CA2130820A1

CA2130820A1 - Apparatus and method for making a reclosable bag

Info

Publication number: CA2130820A1
Application number: CA002130820A
Authority: CA
Inventors: Dwight P. Fowler; Andrew Mcg. Martin
Original assignee: Dwight P. Fowler; Andrew Mcg. Martin; Simple Packaging Solutions, Inc.
Current assignee: Simple Packaging Solutions Inc
Priority date: 1992-02-25
Filing date: 1993-02-25
Publication date: 1993-09-02
Also published as: NO943125L; BR9306010A; WO1993016931A1; AU675061B2; JPH07503930A; EP0628006A4; EP0628006A1; AU3793193A; NO943125D0

Abstract

A storage bag (100) and a method and apparatus for forming such a storage bag. The storage bag contains a reclosure tie (101) formed as an integral marginal portion (between 101 and 104) of the bag beyond an edge of the bag. The marginal portion includes overlying layers (111, 112) of bag material that form an elongated structure along an axis with first and second ends (113, 114). A
fused closure (116, 117) is formed in the marginal portion parallel to the axis and over a portion of the marginal portion spaced from one end thereof. This structure defines a tail (120) and open loop (121) that wrap around an opened bag (100) thereby to close the bag in a positive fashion.

Description

WO 93/16931 ~ ~ t~ U ~ ~ PCr/VS93/02032 Description A~Paratus and Method ;
For Makinq A Reclosable Baq Technical Field This invention generally relates to packaging and more specifically to a storage bag that is easily reclosed and to the methods and apparatus for making such a storage bag.

Backaround Art There is a long-running effort to make a storage bag that is easily opened and then reclosed. This effort has led to cri~eria ~for judging the potential success of such s~orage bags. Consumers require that such ~ags must be easily opened, reclosed, and then reopened. The method 15 of reclosure must be positive. From a manufacturer's standpoint, the method and apparatus required for forming the bag and reclosure structure must be easily added to a production line~, operate without any appreciable reduction in~production rates,~add minimal production costs, have 20 the capacity to be used with bags requiring a freshness - seal and produce little or no waste material. Generally this prior effort has produced bags that either incorporate a separate reclosable tie or an integral structure that forms a tie.
The following patents are examples of bags with separate reclosure ties:
3,311,288 (19~7~ ~emelson 3,426,959 (1969) Lemelson 3,6?4,135 (1972) Simon ,- 30~ 3,779,139 (1973) White Each Lemelson patent discloses packages-with a tear strip of plastic or metallic foil. The tear strip may ~ include a thr-ad, string, wire or ~eld for added strength.
-- ~ The~bag is reclosèd~by~separating the tie from the bag and 35 ~then~wrapping~and twisting;the tie around the bag.
The~Simon pat-nt discloses a roll of separable bags.
A line of perforations along an edge or top of each bag , , .

SUBSTlrUTE SHEET

WO93/16~31 ~ ~;20 PCT/US93/02032 1 -2- ~

enables a section of the material to be removed for use as a reclosure tie or tear strip. The tear strip may be reinforced by one or more heat seals or by the application of separate strengthening materials such as string, 5 deformable metal or another ply of film.
The White patent discloses a bag with a transverse tear strip that can be removed from the end of the bag.
This tear strip then can be tied in an overhand knot to reclose the bag.
Each of the foregoing reclosure tie structures achieve some of the previously discussed criteria. Most are relatively easy to use in reclosing a bag. Twisted tie wraps are also relatively easy to remove in order to reopen the bag. Those tied with overhand knots may or may 15 not be eaæy to open depending upon the ease with which the oYerhand knot releases. However, these approaches have not found great acceptance because they all incorporate special structures or require very specialized apparatus that can reduce production rates or increase materials and 20 manu acturing costs unacceptably. For example, the W~ite patent discloses the formation of a bag with a series of steps that is not readily adapted to continuous form and fill processes as conventionally used in the food industry and other industries. It requires special apparatus~ The 25 following patents disclose packaging that uses integral tie strips that remain attached to a bag:
3,2l7,97l (1965~ Shvetz l,l50,037 (1969) Plusplan (GB) 3,480,198 t1969) Repko The Shvetæ patent discloses a bag that opens along a transverse tear line that terminates inwardly of the edges of the bag to form a tie. A longitudinal tear line allows a portion of a reclosable tie to be separated into two halves 8Uch that the reclosure tie or strip forms two WO93/16931 ;~ PCT/US93/n2032 individual tie strips attached to opposite edges of the bag. The two ties can be k~otted together. In another version a side strip formed along an edge of the bag can be partially separated to form a single tie strip.
The Plusplan patent discloses a similar structure in which a marginal section of a ~ag separates from the main portion of the bag along a tear line. However, the reclosure tie does not completely separate from the bag.
The Repko patent discloses a similar structure in lO which a~marginal portion, with a weld or heat seal for strenqth, partly separates from a bag along a tear line defined by a series of apertures. The tear termina~es at an end point, so the marginal portion remains physically attached to the bag.
Each of these structures either requires additional materials or prevents the bag from opening fully when the contents~are to be dispensed. Noreover, the ~epko patent requires a sophisticated structure for forming the plurality of apertures with seals intermediate and about 20 each aperture to maintain any freshness seal.
The following patents disclose the bags in which a reclosure tie has an integral loop and tail section:
3,664,575 ~l972) Lake 4,549,657 (1985) Martin 25 4,609,107 (1~86) Martin et al 4,682,976 (~987) Martin et al 4,787,517 ~l988) Martin In accordance with the Lake patent a p~rtion of a bag , adjacent the top is formed with an intermediate seal that 30 extends partially across the bag to form a tail of a - reclosure tie. Another transverse seal spaced from the first seal ioins the layers of film to form a loop - sectlon. This réolosure tie~can be separated from the bag nd then cinches~the bag when the tail is wrapped around :

-, ,~t~ 4_ the bag and thread through the loop. However this reclosure tie is disclosed in connection with storage bags without freshness seals. That adaptation of this structure to a bag with a freshness seal could increase 5 material costs unaccept~bly.
The Martin patents, U. S. Letters Patent Nos.
4,549,657 and 4,787,517, disclose a number of embodiments of easily opened and reclosable bags. Oppositely disposed sealing jaws form a closure seal with a reclosure tie and l0 a freshness seal. The reclosure tie can be removed from the bag without disturbing the freshness seal. The bag is reclosed by wrapping the reclosure tie around the bag and extending one end through a loop formed at the intermediate section by the unsealed plies. In one 15 embodiment it is suggested that the reclosure tie be formed as sealed plies of material except at an intermediate section offset to one end of the tie, thereby to form a tail.
In each of the Lake and Martin patents the loop 20 section incorporates a seal. ln many applications, particularly those involving polyethylene-based film bags, this seal is subject to failure. More particularly, as a cinching force is applied by the tail portion, a large portion of that force concentrates at an edge of the seal 25 in the loop section. The seal then can begin to fail due to delamination of the plies and tearing of the material.
When this occurs, the integrity of the loop section is lost and the reclosure tie no longer is functional. The ! Martin et al patents, U. S. Letters Patent Nos. 4,609,107 30 and 4,682,976, disclose a reclosure tie formed as a tear strip across a top of a polypropylene bag in a margin portion beyond a freshness seal. The tear strip has a mold formed transversely in the bag for strength; ît tears along a series of specially formed slots or perforations WO93/16~31 ~ U PCT/US93/02032 through the material in the margin portion beyond th~
freshness seal. In one embodiment a portion of the bag omits the mold proximate an edge thereby to provide a reclosure tie with a short mold channel and a loop spaced 5 from one end. It is suggested that the other end of the reclosure tie pass through the loop as a tail to cinch the bag. Cinching, in this case, is also dependent upon an interaction of nubs formed on the edges of the reclosure tie. This approach is disclosed in connection with heat lO sealable, treated ceIlophane or other thin organic polymer materials. In fact, the bag has been used with polypropylene bags, but is not readily adapted for - polyethylene-based~bags. First, it is difficult to form a mold and channel in such material. Second-, the cinching 15 forces still act against a s~al thereby incorporating a potential failure point.
.
Disclosure of Invention T~erefore it is an object of this invention to provide a method and apparatus for manufacturing a 20 reclosable bag that is easy to open and contains a reclosure tie that facilitates the subsequent closure and reopening of the bag.
It is another object of this invention to provide a method and apparatus for manufacturing a reclosable bag 25 with an integral reclosure tie that does not require the addition of discrete elements or special components.
Another object of this invention is to provide a method and apparatus for manufacturing a reclosable bag with an integral reclosure tie that can be manufactured 30 without the generation of waste materials.
Still another object of this invention is to provide ~;~ a metbod and~apparatus for manufaaturing a reclosable bag and~reclosing tie structure in which additional , , ~

~ 6-manufacturing costs are limited primarily to the cost of ;~
additional material.
Still another object of this invention is to provide a method and apparatus for manufacturing a reclosure tie for a reclosable bag in the form of an integral reclosure ~ie with a strong integral loop portion and a tail portion.
In summary and in accordance with one aspect of this invention a storage bag with a reclosure tie is produced 10 by forming a sealable, elastic, polymeric film into an open-ended, hollow structure formed by walls of the film ~nd extending along a first axis. A portion of the hollow structure is clamped along a second axis that is transverse to the first axis to form a margin portion in 15 coextensive film wall portions. The margin portion has first and seeond sections disposed along the second axis to provide a boundary between successive storage bags. A
line of perforations is formed in the margin portion that is parallel to the second axis. The film walls are also 20 severed in the margin portion along a severance line that is parallel to in space from the second axis. The perforation and severanc line define a removable closure - tie between the perforation and severance lines and an àdjacent first sealing area. A first seal is formed in 25 the film walls along a line in the first sealing area that is parallel to khe second axis and is coextensive with both the f irst and second sections. A second seal is formed in the removable closure that is para1lel to the second axis and extends only across the first section 30 whereby the film walls in the second section remain unsealed. The unsealed film walls are free of any film structure that fails by delamination.
In accordance with another aspect of this in~ention, apparatus for~s storage bags from a continuous cylinder WO93/16s31 i ~ PCT/US93/02032 lying along a first axis and formed of a sealable elastic polymeric film. Each bag includes a contents pouch and an integrally formed reclosure tie for reclosing the bag.
This apparatus includes a clamping structure for clamping 5 a portion of the continuous cylinder along a second axis that is transverse to the first axis to form a margin portion in coextensive film wall portions of the continuous cylinder. The margin portion has first and second sections disposed along the second axis for 10 providing a boundary between successive storage bags. A
perforating structure perforates the film walls in the ~argin portion along a perforation line that is parallel to the second axis. A severing structure severs the film walls in the margin portion along a severance line that is 15 parallel to and spaced from the second axis there~by to form a removable closure tie in between the perforation ana~severance lines and an adjacent first sealing area. A
first sealing structure forms a first seal between the film walls along a line in the first sealing area that is 20 parallel to the second axis and that is coextensiYe with the first and second sections. A second sealing structure forms a second seal along a line in the removable closure tie that is parallel to the second axis and that extends only across the first end to form a tail in the remo~able 25 reclosure tie. The film walls in the second section remain unsealed to form a loop that remotely to the tail is free of any film structure that fails by delamination.

Brief Descri~tion of Drawi~s ,. , i The appended claims particularly point out and 30 distinctly claim the subject matter of this invention.
The various objects, advantages and novel features of this invention will be more fully apparent from a reading of the ~following detailed description in conjunction with the ~' , ~ .

W O 93/16931 PC~rtUS~3/02032 accompanying drawings in which like reference numerals refer to like parts, and in which: ~
Fig. 1 is a perspective view of one embodiment of a storage bag constructed in accordance with this invention;
Fig. 2 is a perspective view of the storage bag shown in Fig. 1 with a reclosure tie removed;
Fig. 3 is a view of the storage bag shown in Fig. 1 with the reclosure tie used for resealing the bag;
Fig. 4 is a perspective, in schematic form, of 10 assembly equipment used for filing bags such as the storage bag in Fig. 1;
- Fig. 5 is an side view of front and rear sealing jaws ;
of Fig. 4 in a separated position; ~:
Fig. ~ depicts the sealing jaws in Fig. 5 moved to an 15 operating position;
Fig. 7 is a perspective of a portion of a rear sealing jaw;
Fig. 8 is a top view of a portion of a front sealing jaw useful in accordance with the equipment shown in Fig.
20 4;
Fig. 9 is a side Yiew of the front sealing jaw shown in Fig. 8;
Fig. 10 is a view of a cutting blade used in the front sealing jaw of Fig. 7;
Fig. 11 is a view of a perforation blade used in the front sealing jaw of Fig. 7;
Fig. 12 is a perspective view partially in exploded foxm that discloses an end portion of the rear sealing jaw shown in Fig. 5;
Fig. 13 is a perspective view of an alternative embodim~nt o~ a storage bag shown in Figs. 1 through 3;
Fig~ 14 is another embodiment of a storage bag that utilize~ this invent.ion;

WO93/16931 ~ V PCT/US93/02032 _g_ Fig. 15 is a perspective view of still another embodiment of a storage bag that utilizes this invention;
Fig. 16 is a perspective, in schematic form of a sealing jaw that utilizes resistance heating;
Fig. 17 is an exploded view of a portion of the sealing jaw shown in Fig. 16;
Fig.18 is a cross-sectional view of front and rear sealing jaws in an open state and taken along lines 18-18 in Fig. 16.
Fig. l9 is a cross-sectional view of the sealing jaws - as shown in Fig. 18 in a closed position and taken along lines 18-18 in~Fig. 16; and Fig. 20 is a cross-sectional view of the sealing ~s shown in Fig. 19/ but taken aIong lines 20-20 in Fig. ~.

15 Best Mode for CarrYina Out the Invention Fig. 1 o~ the drawings depicts a storage bag indicated generally at 100. Typically the bag 100 wiIl be - formed of an elastic coextruded polymer such as high -~ density polyéthylene and ethyl vinyl acetate or a 20 c~polymer including polyethylene. When heat is applied to adjacent film layers, the~ material seals, typically by ~fusing. These films are also characterized by reasonably high~ resistance to puncture and to the initiation of a tear. It is intended that the phrase "sealable elastic 25 polymeric material" include al~ such polyethylene-based materials ~s well as ~ther~materials that e~hibit similar characteristic~. Such materials may al50 be co-extruded , with other films for particular applications and still use the foregoing characteristics.
~; 30 Fig. 1 also depicts an adjacent, or lower, bag 101 ;~ ~ after as being severed from the bag 100 as occurs in a normal production o~ successive storage bags. Each bag has~the same basic construction. Using the storage bag ;"~

--10-- , :

100 as an example, the film forms a generally cylindrical open-ended pouch 102 comprising a sheet of a sealable elastic polymeric film wrapped around a cylinder. The edges overlap and produce a longitudinally extending back 5 seam 103. A "bottom" seal 104 and a "top" seal 105 close the ends of the pouch 102 so the bag can store food or other articles. A perforation line 106 defines a boundary between the storaqe bag 100 and an attached, integral réclosable tie 110.
Specifically the reclosable tie 110 constitutes a margin portion and includes film layers on extensions 111 `
and 112~ beyond the~seal 105. The~extensions 111 and 112 ter inate at margin~end portions 113 and 114 and the reclosure tie 110 lies along an axis 115 that parallels 15 the~top seal 105. Two fused seals 116 and 117 parallel the~axis 1~15 and~-xtend from the margin end 113 to a position~inter ediate~the back seam 103 and the margin end 114~and~spaced from the margin end 114. A top edge 118 of the-extensions lll and 112 constitutes a parting line for 20~ adjàcent bag. ~Reference numeral 118 also designates the parting line for the bags 100 and 101.
- The portion of the extensions 111 and 112 that are ; coextensive with the fused lines 116 and 117 along the axis 115 produce a tail portion 120 in which the layers 25 111 and 112 are fused together. The remaining portions of the extensions 111 and 112 including the end 114 form a loop portion 121. As shown in Fig. 1, therefore, each of a series of storage bags such as storage bags 100 and 101 ~! i has an integral extension of the film forming two layers 30 beyond a top seal line. The extensions form a tail and loop structure that ¢an be readily torn from the bag along the perforation line 106.
To open the bag, a consumer tears the reclosable tie ;~fr#~the bag 100 along t~e perforation 106 as shown in ~" , ,~

,,, WO 93/16931 ~ O PCr/US93/02032 Fig. 2. Then the consumer separates the film layers along the top freshness seal 105 to open the bag fully. After some of the contents are removed, the individual gathers the bag 100 above the remaining contents to form a closed 5 neck 122 as shown in Fig. 3, wraps the reclosure tie 110 around the neck 122 and passes the tail portion 120 through the loop portion 121. When the consumer pulls the tail portion 120, reclosure tie 110 slides longitudinally such that the loop 121 adjacent the margin end 114 slides 10 along and tightens the noose formed around the gathered neck 122.
All pressure on loop 121 is applied against the end 114 that is free of any material that might otherwise delaminate, such as the back seam 103. When the loop 121 lS is~fiDly cinched in place and the tail portion 120 is released,~ the material, that stretched in tension, relàxes.~ The end margin 114 of the loop 121 cinches against the tail portion 120 thereby preventing its inadvertent loosening.~ However, as is characteristic in 20 such }oops, intentional release of the reclosure tie 110 is readily accompl`ished by sliding the end of the loop 121 toward the margin end 113 of the tail portion 120 thereby releasing the cinching action and enabling a consumer to readily remo~e the closure tie.
The bag 100 achieves all the above objects of this invention. The reclosure tie 110 is formed integrally with the bag during the bag forming and filling processing and only with a nominal amount of additional material.
Thus, the cost of the bag 100 should not be significantly 30 greater than that of a conventional bag without the -~ reclosure tie 110.
Moreover, comentional form, fill and æeal pouch - ~ ~ - appar~tus~can produce ~ags,~ such as the bag 100 of Figs.
through ~3~, ~successi~ely w~ithout significant modification.

,, ,, ~ ~, . ,. , . :

WO93/16931 ,J ~. ~ U ij ~J i] PCT/US93/02032 As shown in Fig. 4, such apparatus passes fusible, elastic polymeric film 149 from a roll 150 past a guide roller 151 to a panning shoulder 152. The panning shoulder 152 forms the film 149 into a folded, double thickness, vertically 5 moving web 153 about a cylindrical mandrel 154~ Heat sealing apparatus 155 coacts with rollers 156 to insure formation of the back seam 103. Thus the panning shoulder 152 and the mandrel 154 transform film in sheet form into a continuously advancing open-ended cylindrical structure 10 153 that receives a measured amount of contents from a hopper 157 dispensed through a cylindrical passage 160 in the mandrel 15A. The contents then fall into a pouch that has been formed above:the bottom seal 104 by front and rear sealing jaws 161 and 162 that are shown only,in 15 diagrammatic form in Fig. 4.
More specifically, sealing jaws 161 and 162 initially are brought together (in a horizontal plane in Fig. 4) to grab the web material 153 from either side and then moved along the axis of the mandrel (vertically in Fig. 4) to 20 pull the material 153 to a lower position. During thi,s travel the.bags initially are perforated and cut along lines 106 and 118. Then the sealing jaws form the upper seal 105 in the bag 100 and the lower seal 104 in the next ~ag lOOA and the seals 116 and 117. The apparatus 25 simultaneously dispenses contents from the hopper 157 to fill the bag lOOA.
When the jaws 161 and 162 reach the bottom of travel along the mandrel axis they retract. At this point ths lower bag, bag 100 in Fig. 4, drops away with its 30 contents. The jaws 161 and 162 then move baak along the mandrel axis to a positi'on corresponding to the top of the - filled bag. This is vertical motion shQwn by arrows 118 in Fig. 4. At the top of this motion the jaws again close and grab the web 153 above the fill contents and begin a t3~

next cycle to pull another section of film intoappropriate position to form another ~ag.
With the exception of the sealing jaws 1~1 and 162, Fig. 4 depicts conventional form and fill processing 5 equipment. In accordance with this invention, it is merely necessary to substitute new sealing jaws 161 and 162 in this conventional apparatus to provide bags as shown in Figs. 1 through 3. The controls and actuating mechanisms that are involved with conventional heat 10 sealing jaws remain substantially unchanged.
SEALING JAWS
, One function for the front and rear sealing jaws 161 and 162 is gripping the material of the web 153 to pull material down the mandrel for forming and filling a next 15 bag. Referring to Figs. 5 through 9, the front jaw 161 inc-ludes an upper gripper bar 163 that has a position corresponding to an oppositely facing upper gripper bar 164 in the rear jaw 162. The front and rear sealing jaws 161 and 162 additionally have lower oppositely facing 20 gripper bars 165 and 166. When the sealing jaws 161 and 162 move from the retracted position shown in Fig. 5 to the closed position shown in Fig. 6, they engage and grip, - or clamp, the web material 153. As previously described, web material between the upper and lower gripping bars 25 constitutes a margin portion between the bottom of the upper bag and the ~op of the lower bag.
As the jaws 161 and 162 in the closed position shown in Fig. 6 pull along the mandrel axis, that is downward in ! Fig. 6, two operations occur. First, a cutting blade 167 30 in the front sealing jaw 161 ad~ances through the web 153 into a recess 168 in the rear sealing jaw 162. This produces the parting line 118 shown in Fig. 1.
Simultaneously a~perforation blade 169 moves from a ~; retracted position in the front sealing ~aw 161 through ,~

:: , ', ' -~ .. , ...... " . , .. .. .. ~, WO93/16931 PCT~US93/02032 the web material and into a recess 170 in the rear sealing jaw 162 thereby to form the perforation line 106 shown in Fig. 1. A front sealing jaw body portion 171 carries the blades 167 and 169 and recesses 168 and 170 in a 5 stationary water jacket 172 receive the blades 167 and 169.
The second operation occurs when an electrical impulse passes through a set of parallel wires. More specifically the body portion 171 carries an upper 10 pressure pad 173 tha~ presses the web material 153 against a heating filament 174. A similar resilient pad 175 ~resses a portion of the web material around a lower heating filament 176. A single central pad 177 on the body portion 171 presses the web material 153 against 15 parallel filaments 178 and 179. When these wires receive an electrical impulse:, they produce sufficient heat to fuse the film at the wires. The filament 174 produces the bo~ttom seal 104 in Fig. 1. The filament 176 produces the top seal 105 in Fig. 1. The filaments 178 and 179 produce 20 the sea}s 116 and 117 shown in Fig. 1 that extend partially across the bag as described later~
SEAI,ING JAWS-GRIPPING STRUCTURE
-The structure of the rear jaw gripper bars can be seen by referring to Fig. 7. Both the upper and lower 2S gripper bars 164 and 166 have tha same basic structure therefore only the gripper bar 164 is described in detail.
A frame member 180 supports the sealing jaw 162 and a mounting plate 181 attaches by bolting or other i conventional means to the frame memb~r 180. The mounting 30 plate 181 extends across the width of the frame. An upper gripper plate 182 bolts or otherwise attaches across the face of the mounting plate 18~ to form a secure L-shaped mounting bracket for the upper gripper 164. The resulting rigid structure provides a front surface for the gripper ; .
',~:' :, ~

WO93/16931 } ~ PCT/US93/02032 bar 164 that stays in a vertical plane across the width of the rear sealing jaw 162.
Now referring to Figs. 5, 6, 8 and 9, the front sealing jaw 161 mounts the upper and lower gripper plates 5 163 and 1~5 in a resilient fashion. More specifically, the front sealing jaw 161 includes a frame structure generally designated by reference numeral 183 that slides along rails 184 thereby to move from the position shown in Fig. 5 to the position shown in Fig. 6. The frame 10 structure 183 includes a frame bracket 185 at each end of the front sealing jaw 161. A face plate 186 spans these two spaced brackets 185 and supports the various elements of the front heat sealing jaw including the gripper bars 163 and 165 and the pads 173, 175 and 177.
15As the upper and lower gripper bars 163 and 165 have a symmetrical construction, these are described with - distinction and the same reference numerals identify like elements. Mounting bars 190 extend from and are bolted to the face plate 186 ~nd to the brackets 185 to provide 20 rigid supporting structures. Machine screws 191 thread into the upper gripper plates 190. Each of the upper and lower gripper bars 163 and 165 has at least two apertures 192 that are elongat d along axes perpendicular to the face plate 186. These apertures 192 receive shoulder 25 extensions 193 on each machine screw 191.
Thus, the mounting ~ars 19 0 and the body 171 capture the upper and lower gripper bars 163 and 165 vertically, but permit horizontal motion over a limited range j determined by the elongated apertures 192. Spring 30 structures 194 mount to the bracket 185 and through the face plate 186 to urge the upper and lower gripper bars 163 and 165 to the right as shown in F`ig~. 5, 6 and 9 when the sealing jaws 161 and 162 are retracted.

WO93/16931 i~ U PCT/US93/02032 When a drive unit, not shown, moves the sealing jaw 161 toward the sealing jaws 162 along the rails 184, the ends of the upper and lower gripper bars 163 and 165 initially displace the web material 153 against the 5 gripper bars 164. As the sealing jaw 161 moves to a final position, the upper gripper bars 163 and 164 and the lower gripper bars 165 and 166 begin to produce a clamping force. When the sealing jaws 161 and 162 come together, the contents in the web material 153 tension the web 10 material lS3 80 the web material remains in essentially a vertical plane when gripping occurs.
More specifically, the upper gripper bars 163 and 164 ~-and the lower gripper bars 165 and 166 make initial contact with the intermediate web 153. Thereafter the 15 front ~eal bar 161 continues to move to~ard the rear seal bar~l62 through~an incremental distance until it reaches a mechanical stop (not shown). During this incremental motion,~the gripper bars 163 and 165 displace horizontally on~the shoulder extensions 193 and compress the spring 20 mechanisms 194. Adjusting the spring mechanisms establishes the final gripping force that the gripper bars 163 through 166 exert on the web 153. This provides a firm grip on the web material 153 and enables vertical - motion of the jaws, in the context of Figs. 5 and 6, to 25 pull additional web material from the mandrel 154.
SEALING JAWS-SEA~ING FUNCTION
The pads 173, 175 and 177 simultaneously press the web material 153 against the wires 174, 176, 178 and 179 - i I respectively. With particular referen~e to Fig. 7, the 30 rear water jacket 172 includes fingers 200, 201 and 202 that rOr ~the 810ts 168 and 170. A thermally-conducting insulating film 203 overlies tbe surface of the water a¢kQt~172. This~il~ extends between the upper gripper bar~164 and the~watèr jacket~172, overlies all the ,-" . ~ ,:

~, :: :

WO 93tl6931 i~ V PCr/US93/02032 surfaces facing the front sealing jaw 161 including the ends of the fingers 200, Z01 and 202 and the surfaces forming the receiving slots 168 and 170 and then extends between the water jacket 172 and the lower griPper bar 5 166.
The finger 200 backs the heating wire 174; the film 203 electrically insulates the heating wire from the water jacket 172. Similarly, the finger 201 backs the wires 178 and 179 while the finger 202 backs the wire 176. A
10 conductor support structure 204 at each end of rear sealing jaw 162 supports the wires across the face of the water jacket 172..
Referring now to Figs. 5, 6 and g, a slot formed at the end of each of fingers 210, 211 and 212 on the sealing 15 pad body 171 carries the resilient pads 173, 177 and 175, -- respe~tively. The pads may be attached by adhesive or :~ other means. Pins 213 support the body 172 for displacement with respect to the face plate 186. Other spring structures 214 bias the body 172 to the rear 20 seal~ing jaw }62. When the jaws come together as shown in Fig. 6, the resilient pads 173, 177 and 175 initially - press the web material against the hea~ing wires 174, 178 and 179, and 176 respectively. The spring structures 214 limit the force that the pads exert against the material : 25 153 and the wires by compressing as the body 171 shifts to the left with respect to the face plate 186 in Fig. 9.
Still referring to Figs, 5, 6) 8 and 9, the seal pad body 171 also supports standoffs 215 that pass through apertures in the plate 186 and move with the body 172.
30 The standoffs 215 shown in Figs. 8 and g support a mounting bar 216 for pneumatically or electrically operated solenoids 220 with armatures 221. The armatures reciprocate along axes perpendicular to the face plate ~: 186~. Each ar~ature 221 connects to a block 222 that ,~; .

WO93~16931 ~ PCT/US93~02032 attaches to tabs 223 on the cutting blade 167 and perforation blade 169.
When the solenoids 220 are not energized, the blades 167 and 169 are positioned as shown in Figs. 5 and 9.
5 Energizing the solenoids 220 advances the blades to a position shown in Fig. 6. Internal solenoid stops limit the displacement of the blades 167 and 169.
SEALING JAWS-CUTTING AND PERFORATIQN BLADES
The cutting blade shown in Figs. 9 and lO comprises a -10 plurality of vee-shaped teeth 230 ground into the surface of the blade 167. Each tooth has a vee-shape running from front apex point 2~1 to a root 232., One sur~ace, the lower surface 233 of the blade Y67, is beveled. In one specific embodiment, the teeth have a pitch of about 1/8"
15 and a depth of about 3/8" with a tooth angle of about 30 inclusive. When the blade 167 extends, it severs the material 153.
~ The perforation blade 169 shown in Figs. 9 and 11 comprises a plurality of vee-shaped teeth that extend from 20 a front apex 236 to a root 2'37. Notches 238 in alternate tooth sections extend toward the roots 237. When the blade 169 extends it initially produces a series of small apertures and each of the apertures begins to expand transversely as,the blade 169 extends. However, when the 25 blad~ 169 fully extends, it does not sever the web material 153 at po itions corresponding to the notches.
This'produces a solid intermediate portion and the perforated line 105 in Fig. 1.
SEALING JAWS - HEATING WIRE SUPPORT
Fig~. 7 and 12 illustrate a portion of the rear sealing jaw a62, particularly the conductor support structure 204 for the various heating wires. Each conductor support structure 204 includes an insulating block 240 with a mounting hole fox a machine screw 241 or WO93/16931 . ~ 2 ~ PCT/US93/02032 --19-- ~

other device that affixes a block 240 to each end of the gripper mounting plates 182. Parallel slots 242, 243, 244 and 245 extend through the block 240 in alignment with the wires 174, 176, 178 or 179, respectively. A pivot pin 246 5 extends vertically through a pivot hole 247 in the block 240.
A pair of wells 248 in the bottom wall of each of the slots 242 through 245 seat springs 249 for pivoting toggle arms 250 in each of the slots 242 through 245 away from 10 the water jacket 172. Each toggle arm 250 has a body portion 251 and an arm extension 252. An edge 253 common to the body portion 251 and the arm extension 252 contains two wells 254 that receive the other ends of the springs 249. An aperture 255 in the body portion 251 receives an 15 annular spacer 256 with an aperture 257 that rotates about the pivot pin 246. When a toggle arm 2S0 and its springs 249 are properly mounted in one of the slots, such as slot . 242, the springs 249 urge the arm 252 away from the center of the rear sealing jaw 162.
Each arm extension 252 contains a transverse slot 260 and a longitudinal recess ~61 in a surface 262 that is spaced from the surface 253. The slots 260 and 261 receive the terminal structure of a heating filament.
Thus, when the system is loaded, the springs 249 act on 25 the toggle arms 250 at opposite ends of each filament to tensions the filament acros~ the width of the sealing jaw 162.
. The toggle 250 is conductive. A terminal screw 263 and aperture 264 provide a convenient means for connecting 30 an electrical conductor to the toggle arm 251 thereby to complete a conductive path with an attached filament.
Referring to Fig. 7, the four filaments 174, 176, 178 ~ and 179 extend completely across the rear heat sealing jaw - ~ ~ 162 at the face of the fingers 200, 202 and 201 WO93/16931 , PCT/~S93/02032 --~o--respectively. When power is supplied simultaneously to the four filaments, they heat instantaneously to a temperature that is sufficient tv fuse the film pressed against those wires. A plurality of apertures 265 extend 5 through each of the fingers 200, 201 and 202 proximate the ends thereof. Cooling water circulates through these passages to remove heat from the fingers and the filaments. As a result, the water-cooled jacket 172 localizes the heating and sealing to an area at the 10 filament. Thus the filaments 174 and 716 fuse the materials essentially along a line and praduce the linear seals 104 and 105 as shown in Fig. 1.
The filaments 178 and 179, however, are coated with a highly heat conducting material, such as silver solder, 15 over a portion of each of the filaments 178 and 179 that is coextensive with the loop 121. The silver solder or equivalent coating dissipates heat from the filaments 178 and 179 to the water jacket 172. This limits the temperature to a level below that required for fusing the 20 web material. The web material therefore remains unsealed along a line coextensive with the coated portion and forms the loop 121.
Still refexring to Fig. 7, a plurality of apertures 265 extend through each of the fingers 200, 201 and 202 25 proximate the ends thereof. Cooling water circulating through these passages removes heat ~rom the structure and allows the rear jaw and wires to cool between successive operations.
Sealing jaws as shown in Figs 5 through 11 produce 30 bags having a structure as shown in Fig. 1 without significant modification to the form, fill and seal pouch apparatus. These sealing jaws operate with ancîllary actuators and power sources that are in use in con~entional apparatus. In acoordance with the ob~ects of WO93/16931 1 ~ U PCT/US93/02032 -21- ~ ~

this invention, the apparatus includes a cutting blade -intermediate two sealing wires to close the ends of successive bags and sever successive bags. A perforation blade produces a tear line for facilitating the removal of 5 a margin portion from an adjacent bag. A pair of sealing filaments between the cutting and perforation blades seal the margin portion only partially across the sealing jaws.
So long as this partial seal crosses any back seal, a resulting loop structure is not subject to delamination.
lO This margin portion is thereby readily detached from a bag to form a reclosure tie with a loop and tail structure.
- ALTERNATI~VE BAG EMBODIMENTS
Fig. 13 discloses an~alternative bag structure that a consumer could buy in a folded or rolled configuration or 15 in a package of individual bags. Fig. 13 shows two such ~storage~bags;300`~and 301 as they miqht be taken from a roll. The bag 300 has a film formed as a pouch 302 with a back;seam 303 and a bottom seal 304. A perforation line - -306 across the bag defines a margin portion or reclosable 20 tie~section 310 beyond the pouch 302. This embodiment has no freshness seal across the bag proximate the perforation line 306 such as the seal 105 in Fig. l.
As in Figs. l through 3, extensions 311 and 312 beyond the perforation line 306 form the reclosure tie.
2S Margin ends 313 and 314 lie at opposite edges of a bag on a traverse axis 315. Seals 316 ~nd 317 extend from the end 313 to a point beyond back seam 303 to produce a tail portion 320. The unsealed portion of the reclosure tie 310 forms a loop 321.
In this embodiment the bags are shown after separation from a continuous roll. A top edge 322 extends ;~ across the lower bag 301; a bottom edge 323 across the bag 300. ~ If~the~bags are to be supplied on a continuous roll, th~sealing~aws can form a~perforated parting line ,~, , , .
" .
~,, ~J ~ 22 coextensive with the top edge 322 and the bottom edge 323 that tears with less force than required to separate the reclosure tie 310 along the perforation line 306.
In use a consumer would separate the bag 300 from the S roll or remove a bag 300 from a package. Then the consumer would tear the reclosure tie 310 off the bag along the perforation line 306. This would open the bag for full access. When the bag was filled, the consumer would twist the top of the bag to form a neck portion and 10 use the reclosure tie 310 to cinch the bag closed at the neck.
Fig. 14 discloses~a similar bag in which the reclosure tie and bag separate at the bottom, rather than at the top opening. With this approach it is possible to 15 fill the bag without removing the reclosure tie. More specifically, Fig. 14 discloses two bags 400 and 401. A
~ ~ back~ seam 403 extends along the length of each bag. A
- bottom seal 404 forms a bottom of the bag. A perforation line 406 is formed across the bag proximate the seal 404 20 in the material that~forms the reclosure tie 410. More ;~ specifically, film extensions 411 and 412 extend from the ~ seal 404 thereby to form a reclosure tie with ends 413 and , ~ :
414 centered on a transverse axis 415. Seals 416 and 417 are formed in the extensions from the edge 413 to a 25 portion beyond the back seal 403. This forms a tail portion 420 and a loop portion 421. In this configuration - each bag is open at the top 422. A bottom edge 423 and the;top edge 422 form a parting line- that may comprise a cut line for bags stored individually or a perforation 30 line for bags stored on a roll.
- Bags formed in accordance with this invention can - also be formed~by folding the film. As shown in Fig. lS, ~ a bag~SQO~include~a~pouah 502 formed of two layers of ;~ ~ fil~. ::~Parallel, spaced side seals 504 and 505 form the ,,, ~ :

WO 93/16931 PCI`/US93/02032 2 il~

pouch 502. The seal 505, however, is disposed inwardly of an edge 507 of the bag to define a reclosure tie 510 formed by the film layers 511 and 512 between the seal 505 and the edge 507. The reclosure tie 510 has a structure 5 that is similar to that shown in Fig. 1, namely ends 513 and 514 lie transverse to an axis 515 parallel to the seal S05. Seals 516 and 517 formed intermediate the perforation line 506 on the edge 507 form a tail portion 520 and leave loop portion 521. In this bag the top 10 opening 522 is formed merely by the edges of the overlapped portion and a bottom closed portion of the bag ~23 is formed~ by the bight when the two layers of film are folded over one anoth-r.
RESISTANCE HEATING APPARATUS
Apparatus in Figs. 5 through 12 depict apparatus for producing storage bags~ with integral removable closure t$es such as shown in Figs. 1 through using impuIse heating techniques. It is also possible to form storage bags using resistance heating to form the seals. To 20 distinguish impulse heating and resistance heating jaws, the following description uses reference numerals 161' and 162' to denote resistance heating jaws, even though Fig. 4 contains only reference numerals 161 and 162. As applied to the general structure shown in Fig. 4, resi tance 25 heating jaws, such as the jaws 161' and 162', initially close to grip the material as previously described with Fi~. 4. Thereafter, a sealing jaw body portion including resistance heating elements extends to form seals, and a knife extends~to sever adjacent bags. Then the knife and 30 sealing jaws body retract prior to retraction of the~
sealing jaws 161' and 162' with the consequent release of the bag 100. The apparatus as shown in Figs. 16 through 20, depicts on- specif~ic emb~odiment of sealing jaws 161~a~nd 162' that incorporate resistance heating ~: :

WO93/16931 ~ PCT/US93/02032 techniques for the manufacture of bags with integral removable closure ties. This apparatus includes an upper gripper bar 601 on the front sealing jaw 161', an upper gripper bar 602 on the rear sealing jaw 162' and a 5 com~ressible insert 603 that lies along one face of the upper gripper bar 601. The sealing jaws 161' and 162' have a symmetrical structure and include a lower gripper bar 604 on the front sealing jaw 161' and a lower gripper bar 605 on the rear sealing jaw 162'. A compressible 10 insert 606 lies in the face of the lower gripper bar 604.
The front~seal mg ~aw 161' has a frame 607 that interconnects the upper gripper bar 601 and lower gripper bar 604. A similar frame 608 interconnects the upper gripper bar 602 and the lower gripper bar 605 for the rear 15 sealing jaw 162'. ~ Various~mechanisms, not shown in these particular figures, independently reciprocate the sealing jaws~161~' and 162' along an axis 610 between a retracted ~position~such as shown in Fig. 18 and a closed position such~;as shown in Figs. 19 and 20. Normally the axis is 20 horizontal.
-In the retracted position of Fig. 18, the upper gripper bars 601 and 602 and lower gripper bars 604 and - 60S~are disposed on opposite sides of two layers of film that form walls 611 and 612 of an open-ended hollow 25 structure that extends along an axis 613. Normally the axis 613 is vertical. The gripper bars deflect the wall 611 and 612 from a cylindrical form leaving a mandrel, such as the mandxel 154 shown in Fig. 4, to a flattened form. In a closed position as shown in Figs. 19 and 20, 30 the inserts 603 and 606 engage the wall 611 and force it against the wall 612 and the faces of the upper and lower gripper bars 602 and 605 respectively.
As botter understood by reference to Figs. 16 and 17, thi~ol~ ping~ action of the gripper bars 601 and 602 and ,, , W~93/1693l PCT/US93/02~32 the gripper bars 604 and 605 extends across the width of the bag and parallel to an axis 614 that is orthogonal to the axes 610 and 613. Normally the axis 614 is horizontal. Moreover, the portion of the walls 611 and 5 612 intermediate the insert 603 and 606 constitutes a margin portion 615 in co-extensive portions of the film walls 611 and 612 as shown in Figs. 18 through 20. The margin portion, as previously indicated, provides a boundary between successive storage bags, such as storage 10 bags 100 and 100A in Fig. 4.
The front sealing jaw, 161' also carries a sealing jaw body 616 that is reciprocal wi~h respect to and movable with the frame 607. The sealing jaw body 616 includes a main body portion 617 that includes two 15 cylindrical receptacles 620 and 621 that extend parallel to the axis 614. The receptacles 620 and 621 carry resiætive heating elements 622 and 6~3 respectively, as shown in Fig. 18 through -20. When energized, the resistance heating elements 622 and 623 elevate the 20 temperature of the sealing jaw body 616 to some controlled level in accordance with techniques and apparatus that are well known in the art. Details of the heating controls and energizing apparatus are omitted from this description for purposes of clarity.
The main body portion 617 also supports an upper sealing arm 624 that further divides~into an upper sealing finger 625 and an upper intermediate sealing finger 626.
These sealing fingers extend generally parallel to the axis 614. A recese 627 intermediate the sealing fingers 30 625 and 626 receives a severing knife 630 of the type shown in Fig. 10. Other structures, again not shown but generally described with respect with Figs. 5 through 12 are adapted to move the`severing knife 630 with and reI~ti~e to the sealing body portion 616. This is W O 93/16931 , ~ ~ PC~r/US93/02032 particularly shown in the sequence of operations shown in Fig. 18 and where initially the sealing jaw 616 moves to the position shown in Fig. 19 before other apparatus extends the knife 630 relative to the body 616.
The sealing body portion 617 also supports a lower arm sealing structure 631 that includes a lower sealing finger 632 and a lower intermediate sealing finger 633 that are also parallel to the axis 614. The sealing fingers 632 and 633 are also spaced and defined a recess 10 634 that receives and supports a perforating knife 635 of the type shown in Fig. ll. Like the severing knife 630, the perforating knife 635 can move with and relative to the sealing jaw body portion 617.
A rear sealing jaw body 636 shown in Figs. 18 through 15 20, has a similar structure to the front sealing jaw body 616~ More -specifîcally, the rear sealing jaw body 636 includes a body portion 637 that has an upper arm 640 with - an upper sealing fingers 641 and a spaced parallel upper intermediate sealing finger 642 extending in a plane, 20 normally a horizontal plane, that is parallel to the plane defined by the axes 610 and 614 as shown in Fig. 16. The sealing fingers 641 and 642 are spaced by a recess 643. A
- lower arm 644 carri~s a lower sealing finger 645 and a lower intermediate sealing finger 646 that are also spaced 25 apart by a recess 647 that lies in another plane parallel to the plane defined by the axis 610 and 614. Like the front sealing jaw body 616, the rear sealing jaw body 636 can move with and relative to the frame 608.
Each of the fingers 641, 642, 645, and 646 30 terminates in a flat end surface such as end surface 650 for finger 641 that lies in a plane, normally a vertical plane, that i5 parallel a plane defined by axes 613 and 614. Similarly, each of the sealing fingers 625, 626, 632 and 633 terminates in a vertical plane. Referring W093/1~931 ~ J~ PCT/US93~02032 specifically to the sealing finger 625, an end surface 651 is formed as the apex of the finger 625 and is defined by an upper chamfer 652 and a lower chamfer 653. Like the structure shown in Fig. 7 where a thermally conductive 5 insulating film 203 overlies the surface of the water jacket 172, the specific embodiment of Figs. 16 through 20 -can include a surface treatment for the end surfaces, such as the end surfaces 650 and 651. A coating or layer of a material, such as Teflon~ will facilitate the release of 10 the surfaces 650 and 651 from the walls 611 and 612 after the corresponding seals are formed~
- When the front and rear sealing jaw bodies 616 and 636 are in a closed position as shown in Fig. 19 and the severing knife 630 and the perforating knife 635 have ~5 extended into the recesses 643 and 647 respectively, perforation, cutting and sealing operations occur. More specifically, the severing knife 630 severs the film wall 611 and 612 in the margin portion 615 along a severance line that is parallel to and spaced to the axis 614 shown 20 in Fig. 16. It is analogous to the top edge 118 in Fig.
1. ~he perforating knife 635 perforates the film walls 611 and 612 in the margin portion 615 along a perforation line that is analogous to the perforation line 106 in Fig.
I that is also parallel to the axis 614. The area of the 25 margin portion between the severing knife 6~0 and the per~orating Xnife 635 constitutes the removable closure tie 654 that corresponds to the reclosable tie 110 shown in Fig 1. The sealing jaws 161' and 162' further define I the adjacent areaæ that can be used for other sealing 30 purposes. One such area 655 lies between the clamping point defined by the compressible insert 603 and the severing blade 630. Another sealing area 656 lies between the~perforating knife 635 and the contact point defined by the compress~ble insert 606.
,~

WO 93~16931 PCr/US93/02032 2 8 - i When the sealing jaws 161~ and 162~ close, and the front and rear sealing jaw body 616 and 636 also close as shown in Figs. 19 and 20 to form a seal in each of the sealing areas 655 and 656 adjacent in the reclosable tie 5 654. As contact exists between the surface 651 and the edge 650 of the finger 641 across the entire width of the bag i.e., parallel to the axis 614, the heat transferred through the plastic film 611 and 612 fuses the walls 611 and 612 together to form a seal that corresponds to the lo seal 104 in Fig. 1. Likewise, the end surface of the finger 632 engages the end surface of the finger 645 thereby to produce a seal across the bag that corresponds to the seal 105 shown in Fig. 1. Both these seals are coextensive with 'the first section 660 and the second 15 section 661 disclosed in Figs. 16 and 17 and lie on the sealing areas 655 and 656 respectively.
The structure for forming seals, such as seals 116 and lI7 in Fig. 1 incorporates the fingers in 626 and 633 on the front rear sea~ing jaw 161' and the fingers 642 and 20 646 on the rear sealing jaw 1'62'. As shown more specifically with respect to Figs. 16 and 17 and for - purposes of definition, the sealing ~aws 161~ and 162' can be considered to include a first section 660 and a second section 661 that are disposed along the axis 614. Any 2S back seal such as the back seal 103 in Fig. 1, traverses the sealing jaws 1~1' and 162' parallel to the axis and in the first section 660. Thus where finger 625 and its corresponding'sealing finger 641, and sealing finger 632 and its corresponding sealing finger 645 are coextensive 30 with both the first section 660 and the second section 661, corresponding seals formed in the bag produce a seal that completely traverse the bag including any back seal, represented by a back seal 662 formed in the back wall 612 Or a baq. How ver, the active heating area defined by .: .

s~ u ~
WO93/16931 ~ PCT/US93/02032 sealing fingers 626 and 642 and sealing fingers 633 and 646 are coextensive with only the first section 660 shown in Figs. 1~ and 17. Essentially the length of these active heating areas along the axis 614 is such as to 5 include the bag from one edge to a point beyond any back seal 662 such that the remaining portion of the reclosable tie 651 as shown in Figs. 18 through does not contain the back seal 662 or any similar seam or seal. The transverse seals formed thereby correspond to the seals 116 and 117 10 shown in Fig. 1.
In order to obtain the loop 121 shown in Fig. 1, the portion of the sealing jaws in the second section 661 are modified as shown in Figs. 16 and 17. Any extension of the sealing fingers 626 and 633 into the second section 15 661 is eliminated. The arms 624 and 631 are modified to receive an insulating insert 663 that is secured to a back surface 664 formed by removing material that otherwise would constitute an extension of fingers 626 and 633 into an area coextensive with the second section 661. The back 20 surface 664 can be tapped such that machine screws, such as machine screw 666, can pass through apertures, such as aperture 667, in the inserts 663 to be secured in a tapped hole, such as tapped hole 668. A plurality of such securing structures typically are included.
Still referring to Figs. 16 and 17, the insert 663 is formed of a heat insulating material. It includes a central air passage 670 that passes along through the insert 663 parallel to the axis 614. This passage serves as a header for a plurality of air passages 671 that 30 extend to an upper edge 672 and a plurality of air passages 673 that extend to a lower edge 674 of the insert 663. An outer edge 675 includes a`means for connection to an air supply 676. At an opposite end 677, a threaded aperture 680~exte~nds parallel to the axis 610 and ,~ ~

WO93/16931 PCT/US93/0~032 ~ 30-intersects the central air passage 670. A machine screw or valve screw 681 can be added to the structure to control the relative air flows between the apertures 671 and 673 and an exit aperture 678. Air leaving the exit 5 aperture 678 flows toward the first section 660 and can be useful in the cooling the structure coextensive with the first section 660 immediately adjacent the second section 661. Air leaving the air passages 671 cools the severing knife 630 in the ~econd section 661. Air leaving the air 10 passages 673 cools the perforating knife blade 635 in the second section 661. This cooling prevents the temperature of the blades 630 and 635 from reaching a value at which their contact with the walls 611 and 612 could produce any sealing in the second section 661.
Referring to Fig. 20, the rear sealing jaw 162 has a similar modification. Sealing fingers 642 and 646 are relieved to receive a heat insulating block 6~2 that is coextensive with the second section 661. Consequently when the jaws 161' and 162' reach the position shown in 20 Figs. 19 and 20, the temperature of the inserts 663 an~
682 at the sur~aces that contact the walls 611 and 612 remains below the fusing temperature for the film.
When the sealing jaws 161' and 162' separate, the area of the bag that falls from the jaws 161' and 162' 25 contains a reclosable tie with a structure that is similar to the structure shown in Figs. 1 and 20 The heat sealing fingers 626 and 642 and the heat sealing fingers 632 and 646 have formed second seals, between the film wall 611 and 612. These seals are formed 30 in the removable closure tie section 654 that is parallel to the axis 614. They are coextensive with only the first section 660. The insulating inserts 663 and 682 assure that the second section 661 remains unsealed. `Moreover, a8 the unsealed portion does not include any back seal or .

WO93/16931 j, ?~ PCT/US93/02032 similar structure, t~e resulting loop formed in the second section 661, such as the loop 121 shown in Fig. 1, is formed as a monolithic polymer film layer from the tail and produces a structure remote from the tail that is free S of any film structure that can fail by delamination. :~
In operation, mechanisms actuate the various components of the sealing jaws 161' and 162' in any of a number of sequences. Typically the sequence for closing the jaws 161' and 162', drawing the clamped bag material 10 downwardly over the mandrel 154 as shown in Fig. 4, producing the heat sealing, cutting and perforating dperations, releasing t~e bag by retracting the heat sealing jaws 161' and 16~' and returning them to an upper -;
position constitutes a cycle that is divided into 360-. -15 Assuming 0- corresponds ~o the initiation of the closure of the heat sealing jaws 161' and 162', the following represent two possible operating sequences:
.
~ . . - ~

OPERATION ~
_ _ _ . __ S;aling jaws 161' and 162 95~ - 330O 95 - 300 Sealing jaw bodies 616 and 120 - 290 90 - 305 636 closed to form seals l . _._ . _ I
Severing knife 630 and perforation knife 635 230 - 290 50 - 316 25 extended ~ ~ l Procedure 1 is based upon prior art operations.
Initially, the sealing jaws 161' and 162' close to the position shown in Figs. 19 ana 20 to grip the wall 611 and 612 thereby defining the margin portion 615. Subsequently 30 the front and r;ear sealing jaw bodies 616 and 636 close to WO93/16931 PCT/U~93/02032 the position shown in Fig. 19 by moving relative to the frames 607 and 608 respectively thereby to begin a sealing operation. Other apparatus corresponding to the solenoids 220 in Fig. 8 next drives the severing blade 630 and 5 perforating blade 635 from the recesses 624 and 627 as shown in Fig. 18 to the position shown in Figs. 19 and 20 where the blades 630 and 635 pass through the walls 611 and 612 and enter the recesses 643 and 647. Typically the severing and perforating blades 630 and 635 extend 10 simultaneously. After a short dwell intèrval the solenoids 220 (Fig. 8) and similar apparatus retract the severing and perforating knives 630 and 63~ into the recesses 627 and 634 and separate the heat sealing jaw bodies 616 and 636. Thereafter other apparatus retracts 15 the sealing jaws 161' and 162' along the axis 610 to complete the operation and release a lower bag, such as the bag 101 in Fig. 1.
In accordance with Procedure 2, the severing knife 630 and perforation knife 635 extend in advance of any 20 clamping operation. Then the sealing jaws ~ody 613 and 636 close to initiate heat sealing foliowed immediately by the closure of the jaws 161' and 1~2' to prsduce the clamping operation. At the end of this operation the sealing jaws 161' and 162 retract. Then the sealing jaws 25 body 161 and 636 retract followed by the severing and pèrforation knives 620 and 635. Consequently, during the initial and ending sequences of Procedure 2, the perforation knife 635 holds the lower bag, such as the bag I101 in Fig. l, in place vertically and subsequently 3~ releases the bag rather than the gripper bars 601 and 602 and the gripper bars 604 and 605.
Procedure 1 and Procedure 2 represent specific examples of various operating sequences. Other sequences can b- utilized. A particular æelection will depend upon WO93/16931 ~ PCT/US93/02032 bag size, the thickness of the walls 611 and 612, operating speed and other considerations.
In summary there have been disclosed diverse embodiments of storage bags with integral reclosure ties 5 and apparatus for effecting methods of manufacturing certain of these embodiments. Each embodiment provides a bag that is easy to open. Each bag contains a reclosure tie that facilitates subsequent closure and reopening of the bag. The bag, with its integral reclosure tie, does 10 not require the addition of any discrete elements or special components. Manufacturing does not produce waste materials and any additional manufacturing costs are limited primarily to the cost of additional material in a small margin portion. In each bag the reclosure tie is 15 readily detached and used and, with its strong integral loop portion and tail portion, provides a secure and an easy to use reclosure structure.
~ It will be apparent that many modifications can be made to the disclosed apparatus without departing from the 20 invention. The location and orientation o~ reclosure ties can vary among different bags. Bags may or may not have back seals or seams. If bags do not have back seals or seams, the extension of the partial seals can be varied - for optimizing different relationships between the lengths 25 of the loop and tail portions. Bags may or may not contain freshness seals at either opening. Alternate methods, operating sequences and apparatus may also be substituted for the specifically disclosed methods and apparatus with the attainment of some or all of the 30 specific advantages of the disclosed embodiments.
Therefore, it is the intent vf the appended claims to cover ail such variations and modifications as come within - the true spirit and~scope of this invention.

:

Claims

1. In a storage bag formed of overlying layers of a sealable elastic polymeric film with at least one edge portion, the improvement of an integrally formed, elongated reclosure means for reclosing the bag comprising:
A. extensions of the overlying layers beyond the one storage bag edge for forming said elongated reclosure means along an axis parallel to the one edge with first and second ends thereof, B. fused closure means for sealing the layers in the extensions together over a portion thereof from the first end to a position spaced from the second end thereby to define a tail portion of said reclosure means, said portions of said layers between said fused closure means and said second end defining a loop free of any structure that is subject to failure by film delamination, and C. separation means formed in said extensions intermediate said fused closure means and the storage bag edge and proximate the storage bag edge for facilitating the detachment of said reclosure tie from the storage bag.

2. A reclosable storage bag as recited in claim 1 wherein the overlying layers of film incorporate a back seam extending transversely to the axis intermediate said first and second ends, said fused closure means extending from said first end to a position intermediate said second end and the back seam.

3. A reclosable storage bag as recited in claim 2 wherein said fused closure means comprises a line parallel to the axis along which the overlying film layers in said extensions are fused.

4. A reclosable storage bag as recited in claim 2 wherein said separation means includes a line of spaced perforations formed through said overlying layers of film.

5. A reclosable storage bag as recited in claim 4 additionally comprising second fused closure means extending across the bag at the one edge and being oppositely disposed of said perforation line from said first fused closure means thereby to close the bag at the one edge independently of the removal of said marginal extensions at said perforation line.

6. A reclosable storage bag as recited in claim 5 wherein said storage bag includes a second edge formed parallel to the one edge and spaced therefrom, said storage bag additionally comprising third fused closure means extending across the storage bag at the second edge thereby to close the storage bag at the second edge.

7. A reclosable storage bag as recited in claim 1 wherein said fused closure means comprises at least one line parallel to the axis along which the overlying film layers in said extensions are fused.

8. A reclosable storage bag as recited in claim 7 wherein said separation means includes a line of spaced perforations formed through said overlying layers of film.

9. A reclosable storage bag as recited in claim 7 additionally comprising second fused closure means extending across the bag at the one edge and being oppositely disposed of said perforation line from said first fused closure means thereby to close the bag at the one edge independently of the removal of said marginal extensions at said perforation line.

10. A reclosable storage bag as recited in claim 9 wherein said storage bag includes a second edge formed parallel to the one edge and spaced therefrom, said storage bag additionally comprising third fused closure means extending across the storage bag at the second edge thereby to close the storage bag at the second edge.

11. A reclosable storage bag comprising:
A. a sealable elastic polymeric film formed as a continuous structure open at first and second ends thereof, B. first closure means for closing one of said first and second ends, C. a marginal extension of said film detachably connected to one of said first and second ends for forming a reclosure means that extends between first and second axial end portions along an axis parallel said first and second ends of said structure, and D. second closure means for attaching portions of said marginal extension together from said first axial end portion to a position spaced from said second axial end portion such that said marginal extension between said second closure means and said second axial end portion is free of any structure that fails by film delamination.

12. A reclosable storage bag as recited in claim 11 wherein said film is formed with a back seam between said first and second ends, said second closure means extending from said first axial end portion to a position intermediate said back seam and said second axial end portion.

13. A reclosable storage bag as recited in claim 11 wherein said first and second closure means are proximately located at said first end, said first closure means defining a boundary between said marginal extension and the remainder of said storage bag.

14. A reclosable storage bag as recited in claim 13 wherein said marginal extension comprises overlying layers of said film and a line of spaced perforations formed through said film intermediate said first and second closure means.

15. A reclosable storage bag as recited in claim 13 wherein said film is formed with a back seam between said first and second ends, said second closure means extending from said first axial end portion to a position intermediate said back seam and said second axial end portion.

16. A reclosable storage bag as recited in claim 13 wherein said marginal extension comprises overlying layers of said film and said second closure means comprises a seal along a line parallel to the axis along which overlying layers in said marginal extension are fused.

17. A reclosable storage bag as recited in claim 13 wherein said marginal extension comprises overlying layers of said film and said second closure means comprises a plurality of seals along spaced, parallel lines, said overlying film in said marginal extension being attached by fusing said lines.

18. A reclosable storage bag as recited in claim 13 additionally comprising third closure means proximate the second end of said film structure.

19. A reclosable storage bag as recited in claim 11 wherein said first closure means is located at said first end of said film structure and said marginal extension is located at said second end.

20. A reclosable storage bag as recited in claim 19 wherein said film structure is formed with a back seam between said first and second ends, said second closure means extending from said first axial end portion to a position intermediate said back seam and said second axial end portion.

21. A reclosable storage bag as recited in claim 19 wherein said marginal extension comprises overlying layers of said film and a line of spaced perforations formed through said film intermediate said second closure means and the juncture of said extension means with said structure.

22. A reclosable storage bag as recited in claim 19 wherein said marginal extension comprises overlying layers of said film and said second closure means comprises a line parallel to the axis along which overlying film layers in said marginal extension are fused.

23. A reclosable storage bag as recited in claim 19 wherein said marginal extension comprises overlying layers of said film and said second closure means comprises a plurality of spaced, parallel lines along which said overlying film layers in said marginal extension are attached by fusing.

24. A method for forming a storage bag with an integral reclosure tie comprising the steps of:
A. forming a sealable elastic polymeric film into an open ended structure with a margin portion of overlying film extending across one end of the structure having first and second margin ends, B. forming between the margin ends a detachable connection in the film for facilitating the removal of said marginal portion from the structure, C. closing one of the ends of the open ended structure, D. sealing a portion of the margin portion from the first margin end to a position spaced from the second margin end thereby forming the film proximate the second margin end into a loop free of any structure that is subject to failure by film delamination.

25. A method for forming a storage bag as recited in claim 24 wherein said step of forming a detachable connection comprises the step of forming a line of spaced perforations through the margin portion.

26. A method for forming a storage bag as recited in claim 24 wherein said steps of closing one of the ends of the open ended structure and of sealing occur essentially simultaneously by impulse sealing and said sealing step further includes the step of forming an impulse seal in the film at the margin portion thereby to join the films between the first margin end and the intermediate position spaced from the second margin end.

27. A method for forming a storage bag as recited in claim 25 wherein said impulse sealing step produces first and second seals formed along a parallel lines between the first margin end and the intermediate position spaced from the second margin end.

28. A method for forming a storage bag as recited in claim 24 additionally comprising the step of closing, by impulse sealing, the other end of the structure.

29. A method for forming a storage bag as recited in claim 24 wherein said step of forming the open-ended structure includes the step of wrapping the film in sheet form about a cylinder with overlapping edges and forming the edges into a back seam thereby to produce an open-ended cylindrical structure.

30. A method for forming a storage bag as recited in claim 29 wherein said step of forming a detachable connection comprises the step of forming a line of perforations through the margin portion including the back seam.

31. A method for forming a storage bag as recited in claim 30 wherein said steps of closing one of the ends of the open ended structure and of sealing occur essentially simultaneously by impulse sealing and said sealing step further includes the step of forming an impulse seal between the film layers of the structure thereby to join the layers between the first margin end and the intermediate position between the back seam and the second margin end.

32. A method for forming a storage bag as recited in claim 31 wherein said impulse sealing step produces first and second seals formed along a parallel lines between the first margin end and the intermediate position spaced from the second margin end.

33. A method for forming successive storage bags from an indeterminate length of polyethylene-based film, each storage bag having a removable closure tie, said method comprising the steps of:
A. forming the film into a wall of an open-ended, hollow structure extending along a first axis, B. clamping a portion of the hollow structure along a second axis that is transverse to the first axis to form a margin portion in coextensive film wall portions, said margin portion having first and second sections disposed along the second axis and providing a boundary between successive storage bags, C. perforating the film walls in said margin portion along a perforation line that is parallel to the second axis, D. severing the film walls in the margin portion along a severance line that is parallel to and spaced from the second axis thereby to form a removable closure tie between the perforation and severance lines and to form an adjacent first sealing area, E. forming a first seal between the film walls along a line in the first sealing area that is parallel to the second axis and that is, coextensive with the first and second sections, F. forming a second seal between the film walls along a line in the removable closure tie that is parallel to the second axis and that is coextensive with only the first section whereby the film walls in the second section remain unsealed and the unsealed film wall is free of any film structure that fails by delamination.

34. A method for forming storage bags as recited in claim 33 wherein said method additionally comprises the step of unclamping the film upon completion of said perforating, severing and sealing steps thereby to release an individual storage bag.

35. A method for forming storage bags as recited in claim 34 wherein said perforating and severing steps occur substantially simultaneously and wherein said seal forming steps occur substantially simultaneously.

36. A method for forming storage bags as recited in claim 33 wherein said step of forming the film into the structure includes the steps of:

i. wrapping the film in sheet form about a cylinder, ii. overlapping edges of the film parallel to the first axis, and iii. sealing the edges into a back seal parallel to the first axis thereby to produce the open-ended, hollow structure that traverses the margin in the first section remotely from the second section.

37. A method as recited in claim 33 wherein said step of forming the second seal includes forming in the removable closure tie two spaced, parallel seals that are parallel to the second axis and are coextensive with only the first section.

38. A method as recited in claim 37 wherein said steps of forming said first and second seals includes the step of impulse heating the film layers.

39. A method as recited in claim 37 wherein said steps of forming said first and second seals includes the step of resistance heating the film layers.

40. A method for forming storage bags as recited in claim 33 wherein the perforation line defines a boundary between the removable closure tie and an adjacent second sealing area and wherein said step of forming the first seal forms a seal in the second sealing area that is coextensive with the first and second sections.

41. A method as recited in claim 40 wherein said steps of forming said first and second seals includes the step of impulse heating the film layers.

42. A method as recited in claim 40 wherein said steps of forming said first and second seals includes the step of resistance heating the film layers.

43. A method as recited in claim 33 wherein said step of forming the film into the structure includes the step of:
i. wrapping the film in sheet form about a cylinder, ii. overlapping edges of the film parallel to the first axis, and iii. sealing the edges into a back seam parallel to the first axis that traverses the margin portion in the first section remotely from the second section and produces the open-ended, hollow structure, wherein said perforating and severing steps occur substantially simultaneously, and wherein said seal forming steps occur substantially simultaneously, and wherein said step of forming the second seal includes forming in the removable closure tie two spaced, parallel seals that are parallel to the second axis and coextensive with only the first section.

44. A method as recited in claim 43 wherein said steps of forming said first and second seals includes the step of impulse heating the film layers.

45. A method as recited in claim 43 wherein said steps of forming said first and second seals includes the step of resistance heating the film layers.

46. A method for forming storage bags as recited in claim 43 wherein the perforation line defines a boundary between the removable closure tie and an adjacent second sealing area and wherein said step of forming the first seal forms a seal in the second adjacent sealing area that is coextensive with the first and second sections.

47. A method as recited in claim 46 wherein said steps of forming said first and second seals includes the step of impulse heating the film layers.

48. A method as recited in claim 46 wherein said steps of forming said first and second seals includes the step of resistance heating the film layers.

49. Apparatus for forming, from a continuous cylinder lying along a first axis and formed of a sealable, elastic polymeric film, storage bags with contents pouches and integrally formed, reclosure tie means for reclosing each bag, said apparatus comprising:
A. clamping means for clamping a portion of the continuous cylinder along a second axis that is transverse to the first axis to form a margin portion in coextensive film wall portions of the continuous cylinder, said margin portion having first and second sections disposed along the second axis for providing a boundary between successive storage bags, B. perforating means for perforating the film walls in said margin portion along a perforation line that is parallel to the second axis, C. severing means for severing the film walls in the margin portion along a severance line that is parallel to and spaced from the second axis thereby to form a removable closure tie in the margin portion between the perforation and severance lines and to form an adjacent first sealing area, D. first sealing means for forming a first seal between the film walls along a line in the first sealing area that is parallel to the second axis and that is coextensive with the first and second sections, E. second sealing means for forming a second seal between the film walls along a line in the removable closure tie that is parallel to the second axis and that is coextensive with only the first section to form a tail in the first section and to form a loop in the second section that is free of any film structure that fails by delamination.

50. Apparatus for forming storage bags as recited in claim 49 wherein said clamping means includes first and second counterfacing sealing jaw means mounted for relative movement along a third axis that is transverse to the first and second axes, each of said sealing jaw means including spaced, transversely oriented, counterfacing gripper means parallel to the second axis for clamping the film thereby to form the margin portion therebetween.

51. Apparatus for forming storage bags as recited in claim 50 wherein one of said sealing jaw means includes means for biasing said gripper means toward the other of said sealing jaw means, said gripper means on said one sealing jaw means being displaced during a clamping action whereby said biasing means establishes a clamping force.

52. Apparatus for forming storage bags as recited in claim 50 wherein said first and second sealing means includes a plurality of spaced heating filaments disposed parallel to the second axis and wherein one of said sealing jaw means includes means for supporting said filaments and the other of said sealing jaws means includes filament clamping means for placing the film against said filaments, said filament clamping means being biased on said supporting sealing jaw means for limited reciprocation with respect thereto to establish the clamping force against said filaments, said apparatus additionally including means for directing an electrical current pulse through said filaments.

53. Apparatus for forming storage bags as recited in claim 52 wherein said second sealing means includes one of said filaments having an insulator formed over a portion thereof coextensive with the loop thereby to prevent a heat transfer to the film in the loop.

54. Apparatus for forming storage bags as recited in claim 53 wherein said first sealing means includes first and second spaced heating filaments that are parallel to the second axis and coextensive with the first and second sections of the margin portion and wherein said sealing jaw means includes means for supporting said first and second uninsulated filaments in alignment with the first sealing area and a second sealing area oppositely disposed with respect to the removable closure tie, said uninsulated filament being pulsed simultaneously with said partially insulated filaments.

55. Apparatus for forming storage bags as recited in claim 53 wherein said first sealing means includes first and second spaced heating filaments that are parallel to the second axis and coextensive with the first and second sections of the margin portion and wherein said sealing jaw means includes means for supporting said uninsulated filaments adjacent to said gripper means thereby to form transverse seals at the edges of the margin portion adjacent the contents pouches.

56. Apparatus for forming storage bags as recited in claim 55 wherein said perforation and severing means comprise reciprocally operating perforation and severing blade means respectively, one of said sealing jaw means supporting said perforation and severing blade means for reciprocating motion to advance said blade means toward the other sealing jaw means, said other sealing jaw means including recesses for receiving each of said perforation and severing blade means.

57. Apparatus for forming storage bags as recited in claim 50 wherein each of sealing jaw means is movable along a third axis transverse to the first and second axes and said gripper means on one of said sealing jaw means includes compressible means for clamping the film wall portions against said counterfacing gripper means.

58. Apparatus for forming storage bags as recited in claim 57 wherein each of said first and second sealing means includes first and second counterfacing sealing finger means that extend parallel to the second axis each of said first and second sealing jaw means includes a sealing jaw body portion for supporting said first and second counterfacing sealing finger means, respectively, and wherein each of said first and second sealing jaw body portions is movable with and independently of said gripper means.

59. Apparatus for forming storage bags as recited in claim 58 wherein said first sealing jaw body portion further includes heating means for elevating the temperature of the first sealing jaw body portion and the first sealing finger means attached thereto.

60. Apparatus for forming storage bags as recited in claim 59 wherein each of said sealing finger means in said first sealing means extends parallel the second axis and is coextensive with the first and second sections thereby to form a seal at the contents pouch that traverses the storage bag.

61. Apparatus for forming storage bags as recited in claim 60 wherein each of said sealing fingers in said second finger means is coextensive with only the first section and each of said sealing jaw body portions carries an insulating insert means as an extension of the second sealing means that is coextensive with the second section.

62. Apparatus for forming storage bags as recited in claim 61 wherein said perforation and severing means comprise reciprocally operating perforation and severing blade means respectively, said first sealing jaw means supporting said perforation and severing blade means for reciprocating motion relative to said sealing jaw body portion to advance said blade means toward said second sealing jaw means, said second sealing jaw means including recesses for receiving each of said perforation and severing blade means.

63. Apparatus for forming storage bags as recited in claim 62 wherein said insulating insert means affixed to said first sealing jaw means includes an array of air passages for directing cooling air toward portions of said severing and perforation blade means.

64. Apparatus for forming storage bags as recited in claim 63 wherein said insulating insert means additionally includes an air passage for directing cooling air along the second axis toward the first section.

65. Apparatus for forming storage bags as recited in claim 60 wherein the margin portion additionally includes a second sealing area parallel to the first sealing area and oppositely disposed with respect to the removable closure tie from the first sealing area and wherein said first sealing means comprises first and second sets of counterfacing sealing finger means formed on said first and second sealing jaws for forming seals in the first and second sealing areas respectively that parallel said second axis and that are coextensive with the first and second sections thereby to form a pair of seals at the contents pouches of adjacent storage bags that traverse the storage bag.

66. Apparatus for forming storage bags as recited in claim 65 wherein said second sealing means comprises third and fourth counterfacing sealing fingers on said first and second sealing jaws for forming spaced, parallel seals in the releasable closure tie that are coextensive with the first section and wherein each of said sealing jaw body portions carries an insulating insert means as an extension of the sealing finger means in the second sealing means over a part of the margin portion that is coextensive with the second section.

67. Apparatus for forming storage bags as recited in claim 66 wherein said perforation and severing means comprise reciprocally operating perforation and severing blade means respectively, said first sealing jaw means supporting said perforation and severing blade means for reciprocating motion relative to said sealing jaw body portion to advance said blade means toward said second sealing jaw means, said second sealing jaw means including recesses for receiving each of said perforation and severing blade means.

68. Apparatus for forming storage bags as recited in claim 67 wherein said insulating insert means affixed to said first sealing jaw means includes an array of air passages for directing cooling air toward portions of said severing and perforation blade means.

69. Apparatus for forming storage bags as recited in claim 68 wherein said insulating insert means on said first sealing jaw means additionally includes an air passage for directing cooling air along the second axis toward the first section.