having first and second interlocked fastener profile strips 2012 and 2022;
positioning continuous strip of barrier material 2210 on continuous strip of tape 2206;
securing continuous strip of barrier material 2210 to continuous strip of tape 2206 to obtain a continuous strip of barrier tape 3017; folding, (off center, or center folding) barrier tape to obtain a fold and two opposing barrier tape fastener strip connecting 15 portions; positioning fasteners 2226 having first and second interlocked fastener ' profile strips 2012 and 2022 between the two opposing barrier tape fastener strip connecting portions; securing the first interlocked fastener profile strip 2012 to one of said opposing barrier tape fastener strip connecting portions; securing the second interlocked fastener profile strip 2022 to the other barrier tape fastener strip 20 connecting portion; and, slitting the fold to form two separate continuous strips of barrier material 2210 (strips 2014 and 2020), and slitting the base web 2032 and 2154 to separate the base web 2056 into strips of thermoplastic material.
The invention described herein which secures the segment 2047 to a base film CA 02273266 1999-OS-27 ~ ~ 7 ~ 1 3 0 2 8 F.~/U~ 2 1 ~ U L 1998 is independent of the forth fill seal apparatus 1140 ultimately used to form fill and seal bag 2001. Two sets of dancers 2134 and 2136 (FIG. 29) are used so that any bagger apparatus 1140 can be retrofitted. Barrier material 2210 is polypropylene on the inside and polyethylene on the outside so that seals 2018, 2052, 2016, and can be formed, while the inside surfaces 3073 are non-sealable one to another.
In a preferred embodiment, the sealing side of barrier material 2210 has blended therein metalasine. The materials described herein are commercially available from Curwood Co., 220 Badger Ave., Oshkosh, Wisconsin, Atlanta Film in the State of Atlanta, and Print Pak, Inc.
In yet a further embodiment, it is possible to eliminate barrier material 2210.
In this embodiment shown in FIG. 42, a substantially pure, food grade, nitrocellulose coating 3990 is applied to base tape material 2206 as shown in FIG. 42. The other method steps described above are then performed to obtain the final fastener tape.
Application of coating 3990 makes strips 2026 and 2006 (FIG. 16) non-sealable to one another in the inside loop area which is ultimately slit. It is further contemplated __~ that other food grade coatings may be used to render strips 2026 and 2006 non-sealable one to another.
FIG. 43 illustrates the top portion of a mono-polymer package 5003, as for IQF (instant quick freeze) vegetables. In this variant, the embodiment of fastener tape as processed in FIG. 41 is used such that the tape has the substantially pure, food grade, nitrocellulose coating 3990 illustrated in FIG. 42. Web 2206 is folded onto itself so that fasteners 2012 and 2022 interlock. Web 2206 is then slit as described above to obtain tape 2240 but without the barrier material strips.
Suitable Ann inks can also be used to make the strips non-sealable to one another.
Seal 5000 is made with a bagger sealing jaw (not shown) in the shape of the seal illustrated in FIG. 43. Seal 5000 is disposed approximately 3/4" below top seal 5002 in a preferred embodiment. Seal 5000 is similar to top seal 2058 and bottom seal 2060 in the other figures, but in this variant top seal 5002 and bottom seal 2060 (not shown) can be of the same size. The extra layers of strips 2006 and 2026 (FIG. 16) that are sealed to bag walls 2028 and 2004, while they do create some extra thickness, do not create a thickness of material that is beyond the capability of the sealing jaw to properly seal, even when the bagger sealing jaw is in the same plane as the sealing jaws that create the top and bottom seals 2060. Due to the lack of thickness of the strips 2006, 2026, seal 5000 readily blends from four thicknesses to about two thicknesses.
Hence, seal 5000 is continuous with no break in seal quality even though it comprises a step down from the four thicknesses to the two thicknesses.
In some applications, such as IQF that do not require the bag to be hermetically sealed, there is no need to seal off the ends of the fastener strip. Seal 5000 extends to and through the side fold of bag 5003, as top seal 5002 and bottom seal 2060 (not shown) do. This allows seal 5000 to be made with the same seal bars, regardless of bag width. The finished package 5003 can be filled with its contents above the zipper profile line 5004. The fastener strip is sealed to the front panel of bag 5003 and the product content of the package can be filled above and behind the profiles horizontal location, as the thin strip material will align itself with and be pushed against the front panel when being filled. The extra length of the package is the pCT/US 9 7 ~ 13 0 2 8 IPE~U~ 2 1 J U L 1998 distance between the bottom of the top seal 5005 and the bottom of seal 5000.
This distance is proportional to the accuracy of bagger registration.
FIGS. 44 and 45 illustrate reclosable plastic bag 1 of the present invention.
Reclosable plastic bag 1 includes a top end generally indicated by numeral 2 and a bottom end indicated by numeral 16. Bag 1 has a front wall 3, a back wall 4, and a seal 5 at top end 2 at which interlocking fastener profile lip 6 is sealed to front wall 3 and sealed to back wall 4. The tri-laminate structure at top end 2 of walls 3, 4, and lip 6 increases the strength of top end 2, producing increased tear resistance at this portion of the bag during the manufacturing process and also when the bag is displayed at a retailer. Top end 2 optionally contains an aperture 14 that extends through walls 3, 4, and lip 6 that is used to hang reclosable plastic bag 1 on hooks in retail stores. Bag 1 also has seal 2' at bottom end 16 at which front wall 3 and back wall 4 is connected. Back wall 4 includes two vertical portions 52, 54 (FIG.
47) having ends 56, 58 thereof that are sealed to create seal 24.
Interlocking fastener lip 6 is sealed to front wall 3, and back wall 4 at top end 2 as indicated by seal 5 at top end 2. Sealing of lip 6 is an important feature of the present invention since the size, shape and location of lip 6 allow for a single simultaneous sealing step to be used to seal front wall 3 to lip 6, and lip 6 to back wall 4. The seals of the present invention are preferably made by heat sealing as is well known in the art to prevent air or liquids from entering or leaving bag 1.
However, other forms of sealing can also be utilized herein. It is appreciated that the lip 6 can, in one variant, be disposed on the sides or bottom of bag 1 as required.
Interlocking fastener lip 6 forms a portion of interlocking fastener strip CA 02273266 1999-OS-27 ~ ~ ~ / 1 3 0 2 g ~P~~S 2 1 ~ U L 1998 assembly 18 that includes first engaging member 7 and a complimentary engaging member 8. As illustrated in FIG. 45, complimentary engaging member 8 is illustrated as having a male engaging prong that releasably interlocks with engaging member 8 which is shown as a female receptacle. Male and female portions of members 7 and 8 can be readily interchanged. Many types of fastener assemblies are known in the reclosable plastic bag art and can be used with the present invention.
Optionally, ends 20 of interlocking fastener lip 6 are heat sealed to front wall 3.
Lip 6 both reinforces top end 2 to prevent top end 2 from tearing where walls 3 and 4 are sealed to lip 6. This serves to flexibly attach first engaging member 7 to bag 1, to support first engaging member 7, and to align first engaging member 7 with complimentary engaging member 8; and, serves as a fail-safe barrier to prevent or reduce the risk of contamination or release of the contents of bag 1 in the event of inadvertent or accidental separation of upper portion 9 from lower portion 10 of front wall 3 along optional rupture line 11. Preferably, score or rupture line 11 is frangible upon manual manipulation thereof by the user to separate upper portion 9 from lower portion 10, and is located above and substantially parallel to seal 12, at which complimentary engaging member 8 is joined to wall 3. Score line or rupture line 11 serves the dual purpose of protecting the contents of the container and providing a safety seal to show that bag 1 has not yet been opened. Lip 6 can be formed of any material, but is preferably formed of the same material as the rest of bag 1. Lip 6 can further contain advertising, nutritional or gaming indicia thereon.
It is appreciated that lip 6 and front wall 3 further provide a pouch into which '.

CA 02273266 1999-OS-27 9 7 ~ ' 3 0 2 s IP C~~ 2 I ~ U L 199 cougoas, product samples, and/or other advertising material (not shown) can be placed. As such a consumer first opens front wall 3 along rupture line 11 to expose the material in the pouch without opening up the contents of the larger storage volume in bag 1. It is further appreciated that this informational material is 5 separated and protected from the contents of the remainder of bag 1 during the shipping and display process. The pouch of bag 1 can also contain material that is to be used in conjunction with the contents of the larger storage volume, but that needs to be separated from the larger storage volume material until it is needed.
Multiple bags 1 as illustrated in FIGS. 44-46 are manufactured by supplying 10 web material 32, whether single ply or laminated to a form, fill and seal machine 28 as shown in FIG. 46. Such machines are known in the art and include a combination bag forming and filling nozzle cylinder 29 adapted to receive products to be filled into the formed bags from a hopper 30. Bag making web 31 has thereon complementary engaging members 8 sealed to portions of bag making web 31 that 15 will become the front walls 3 of bags 1 in the manufacturing process. The «._. ., complementary engaging member is releasably interlocked to engaging member 7 either before or after member 8 is sealed to wall 3 at appropriate intervals.
At this juncture, end 27 of lip 6 is not joined to wall 3. Web 31 is guided by means of guide roller 32 to the cylinder outer surface of cylinder 29.
20 At cylinder 29, a folding or wrapping arm device 33 guides and wraps web 31 about the cylinder 29 with the longitudinal margins of web 31 brought together into a longitudinal assembly which is sealed to form closure seam 24. Closure seam 24 is formed by vertical sealing bars 35 which move inward as indicated by numeral 97~1302g IP~'~S 2 1 ~ U L 199 37. - Bars 35 then separate to release the heat sealed seam 24 of the closed bag forming tube of web material 31. Closed bag forming tube of web material 31 is advanced by means of a pair of horizontal, parallel bag end sealing bars 39 that reciprocate to clamp the bag web tube below the end of the cylindrical forming and filling nozzle member 29 and simultaneously seal the top end 2 of a filled bag section and the bottom end of a succeeding bag section.
It is appreciated that sealing bars 39 simultaneously seal front wall 3 to end 27 of lip 6, and end 27 of lip 6 to back wall 4 in a single step. Then sealing bars 39 still gripping the bag web tube move downwardly a bag section length as indicated by directional arrow 40 to pull and advance the entire bag making tube one bag length. As this step occurs, the next succeeding bag is filled with product dropped down cylinder 29 from hopper 30. As bags are sealed and pulled down, a cut off ba.~
41 cuts midway across seals 2' and 5, thus releasing the previously filled bags 1.
Having completed its downward stroke, cut off 41 returns to its starting position as indicated by arrow 43.
Bag 1 is airtight prior to the separation of upper portion 9 of front wall 3 from lower portion 10 of front wall 3 to gain access to recloseable fastener assembly 18. Generally, a user will manually separate upper portion 9 from lower portion 10 manually at score, rupture line or perforation 11. Separation of portions 9 and 10 will open up the first storage volume defined by upper portion 9 and lip 6, to the environment. Fastener assembly 18 is then manipulated to open the second storage volume of bag 1 to the environment. Optionally upper portion 9 of wall 3 is scored to form a flap that includes three score lines, e.g. score line 11 and two score lines As~tl~M' lP 328 ~ 2 1 JUL 1998 perpendicular thereto that start at score line 11 and terminate at seal 5 (not shown).
The flap includes upper portion 9 of wall 3 and is pivotally connected to bag 1 at seal 5. It is appreciated that provision of this flap allows for ease of access to fastener assembly 18.
S The invention further provides a method of making reclosable bags that is more efficient and economical than conventional methods, and requires fewer steps.
For example, lip 6 is joined to walls 3, 4 in a single sealing step rather than multiple sealing steps. As such the manufacturing process requires fewer sealing steps as only ...
seals 5, 2', 12, and 24 are required to form the storage volume of bag 1 and also provide for the attachment of fastener assembly 18. It is further appreciated that two distinct storage volumes are formed using the same number of sealing steps.
Initially, interlocking fastener lip 6 forming a portion of engaging member 7 is not sealed to walls 3 or 4, but rather rests against the inside surface of front wall 3 and is attracted to front wall 3 by electrostatic forces. The fastener assembly (members 7 and 8) are suitably longitudinally spaced at intervals along web 31.
Preferably, the width of fastener assembly is less than one half the width of web 31 so as to enable seal 24 to be formed. It is appreciated that the speed at which web 31 is fed into apparatus 28 is increased due to the performance of multiple sealing steps simultaneously, and the time required to form, fill and seal bag 1 is thereby decreased.
As illustrated in FIG. 47, web 50 includes a multiplicity of flexible interlocking fastener lips 6 which are free of connection to web 50. That is, lips 6 simply rest on each respective sheet 55 of web 50 at this juncture. Each lip 6 is pi~~n«

CA 02273266 1999-OS-27 CT~~ 9 7 ~ 1 3 0 2 8 ~~~ 2 1 JUL 1998_ permanently connected to a fastener assembly 18, is integral therewith, or optionally can be releasably attached thereto. Each fastener assembly 18 includes an engaging member releasably connected to a complimentary engaging member 8.
Complimentary engaging member 8 is connected to front wall portion 3 of web 50.
The web or bag film of the present inven~ion is commonly referred to as plastic film and includes polymeric materials as are known in the art. It is appreciated that sealing or connecting only complimentary engaging member 8 to web 50 prior to formation of bag 1 or utilization of web 50 with apparatus 28 greatly simplifies and facilitates that manufacturing process. Sealing of lip 6 to front wall 3 during the formation of bag 1 provides numerous advantages in the manufacturing process including, by way of example, faster web feed times and the like.
FIG. 48 is a side cross-sectional view of optional recloseable tape 150 used in bag 1. Tape 150 has inside loop surface 152 that is treated to be non-sealable.
Many compositions are known in the art that can make a surface non-sealable.
As an example, one such composition is lacquer. In this embodiment, lip 6 has bend 154 and opposite wall 156 and lower flange area 158. Both lower flange portion and opposite wall 156 are sealed to front wall 3 of web 50 (FIG. 49). In a preferred embodiment, distance D is about 3/4 inches long and distance D' is about 1 1/4 inches long. It is appreciated that distance D and distance D' can be varied as required for the type of bag 1 manufactured (FIGS. 48 and 51). Preferably, lip 6, bend 154, opposite wall 156, and lower flange area 158 are formed from one piece of plastic material.
It is appreciated that fastener or zipper 18 is completely sealed in the inside storage volume of bag 1 as illustrated in FIGS. 50 and 53. In this embodiment, bag 1 is free of tear tabs with perforations or tear strips. Rather, a dotted line 70' or other indicia is printed across bag 1, below or just below, top seal 5. Bag 1 is opened along dotted line 70' with scissors or other suitable cutting utensil and used as a normal recloseable bag 1 upon severance of bag 1 along the dotted line 70'.
It is appreciated that bi-laminate upper gripping portions 72 created by sealing front wall 3 to lower flange area 158 and opposite wall 156 and lip 6 to back wall 4 greatly extend the life of the gripping portion 72 even after multiple continued openings and closings of fastener 18. They also provide a reinforced base upon which both portions of fastener 18 are mounted. It is further appreciated that bi-laminate upper gripping portions 72 are more rigid than either walls 3, 4, lip 6, or opposite wall 156 alone and facilitate the direct vertical insertion of products back into bag 1 through mouth 78 as indicated by arrow 74', after severance of bag 1 along line 72' and opening of fastener 18 (FIG. 57). Bag 1 can have various degrees of flexibility. These varying degrees of flexibility include more flexibility at front wall portion 3' below lower flange 158 and at back wall 4 below fastener 18 relative to the upper portion of bag 1, that includes the various tape 150 or flange 60 sealed thereto. This feature allows the storage volume 76' to readily adapt to the size and shape of products contained therein while simultaneously providing less flexible upper gripping portions 72, which facilitates alignment of the fastener 18 elements one with another and closure thereof.
The arrangement of the elements of the invention as described herein eliminates the risk of outside contamination during storage of bag 1 or during store display due to the fail-safe recloseable features described herein. Only, when top seal 5 is cut off bag 1 does the recloseable fastener 18 reclosably seal off the bag contents in the bag storage volume without the protection of top seal 5. Upper temporary storage volume 80 (FIGS.
50 and 53) may also optionally retain advertising literature and coupons as described above.
FIG. 52 is a partial side cross-sectional view of lower flange portion 158 and 5 opposite wall 156 of recloseable flange 60 sealed to a front web wall 3 of web 50. In this variant high flange portions 62 and 63 are treated to be non-sealable. It is further appreciated that tape 150 and flange 60 can be constructed of materials that are about 3 mils in thickness or less. Also, use of a bi-laminate structure 72 allows for materials of decreased thickness to be used while still retaining the desired properties of bag 1.
10 Preferably, however, web 50 is constructed of materials of standard thickness in disposable bags; 3 to 10 millimeters.
FIG. 55 is a side cross sectional view of the tape of FIG. 54 in an assembled bag 1. Phantom line 55 of FIG. 54 indicates the location of the cross sectional view of FIG. 55. Walls 3 and 4 are fusibly sealed one to another at fused seal 80 through 1~ apertures 70 and 71 disposed near ends 74 and 76. Fused seal 80 is juxtaposed around the periphery 71' of aperture 71.
An apparatus, not shown, is also provided to make recloseable tape 150 or flange material 60 and wind tape 150 or flange 60 into rolls 245 (FIG. 56).
The appara-tus is located upstream of apparatus 28 and apparatus 200. Apparatus 200 unwinds a 20 roll of tape 150 or flange 60, indexes as appropriate (advancing and indexing device 300) and optionally punches holes 70 and 71 with hole punching device 160 near opposite ends 74 and 76 of lip 6. Preferably holes 74 and 76 are in the range of about 3l8 of an ~2 1 JUL 1998 incl3 to about 1/2 of an inch in diameter (FIG. 54) and are equidistant from ends 74, 76 respectively. Holes 70 and 72 are made of a desired size and geometric shape, e.g. circular, oval, square, rectangular, etc., depending upon the type of fusible seal 80 that is desired to be created (FIG. 55).
As illustrated in FIG. 56, apparatus 200 indexes again to a location centered above the backside of the intended front panel 3 of the basic web material 202 (cross web) and tape 150 or flange 60 is cut to a length that is less than the width of front panel 3 of bag 1. Concurrent with the unwinding step described above, base web 202 is fed or indexed to a position that allows registration of zipper strip 18 (cross web) to just below the intended top of the finished bag 1 (advancing and indexing device 400). Lower flange area 158 and ends 74 and 76 of lip 6, fold 154 and opposite wall 156 adjacent to the inside surface of front panel 3 are substantially sealed to the inside surface of front panel 3, (using seal bars 220). As discussed above, the prepared web 50 is then fed to apparatus 28. Apparatus 28, in addition to making the normal cross sealing and cutting operations, utilizes sealing bars that are modified and of a size and shape to seal the opposite side of the loop or flange area.
While the invention is susceptible of embodiment in many different forms, there is shown in the drawings and described herein, several specific embodiments with the understanding that those of ordinary skill in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the central spirit and scope of the invention. Thus, the preferred embodiment described hereinabove is to be considered in all respects as illustrative ~~~ 2 I JUL 1398 and not restrictive, of the scope of the invention being indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced herein.
I~t~~ww~~

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. ~An apparatus for dispensing, applying and sealing individual sections of thermoplastic tape having at least one fastener profile attached thereto, said tape being sealed across a portion of a web of thermoplastic material, said apparatus comprising:
means for dispensing said tape and fastener profile; a tape applicator apparatus; means for delivering tensioned tape and fastener profile from said tape dispensing means, said means for delivering comprising a tape registration assembly for adjusting the position of said tape and fastener profile and a tape drive assembly for advancing said tape and fastener profile; a tape cutter assembly for cutting said tape and fastener profile into individual sections of a preselected length; vacuum belt means for advancing said section of tape and fastener profile into a position across said web of thermoplastic material; a tape sealing mechanism for applying pressure and heat to said tape section on said web for a specified dwell time and means for sequentially advancing said web.

2. ~The apparatus of claim 1 wherein said vacuum belt means fixedly forces said section of tape and fastener against said web.

3. ~The apparatus of claim 1 or 2 wherein said means for dispensing said tape comprises: a roll of said tape pivotally mounted on a powered unwind seal, a tension arm having said tape round thereon, said tension arm being slidably mounted so as to rise or discard in response to tension on said tape and means for controlling rotation speed and tension of said unwind reel in response to said rising or descent of said tension arm.

4. ~The apparatus of said claim 1 or 2 wherein said means for delivering tensional tape comprises: a plurality of dancer rollers thereon, the position of said tensioned dancer rollers indicating tension on said tape, film synchronizes means for synchronizing said tape with said tape application, said film synchronizer means having one or more vertically adjustable rollers therein, said rollers being vertically adjustable in response to tension on said tape disposed through said rollers and a tape registration assembly for adjusting the registration of said tape and a nip drive assembly for feeding said tape in response to the position of said rollers in said film synchronizer means and the position of said dancer rollers.

5. ~An apparatus for dispensing, applying and sealing individual sections of thermoplastic tape having one or more fastener profiles attached thereto, said tape being sealed across a portion of a web of thermoplastic material, said apparatus comprising:
means for advancing said web of thermoplastic material, said means including a motorized drive roll for dispensing said web, one or more dancer rollers having said web threaded therethrough, a dancer arm supporting at least one of said dancer rollers, a pair of motorized nip rollers for advancing said web through said apparatus, means for detecting the position of said dancer arm and actuating said motorized drive roll and said motorized nip rolls at the speed required to maintain a selected tension on said web, means for detecting the position of said tape and fasteners and for signaling said web drive roll and said nip rollers to speed up or stow down in response thereto and control means for coordinating the signals from said means for detecting the position of said tension arm and said means for detecting the position of said tape and fasteners and for controlling the speed of said web and said tape and fasteners.

6. ~The apparatus of claim 5 and further comprising: a form fill seal machine having a set of dancer rollers on the front portion thereof for carrying said web having said sections of tape thereon, a sensor for determining the position of at least one of said dancer rollers so as to determine the tension on said web and means for signaling said control means for controlling the speed of said web and said tape.

7. ~The apparatus of claim 5 wherein said control means comprises: a computer electronically connected to said tension arm, said motorized drive roll, said means for detecting the position of said dancer arm, said motorized nip rollers, said means for detecting the position of said tape, said tape drive roll and said tape nip rollers.

8. ~The apparatus of claim 5 wherein said control means comprises fluid logic controls to said tension arm, said motorized drive roll, said means for detecting the position of said dancer arm, said motorized nip rolls, said means for detecting the position of said tape, said tape drive roll and said tape nip rollers.

9. ~The apparatus of claim 1 or 2 and further comprising: means for ultrasonic sealing the ends of said sections of said tape prior to cutting of said tape, positioned between said means for dispensing said tape and said tape applicator.

10. The apparatus of claim 1 or 2 wherein said vacuum belt means, said tape registration assembly and said tape cutter assembly are interconnected by a belt drive constructed and arranged for maintaining the relative speed of operation of said vacuum belt means, said tape cutter assembly and said nip rollers and for retaining the relative position of said tape and said tape segments driving operation of said apparatus.

11. ~The apparatus of claim 10 wherein said belt drive is powered by a single motor so as to provide constant speed and tension.

12. The apparatus of claim 10 wherein said tape drive assembly comprises:
a double hub, having a first hub and a second hub, said first hub being connected by a toothed belt to a third hub on said drive motor, said third hub being mounted on a first shaft powered by said drive motor so as to rotate said third hub thereby causing said double hub to rotate, said double hub being mounted on an end of one of said nip rollers so as to cause rotation of said nip roller when said double hub is rotated, said vacuum belt having a drive shaft extending through one end thereof and a fourth hub extending from said drive shaft, said fourth hub having a toothed drive belt disposed thereon, said toothed drive belt being connected to first said hub so as to cause said fourth hub and said drive shaft to rotate when said first hub rotates, thereby driving said vacuum belt means in synchronization with said cutter assembly and said nip rollers.

13. The apparatus of claim 1 or 2, wherein said tape cutter assembly comprises: an air piston mechanism having a shaft extending downwardly therefrom, said air piston being constructed and arranged to selectively raise and lower said shaft, a cutter blade and clamp affixed to the distal end of said shaft for clamping and cutting of said tape, a slidable die plate for selectively being positioned under said tape, said die plate having a slot extending therethrough and a spring loaded stripper block proximate said slot, said clamp being constructed and arranged for pushing down said stripper block when said shaft is extended so as to facilitate cutting of said tape, said stripper block being constructed and arranged to press upwardly when said clamp is pulled upwardly by said shaft, said stripper block being constructed and arranged to push the distal end of said tape towards said vacuum belt means.

14. The apparatus of claim 1 or 2 wherein said vacuum belt means comprises:
a vacuum belt having a plurality of holes extending therethrough, said vacuum belt being rotatably mounted on a pair of rollers, at least one of said rollers being powered so as to selectively cause rotation of said belt and incremental advancement of said belt a desired distance, a ledge extending below said belt constructed of a slick thermoplastic elastomer and sized and positioned so as to serve as a barrier to air from said web moving thereunder and as an eliminator of static electricity.

15. The apparatus of claim 14 wherein said vacuum belt is approximately one inch wide and said holes are centered 5/8" from the edge of said belt.

16. The apparatus of claim 1 or 2 wherein said tape comprises a folded loop having a pair of interlocked fastener profiles attached thereto on the inside surface thereof, said interlocked fastener profiles being constructed and arranged for selectively opening and resealing, whereby when said tape is positioned and sealed on said web, said web is suitable for conversion into a plurality of resealable bags.

17. The apparatus of claim 1 or 2 and further comprising: computer means for coordinating said means for dispensing said tape, said tape applicator, said tape cutter, said tape drive, said vacuum belt means and said means for sequentially advancing said web.

18. The apparatus of claim 17 and further comprising: keyboard means for adjusting the length of said tape sections, the space between said tape sections sealed on said web and the speed of operation of said apparatus for dispensing, applying and sealing said individual sections of tape to said web.

19. A method of sealing individual sections of thermoplastic tape across a portion of a web of thermoplastic material comprising the steps of: dispensing said tape a desired distance, cutting said tape to a desired length of the individual sections of said tape, grasping the end of said individual section through the use of a vacuum, sequentially applying vacuum to the length of said individual section of tape and simultaneously advancing said individual section of tape over said web, pressing said individual section of tape to said web and heat sealing said individual section of tape to said web.

20. The method of claim 19 and further comprising the step of coordinating the advancement of said web with the advancement of said tape and said section of tape.

21. The method of claim 20 and further comprising the steps of: running said web from an unwind roll through a series of dancer rollers, reading the portion of said dancer rollers, signaling a drive motor to advance or retard said web based on the position of said dancer rollers, signaling a tape drive the position of said dancer roller, running said tape through a series of tape dancer rollers, signalling said tape drive the position of said tape dancer rollers, thereby causing said tape drive to advance or retard said tape, signalling said drive motor to advance or retard said web.

22. The method of claim 21 and further comprising: feeding said web with sections of tape sealed thereon into a form fill seal machine and through a set of form fill seal dancer rollers at the back thereof, signalling the position of said form fill seal dancer rollers to said tape drive and said web drive motor so as to control movement of said tape and said web.

23. The method of claim 19 wherein said vacuum source is continuously applied to said vacuum belt means without cycling on and off, whereby precise positioning of said tape segment on said vacuum belt is maintained.