GB2366596A - Mounting slider onto zip simultaneously with formation of end stops - Google Patents

Abstract

A resealable container 10 has a zipper closure 20, with a slider 50 and ends stops 33 and 35. A number of the closures 20A, 20B are made as an extended strip - strips of closure profile are passed through apparatus which simultaneously mounts a slider 50 and forms the end stops 33 and 35, and optionally forms a notch 25.

Description

2366596 METHODS AND APPARATUS FOR MOUNTING SLIDER DEVICES ONTO ZIPPER

CLOSURES, AND PACKAGES MADE THEREBY The present invention generally relates to packages having interlocking zipper closure profiles that are mated and unniated by a slider device.

5 In particular, the present invention relates to methods of mounting the slider device onto the closure profiles, the zipper closure profile with the slider device mounted thereon, and the packages made therewith.

Many packaging applications use resealable containers to store or enclose various types of articles and materials. These packages may be used to 10 store food products, non-food consumer goods, medical supplies, waste materials, and many other articles. Resealable packages having zipper closure mechanisms are convenient in that they can be closed and resealed after the initial opening to preserve the enclosed contents. Goods that are not used completely when the package is initially opened rely on the zipper closure to reclose the package and 15 keep the remaining contents fresh. The need to locate a storage container for the unused portion of the products in the package is thus avoided. In some instances, providing products in resealable packages appreciably enhances the marketability of those products. Examples of consumable goods that are often packaged in packages, such as bags, with a zipper closure include potting soil, fertilizer, pet 20 food, dog biscuits, vegetables, cereal, and many different foods edible by humans.

For some types of resealable packages, the opening and closing of the zipper closure is facilitated by a slider device that is mounted on the zipper closure.

The slider device typically includes a separator or spreader-type structure at one end that opens a closure mechanism, having profiled elements or closure profiles, when 25 the slider device travels in a first direction along the mechanism. The sidewalls of the slider device are configured so that the sidewalls engage the closure profiles and progressively move them into engagement to close the resealable package when the slider device is moved along the closure mechanism in a direction opposite the first direction.

30 Improvements in the manufacturing of the resealable packages, in CASE: 09/649,557 particular in the process of mounting the slider device on the zipper closure, are desired.

In one aspect of the present disclosure, methods of applying or mounting slider devices for opening and closing resealable zipper closures are 5 disclosed. The method is directed at doing multiple steps to the zipper closure; that is, the slider device is mounted and end slider stop seals are made simultaneously or essentially simultaneously, In some embodiments, a home notch position for the slider device is made prior to, or essentially simultaneously to the other steps. The zipper closure may be mated (interlocked) or uninated (disengaged) when the 10 various steps are done.

In particular, the present disclosure relates to a method of making a zipper closure, the method comprising: providing a first closure profile and a second closure profile; mounting a slider device onto each of the first closure profile and the second closure profile; and forming a first slider stop and a second slider 15 stop, with the slider device positioned between the fast slider stop and the second slider stop The steps of mounting a slider device and forming a first slider stop and a second slider stop are done essentially simultaneously. Optionally, the method can include punching a notch in the first and second closure profiles.

In another aspect of the present disclosure, an extended length of

20 zipper closure is provided. The extended length of zipper closure has a plurality of segments, each segment having a length corresponding to the width of the package in which the zipper closure will be incorporated. Each segment includes a first slider stop and a second slider stop, and a slider device mounted onto the zipper closure between the first slider stop and the second slider stop.

25 In particular, the present disclosure relates to an extended length of zipper closure comprising a plurality of sections, each section defined by a first end and a second end, and each section comprising a first closure profile interlockable with a second closure profile, the first closure profile and the second closure profile being continuous along the plurality of sections. A slider device, constructed and 30 arranged to interlock the first closure profile with the second closure profile when the slider device is moved in a first direction, and disengage the first closure profile from the second closure profile when the slider device is moved in a second opposite direction, is, operably mounted on the first closure profile and the second closure profile. A first slider stop is present at the first end of the section, and a second slider stop is present at the second end of the section, with the slider device mounted therebetween.

5 The extended length of zipper closure can be incorporated into packages, or can be stored, for example, on a core or spool, for later incorporation into packages.

FIG. 1 is a perspective view of a flexible, resealable package having a slider device, according to principles of this disclosure;

10 FIG. 2 is a cross-sectional view of the flexible, resealable package taken along line 2-2 of FIG. 1; FIG. 3 is an enlarged, schematic cross sectional view of a zipper closure such as of the flexible, resealable package of FIGS. 1 and 2, without a slider device mounted thereon; 15 FIG. 4 is a front perspective view of a process for mounting slider devices onto An elongated supply of zipper closure, including a first embodiment of a device for mounting slider devices onto a zipper closure; FIG. 5 is an enlarged, front perspective view of the device for mounting slider devices of FIG. 4; 20 FIG. 6 is an enlarged, rear perspective view of the device for mounting slider devices of FIG. 4; FIG. 7 is a schematic front view of a second embodiment of a device for mounting slider devices onto a zipper closure; FIG. 8 is a schematic side view of the device of Fig. 7 for mounting 25 slider devices onto a zipper closure; FIG. 9 is a partial cross-sectional view of a slider device positioned for mounting on the zipper closure; FIG. 10 is a front elevational view of a first embodiment of an extended length of zipper closure having slider devices mounted thereon; 30 FIG. 11 is a front elevational. view of a second embodiment of an extended length of zipper closure having slider devices mounted thereon; FIG. 12 is a front elevational view of a third embodiment of an extended length of zipper closure having slider devices mounted thereon; FIG. 13 is a partial perspective view of a portion of the process for producing the zipper closure of FIG. 12; FIG. 14 is a front view of a flexible, resealable package having a 5 slider device, incorporating the zipper closure of FIG. 10; FIG. 15 is a front view of a flexible, resealable package having a slider device, incorporating the zipper closure of FIG. 11; FIG. 15A is an enlarged view of a portion of the flexible, resealable package of FIG. 15; and 10 FIG. 16 is a front view of a flexible, resealable package having a slider device, incorporating the zipper closure of FIG. 12.

Attention is directed to FIGS. 1 and 2, which illustrate an example packaging arrangement in the form of a resealable, flexible package 10, for example, a polymeric package such as a plastic bag, having a resealable zipper 15 closure 20. The flexible package 10 includes a surrounding body formed by first and second opposed panel sections 12, 14, typically made from a flexible, polymeric, plastic film. The film can be a single layer or a multi- layered polymeric film, In some embodiments, it may be desired to combine at least one layer of polymeric film with an additional layer, such as paper, to form a multi- component 20 film.

With some manufacturing applications, the first and second panel sections 12, 14 are heat-sealed together along two side edges 13, 15 and meet at a fold line 17 in order to form a three-edged containment section for a product within an interior 11 (FIG. 2) of the package 10. In the embodiment shown, the fold line 25 17 comprises the bottom edge 18 of the package 10. Alternatively, two separate panel sections 12, 14 of plastic film may be used and heat-sealed together along the two side edges 13, 15 and at the bottom edge 18. In yet another embodiment, panel sections 12, 14 can be formed from a tube-like sheet of material configured to form folds at each of side edges 13, 15; side panels 12, 14 are heat-sealed together along 30 bottom edge 18. Access is provided to the interior 11 of the package 10 through a mouth 30 of the package 10. In the particular embodiment shown, the mouth 30 extends the width of the package 10; that is, mouth 30 extends from first side edge 13 to second side edge 15.

Bottom edge 18 can include a gusset 31, seen in FIG. 2. Gussets are known for providing packages with "stand-up" features. Gusset 31 of package 10 has first and second gusset sections 32, 34, which are essentially equal in length.

5 Preferably, each of the first and second gusset sections 32, 34 is made from the same piece of material as the first and second panel sections 12, 14, respectively.

Typically when making the gusset 3 1, a single piece of film is folded to form the opposing panel sections 12, 14.

The fold 38 is then formed between the first and second panel 10 sections 12, 14, which results in the first and second gusset sections 32, 34 with the fold line 38 therebetween. Eventually, heat is applied to form the side edges 13, 15 (FIG. 1). The side edges 13, 15 will form a seal between all four layers of the package along each respective gusseted side edge of the package.

A zipper closure arrangement 20 having closure profiles to open and 15 close (unseal and reseal) the mouth 30 of package 10 extends along the mouth 30, preferably across the width of package 10; that is, zipper closure 20 preferably extends from first side edge 13 to second side edge 15. The zipper closure 20 can include a variety of configurations and structures. Zipper closure 20 can be configured in any known manner, for example, such as disclosed in U.S. Patent 20 Nos. 4,240,241; 4,246,288; and 4,437,293; each of which is incorporated by reference herein. By the term "zipper closure" or "zipper closure mechanism," it is meant a structure having opposite interlocking or closure profiled elements that, under the application of pressure, will interlock and close the region between the profiles.

25 Referring to FIGS. 2-3, zipper closure 20 has a first closure profile 22 and a second closure profile 24 which engage and disengage, as appropriate, to open and close package 10. In particular, first mating member 26 of first closure profile 22, and second mating member 28 of second closure profile 24 interlock as appropriate, to engage and disengage closure profiles 22, 24. First and second 30 closure profiles 22, 24 of zipper closure 20 are attached to side panels 12, 14, respectively, by sealing flanges 42, 44 (FIGS. 2 and 3) as will be described in detail below. The transition area between mating members 26, 28 and sealing flanges 42, 44 is identified by shoulders 212, 214. Opposite sealing flanges 42, 44 are the distal ends 43, 45 (FIG. 3) of closure profiles 22, 24.

In the embodiment shown, the resealable zipper closure 20 extends the width of the mouth 30 from first side edge 13 to second side edge 15.

5 Alternatively, the mouth 30 and zipper closure 20 could be positioned on the package 10 at a location different from the mouth 30 of the package 10, depending on the application needs for the package 10. For example, mouth 30 and zipper closure 20 can be positioned within one of side panels 12, 14.

In some applications, the closure profiles 22, 24 are formed by two 10 separate extrusions or through two separate openings of a common extrusion.

Typically, the resealable zipper closure 20 is made of conventional materials, such as a polymeric, plastic material, for example, polyethylene, polyvinylchloride or polypropylene. In other application, the closure profiles 22, 24 are formed as a single extrusion, which may they be slit apart to form the two individual profiles.

15 Referring again to FIGS. I and 2, slider device 50 is mounted on zipper closure 20 to facilitate opening and closing zipper closure 20. Slider devices and how they function to open and close zipper closures, in general, are taught, for example, in U.S. Patent Nos. 5,063,644; 5,301,394; and 5,442,837, each of which is incorporated by reference herein. One preferred slider device is taught in U.S.

20 patent applications 09/365,215 and 29/108,657, both filed July 30, 1999 and incorporated herein by reference in their entirety. Another preferred slider device is taught in U.S. patent application 60/222,132 filed July 31, 2000, which is incorporated herein by reference.

Referring to slider device 50 in FIG. 2, slider device 50 has a top 25 wall 51 from which depend first arm 52 and second arm 54; first and second arms 52, 54 form sidewalls of slider device 50. First arm 52, in particular first hook 62, engages over shoulder 212 and second arm 54, in particular second hook 64, engages over shoulder 214, Extending from top wall 52, and positioned between distal ends 43, 45 (FIG. 3) of closure profiles 22, 24, is spreader 55, which pries 30 apart closure profiles 22, 24 when slider device 50 is moved in a first direction along zipper closure 20; when moved in a second opposite directional along zipper closure 20, slider device 50 mates closure profiles 22, 24.

Another preferred slider device is shown in FIG. 9 as slider device 50'. Slider device 50' has a top wall 51' from which depend first arm 52' and second arm 54', which form sidewalls of slider device 50'. First arm 54', in particular first hook 62', engages over.shoulder 212 of first closure profile 22 of 5 zipper closure 20, and second arm 54', in particular second hook 64', engages over shoulder 214 of second closure profile 24. Hook 62' has an inner surface 61 and hook 64' has an inner surface 63. Each of inner surfaces 61, 63 is inwardly angled, to facilitate mounting of slider device 50' onto zipper closure 10.

Referring again to FIG. 1, positioned on zipper closure 20, close to 10 first side edge 13 and second side edge 15, are first slider stop 33 and second slider stop 35, respectively. Slider stops 33, 35 can be any physical obstruction that stops the movements of slider device 50 on zipper closure 20. The slider stops 33, 35 are areas or regions of zipper closure 20 that have been deformed, typically ultrasonically welded, thermally melted, crushed, or otherwise melted or deformed.

15 The deforming results in a mass of plastic (polymeric) material, typically melted together. In some embodiments, slider stops 33, 35 may be devoid of material.

Slider stops 33, 35 can be located in upper Ranges 43, 45 (FIGS. 2 and 3), in sealing flanges 42, 44 (FIGS. 2 and 3), in mating members 26, 28 (FIGS. 2 and 3), or any combination thereof. Multiple slider stops can be used at each or either end 20 of zipper closure 20. Slider device 50, mounted on zipper closure 20, can travel from first slider stop 33 to second slider stop 35 and does not contact either of first side edge 13 or second side edge 15.

A notch 25 is disposed within zipper closure 20 adjacent to first side edge 13 in package 10. Notch 25 is designed to provide a "park place" into which 25 slider device 50 settles when zipper closure 20 is sealed and slider device 50 is at first side edge 13. Such a notch 25 may decrease any tendency for an incomplete interlock between first closure profile 22 and second closure profile 24. The width of notch 25 may be any width. In some embodiments, notch 25 may be so narrow that it may be simply considered to be a slit or cut. A preferred notch 25 includes 30 two straight edges or sides generally perpendicular to each other, and an opposed side that extends at, in a preferred embodiment, an oblique angle relative to its adjacent side. By "oblique angle", it is meant an angle that is not substantially perpendicular or straight.

Methods and AMaratus for Processing Zipper Closure Referring now to FIG. 4, a process 100 for mounting slider devices onto an extended length of zipper closure 20 is shown. In this embodiment 5 according to the present disclosure, the slider devices 50 are mounted on the zipper closure 20, in particular on first and second closure profiles 22, 24 (FIGS. 2 and 3), prior to attaching zipper closure 20 to side panels 12, 14 (FIGS. I and 2) to create package 10. At least two different styles or types of packages can be made using the zipper closure 20 from process 100: those where the package is filled through 10 the zipper closure 20, and those where the package is filled through the bottom 18 (FIGS. 1 and 2).

Packages intended to be filled through the zipper closure 20 will generally have closure profiles 22, 24 (FIGS. 2 and 3) unmated. After filling, the profiles 22, 24 are sometimes mated, or left unmated, and a tamper evident-structure 15 60 (FIGS. 14-16) can be applied. Packages intended to be filled through the bottom 18 (FIGS. I and 2), such as through a gusset 31 (FIG. 2) generally have the closure profiles 22, 24 are mated and any tamper evident-structure 60 (FIGS. 14- 16) intact prior to filling the package.

Packages intended for filling by the consumer can also be made using 20 the zipper closure 20 from process 100.

An extended length of zipper closure 20, with first and second closure profiles 22, 24 (FIGS. 2 and 3), is provided via spool 120. In another embodiment, zipper closure 20 may be extruded, cast or otherwise formed immediately before this process 100, thereby eliminating the step of winding the 25 zipper closure 20 onto spool 120 after forming the zipper closure 20 and then unwinding when the slider devices 50 are mounted.

First and second closure profiles 22, 24 (FIGS. 2 and 3) may be interlocked (mated) or unmated while retained on spool 120. If the closure profiles 22, 24 are unmated, in some embodiments it may be desired to have first closure 30 profile 22 on a first spool and second closure profile 24 on a second spool. It should be noted, that interlocked profiles can be unmated as desired, and umnated profiles can be mated as desired. In most embodiments, it is desired that the profiles 22, 24 are mated.

Zipper closure 20 is unwound from spool 120 and fed to slider mounting system 200. A zipper drive or tensioning unit 122 can be provided to control the zipper closure 20 from spool 120. At slider mounting system 200, 5 zipper closure 20 undergoes various processes, including having a slider device 50 mounted thereon.

Slider device 50, to be mounted on zipper closure 20, is fed by a slider source such as bowl feeder 150, which properly orients slider device 50 for mounting onto flanges 43, 45 (FIGS. 2 and 3) of zipper closure 20. In FIG. 4, 10 bowl feeder 150 is positioned on a table or other support 110. The slider devices progress from bowl feeder 150 along feedtrack 152 to slider mounting system 200. Alternately, slider device 50 can be fed to slider mounting system 200 by multiple bowl feeders feeding a single track 152, a vibratory feeder, a spool of slider devices adhered to or carried on or by a carrier tape, a connected chain of 15 slider devices, be manually fed, or by any other process that can provide a continuous supply of slider devices to slider mounting system 200. Gravity, an air stream, and other methods can be used to facilitate feeding of the slider devices. In one embodiment, a multi-channeled bowl feeder is used to orientate slider devices to the proper position for application to zipper closure 20 by slider mounting 20 system 200.

Slider mounting system 200, supported by table 110, has zipper closure 20 passing therethrough. Table I 10 can include a registration system 125 for providing fine tuning of spacing and positioning, as needed, of slider mounting system 200. Slider mounting system 200, shown in FIGS. 4 and 5, and rotated in 25 FIG. 6, includes a slider home position punch unit 240, a profile clamping unit 250, a slider installation mechanism 260, and a slider stop seal unit 270; a punch unit 240 may not be present in all embodiments. The various features of slider mounting system 200 provide the following functions: punch unit 240 provides notch 25 (FIG. 1); profile clamp 250 securely holds zipper closure 20 during the 30 various operations; slider installation mechanism 260 mounts slider device 50 onto zipper closure 20; and stop seal unit 270 forms slider stops 33, 35 (FIG. 1). Slider mounting system 200 is designed to have each of these various units (i.e., punch unit 240, profile clamp 250, slider installation mechanism 260, and slider stop seal unit 270) function together, in essence simultaneously, to provide an extended length of zipper closure 20 processed and ready to be incorporated into a package, such as a plastic bag. Zipper closure 20 is incrementally indexed through slider 5 mounting system 200, so that the processed zipper closure 20 has repeating features, that is, slider device 50, slider stops 33, 35 (FIG. 1), and notch 25 (FIG. 1).

When zipper closure 20 enters slider mounting system 200 from spool 120 or other supply, the first and second closure profiles 22, 24 (FIGS. 2 and 3) are preferably unmated; if mated, slider mounting system 200 can include a unit 10 to unmate the profiles. However, in some embodiments, such as when the resulting package will be filled through bottom 18 (FIGS. I and 2), closure profiles 22, 24 can be mated. Profile clamp 250 secures zipper closure 20 during the time the various procedures of slider mounting system 200 are performed on zipper closure 20. Profile clamp 250 can be any mechanism that can secured hold zipper closure 15 20; such mechanisms can include hinged clamps, arms, fingers, or any such items.

Profile clamp 250 can be mechanical, pneumatically operated, or servodriven. In some embodiments, a programmable servo motor can be -connected to a cam which engages a linkage to actuate profile clamp 250.

Profile clamp 250 holds each of first and second closure profiles 20 22, 24 (FIGS. 2 and 3) individually, or can hold the profiles 22, 24 with a single mechanism or surface. In some embodiments, it is preferred that profile clamp 250 has two opposed portions between which the zipper closure 20 is retained. Further, it is preferred that the surfaces of profile clamp 250 that contact zipper closure 20 are at least somewhat contoured to the profile zipper closure 20, so that the 25 clamping pressure is fairly evenly distributed across first closure profile 22 and second closure profile 24.

Punch unit 240, if present, provides notch 25 (FIG. 1) to zipper closure 20. Punch unit 240 may be a die, knife, stamp or other such process. As discussed earlier, notch 25 may be a narrow slit. In one embodiment, punch unit 30 240 is a hydraulic punch. In another embodiment, punch unit 240 is a pneumatic punch. In some embodiments, a programmable servo motor can be connected to a cam which engages a linkage to actuate punch unit 240.

The small piece of polymeric material removed by punch unit 240 (herein referred to as a "slug") that defines notch 25 (FIG. 1) may be removed from the area of punch unit 240 by an air blast or by vacuum.

In some embodiments, it may be desired to have a punch unit 5 separate from slider mounting system 200; rather, a separate punch unit can be positioned upweb or downweb of slider mounting system 200. A separate punch unit can be mechanically, hydraulically, or pneumatically controlled. In embodiments where a servo-driven motor is used to actuate a separate punch unit, it may be desired to use a servo separate from one used to control profile clamp 250 10 and other features of slider mounting system 200.

Slider device 50 is applied to zipper closure 20 by slider installation mechanism 260, which can be any device or method for applying slider device 50 onto zipper closure 20. Generally, if closure profiles 22, 24 (FIGS. 2 and 3) are mated, slider device 50 typically is applied at notch 25 (FIG. 1); if closure profiles 15 22, 24 are unmated, slider device 50 typically is applied at the opposite end of zipper closur6 20, for example, close to second slider stop 35 (FIG. 1).

Generally, slider installation mechanism 260 applies slider device 50 onto zipper closure 20 in a straight on approach; that is, slider device 50 is brought to zipper closure 20 axially aligned with upper flanges 43, 45 (FIGS. 2 and 3). See 20 for example, FIG. 9 which shows slider device 50 axially aligned with zipper closure 20.

A first embodiment of a slider installation mechanism 260 is shown in FIGS. 4 through 6. This slider installation mechanism 260 is a horizontally loading mechanism that applies slider devices 50 onto zipper closure 20 in a straight 25 on approach. By the term "horizontally loading", it is meant that the slider device 50 and zipper closure 20 have a horizontal axis extending between them during the mounting process. In FIG. 5, the orientation of slider devices 50 and zipper closure 20 is shown. Zipper closure 20 is oriented with upper flanges 43, 45 positioned closer to slider device 50 than sealing flanges 42, 44. This slider installation 30 mechanism 260 could be refitted to be a vertically -loading mechanism. By the term "vertically loading", it is meant that the slider device 50 and zipper closure 20 have a vertical axis extending between them during the mounting process.

Slider devices 50 are fed via track 152 to slider mounting system 200, and in particular, to slider installation mechanism 260. Slider devices 50 are oriented in relation to zipper closure 20 as shown in FIG. 9, so that arms 52, 54 (FIG. 9) of slider device 50 engage over shoulders 212, 214 (FIG. 9). Cylinder 262 5 pushes slider device 50, from where it is fed via track 152, onto zipper closure 20, in particular over upper flanges 43, 45; slider device 50 is installed onto zipper closure at installation point 269.

A second embodiment of a slider installation mechanism is shown in FIGS. 7 and 8. Slider installation mechanism 260' is a vertically loading 10 mechanism that applies slider devices 50 onto the zipper closure 20 in a straight on approach. In FIG. 7, zipper closure 20 is shown in end view, and in FIG. 8, zipper closure 20 shown in phantom. A plurality of slider devices 50 are aligned and fed through a chute where the slider devices 50 are horizontally aligned at load point 266'. The aligned slider devices 50 are then stacked and aligned vertically at drop 15 point 268' by first cylinder 262'. A slider device 50 from the bottom of the stack is pushed forward and over the zipper closure by first cylinder 262' at slider installation point 269'; gravity, an air jet, or the like, pushes a next slider device 50 to the bottom of the stack. In the same stroke, first cylinder 262' pushes one of the horizontally aligned slider devices 50 forward to the top of the stack. Before the 20 slider device 50 is pushed over the zipper closure, a second cylinder 264' activates profile clamp 250 to hold zipper closure securely. Second cylinder 264' of profile clamp 250 unclamps the zipper closure and the zipper closure is indexed. It is understood that other techniques, such as a belt driven system, can be used to provide slider devices 50 to the desired positions.

25 Any of cylinder 262, 262', 264, and the like may be mechanically, pneumatically, hydraulically, or servo-driven. A programmable servo motor can be connected to a cam which engages a linkage to actuate one or any of the cylinders.

The servo motor used can be the same one, or a different one than used for other features of slider mounting system 200. It is understood that the timing, step 30 sequence, and the like can be carefully controlled by a programmable servo motor.

Referring again to FIGS. 4 and 5, slider stop seal unit 270 forms sliderstops 33, 35 (FIG. 1) or the like on upper flanges 43, 45 (FIGS. 2 and 3) of zipper closure 20. Slider stops 33, 35 decrease the opportunity for slider device 50, when slid along zipper closure 20 when incorporated into a package, to abut either side edge 13, 15 (FIG. 1). Slider stop seal unit 270 can be any process that provides a physical barrier. to moving slider device 50 farther along zipper closure 5 20. Typically, the physical barrier is a mass of plastic (polymeric) material. This material can be ultrasonically welded, thermally melted, crushed, or otherwise melted or deformed by stop seal unit 270. In some embodiments, heat, pressure, ultrasonics, or the like can be applied from both sides of zipper closure 20, that is, from both the side of first closure profile 22 (FIGS. 2 and 3) and the side of second 10 closure profile 24 (FIGS. 2 and 3). The application of the heat, pressure, ultrasonics, or other step can be controlled by a servo.

Providing the slider stops 33, 35 may be a two step process in some embodiments: first, a portion of the closure profiles 22, 24 (FIGS. 2 and 3) are crushed to decrease the width, and second, the slider stops 33, 35 are made.

15 Additionally or alternatively, slider stop 33 can be made in a step separate from the making of slider stop 35.

Slider mounting system 200 is constructed to have various processes performed on the zipper closure 20 essentially simultaneously. By the term flessentially simultaneously", it is meant that the various processes are performed 20 with no more than about 0.01 second between the initiation of one step and the initiation of a second step. In many embodiments, the time between initiation of all steps within slider mounting system 200 is no more than about 0.005 second. The overall time period to accomplish all the steps is referred to as a "cycle". Generally each cycle is no more than 2 seconds long, preferably no more than 1 second, more 25 preferably no more than 0.75 second, and most preferably no more than 0.5 second long. These timings, which can include the short period of time needed to incrementally move zipper closure 20, provide process of speeds of at least 30 cycles per minute, preferably at least 60 cycles per minute, more preferably at least cycles per minute, and most preferably at least 120 cycles per minute. In some 30 embodiments, process speeds of up to, and exceeding, 150 cycles per minute can be obtained; however typically, process speeds of about 85-115 cycles per minute are used.

The order of the steps done by slider mounting system 200 can vary; additionally, the preferred order of the steps may vary depending on the type of package which will eventually be made; that is, whether the package will be filled through the top or bottom edge.

5 For example, if it is desired that the eventual packages will be filed through zipper closure 20 at the top of the package (see FIG. 1), the closure profiles 22, 24 (FIGS. 2 and 3) will be unmated. Thus, in some embodiments, first and second closure profiles 22, 24 (FIGS. 2 and 3), if mated, are first separated by slider mounting system 200. The uninated profiles are clamped by profile clamp 10 250, and then sealed by stop seal unit 270, punched by punch unit 260, and slider device 50 installed by slider installation mechanism 260 all during the same cycle.

In other embodiments, the closure profiles 22, 24 (FIGS. 2 and 3) are separated, notch 25 (FIG. 1) is punched first by punch unit 260, and slider device 50 is installed by slider installation mechanism 260 at essentially the same time as stop 15 seal unit 270 provides slider stops 33, 35. Alternately, stop seal unit 270 may provide slider stops 33, 35 before or after slider device 50 is installed. In yet another variation, notch 25 can be punched by punch unit 260 prior to separation of the closure profiles 22, 24. However, it is preferred that closure profiles 22, 24 are unmated when slider stops 33, 35 are made by stop seal unit 270.

20 If it is desired that the eventual packages will be filled through the bottom edge 18 (FIGS. 1 and 2), the closure profiles 22, 24 (FIGS. 2 and 3) are mated. When mated, the various steps of slider mounting system 200 can be done in any order. For example, slider device 50 can be installed prior to punching notch or making slider stops 33, 35. Or, slider stops 33, 35 are made prior to 25 punching notch 25 and mounting slider device 50. As stated, any order of steps can be used.

Typically, the various steps are done without moving the zipper closure; however, in some embodiments, the zipper closure may be indexed for the various steps.

30 As discussed above, zipper closure 20 is processed by slider mounting system 200 prior to zipper closure 20 being incorporated into packages. Referring now to FIGS. 10, 11 and 12, three embodiments of extended lengths of zipper closure 20 which have progressed through slider mounting system 200 are shown.

The processed zipper closures have segments which include the various features provided by slider mounting system 200.

The zipper closure 20' of FIG. 10 includes the first and second 5 closure profiles (not depicted) sealed together at slider stops 33, 35; these slider stops 33, 35 define a first zipper closure segment 20'A and an adjacent, continuous, and contiguous second zipper closure segment 20'B. In particular, slider stops 33, 35 of zipper closure 20' are spot seals 33', 35'. Positioned near each slider stop 33 is notch 25, which, as described above, facilitates proper mating of the first and 10 second closure profiles by slider device 50. Slider device 50 is mounted on zipper closure 20' over distal. ends 43, 45 (FIG. 10 and FIGS. 2 and 3). Sealing flanges 42, 44 (FIG. 10 and FIGS. 2 and 3) are also shown.

It is understood that the length of each zipper closure segment 20'A, 20'B will depend on the desired width of the package into which the zipper closure 15 20' will be incorporated. Each package will have a first slider stop 33, a second slider stop 35, slider device 50, and optionally a notch 25.

The zipper closure 20" of FIG. 11 includes the first and second closure profiles (not depicted) sealed together at intervals at slider stops 33, 35.

Zipper closure 20" has at least first zipper closure segment 20"A and second zipper 20 closure segment 20"B; each zipper closure segment 20"A, 20"B has each of the features provided by slider mounting system 200. In particular, slider stops 33, 35 of zipper closure 20" are crush regions 33", 35"; crush regions 33", 35" extend from distal ends 43, 45 into sealing Ranges 42, 44. As seen in FIG. 11, a second crush region 35"A of a first segment.of zipper closure 20"A is connected to a first crush 25 region 33"B of a second segment of zipper closure 20"B. In the embodiment shown in FIG. 11, slider stops 3 3, 3 5 are slanted or angled toward the zipper closure segment of which it is a part. A notch or "v" is formed between slider stops 33, 35.

In some embodiments, slider stops 33, 35 may extend continuous along distal. ends 43, 45, thus having no notch or "v" therebetween.

30 Positioned near each slider stop 33 is notch 25, which, as described above, facilitates proper mating of the first and second closure profiles by slider device 50. Slider device 50 is mounted on zipper closure 20" over distal. ends 16- 43,45.

The zipper closure 20"' of FIG. 12 includes the first and second closure profiles (not depicted) sealed together at intervals at slider stops 33, 35.

Zipper closure 20"' has at least first zipper closure segment 20"'A and second 5 zipper closure segment 20"'B; each zipper closure segment 20"'A, 20"'B has each of the features provided by slider mounting system 200. In particular, slider stops 33, 35 of zipper closure 20"' are void-regions 33"', 35"', which are areas of zipper closure 20"' devoid of material. Void-regions 33"', 35"' are formed by a stop seal unit 270' shown in FIG. 13. Positioned near each slider stop 33 is notch 25, which, 10 as described above, facilitates proper mating of the first and second closure profiles by slider device 50. Slider device 50 is mounted on zipper closure 20"' over distal ends 43, 45.

Referring now to FIG. 13, stop seal unit 270', having first and second V-posts 273, 275, respectively, forms void-regions 33"', 35"', as shown on zipper 15 closure 20"' of FIG. 12. V-posts 273, 275 are heated, for example to about 650'F.

The heated V-posts 273, 275 are sufficiently hot to burn or melt away portions of upper flanges 43, 45, so that when brought into contact with the upper flanges 43, 45, the result is regions devoid of flange material. In most embodiments, at the edges of void-regions 33"',35"', shown as edges 333, 335 in FIG. 13, the upper 20 flanges 43, 45 have been at least partially sealed or otherwise connected together by the melted material of upper flanges 43, 45. Void- regions 33"', 35"', although shown as triangular areas in FIG. 13, can be any shape, such as square, circular, and the like.

The various zipper closures 20, such as zipper closures 20', 20", and 25 20"' of FIGS. 11 through 13, can be immediately incorporated into packages, or can be rolled or otherwise stored for later incorporation into packages. The packages can be made by conventional methods, such as vertical form, fill and seal (VFFS) techniques, horizontal form, fill and seal (HFFS) techniques, or by any method.

One or more tamper evident-structures or features, such as peel seals or tamper 30 evident-structures, can be included in the package.

Zipper closure 20' of FIG. 10 is shown incorporated into package 10' in FIG. 14. Zipper closure 20' includes spot seals 33', 35', notch 25, and slider device 50, all which were incorporated with zipper closure 20' by slider mounting system 200.

Package 10' is defined by a surrounding body, such as first and second side panels (first side panel depicted at 12), which are joined at first side 5 edge 13 and second side edge 15. Zipper closure 20' extends from first side edge 13 to second side edge 15 and is attached to the side panels by sealing flanges 42, 44. Slider device 50 mounted on zipper closure 20' over upper flanges 43, 45, can travel from first spot seal 33' to second spot seal 35' and does not contact either of first side edge 13 or second side edge 15.

10 A tamper-evident structure 60 is disposed over zipper closure 20' and slider device 50 opposite bottom edge 18. By "tamper-evident", it is meant that it provides an indication to the consumer as to whether the package 10' has been previously opened. In order to access the interior of package 10', the tamper-evident structure 60 needs to be penetrated. A line of weakness 65 is 15 provided to facilitate removal of tamper evident-structure 60. Line of weakness can be a perforation, tear strip or bead, die line, laser score line, or other weakness that provides easy removal of tamper evident-structure 60, and can be provided to tamper evident-structure 60 before or after zipper closure 20' is incorporated into package 10'.

20 Zipper closure 20" of FIG. 11 is shown incorporated into package 10" in FIG. 15. Zipper closure 20" includes crash regions 33", 35", notch 25, and slider device 50, all which were incorporated with zipper closure 20" by slider mounting system 200.

Package 10" is defined by a surrounding body, such as first and 25 second side panels (first side panel depicted at 12), which are joined at first side edge 13 and second side edge 15. Zipper closure 20" extends from first side edge 13 to second side edge 15 and is attached to the side panels by sealing flanges 42, 44. Slider device 50, mounted on zipper closure 20" over upper flanges 43, 45, can travel from first crush region 33" to second crush region 35" and does not 30 contact either of first side edge 13 or second side edge 15. FIG. 15A shown an enlarged view of second side edge 15 and second crush region 35". Second crush region 35" includes a section 37 which extends inward from and provides a spacing from side edge 15. Section 37 can be angled, as shown in FIG. 15A, or can be any shape, and can be formed simultaneously with crush region 35".

A tamper-evident structure 60 is disposed over zipper closure 20" and slider device 50 opposite bottom edge 18. In order to access the interior of package 5 10", tamper-evident structure 60 needs to be penetrated. A line of weakness 65 is provided to facilitate removal of tamper evident-structure 60.

Zipper closure 20"' of FIG. 12 is shown incorporated into package 10"' in FIG. 16. Zipper closure 20"' includes V-regions 33"', 35"', notch 25, and slider device 50, all which were incorporated with zipper closure 20"' by slider 10 mounting system 200.

Package 10"' is defined by a surrounding body having first side edge 13 and second side edge 15. Zipper closure 20"' extends from first side edge 13 to second side edge 15 and is attached to the side panels by sealing flanges 42, 44.

Slider device 50, mounted on zipper closure 20"', can travel from first Vregion 15 33"' to second V-region 35"' and does not contact either of first side edge 13 or second side edge 15. A tamper-evident structure 60 is disposed over zipper closure 20"' and slider device 50 opposite bottom edge 18. A line of weakness 65 is provided to facilitate removal of tamper evident-structure 60.

The resulting packages may be filled, for example through the top (if 20 tamper evident-structure 60 is not permanently sealed, and preferably, if closure profiles 22, 24 (FIGS. 2 and 3) are mated, or through the bottom edge 18. Alternately, the packages can be sold to consumers empty, for filling at a later time.

To open any of package 10' of FIG. 14, package 10" of FIG. 15, or package 10"' of FIG. 16, tamper evident-structure 60 is removed by separating 25 tamper evident-structure 60 from first and second side panels along line of weakness 65. This is shown in FIGS. 14 and 16.

The above specification and examples are believed to provide a complete description of the manufacture and use of particular embodiments of the invention. Many embodiments of the invention can be made.

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Claims (1)

1. A method of making a zipper closure; the method comprising:

(a) providing a first closure profile and a second closure profile, the first closure profile releasably interlockable with the second closure profile, 5 each of the first closure profile and the second closure profile having an upper flange; (b) mounting a slider device onto each of the first closure profile and the second closure profile, the slider device constructed and arranged to interlock the first closure profile with the second closure profile when the 10 slider device is moved in a first direction, and to disengage the first closure profile from the second closure profile when the slider device is moved in a second opposite direction; and (c) forming a first slider stop and a second slider stop at least on the upper flange of each of the first closure profile and the second closure profile, 15 with the slider device positioned between the first slider stop and the second slider stop; wherein the steps of mounting a slider device and forming a first slider stop and a second slider stop are done essentially simultaneously.

2. The method according to claim 1, wherein prior to the steps of 20 mounting the slider device and forming a first slider stop and a second slider stop, the method further comprises:

(a) releasably fixedly securing the first closure profile and the second closure profile.

3. The method according to claim 2, wherein the step of forming a first 25 slider stop and a second slider stop comprises:

(a) forming a first slider stop and a second slider stop by the application of heat and pressure for a time period to the first closure profile and the second closure profile.

4. The method according to claim 2, further comprising:

30 (a) punching a notch in the zipper closure.

5. The method according to claim 4, wherein the step of releasably securing the first closure profile and the second closure profile is done prior to the step of punching a notch in the zipper closure.

6. The method according to claim 4, wherein the step of providing a first closure profile and a second closure profile comprises:

(a) providing the first closure profile interlocked with the second 5 closure profile.

7. The method according to claim 6, wherein the step of the step of punching a notch is done essentially simultaneously with the steps of mounting a slider device and forming a first slider stop and second slider stop.

8. The method according to claim 6, wherein the step of the step of 10 punching a notch is done prior to the steps of mounting a slider device and forming a first slider stop and second slider stop.

9. The method according to claim 6, wherein after the steps of punching a notch, mounting a slider device, and forming a first slider stop and a second slider stop, the method further comprises:

15 (a) indexing the first closure profile and the second closure profile.

10. The method according to claim 4, wherein:

(a) the step of providing a first closure profile and a second closure profile comprises providing the first closure profile disengaged from the second closure profile; and 20 (b) the step of punching a notch is done prior to the steps of mounting a slider device and forming a first slider stop and second slider stop.

11. The method according to claim 10, wherein after the steps of mounting a slider device and forming a first slider stop and a second slider stop, the method further comprises:

25 (a) indexing the first closure profile and the second closure profile.

12. An extended length of zipper closure comprising:

(a) a plurality of sections, each section defined by a first end and a second end, and each section comprising:

(i) a first closure profile and a second closure profile, the first 30 closure profile interlockable with the second closure profile, the first closure profile and the second closure profile being continuous along the plurality of sections; (ii) a slider device operably mounted on the first closure profile and the second closure profile, the slider device constructed and arranged to interlock the first closure profile with the second closure profile when the slider device is moved in a first direction, and disengage the first closure profile from the second closure profile when the slider device is moved in a second opposite direction; and 5 (iii) a first slider stop at the first end of the section, and a second slider stop at the second end of the section, the slider device mounted between the first slider stop and the second slider stop.

13. The extended length of zipper closure according to claim 12, further comprising:

10 (a) a notch within the first closure profile and the second closure profile, the notch positioned in close proximity to the first slider stop.

14. The extended length of zipper closure according to claim 13, wherein:

(a) the first closure profile and the second closure profile are interlocked.

15. The extended length of zipper closure according to claim 14, wherein:

(a) the slider device is positioned in close proximity to the first slider stop.

16. The extended length of zipper closure according to claim 12 wherein:

(a) the first closure profile and the second closure profile are disengaged.

17. The extended length of zipper closure according to claim 16, wherein:

(a) the slider device is positioned in close proximity to the second slider stop.

18. The extended length of zipper closure according to claim 12, wherein:

(a) each of the first slider stop and the second slider stop is an area of at least partially melted polymeric material.

19. The extended length of zipper closure according to claim 18, wherein:

(a) the second slider stop of a first section is connected to the first slider stop of a second section.

20. The extended length of zipper closure according to claim 18, 5 wherein:

(a) each of the first slider stop and the second slider stop comprise an area devoid of polymeric material.

21. The extended length of zipper closure according to claim 12, wound on a core.

10 22. An apparatus forprocessing an extended length of zipper closure, the apparatus comprising:

(a) a profile clamping unit for releasably holding the zipper closure; (b) a slider installation mechanism for mounting a slider device onto the zipper closure; and 15 (c) a slider stop seal unit for forming slider stop seals on the zipper closure, each of the profile clamping unit, slider installation mechanism, and slider stop seal unit within the apparatus to essentially simultaneously act on the zipper closure.

23, The apparatus according to claim 22, further comprising:

20 (a) a notch punch unit.

24. A method substantially as hereinbefore described with reference to the accompanying drawings.

25. An extended length zipper as hereinbefore described with reference to the accompanying drawings 26. An apparatus substantially as hereinbefore described with reference to the accompanying drawings -