US20100284633A1 - Discrete pouch having a closure system secured thereto - Google Patents

Abstract

A discrete pouch is disclosed having a closure system transversely secured across an open end thereof. The discrete pouch includes first and second major surfaces joined together by a pair of sides. The discrete pouch also has a closed bottom, an open top, and a closure system secured to the second major surface adjacent to the open top. The discrete pouch is designed to have the open top sealed after it is filled with products and the closure system is capable of being opened and closed multiple times.

Description

FIELD OF THE INVENTION
• This invention relates to a discrete pouch having a closure system secured thereto. The closure system is secured in a transverse direction which is perpendicular to the machine direction in which the discrete pouch is advancing.
BACKGROUND OF THE INVENTION
• Today, it is commonplace to find a variety of flexible pouches which include a closure system, such as a zipper, that can be opened and closed multiple times by the ultimate consumer. These reclosable pouches are used to enclose and/or hold a wide variety of items, articles or products in solid, semi-solid or liquid form. One or more items, articles or products can be manufactured or assembled and then be packaged in these pouches. The pouches and the enclosed items, articles or products can then be shipped to wholesalers, distributors and retailers for sale to the general public. The ultimate consumers can purchase the items, articles or products packaged in these pouches at grocery stores, mass merchandise stores, home improvement stores, garden supply stores, feed stores, etc. Examples of some items, articles and products that can be enclosed in such pouches include but are not limited to: food items in solid form such as fruit, vegetables, meats, candy, cookies, snacks, etc. and food items in liquid form such as non-carbonated juices, milk, sauces, etc; personal items such as medicine, cough drops, tobacco, cosmetics, toys, office supplies, etc; household items such as plastic knives, forks and spoons, cups, rubber bands, tacks, screws, hooks, laundry detergent, soap, etc; lawn and garden items such as grass seed, fertilizer, flower seeds, pet food, animal bedding material such as wood chips, etc., and various other items such as medical instruments, dental instruments, hardware, computer parts, sporting goods, etc.
• The closure system used on such pouches can vary in design. A common closure system is in the form of a zipper having a track with an opening/closing mechanism and a slide member movably attached to the opening/closing mechanism. The slide member is designed to be manually moved back and forth along the track such that the pouch can be opened or closed multiple times. This ability to open and close the pouch multiple times, permits the ultimate consumer to remove only a portion of the items, articles or products enclosed therein at any one time. Alternatively, a consumer can insert or refill the pouch if desired. The pouch can be closed or resealed to keep the remaining items, articles or products together. If the pouch is constructed from an air tight material or a fluid or liquid tight material, it may also be able to keep the items, articles or products enclosed therein fresh. This is especially important for many food items which are not all consumed at one time.
• Up until now, such reclosable pouches have been constructed using two basic methods. In the first method, which involves a two step process, a pouch without a closure system is manufactured in a first machine. The pouch includes a first major surface, an oppositely aligned second major surface, a pair of sides joining the first and second major surfaces together, a closed end and an open end. The pouch is then removed from the first machine and transported to a second machine. At the second machine, the pouch is reoriented such that its open end is aligned parallel to the machine direction. A closure system is then secured to the open end in the machine direction. This method tends to be cumbersome and limits the pouches from being manufactured at high speeds.
• The second method for manufacturing reclosable pouches involves an in-line process using a single machine. The closure system is first secured to a continuous flat strip of material. After the closure system is in place, the material is folded upon itself to form a tubular member. The tubular member is then intermittently sealed and transversely slit adjacent to the closure system to form discrete pouches. Although the second method is somewhat more efficient than the first method, it suffers from a major design flaw. That design flaw is that the closure system does not extend outward from the top end of the finished pouch. This makes it difficult for the ultimate consumer to locate and maneuver the slide member along the track when he or she desires to open and/or close the pouch.
• Now a discrete pouch having a closure system secured thereto has been invented. Each discrete pouch is constructed before the closure system is applied. The closure system is secured to each of the discrete pouches in a cross direction, perpendicular to the machine direction. The closure system is applied while each pouch advances in the machine direction. This allows a higher quality pouch to be manufactured as well as permitting the closure system to extend outward from the top end of the pouch. The finished, discrete pouches that are produced are aesthetically pleasing to the consumer and can be manufactured at a lower cost.
SUMMARY OF THE INVENTION
• Briefly, this invention relates to a discrete pouch having first and second major surfaces. The first major surface has a transverse edge with a predetermined pattern formed therein. The transverse edge has a pair of opposite ends. The second major surface is aligned opposite to the first major surface and also has a transverse edge with the predetermined pattern formed therein. The predetermined pattern formed in the first and second major surfaces has a contiguous boundary. The second major surface also has an inner surface. A pair of sides joins the first and second major surfaces together. The pair of sides can be secured to the first and second major surfaces by at least one longitudinal bond to form a tubular structure. Each of the discrete pouches also includes a seal which extends transversely across the tubular structure to form a closed bottom. Lastly, each of the discrete pouches includes a closure system. The closure system includes a track having a first leg and a second leg, with each leg having an outer surface. The outer surface of the first leg is secured to the inner surface of the second major surface adjacent to the transverse edge. The first and second legs are joined together by an opening/closing mechanism which includes a member capable of being manually moved back and forth such that the opening/closing mechanism can be sequentially opened and closed. The pair of opposite ends of the first major surface is secured to the outer surface of the second leg to form an open top located adjacent to the transverse edge of the first major surface. The open top is aligned opposite to the seal and is spaced apart therefrom.
• The general object of this invention is to provide a discrete pouch having a closure system secured thereto. A more specific object of this invention is to provide a discrete pouch having a closure system transversely secured across an open end of the discrete pouch.
• Another object of this invention is to provide a discrete pouch wherein the closure system is attached after the discrete pouch is constructed.
• A further object of this invention is to provide a discrete pouch having a closure system which is economical to manufacture.
• Still another object of this invention is to provide a discrete pouch having a closure system which can be manufactured at high speeds.
• Still further, an object of this invention is to provide a discrete pouch having a closure system transversely secured across an open end thereof, wherein the closure system can be opened and closed multiple times.
• Other objects and advantages of the present invention will become more apparent to those skilled in the art in view of the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a machine capable of producing discrete, reclosable pouches.
• FIG. 2 is a perspective view of a discrete pouch having a closure system that can be manually moved back and forth to open and close the discrete pouch multiple times.
• FIG. 3 is a side view of a closure system which includes a track having first and second legs, the first and second legs being joined together by a thin membrane, an opening/closing mechanism joined to the first and second legs, and a slide member capable of being manually moved back and forth along the opening/closing mechanism.
• FIG. 4 is an end view of the closure system shown inFIG. 3, taken along line3-3 but without the slide member, and showing the opening/closing mechanism in a closed position and with the first and second legs being joined together by a thin membrane.
• FIG. 5 is an end view of the closure system shown inFIG. 3 when the opening/closing mechanism is in an open position and with the first and second legs being joined together by a thin membrane.
• FIG. 6 is a perspective view of the slide member shown inFIG. 3 which can be manually moved back and forth along the opening/closing mechanism so as to sequentially open and close the closure system.
• FIG. 7 is a perspective view of a web of material being unwound from a supply roll and having a predetermined pattern punched therein.
• FIG. 8 is a top view of the punched web of material depicting six fold lines where it will be folded to partially form a pair of gussets.
• FIG. 9 is a top view of the punched web of material shown inFIG. 7 after it has been folded in half upon itself and folded to form gussets at both sides.
• FIG. 10 is a perspective view of the continuous folded structure shown inFIG. 9.
• FIG. 11 is a cross sectional view taken along line11-11 ofFIG. 10 showing the folds and gussets.
• FIG. 12 is a perspective view of a continuous tubular structure once the web of material is bonded together.
• FIG. 13 is an enlarged view of a portion ofFIG. 12 showing a gusset.
• FIG. 14 is an end view of the tubular structure shown inFIG. 12 after four bonds have been formed.
• FIG. 15 is an end view of an alternative embodiment of a tubular structure having a single longitudinal bond.
• FIG. 16 is a perspective view of the continuous tubular structure with a transverse seal formed therein.
• FIG. 17 is an enlarged view of a portion ofFIG. 16 showing one end of the transverse seal.
• FIG. 18 is a perspective view of the continuous tubular structure with a crease and a stomp seal formed therein.
• FIG. 19 is an enlarged view of a portion ofFIG. 18 showing the crease and the stomp seal.
• FIG. 20 is a perspective view of the continuous tubular structure after being subjected to another punch.
• FIG. 21 is an enlarged view of a portion ofFIG. 20 showing the punched section.
• FIG. 22 is a perspective view of a discrete pouch after it has been slit or cut from the continuous web.
• FIG. 23 is a perspective view of a rearward portion of the machine.
• FIG. 24 is a perspective view of the discrete article shown inFIG. 22 after the lip has been folded back upon itself.
• FIG. 25 is an enlarged view of a portion ofFIG. 24 showing the lip being folded back and exposing the inside of the second major surface.
• FIG. 26 is a perspective view of the discrete article shown inFIG. 24 after a closure system has been secured to the inner surface of the second major surface.
• FIG. 27 is a perspective view of the discrete pouch shown inFIG. 26 after the lip is folded back and its ends are sealed.
• FIG. 28 is a perspective view of a discrete pouch having a closure system secured to its second major surface and having its sides manipulated to form an enlarged opening adjacent to the open top.
DETAILED DESCRIPTION OF THE INVENTION
• Referring toFIGS. 1 and 2, amachine10 and adiscrete pouch12, respectively, are shown. Themachine10 is capable of manufacturing a plurality of thediscrete pouches12 in a cost effective and efficient manner. By “discrete” pouch it is meant a distinct thing. Thediscrete pouches12 can be formed or constructed from one or more different materials. The kinds of material used to construct thediscrete pouch12 can vary. Thediscrete pouch12 can be constructed from a variety of different material including but not limited to: a plastic material, a thermoplastic material, a cloth material, a film material, a polyolefin such as polyethylene or polypropylene, a low density polyethylene, a high density polyethylene, a low density polypropylene, a high density polypropylene, a polyester, a nylon material, a rayon material, a woven fabric, a non-woven fabric, cotton, paper, paper laminate, hemp, canvas, a woven polypropylene, a woven polyethylene, a mono-layered film, a multilayer film, a corn starched material, a compostable material, etc. Thediscrete pouches12 can also be formed from a combination of two or more similar or different materials. Thediscrete pouches12 can further be formed or constructed from any of the new green materials now being manufactured that are environmentally friendly. Desirably, thediscrete pouches12 are formed or constructed from a thermoplastic material. More desirably, thediscrete pouches12 are formed or constructed from polyethylene, polypropylene or a combination thereof.
• Furthermore, thediscrete pouches12 can be formed from a laminate consisting of two or more layers. The various layers of the laminate can be identical, similar or be different in composition from an adjacent layer. At least one of the layers of the laminate can be constructed so as to prevent air from passing therethrough. Alternatively, at least one of the layers of the laminate can be constructed so as to prevent a fluid or a liquid from passing therethrough.
• Thediscrete pouches12 can be formed or constructed from a continuous sheet of material or from two or more individual pieces of material. Desirably, thediscrete pouches12 are formed or constructed from a continuous single web of material. The thickness of the web used to form or construct each of thediscrete pouches12 can vary.
• Referring toFIG. 2, each of thediscrete pouches12 has a firstmajor surface14 and an oppositely aligned secondmajor surface16. For example, the firstmajor surface14 can represent the front of thediscrete pouch12 and the second major surface can represent the back of thediscrete pouch12. Thediscrete pouch12 also has a pair ofsides18 and20 which join the first and second major surfaces,14 and16 respectively, together. The pair ofsides18 and20 can vary in size and configuration. One or both of the pair ofsides18 and20 can be configured as a single fold, as a strip of material having a predetermined width, be shaped as a gusset or have some other desired shape. InFIG. 2, each of thesides18 and20 contain agusset22. By “gusset” it is meant a triangular insert or profile, as in the seam of a garment, for added strength or expansion. Thediscrete pouch12 further has a closed bottom24 and an open top26. The open top26 should extend across at least 50% of a face width w₁of the finisheddiscrete pouch12. Desirably, the open top26 will extend across at least 75% of the face width w₁of the finisheddiscrete pouch12. More desirably, the open top26 will extend across at least 90% of the face width w₁of the finisheddiscrete pouch12. Even more desirably, the open top26 will extend across at least 95% of the face width w₁of the finisheddiscrete pouch12.
• Aclosure system28 can be secured at or adjacent to the open top26 so that thediscrete pouch12 can be sequentially opened or closed. Those skilled in the art sometimes refer to thediscrete pouches12 as “reclosable pouches”. Theclosure system28 can be constructed in various shapes and designs. Desirably, theclosure system28 is a zipper. Those skilled in packaging will be familiar with various zipper designs.
• Referring now toFIGS. 3-6, theclosure system28 will be described and is depicted as a zipper. However, various other closure systems are known to those skilled in the packaging art and can be used as well. Examples of a closure system that includes a zipper are taught in U.S. Pat. Nos. 4,909,017; 5,638,586; 6,805,485; 6,931,820; 6,986,237; 6,991,372 and 7,211,036; and 7,249,400.
• It should be understood that theclosure system28 can vary in construction, profile and configuration. In addition, theclosure system28 does not have to include a zipper although many reclosable pouches do utilize a zipper.
• Theclosure system28 can be constructed from a single material or from two or more similar or different materials. Desirably, theclosure system28 is constructed from a single material. Theclosure system28 can include various components. For purposes of discussion only, theclosure system28 includes at least three components. Theclosure system28 includes atrack30 having afirst leg32 and asecond leg34. Thefirst leg32 has aninner surface36 and anouter surface38. Theouter surface38 can contain a heat activated substance which enables theouter surface38 to bond to another material. For example, the heat activated substance can be an additive, a sealant which assist in forming a thermal bond, a fiber having a low melt temperature, a film having a low melt temperature, an adhesive, etc.
• Thesecond leg34 also has aninner surface40 and anouter surface42. Like theouter surface38 of thefirst leg32, theouter surface42 of thesecond leg34 can contain a heat activated substance as described above which enables theouter surface42 to bond to another material.
• Referring toFIGS. 4 and 5, the first and second legs,32 and34 respectively, can be folded upon themselves or they can be joined together by other means known to those skilled in the art. Optionally, athin membrane44 can join thefirst leg32 to thesecond leg34. Thethin membrane44 can be integral with the first and second legs,32 and34 respectively. When thethin membrane44 is present, it is usually situated away from either end of the first and second legs,32 and34 respectively. Thethin membrane44 functions as a breakable seal that must be broken, ruptured or severed before the contents of thediscrete pouch12 can be removed. Thethin membrane44 can be scored such that it has a cut which extends partially through its thickness such that it can be easily broken or separated. Alternatively, thethin membrane44 can have an area or line of weakness or reduced thickness, be notched to facilitate breakability, or be treated in some fashion to make it susceptible to be easily broken. With the design depicted inFIGS. 4 and 5, as one pulls apart the upper portions of the first and second legs,32 and34 respectively, thethin membrane44 is easily broken.
• Thethin membrane44 can be formed from the same material used to construct theclosure system28. Alternatively, thethin membrane44 can be constructed of one or more materials such that an air tight or a liquid tight seal is created. Thethin membrane44 will serve as a physical barrier to prevent contaminants from contacting the items, articles or products contained within thediscrete pouch12 until thethin membrane44 is broken. Thethin membrane44 can also serve as a tamper resistance seal to alert the ultimate consumer that no one has removed any items, articles or products from thediscrete pouch12 if thethin membrane44 is not broken.
• It should be understood that thethin membrane44 is an optional feature and does not have to be present if it is not needed.
• Referring again toFIGS. 3-5, theclosure system28 also includes an opening/closing mechanism46 having afirst part48 and asecond part50. InFIG. 4, the opening/closing mechanism46 is closed, and inFIG. 5, the opening/closing mechanism46 is opened. Thefirst part48 is connected to the upper end of thefirst leg32 and thesecond part50 is connected to the upper end of thesecond leg34. The opening/closing mechanism46 is constructed such that thefirst part48 is sized and configured to engage with and temporarily lock to thesecond part50. The twoparts48 and50 can be formed from the same material or from a different material. As best shown inFIGS. 4 and 5, thefirst part48 has a generally C-shaped cross-section with a finger which extends upward and inward from the C-shaped cross-section. Thesecond part50 is generally hook shaped with a finger extending upward and inward from the hook shaped cross-section. The hook shaped cross-section of thesecond part50 is sized and configured to engage with and temporarily lock to thefirst part48 when the twoparts48 and50 are pressed together. When so engaged, seeFIG. 4, the pair of upward and inwardly extending fingers will approach and/or abut one another. When the first and second parts,48 and50 respectively, of the opening/closing mechanism46 are separated from one another and moved away from one another, the opening/closing mechanism46 will be in an open position, seeFIG. 5.
• It should be understood that opening the opening/closing mechanism46 will not necessarily break thethin membrane44. In order to break thethin membrane44, when it is present, one must forcibly pull thefirst part48 away from thesecond part50 such that the first and second legs,32 and34 respectively, will move apart and cause thethin membrane44 to break. It should also be noted that once thethin membrane44 is broken, it will remain broken and cannot be resealed.
• It should also be understood that the opening/closing mechanism46, depicted inFIGS. 4 and 5, is but one embodiment. Those skilled in the packaging art will know of other ways to modified or alter the design of the opening/closing mechanism46 while still providing for a similar function.
• Referring now toFIGS. 3 and 6, theclosure system28 further includes amember52. Themember52 can be a slidable member that is sized and configured to allow a person to pinch or grasp themember52 between the tips of his or her thumb and forefinger on either hand. As best depicted inFIG. 6, themember52 has atop wall54 and first and second sidewalls,56 and58 respectively, which extend downwardly from thetop wall54. Thetop wall54 can have a relatively smooth upper surface or be scored. Thetop wall54 can be flat or contoured. The first and second sidewalls,56 and58 respectively, are aligned opposite to one another and each can be flat, contoured. Desirably, eachside wall56 and58 has a concave profile. The concave profile is sized to easily receive the tips of a person thumb and forefinger and allows themember52 to be moved back and forth without escaping from the person's grip. Each of the first and second sidewalls,56 and58 respectively, has an inwardly directed flange,60 and62 respectively. The two inwardly directedflanges60 and62 face one another but do not touch. The two inwardly directedflanges60 and62 are sized and configured such that one will contact theouter surface38 of thefirst leg32 while the other flange contacts theouter surface42 of thesecond leg34. Themember52 also has atongue64, seeFIG. 6, formed at one end thereof which extends downwardly from the inner surface of thetop wall54. Thetongue64 is located between the first and second sidewalls,56 and58 respectively, but is spaced from the inner surfaces of the first and second sidewalls,56 and58 respectively. Thetongue64 is also distally spaced away from theflanges60 and62.
• Themember52 is constructed and designed to interact with the opening/closing mechanism46 so as to cause the opening/closing mechanism46 to open when themember52 is slid or moved in a first direction and to subsequently cause the opening/closing mechanism46 to close when themember52 is slid or moved in a second opposite direction. Themember52 is capable of being manually moved back and forth along the opening/closing mechanism46 such that the opening/closing mechanism46 can be opened and closed. This is accomplished by having thetongue64 engage with opening/closing mechanism46 such that it can cause the twoparts48 and50 to separate from one another. As themember52 is moved in an opposite second direction, the first and second flanges,60 and62 will urge or force the twoparts48 and50 of the opening/closing mechanism46 to contact one another and engage. This allows the twoparts48 and50 to seal close thediscrete pouch12.
• Themember52 can be formed or constructed from the same material as was used to construct the remainder of theclosure system28 or it can be formed or constructed from a different material. Desirably, themember52 is constructed from a different material. More desirably, themember52 is formed from a hard plastic. The material from which themember52 is formed or constructed can include a color additive so that themember52 is more visible to the ultimate consumer who will use thediscrete pouch12.
• Referring again toFIG. 2, when thediscrete pouch12 is filled with items, articles or products and is offered for sale by a retailer, it will usually have the opening/closing mechanism46 in a closed position. In this position, themember52 will be situated at one end of thetrack30. As themember52 is moved or slid in a first direction away from theside18 and towards theopposite side20, the opening/closing mechanism46 will be forced open by thetongue64. With the first and second parts,48 and50 respectively, of the opening/closing mechanism46 spaced apart from one another, the ultimate consumer can pull the firstmajor surface14 away from the secondmajor surface16 and this will cause thethin membrane44, when present, to sever or break. The ultimate consumer will now have access to the items, articles or products contained in thediscrete pouch12. As themember52 is moved or slid in an opposite second direction, back toward theside18, themember52 will urge or force the first and second parts,48 and50 respectively, of the opening/closing mechanism46 to again engage, via theflanges60 and62, and close theclosure system28. Theclosure system28 can be moved back and forth multiple times such that thediscrete pouch12 can be opened and closed multiple times. Once thediscrete pouch12 is empty of its items, articles or products, it can be discarded. Alternatively, thediscrete pouch12 can be refilled with some other items and continue to serve as a usefuldiscrete pouch12.
• Referring now toFIGS. 1 and 7, themachine10 is capable of forming or constructing thediscrete pouch12 in a single in-line process and securing theclosure system28 in a transverse direction as thediscrete pouch12 advances in the machine direction (MD). The transverse direction at which theclosure system28 is secured is aligned perpendicular to the machine direction (MD). Themachine10 has an unwindstation66 which is capable of unwinding a web ofmaterial68 from asupply roll70. Thesupply roll70 is a cylindrical roll of aparticular material68 from which thediscrete pouches12 will be manufactured. Thesupply roll70 can vary in diameter and width. Desirably, thesupply roll70 has a diameter of less than about 4 feet and a width of less than about 6 feet. More desirably, thesupply roll70 has a diameter of less than about 3 feet and a width of less than about 3 feet. Thesupply roll70 can be a roll of thermoplastic or polyolefin material. However, as mentioned above, thematerial68 wound on thesupply roll70 can be also any kind of material known to those in the packaging art that is currently used to construct flexible pouches.
• The web ofmaterial68 can be unwound from thesupply roll70 in either the clockwise or counterclockwise direction. InFIG. 1, the web ofmaterial68 is unwound in the counter clockwise direction and the forward end of the web ofmaterial68 is advanced through themachine10 in a machine direction (MD). The machine direction (MD) extends from right to left inFIG. 1.
• Referring again toFIG. 7, as the web ofmaterial68 is unwound from thesupply roll70 it will become a planar web. The web ofmaterial68 is relatively flat and has afirst surface72 and an oppositely alignedsecond surface74. For example, thefirst surface72 can be the upper surface and thesecond surface74 can be the lower surface. Thefirst surface72 can be folded so as to be either the interior or exterior surface of the finisheddiscrete pouch12. Themachine10 and the process of forming thediscrete pouches12 will be explained with the first orupper surface72 being folded down and under itself such that thefirst surface72 will become the exterior surface of the finisheddiscrete pouches12. As this occurs, the second orlower surface74 will become the interior surface of the finisheddiscrete pouches12. The surface of the web ofmaterial68 that forms the exterior surface of thediscrete pouches12 can be printed to display words, numbers, symbols, graphics, photos, etc. Thefirst surface72 can also be partially or fully colored. One or more colors can be present on thefirst surface72 and each of the colors can vary to suit one's particular printed image. Additionally, the first orexterior surface72 can be treated, contain an additive, a sealant or some other substance to give it a glossy aesthetic appearance. To the contrary, thesecond surface74 of the web ofmaterial68 is usually void of any printing, coloring or coating. However, thesecond surface74 may contain a sealant, if desired. The reason that thesecond surface74 is void of any printing, coloring or coating is that thesecond surface74 will eventually form the interior surface of thediscrete pouches12 and a portion of the second orinterior surface74 will need to be bonded to another interior portion of the web ofmaterial68. The absence of any printing, coating or coloring will facilitate bonding. Those skilled in the art will recognize that, especially for plastic and thermoplastic material, the absence of any printing, coloring or coating is usually a requirement in order to be able to form a good bond. This is especially true if heat and pressure are being used to form the bond.
• The web ofmaterial68 advancing through themachine10 also has afirst side edge76 and an opposite,second side edge78. The web ofmaterial68 has a width w extending perpendicular between the first and second side edges,76 and78 respectively. The width w can vary. Desirably, the width w is less than about 4 feet. More desirably, the width w is less than about 3.5 feet. More desirably, the width w is less than about 3 feet.
• Referring again toFIG. 1, the relatively flat web ofmaterial68 is advanced to afirst dancer80 having a draw nip (not shown). Thefirst dancer80 can be a horizontal dancer or any other form of dancer. Thefirst dancer80 is capable of continuously adjusting the advancement of the web ofmaterial68 such that the material68 can make a transition from continuous motion, as it leaves thesupply roll70, to intermittent motion. Those skilled in art of manufacturing machines will be familiar with the function and operation of thedancer80. Thedancer80 can contain a plurality of vertically movable, cylindrical rolls around which the web ofmaterial68 flows in a serpentine fashion. The cylindrical rolls are capable of constantly changing their vertical position with respect to one another such that theincoming material68 can make the transition from a continuous motion to an intermittent motion.
• Still referring toFIG. 1, located downstream from thefirst dancer80 and from the unwindstation66, as the web ofmaterial68 moves in the machine direction (MD), is apunch station82. Thepunch station82 is capable of punching apredetermined pattern84 through theweb66. Alternatively, thepredetermined pattern84 can be cut using equipment other than a punch. Thepunch station82 can include one ormore punch units86 each capable of punching theparticular pattern84 through the web ofmaterial68. InFIG. 1, twopunch units86,86 are depicted. Each of thepunch units86,86 can be identical or different. For example, each of thepunch units86,86 can punch a portion of the overallpredetermined pattern84. Alternatively, the first of thepunch units86 can punch out theentire pattern84 and the second or subsequent punch unit(s)86 can provide a trim punch to make sure thepredetermined pattern84 is crisp, sharp and registered correctly in the advancing web ofmaterial68.
• Referring again toFIG. 7, thepredetermined pattern84 is repeated at a predetermined dimension b through the web ofmaterial68. The dimension b is measured parallel to the machine direction (MD) of the web ofmaterial68. The dimension b can vary depending upon the size of thediscrete pouches12 one desires to manufacture. Thepredetermined pattern84 can also vary in configuration. Aconfiguration88 illustrates but one of an infinite variety of configurations that one can punch in the web ofmaterial68. As illustrated, theconfiguration88 includes a pair of spaced apart, approximately C-shapedconfigurations88,88 formed across the width w of the web ofmaterial68. Even though a pair of approximately C-shapedconfigurations88,88 is shown, it should be understood that thepredetermined pattern84 can consist of one or more configurations, each having a desired profile.
• It should be understood that when two or more configurations are present, that one configuration can be different from another configuration.
• Each of the pair of approximately C-shapedconfigurations88,88 will form an upper end of one of thegussets22 in the finisheddiscrete pouches12. Thegussets22,22 are formed at thesides18 and20 of each of thediscrete pouches12. If the design of thediscrete pouches12 does not includegussets22,22 then thepredetermined pattern84 would not have to be punched out of the web ofmaterial68.
• Still referring toFIG. 7, each of the pair of approximately C-shapedconfigurations88,88 is aligned along a common centerline a-a. Each of the centerlines a-a is aligned perpendicular to the machine direction (MD). Of the pair of approximately C-shapedconfigurations88,88 located along each of the centerlines a-a, one of the approximately C-shapedconfigurations88,88 is spaced apart from thefirst side edge76 by a dimension c. The dimension c can vary. Desirably, the dimension c is less than about 1 inch so as to reduce trim waste. The other approximately C-shapedconfiguration88 is spaced apart from thesecond side edge78 by a dimension d. The dimension d can vary. Desirably, the dimension d is several inches. InFIG. 7, the dimension d is greater than the dimension c. Furthermore, the pair ofconfiguration88,88 is separated by a distance e. The dimension e can vary. Desirably, the dimension e is usually several inches in length. The dimension e will range from between about 90% to about 99% of a face width w₁, of each of the finished,discrete pouches12. Desirably, the dimension e will range from between about 95% to about 99% of the face width w₁of each of the finished,discrete pouches12. By “face width” it is meant the width w₁measured perpendicular between thesides18 and20 of the firstmajor surface14 of each of the finished,discrete pouches12. The face width w₁is usually less than half of the width w of the web ofmaterial68.
• Each of the pair of approximately C-shapedconfigurations88,88 has abase member90 with two spaced apartlegs92 and94. Thelegs92 and94 extend outward from the ends of thebase member90 in the machine direction (MD). Thebase member90 has a dimension or length f measured parallel to the centerline a-a. The dimension f can vary but is usually several inches in length. For example, for adiscrete pouch12 having a face width w₁of about 16 inches, the dimension f of thebase member90 can range from between about 4 inches to about 10 inches. More desirably, for adiscrete pouch12 having a face width w₁of about 16 inches, the dimension f of thebase member90 can range from between about 6 inches to about 9 inches. The twolegs92 and94 are aligned approximately parallel to one another and approximately parallel to the machine direction (MD). The twolegs92 and94 can be aligned perpendicular to thebase member90 or be oriented at an angle thereto. Desirably, the twolegs92 and94 are aligned perpendicular to thebase member90. The dimension of eachleg92 and94 can vary. Desirably, eachleg92 and94 has the same dimension. Each of the twolegs92 and94 extend outward from an end of thebase member90 in a downstream fashion. The overall size ofbase member90 and each of the two spaced apartlegs92 and94 can vary but will be sized to correspond to a particular sizediscrete pouch12. For example, the overall size of each of the pair of approximately C-shapedconfigurations88,88 can become larger as the size of thediscrete pouches12 get larger.
• InFIG. 7, the dimension or length f of thebase member90 is sized such that it can be folded half way along the length f to form a pair ofgussets22,22. Each of thegussets22,22 will have a width equal to or less than about half of the dimension f.
• One will also notice that a pair of small apertures or holes96,96 are punched through the web ofmaterial68 adjacent to thebase member90 of each of the pair ofconfigurations88,88. Theseapertures96,96 are optional and can vary in size and shape. Desirably, theapertures96,96 are circular in shape and having a diameter of at least about 0.1 inches. Desirably, eachaperture96 has a minimum dimension which ranges from between about 0.1 inches to about 1.5 inches. The presence of the pair ofapertures96,96 makes it easier to form bonds between various portions of the interior surface of thediscrete pouches12. This is especially true at those areas where thegussets22,22 are located. This will be explained in greater detail below when discussing the process.
• Returning toFIG. 1, the web ofmaterial68 is advanced downstream from thepunch station82 to asecond dancer98. Thesecond dancer98 can be equipped with a draw nip (not shown). Thesecond dancer98 can also be a vertical dancer like thefirst dancer80 or it can be any other kind of dancer. Thesecond dancer98 can be identical to thefirst dancer80. Thesecond dancer98 is capable of continuously adjusting the advancement of the web ofmaterial68 such that theweb68 can make a transition from the intermittent motion that it has as it leaves thepunch station82, back to a continuous motion.
• Still referring toFIG. 1, located downstream of thesecond dancer98 and downstream of thepunch station82 is afolding station100. Thefolding station100 is capable of folding the web ofmaterial68 upon itself such that thefirst surface72 forms the exterior of the finished,discrete pouches12, and thesecond surface74 forms the interior of the finished,discrete pouches12. Thefolding station100 can include various stationary or movable components such as bars, plates, moveable fingers, etc. which can fold the web ofmaterial68 into a desired configuration. Such folding machines are well known to those skilled in the art.
• Referring toFIGS. 8-11, the web ofmaterial68 is shown with sixfold lines102,104,106,108,110 and112 shown as dashed lines. Each of thefold lines102,104,106,108,110 and112 are aligned parallel to one another and also are aligned parallel to the machine direction (MD) of the advancing web ofmaterial68. Desirably, the sixfold lines102,104,106,108,110 and112 are aligned parallel to the first and/or second side edges,76 and78 respectively. The web ofmaterial68 is folded at the threefold lines102,104 and106 to form agusset22 at theside18, seeFIG. 2. The web ofmaterial68 is also folded at the threefold lines108,110 and112 to form agusset22 at theopposite side20, seeFIG. 2. In addition, the web ofmaterial68 is folded in half upon itself atfold lines108 and112 to form a foldedweb114, seeFIGS. 9-11.
• Once the web ofmaterial68 is folded upon itself, thepredetermined pattern84, which can consist of one or more cuts, is present in both the first and second major surfaces,14 and16 respectively. Thepredetermined pattern84 formed in the first and second major surfaces,14 and16 respectively, has a contiguous boundary.
• Referring again toFIG. 1 the foldedweb114 is then advanced through athird dancer116. Thethird dancer116 does not include a draw nip. Thethird dancer116 can be a horizontal dancer or any other form of dancer. Desirably, thethird dancer116 is a horizontal dancer. Thethird dancer116 is capable of adjusting the advancement of the foldedweb114 such that the foldedweb114 can make a transition from continuous motion, as it leaves thefolding station100, back to an intermittent motion. Located downstream of thethird dancer116 is a draw mechanism118 which includes a pair of draw rolls (not shown) having a nip formed therebetween. The draw mechanism118 functions to advance the foldedweb112 into abonding station120.
• Referring again toFIG. 1, thebonding station120 is located downstream from thefolding station100 and from thethird dancer116. Thebonding station120 can include one ormore bonding units122. Two spaced apart bondingunits122 are depicted. Eachbonding unit122 is aligned parallel to the machine direction (MD).
• Referring now toFIGS. 12-14, each of thebonding units122 is capable of forming one or more spaced apartbonds124 in the overlapped material. Fourlongitudinal bonds124 are depicted adjacent to thefold lines102,106,108 and112. Each of the fourbonds124,124,124 and124 can be continuous or intermittent. Desirably, each of the fourbonds124,124,124 and124 is a continuous bond. To facilitate a good bond, thesecond surface74 should not be printed, colored, coated or contain any substance which could interfere with establishing a good strong bond. Once the fourbonds124,124,124 and124 are formed, a continuoustubular structure126 is formed. The fourbonds124,124,124 and124 can be located approximate each of the four corners of thetubular structure126. In thetubular structure126, two of thebonds124,124 are formed adjacent to theside18 and the remaining twobonds124,124 are formed adjacent to theside20 of the finished,discrete pouch12. Each of thebonds124,124,124 and124 can be formed by using heat, pressure, heat and pressure, ultrasonics, adhesive, glue, a co-adhesive, double sided tape, etc. In addition, each of thebonds124,124,124 and124 could be created by using a chemical bonding agent. A combination of heat, pressure and/or a chemical bonding agent can also be utilized. Desirably, each of the fourbonds124,124,124 and124 are formed by using a combination of heat and pressure. The fourbonds124,124,124 and124 secure a portion of thesecond surface74 to another portion of thesecond surface74. Theapertures96,96 which were punched in the web ofmaterial68 provide a means by which a portion of thesecond surface74 can be secured to another portion of thesecond surface74 in the vicinity of each of thegussets22,22. At each of the foldedsides18 and20 where thegussets22,22 are located, there are four layers of material. Theapertures96,96 permit the firstmajor surface14 to be directly bonded to the secondmajor surface16, seeFIG. 2. Those skilled in the bonding art will know of the kind of equipment needed in order to form thebonds124,124,124 and124.
• Referring toFIG. 15, an alternative embodiment is depicted showing a continuoustubular structure126′ wherein asingle bond124 is formed at or adjacent to thefold line102. Thebond124 is formed only at theside18 of the finisheddiscrete pouch12.
• Referring again toFIG. 1, when a thermal bond is utilized, a certain amount of heat will be generated which will be retained by the surrounding material. Depending upon the material from which thepouch12 is constructed, it may be advantageous to cool the material in which thebonds124,124,124 and124 have been formed so as to prevent the material from becoming deformed or damaged or to give the material a textured pattern. This is especially true when the material is a polyolefin, such as polyethylene or polypropylene. If too much heat is present or if the heat is maintained for an extended period of time from the bonding step, the material could melt and through holes could develop in thetubular structure126 or126′. This is detrimental to thefinished pouch12 and must be avoided. One way to dissipate or remove the heat that may be present from the bonding step is to advance the continuoustubular web126 or126′ downstream to acooling station128. InFIG. 1, thecooling station128 includes a pair of spaced apart coolingunits130,130 which are coaxially aligned with thebonding units122,122. The coolingunits130,130 are aligned parallel with the machine direction (MD). The coolingunits130,130 are spaced apart approximately the same distance as thebonding units122,122 so that they can cool the same region of the material of the foldedweb114 that was heated by thebonding units122,122.
• It should be understood that if thebonding station120 does not generate any heat or does not generate a sufficient amount of heat that needs to be removed, then thecooling station128 would not be needed.
• Referring again toFIG. 1, adraw unit132 is shown located downstream of both thecooling station128 and thebonding station120. Thedraw unit132 includes a pair of draw rolls (not shown) with a nip formed therebetween. Thedraw unit132 functions to advance thetubular structure126 or126′ through a sealingstation134. Those skilled in the art will recognize that thedraw unit132 could possibly be located downstream of the sealingstation134, if desired. For some applications, it may be possible to eliminate thedraw unit132 completely. However, as indicated inFIG. 1, thedraw unit132 functions to advance thetubular structure126 or126′ in an intermittent fashion.
• Referring now toFIGS. 1,16 and17, the sealingstation134 is located downstream from thebonding station120. The sealingstation134 is capable of forming one ormore seals136, seeFIGS. 16 and 17 in thetubular structure126 or126′. The size, shape and location of theseals136 can vary. Desirably, one of theseals136 will extend transversely across the continuoustubular structure126 or126′. Theseals136 can be formed adjacent to and upstream of each pair of theconfigurations88,88. The sealingstation134 can include one or more sealing units arranged downstream from one another. InFIG. 1, three sealingunits138,140 and142 are depicted. The three sealingunits138,140 and142 can apply heat, a combination of heat and pressure, or some other sealing process to form one or more of theseals136 in thetubular structure126 or126′. The temperature of the three sealingunits138,140 and142 can range from between about 100° Fahrenheit (F) to about 600° F. Desirably, the temperature of the sealingunits138,140 and142 can range from between about 200° F. to about 500° F. More desirably, the temperature of the sealingunits138,140 and142 is at least about 300° F.
• Referring toFIGS. 16 and 17, a particular configuration for theseal136 will be taught. However, it should be recognized that this invention is not limited to thisparticular seal136 configuration.
• Thefirst sealing unit138 can form an approximately K-shapedseal144 or a portion of an approximately K-shapedseal144 transversely across thetubular structure126 or126′. The actual construction of the approximately K-shapedseal144 includes anelongated segment146 and twoshorter segments148 and150. Theelongated segment146 and the twoshorter segments148 and150 can all vary in shape but desirably they are either linear or curvilinear. Most desirably, they are all linear. Theelongated segment146 spans transversely across a portion of or across the entire face width w₁of thetubular structure126 or126′. Desirably, theelongated segment146 spans completely across the face width w₁and is aligned perpendicular to the machine direction (MD). Theelongated segment146 can vary in width and depth but should form a sufficiently strong seal capable of permanently sealing the firstmajor surface14 to the secondmajor surface16, seeFIG. 2. The twoshorter segments148 and150 are angled outward from theelongated segment146 to form an approximately K-shape seal144. The twoshorter segments148 and150 are shown angling upstream from theelongated segment146 such that they extend away from theclosed bottom24. The exact angle theta θ that each of theshorter segments148 and150 are arranged relative to theelongated segment146 can vary. The angle θ can range from between about 5 degrees to about 75 degrees. Desirably, the angle θ is less than about 60 degrees. More desirably, the angle θ is less than about 45 degrees. Each of the twoshorter segments148 and150 intersect with one of thesides18 and20.
• It should be understood that thediscrete pouches12 can be designed to have only a single seal that is either linear or arcuate in configuration. In fact, theseal136 can be of any desired geometrical shape. The approximately K-shapedseal144 produces a much stronger seal and is advantageous when thediscrete pouches12 are large, for example when the discrete pouches have a face width w₁of 16 inches or more, and a height of 18 inches or more.Discrete pouches12 size to retain pet food and having a total weight of 10 pounds or more represent a good example of when the approximately K-shapedseal144 can be advantageously employed.
• Referring again toFIG. 1, all three of the sealingunits138,140 and142 can be utilized to form the approximately K-shapedseal144. This can be accomplished by have each of the three sealingunits138,140 and142 form a portion of the approximately K-shapedseal144. Alternatively, the sealingunit138 can form the complete approximately K-shapedseal144 and the sealingunits140 and142 can create a deeper and morepronounced seal144. Desirably, all three of the sealingunits138,140 and142 form a portion of the approximately K-shapedseal144 such that after the three sealingunits138,140 and142, the approximately K-shapedseal144 is completely formed.
• Referring again toFIGS. 1,18 and19, a crease and stompseal unit152 is located downstream of the sealingunits138,140 and142. The crease and stompseal unit152 is capable of forming acrease154, seeFIG. 18, transversely across thetubular structure126 or126′. Simultaneously or sequentially, the crease and stompseal unit152 is capable of forming astomp seal156 onto the approximately K-shapedseal144. Thestomp seal156 forms twosmall notches158 and160 approximate the location where each of theshorter segments148 and150 intersect with the elongatedlinear seal146. The purpose of thestomp seal156 is to crimp the first and secondmajor surfaces14 and16 so as to prevent products housed in thediscrete pouch12 from escaping or leaking out. This is important when a liquid or a small granular product is stored in thediscrete pouch12. Thestomp seal156 functions to reinforce the two lower corners of the finisheddiscrete pouch12. Thestomp seal156 may not be required in all applications. For example, if large items or articles are to be stored in thediscrete pouches12, one may not need to reinforce the corners of thediscrete pouches12 because such items or articles cannot escape or leak out.
• Referring again toFIG. 1, two coolingunits162 and164 are located downstream of the crease and stompseal unit152 and also downstream of the sealingunits138,140 and142. Thecooling unit164 is located downstream of thecooling unit162. The coolingunits162 and164 function to cool the approximately K-shapedseal144 and thestomp seal156 formed in thetubular structure126 or126′. It should be noted that the coolingunits162 and164 can be eliminated if they are not needed. When present, the coolingunits162 and164 can reduce the temperature of the material where theseals144 and152 were formed down to less than about 100° F., and desirably, down to around room temperature.
• The sealingstation134 can be viewed as including the three sealingunits138,140 and142, the crease and stompseal apparatus152, and the two coolingunits162 and164.
• Referring again toFIG. 1, apunch unit166 is located downstream of the coolingunits162 and164 and the crease and stompunit152. Thepunch unit166 can include a pair ofpunches168 and170 spaced apart from one another. The pair ofpunches168 and170 can be aligned opposite to one another so that they can punch opposite sides of thetubular structure126 or126′.
• Referring now toFIGS. 20 and 21, the pair ofpunches168 and170 can form a pair ofnotches172 and174 in thetubular structure126 or126′. Thenotch172 is formed adjacent to theside18 and thenotch174 is formed adjacent to theside20. The size and shape of each of thenotches172 and174 can vary. Desirably, bothnotches172 and174 are of the same size and configuration. As depicted, the twonotches172 and174 have a rectangular configuration but could have some other configuration, if desired.
• Referring again toFIG. 1, thetubular structure126 or126′ is advanced past a slittingstation176. The slittingstation176 is located downstream of thepunch unit166 and downstream of the sealingstation134. The slittingstation176 can be a servo cut-off knife, a rotary knife, or any other kind of cutting apparatus known to those skilled in the art.
• Referring now toFIG. 22, the slittingstation176 is capable of forming a slit or cut178 transversely across the continuoustubular structure126 or126′. The slit or cut178 occurs at the locations, depicted inFIG. 22, which is at or adjacent to the elongatedlinear seal146. The slittingstation176 slits, cuts or severs the continuoustubular structure126 or126′ into a plurality of thediscrete articles180. A multiplicity ofdiscrete articles180 can be formed from thetubular structure126 or126′. Since themachine10 is an in-line manufacturing process, the speed at which thediscrete articles180 can be manufactured is rather high.
• Referring again toFIG. 1, arearward portion182 of themachine10 is shown. Thisrearward portion182 can be assembled in-line with one or more of theupstream portions82,100,122 and134 of themachine10 as shown. Alternatively, therearward portion182 can be a standalone segment which is separated from the remainder of themachine10. Desirably, therearward portion182 is in-line and attached to theupstream portion134 of themachine10. Therearward portion182 includes afirst station184 which is capable of receiving and advancing each of thediscrete articles180 in the machine direction (MD). Thefirst station184 can be operated at a speed that is equal to or different from the speed of theupstream sealing station134. Desirably, thefirst station184 is operated at a speed that is faster than the speed of the sealingstation134. By running thefirst station184 at a faster speed than the sealingstation134, one can be assured that thediscrete articles180 are moved away from the advancing continuoustubular structure126 or126′ which is being slit at the slittingstation176.
• Referring now toFIG. 23, thefirst station184 includes astationary plate186 which serves as an entry point for thediscrete articles180. Thestationary plate186 is relatively flat and is aligned horizontally so as to provide support for each of thediscrete articles180. Positioned in axially alignment and downstream of thestationary plate186 is a firstcontinuous belt188 that rotates around a plurality of spaced apartrollers190. The exact number ofrollers190 can vary depending upon the length of thecontinuous belt188 and the path of thecontinuous belt188. The firstcontinuous belt188 can run along the entirefirst station184, as shown, or it could extend along the greater length of therearward portion182 of themachine10. Desirably, the firstcontinuous belt188 will run along the length of thefirst station184. The firstcontinuous belt188 is shown moving in a counter clockwise direction since the machine direction (MD) is from right to left. The firstcontinuous belt188 will serve as a movable platform for each of thediscrete articles180 as they advance through thefirst station184.
• The firstcontinuous belt188 can have a width that is equal to or greater than the face width w₁of each of thediscrete pouches12, seeFIG. 2. Desirably, the width of thefirst conveyor belt188 is wider than the face width w₁of each of thediscrete pouches12. More desirably, the width of thefirst conveyor belt188 is at least 4 inches wider than the face width w₁of each of thediscrete pouches12. The firstcontinuous belt188 functions to support the lower surface of each of thediscrete articles180 as they advance through thefirst station184.
• Still referring toFIG. 23, thefirst station184 also includes firstupper belts192 which are continuous and are movable around a plurality of spaced apartrollers194. Three firstupper belts192 are depicted inFIG. 23. It should be understood that one, two, three or more of the firstupper belts192 can be utilized depending upon the face width w₁of the finisheddiscrete pouch12. Each of the firstupper belts192 can have a width ranging from between about 1 inch to about 6 inches. Desirably, each of the firstupper belts192 has a width ranging from between about 1.5 inches to about 3 inches. Each of the firstupper belts192 is spaced apart from anadjacent belt192 and the firstupper belts192 can be aligned parallel to one another. The firstupper belts192 rotate in a clockwise direction.
• The number ofrollers194 around which the firstupper belts192 rotate can vary depending upon the size and configuration of the firstupper belts192. The firstupper belts192 cooperates with the firstcontinuous belt188 to form a nip196 therebetween through which each of thediscrete articles180 can be advanced. The speed of the firstupper belts192 can be adjusted to match the speed of thecontinuous belt188.
• Referring back toFIG. 22, each of thediscrete articles180 can be advanced through therearward portion182 of themachine10 with its K-shapedseal144 serving as the leading edge. In this orientation, thesides18 and20 are aligned parallel or approximately parallel to the machine direction (MD). In other words, theclosed bottom24 of each finisheddiscrete pouch12, seeFIG. 2, will lead thediscrete article180 through themachine10. It is important in attaching theclosure system28 to each of thediscrete articles180 that thesides18 and20 are aligned parallel or approximately parallel to the machine direction (MD). Alternatively, each of thediscrete articles180 can be advanced through therearward portion182 of themachine10 with the open top26, seeFIG. 2, or the unsealed end being the leading edge. This is a very unique aspect of themachine10. Up until now, applicants do not know of any machine that has the ability to feed adiscrete article180, in the machine direction (MD), through themachine10 with either theclosed end24 or theopen end26 serving as the lead.
• Referring now toFIGS. 1,2 and24-25, thefirst station184 also includes a number offingers198, which are capable of lifting and folding a portion of the firstmajor surface14 upon itself to form alip200. The number offingers198 can vary. Thefingers198 can be spaced apart from one another and can be aligned parallel to one another. There should be a sufficient number offingers198 to extend across the face width w₁of thediscrete pouch12. Desirably, there are at least two spaced apartfingers198 which extend across the face width w₁of thediscrete pouch12. More desirably, there are at least three spaced apartfingers198 which extend across the face width w₁of thediscrete pouch12. Even more desirably, there are at least four spaced apartfingers198 which extend across the face width w₁of thediscrete pouch12.
• It should be understood by those skilled in the art that thefingers198 could be replaced by some other mechanism that can accomplish the same function. For example, thefingers198 could be replaced by one or more vacuum bars, rotary brushes, static pinners, etc, or by some combination thereof.
• InFIGS. 24 and 25, thelip200 is shown being aligned approximately perpendicular to the machine direction (MD). Thelip200 has a length l, measured parallel to the machine direction (MD), which ranges from between about 0.25 inches to about 4 inches. Desirably, the length l of thelip200 ranges from between about 0.5 inches to about 3 inches. More desirably, the length l of thelip200 ranges from between about 0.75 inches to about 2 inches. As the material which forms thelip200 is folded, afirst surface202 of thelip200 faces upward and is exposed. The exposedfirst surface202 is a portion of the interior of the firstmajor surface14. The exposedfirst surface202 should not contain any printing, coloring or coating thereon. Thelip200 is distally spaced from atransverse edge204 of the secondmajor surface16 which forms thediscrete article180. The secondmajor surface16 also has aninner surface206 which is located adjacent to thetransverse edge204. Theinner surface206 faces upward and is exposed. The exposedinner surface206 also should not contain any printing, coloring or coating thereon. Furthermore, as thelip200 is formed, theinside surfaces208,208 of each of thegussets22,22 face upward and are exposed. Thesesurfaces208,208 also should not contain any printing, coloring or coating thereon.
• Referring again toFIGS. 1 and 23, thefirst station184 further includes secondupper belts210 which are continuous and are movable around a plurality of spaced apartrollers212. Like the firstupper belts192, the secondupper belts210 can be aligned parallel to one another and be spaced apart from one another. Three of the secondupper belts210 are depicted InFIGS. 1 and 23. However, the exact number of the secondupper belts210 that are utilized can vary. One, two, three or more of the secondupper belts210 can be present. The face width w₁of the finisheddiscrete pouches12 will partially determine how many of the secondupper belts210 are needed. The secondupper belts210 move in a clockwise direction.
• The number ofrollers212 needed can vary depending on the size and configuration of the secondupper belts210. The secondupper belts210 cooperate with thecontinuous belt188 to form a nip214 through which each of thediscrete articles180 can be advanced after leaving thefingers198. The secondupper belts210 can be similar or identical to the firstupper belts192. The secondupper belts210 are located downstream of thefingers198. Each of the secondupper belts210 can have a width ranging from between about 1 inch to about 6 inches. Desirably, the width of each of the secondupper belts210 ranges from between about 1.5 inches to about 3 inches. The speed of the secondupper belts210 can be adjusted to match the speed of thecontinuous belt188. Desirably, the firstupper belts192, the secondupper belts210 and thecontinuous belt188 all move at the same speed.
• Referring again toFIG. 23, thefirst station184 also has avacuum section216 located beneath thefirst station184. Thevacuum section216 can extend throughout the entire length of thefirst station184. Thevacuum section216 includes one ormore vacuum boxes218 and one or more vacuum plenums220 located below thevacuum boxes218. The size and shape of the twovacuum boxes218,218 and the two vacuum plenums220,220 can vary. Thevacuum section216 functions to hold the secondmajor surface16 of each of thediscrete articles180 securely against the continuousfirst conveyor belt188 as thelip200 is folded upon itself. Thevacuum section216 also functions to hold each of thediscrete articles180 such that thesides18 and20 are aligned parallel to the machine direction (MD). This allows thelip200 to be folded perpendicular to thesides18 and20 such that the length l of thelip200 remains constant. In other words, thelip200 will not be skewed relative to the machine direction (MD).
• Referring now toFIGS. 1,23 and26, therearward portion182 of themachine10 also includes asecond station222 located downstream from thefirst station184. Thesecond station222 is capable of positioning and attaching aclosure system28 transversely across the exposedinner surface206 of the secondmajor surface16, adjacent to thetransverse edge204. Thesecond station222 is also capable of cutting the strip material which forms theclosure system28 to a desired length l₁so that it has a length l₁equal to the face width w₁of the finisheddiscrete pouch12. Theclosure system28 is secured in place as each of thediscrete articles180 advances in the machine direction (MD) at a predetermined speed. Alternatively, each of thediscrete articles180 can be temporarily halted as theclosure system28 is attached, although this will slow down the production process. Desirably, theclosure system28 is attached to each of thediscrete articles180 as each of thediscrete articles180 is intermittently moved through therearward portion182 of themachine10. Thesecond station222 can be a commercially available unit from Illinois Tool Works Inc. of Glenview, Ill. The unit from Illinois Tool Works Inc. is designed to secure a zipper to an edge of a tubular structure or to a side of a discrete pouch but it can be modified to work with thepresent machine10. U.S. Pat. Nos. 4,878,987; 4,909,017; 5,557,907 are just a few that teach securing a closure system, for example a zipper, onto a bag material. Those skilled in the art will be familiar with other closure systems and apparatuses which could be utilized with thepresent machine10 with slight modifications.
• Referring toFIGS. 3,4 and26, one way of securing or attaching theclosure system28 to each of thediscrete articles180 is to seal or bond theouter surface38 of thesecond leg34 of each of theclosure systems28 to theinner surface206 of the secondmajor surface16, seeFIG. 26. Desirably, theclosure system28 is initially in the form of a continuous strip of material that can be advanced across the face width w₁of thediscrete article180 and then be cut to the required length l₁. Alternatively, the strip of material can first be secured or attached to theinner surface206 before it is cut to the desired length l₁. Theclosure system28 can be a typical zipper or any variation thereof. Theclosure system28 can be secured or attached by using heat, pressure, heat and pressure, an ultrasonic bond, by using an adhesive, by using a co-adhesive, by using double sided tape, by using a combination of any of the above or by using some other bonding method known to those skilled in the bonding art. Theclosure system28 could also be mechanically attached to theinner surface206. Desirably, theclosure system28 is secured to theinner surface206 by using heat and pressure. The amount of heat and pressure utilized will depend upon the materials from which the secondmajor surface16 and theclosure system28 are constructed of, the thickness of each material, the melting temperature of each material, etc.
• When theclosure system28 is in the form of a zipper, it can be secured to theinner surface206 of the secondmajor surface16 while the opening/closing mechanism46 is in either the closed position, seeFIG. 4, or in the open position, seeFIG. 5. Desirably, theclosure system28 is secured to theinner surface206 of the secondmajor surface16 while the opening/closing mechanism46 is in the closed position. Theslide member52 can be positioned on thetrack30 before, during or after theclosure system28 is secured to theinner surface206 of the secondmajor surface16.
• It should be recognized that theclosure system28 can be temporarily secured to theinner surface206 or be permanently attached to theinner surface206. If theclosure system28 is temporarily attached, then a second securement step will be needed to permanently attach theclosure system28 to theinner surface206. Desirably, theclosure system28 will be permanently attached to theinner surface206 in one step.
• The location of the securement of theclosure system28 to theinner surface206 and whether the securement is continuous or intermittent along the length of theclosure system28 can vary. For example, the securement can be a plurality of spot bonds, a continuous linear seal, an intermittent linear seal, etc. Desirably, the bond or securement will extend along essentially the entireinner surface206 of the secondmajor surface16. More desirably, the securement of theclosure system28 to theinner surface206 will be in the form of a continuous bond which extends along the entire length l₁of theclosure system28.
• It is to be understood that the length l₁of theclosure system28 should be essentially equal to the face width w₁of thediscrete pouch12. However, the length l₁of theclosure system28 could be slightly less than the face width w₁of thediscrete pouch12. For example, the length l₁of theclosure system28 could be slightly less than the face width w₁because of the material that was punched out of the continuous web ofmaterial68. Desirably, theclosure system28 should30310 be bonded or secured along its entire length l₁. Alternatively, theclosure system28 could be bonded or secured along essentially most of its length l₁.
• It should be noted that theclosure system28 can be permanently secured to theinner surface206 of the secondmajor surface16 at thesecond station222. Alternatively, theclosure system28 can be temporarily secured to theinner surface206 of the secondmajor surface16 at thesecond station222 and then be permanently secured using additional sealing units. The use of additional sealing units is shown inFIG. 23.
• Referring again toFIGS. 1 and 23, therearward portion182 of themachine10 includes asecond conveyor belt224 that rotates around a plurality of spaced apartrollers226. The exact number ofrollers226 can vary depending upon the length of thesecond conveyor belt224 and the travel path of the secondcontinuous belt224. Thesecond conveyor belt224 forms a continuous loop. Thesecond conveyor belt224 can be similar to thefirst conveyor belt188. Thesecond conveyor belt224 extends downstream from thesecond station22 to the end of therearward portion182. Thesecond conveyor belt224 is shown rotating in a counter clockwise direction and functions as a moving horizontal support for thediscrete articles180 as they advance through the remainder of therearward portion182.
• Still referring toFIGS. 1 and 23, therearward portion182 also includes anoptional sealing unit228 located downstream of thesecond station222. The sealingunit228 is designed to permanently seal or bond theclosure system28 to theinner surface206 of the secondmajor surface16 adjacent to the trailingend204. The sealingunit228 will not be needed if thesecond station222 can form the permanent bond. When thesealing unit228 is present, it can bond theclosure system28 to theinner surface206 from the top, from the bottom or from both the top and the bottom. Desirably, theclosure system28 is bonded from both sides to theinner surface206 in order to obtain a secure bond that extends completely along the entire length l₁of theclosure system28.
• It should also be understood that the seal or bond can be formed between theclosure system28 and theinner surface206 of the secondmajor surface16 using different kinds of bonding equipment known to those skilled in the art.
• Still referring toFIGS. 1,5,23 and27, therearward portion182 of themachine10 further includes athird station230 located downstream from saidsecond station222 and downstream of thesealing unit228 when it is present. Thethird station230 includes an unfolding andseal unit232, asealing unit234, and acooling unit236. The unfolding andseal unit232 is capable of unfolding thelip200 back to its initial unfolded orientation. In this orientation, the exposedfirst surface202 is no longer exposed but instead now lies over and covers a major portion of theclosure system28. The unfolding andseal unit232 is also capable of forming a pair ofseals238 and240 at the opposite ends,242 and244, respectively, of thelip200. The pair ofseals238 and240 secure portions of thefirst surface202 of thelip200 to theclosure system28. In particular, theseals238 and240 secure portions of thefirst surface202 of thelip200 to theouter surface42 of thesecond leg34, seeFIG. 5. The size of the pair ofseals238 and240 can vary. The opposite ends242 and244 of thelip200 can be sealed or bonded using any of the bonding techniques taught above. A hot seal or bond can be obtained by using heat or heat and pressure works fine. One can also use ultrasonics, an adhesive or a double sided tape to form theseals238 and240.
• The opposite ends242 and244 of thelip200 can be bonded or sealed to theclosure system28 from the top, from the bottom or from both the top and the bottom. Desirably, the opposite ends242 and244 are bonded or sealed to theclosure system28 from both sides in order to form a more secure seal.
• The sealingunit234 can apply additional heat or heat and pressure onto theseals238 and240 to insure that they are permanently formed. The sealingunit234 is optional if the unfolding andseal unit232 is capable of formingpermanent seals238 and240. After theseals238 and240 are formed, thediscrete articles180 are subjected to thecooling unit236. Thecooling unit236 cools the material which forms thediscrete pouches12 and theseals238 and240 down to or towards room temperature. Once thediscrete articles180 have been cooled, thediscrete pouches12 are finished.
• Referring now toFIG. 28, thediscrete pouch12 is shown after itssides18 and20 have been manipulated, such as being squeezed towards one another, so as to form anenlarged opening256 adjacent to theopen end26. One will notice that the firstmajor surface14 of thediscrete pouch12 is not bonded to theclosure system28 along its entire length. Instead, the firstmajor surface14 is bonded only at the opposite ends242 and244 to theclosure system28. The distance between the pair ofends242 and244 is left unbounded and open. The reason for this is that thediscrete pouches12 can be quickly and rapidly filled with items, articles or products at a manufacturing site. Usually for a liquid product or for small granular products, the products can be dispensed into anempty pouch12 via an injection or hopper system. Alternatively, thediscrete pouches12 can be manually filled, if desired. At the filing location, each of thediscrete pouches12 can be manipulated such that theenlarged opening256 appears and items, articles or products can easily and quickly be inserted into thediscrete pouch12. After thediscrete pouches12 have been filled with items, articles or products, the manufacturer will then flatten theopen end26 of each of thediscrete pouches12 and bond or seal theinner surface40 of thesecond leg34 to theinside surface202 of the firstmajor surface14. This action will cause theopen end26 of thediscrete pouch12 to be sealed shut. The bond or seal can be formed using heat, pressure, heat and pressure, ultrasonics, an adhesive, a co-adhesive, a mechanical connector, double sided tape, etc. Once thediscrete pouches12 are filled and sealed, the filledpouches12 can be shipped to a warehouse, distributor, retailer, etc. for sale or distribution to the ultimate consumer.
• Referring again toFIGS. 1 and 23, therearward portion182 of themachine10 also includes aremoval mechanism246. Theremoval mechanism246 can take on many different forms. By way of example and not as a limitation, theremoval mechanism246 is depicted to include afirst belt drive248 and asecond belt drive250. Thefirst belt drive248 is positioned vertically above thesecond belt drive250. The first and second belt drives,248 and250 respectively, cooperate to form a nip252 therebetween. Thefirst belt drive248 can rotate in a clockwise direction while thesecond belt drive250 can rotate in a counter clock wise direction. The first and second belt drives,248 and250 respectively, can include one or more continuous belts movably positioned around two or more spaced apart rollers. Thediscrete pouches12 are conveyed from themachine10 via thenip252. The speed of the first and second belt drives,248 and250 respectively, can be adjusted to be equal to or be greater than the speed at which thediscrete articles180 are advanced through themachine10. Desirably, the speed of theremoval mechanism246 is greater than the speed of therearward portion182 of themachine10. This increase in speed allows thediscrete pouches12 to be removed continuously without interfering with the advancingdiscrete pouches12 leaving therearward portion182 of themachine10. After leaving thenip252, thediscrete pouches12 can be directed away to be packaged and shipped. InFIG. 1, aslant stacker254 is shown for moving the finisheddiscrete pouches12 away from themachine10. Other means known to those skilled in the art can also be used. Such other means include but are not limited to: a movable conveyor belt, being manually conveyed away; being manually stacked and packaged into boxes for shipment; and being directed to an automated stacker or magazine which will stack and assembly thediscrete pouches12 into packages and route then to storage or to a shipment facility.
Method
• A method of securing aclosure system28 onto adiscrete pouch12 is also taught. Each of thediscrete pouches12 has a firstmajor surface14, an oppositely aligned secondmajor surface16, a pair ofsides18 and20 joining the first and second major surfaces,14 and16 respectively, together, a closed bottom24 and an open top26. Each of thediscrete pouches12 can be constructed from a plastic material, from a thermoplastic material, or from some other kind of material. The method comprises the steps of advancing one or more of thediscrete pouches12 through afirst station184 of themachine10. Thediscrete pouches12 are aligned in a machine direction (MD) with the closed bottom24 leading each of thediscrete pouches12 through themachine10. Thediscrete pouches12 can be advanced using a firstcontinuous conveyor belt188. Avacuum source216 can be utilized which will hold each of thediscrete pouches12 secure to theconveyor belt188 and prevent thediscrete pouches12 from becoming skewed. As thediscrete pouches12 are routed through themachine10, the firstmajor surface14 of eachdiscrete pouch12 will face upward. Thefirst station184 is capable of lifting and folding a portion of the firstmajor surface14 upon itself to form alip200 having afirst surface202 which is exposed. The secondmajor surface16 of each of thediscrete pouches12 has aninner surface206 and atransverse edge204 located adjacent to theopen end26. Thetransverse edge204 is distally spaced apart from thelip200 such that a portion of theinner surface206 is exposed. Desirably, at least about 2 inches of theinner surface206 is exposed.
• The method also includes routing each of thediscrete pouches12 downstream from thefirst station184 to asecond station222. Thesecond station222 is capable of positioning and attaching aclosure system28 transversely across the exposedinner surface206. The closure system including atrack30 having afirst leg32 and asecond leg34 each having anouter surface38 and42 respectively. Theouter surface38 of thefirst leg32 is secured to the exposedinner surface206 adjacent to thetransverse edge204. The first and second legs,32 and34 respectively, are joined together by an opening/closing mechanism46. Amember52, such as a slide member, is movably attached to the opening/closing mechanism46. Themember52 is capable of being manually moved back and forth along the opening/closing mechanism46 such that the opening/closing mechanism46 can be opened and closed.
• The method further includes routing each of thediscrete pouches12 downstream from thesecond station222 to athird station230. Thediscrete pouches12 can be routed to thethird station230 on a secondcontinuous conveyor belt224. Thethird station230 is capable of unfolding thelip200 and securing opposite ends242 and244 of thelip200 to theouter surface42 of thesecond leg34.
• After exiting thethird station230, the pair ofsides18 and20 of each of thediscrete pouches12 can be manipulated, such as by being squeezed towards one another, to create anenlarged opening256 located between the firstmajor surface14 and theouter surface42 of thesecond leg34. Thisenlarged opening256 enables items, articles or products to be easily and quickly inserted into thediscrete pouch12. After thediscrete pouch12 has been filled with items, articles or products, theopen end26 is flattened and theouter surface42 of thesecond leg34 is bonded or sealed to theinside surface202 of the firstmajor surface14. The bond or seal can be formed using any of the bonding techniques taught above. Desirable, heat and pressure is used to form the bond. The filleddiscrete pouches12 are then ready to be shipped to the ultimate consumer.
• A more specific method for securing aclosure system28 onto adiscrete pouch12 is also disclosed. As in the method described above, each of thediscrete pouches12 has a firstmajor surface14, an oppositely aligned secondmajor surface16, a pair ofsides18 and20 joining the first and second major surfaces,14 and16 respectively, together, a closed bottom24 and an open top26. The more specific method comprises the steps of unwinding a web ofmaterial68 from asupply roll70 and advancing the web ofmaterial68 to apunch station82. The web ofmaterial68 has afirst surface72 and an oppositely alignedsecond surface74, first and second sides,76 and78 respectively, and a width dimension w extending between the first and second sides,76 and78 respectively. At the punching station82 apredetermined pattern84 is punched completely through the web ofmaterial68. Thepredetermined pattern84 can be an approximately C-shaped configuration. Desirably, thepredetermined pattern84 is a pair of spaced apart C-shaped configurations. The punched web ofmaterial68 is then longitudinally folded upon itself such that the firstmajor surface14 is exposed. The punched web ofmaterial68 can be folded at one or more locations so as to formgussets22,22 adjacent to each of thesides18 and20 of the finisheddiscrete pouches12. Desirably, sixlongitudinal fold lines102,104,106,108,110 and112 are present so that agusset22 is formed adjacent to each of thesides18 and20.
• The method also includes bonding the first and second major surfaces,14 and16 respectively, together along a singlelongitudinal line102 to form a continuoustubular structure126′. Thebond124 can be formed using any of the techniques described above. Desirably, heat and pressure is used to form thebond124. Alternatively, a continuoustubular structure126 can be formed that includes fourbonds124, with eachbond124 being located at each corner of thetubular structure126. Atransverse seal136 is then formed across the continuoustubular structure126 or126′ at select locations. Thetransverse seal136 is aligned adjacent to thepredetermined pattern84 and perpendicular to the machine direction (MD). Thetransverse seal136 can be formed by heating thetubular structure126 or126′ to a temperature ranging from between about 100° F. to 600° F. and pressing the first and second major surfaces,14 and16 respectively, together. Desirably, the temperature will range from between about 200° F. to 500° F. Thetransverse seal136 can have a width of at least about 0.1 inches. The distance that thetransverse seal136 is spaced away from thepredetermined pattern84 can vary. Desirably, thetransverse seal136 is spaced within 2 inches of thepredetermined pattern84. More desirably, thetransverse seal136 is spaced within 1 inch of thepredetermined pattern84. Even more desirably, thetransverse seal136 is spaced within 0.5 inches of thepredetermined pattern84.
• The method further includes transversely slitting at178 the continuoustubular structure126 or126′ adjacent to thetransverse seal136 to formdiscrete articles180. The slitting can be accomplished by making a slit or cut178 in thetransverse seal136. Each of thediscrete articles180 orpouches12 is then advanced through afirst station184 of themachine10 in a machine direction (MD) with the closed bottom24 leading thediscrete article180 through themachine10 and with the firstmajor surface14 facing upward. Thefirst station184 is capable of lifting and folding a portion of the firstmajor surface14 upon itself to form alip200 having afirst surface202 which is exposed. The secondmajor surface16 has aninner surface206 and atransverse edge204 located adjacent to theopen end26. Thetransverse edge204 is distally spaced apart from thelip200 such that a portion of theinner surface206 is exposed. The discrete articles are then routed downstream from thefirst station184 to asecond station222. Thesecond station222 is capable of positioning and attaching aclosure system28 transversely across the exposedinner surface206. Theclosure system28 includes atrack30 having afirst leg32 and asecond leg34 each having an outer surface,38 and42 respectively. Theouter surface38 of thefirst leg32 is secured to the exposedinner surface206 adjacent to thetransverse edge204. The first and second legs,32 and34 respectively, are joined together by an opening/closing mechanism46. Amember52, such as a slid member, is capable of being manually moved back and forth along the opening/closing mechanism46 such that the opening/closing mechanism46 can be opened and closed.
• Lastly, the method includes routing thediscrete articles180 downstream from thesecond station222 to athird station230. Thethird station230 is capable of unfolding thelip200 and securing opposite ends242 and244 of thelip200 to theouter surface42 of thesecond leg34 to form thediscrete pouches12.
• After each of thediscrete pouches12 has theclosure system28 attached thereto, it can be shipped to a manufacturer were thediscrete pouches12 can be filled and sealed. At the manufacturer, thesides18 and20 of each of thediscrete pouches12 can be manipulated. For example thesides18 and20 and/or the first and second major surfaces,14 and16 respectively, can be squeezed, pulled or somehow flexed towards one another, so as to form anenlarged opening256 adjacent to theopen end26. Since the firstmajor surface14 of thediscrete pouch12 is bonded to theclosure system28 only at the opposite ends242 and244, theenlarged opening256 will easily be formed. Theenlarged opening256 permits each of thediscrete pouches12 to be quickly and rapidly filled with items, articles or products. Usually for a liquid product or for small granular products, the products can be dispensed into anempty pouch12 via an injection or hopper system. Alternatively, thediscrete pouches12 can be manually filled, if desired.
• After thediscrete pouches12 have been filled with items, articles or products, the manufacturer will then flatten theopen end26 of each of thediscrete pouches12 and bond or seal theinner surface40 of thesecond leg34 to theinside surface202 of the firstmajor surface14. This action will cause theopen end26 of thediscrete pouch12 to be sealed shut. The bond or seal can be formed using heat, pressure, heat and pressure, ultrasonics, an adhesive, a co-adhesive, a mechanical connector, double sided tape, etc. Once thediscrete pouches12 are filled and sealed, the filledpouches12 can be shipped to a warehouse, distributor, retailer, etc. for sale or distribution to the ultimate consumer.
Article
• The finisheddiscrete pouches12 shown inFIGS. 2-22 and24-28 will now be described. Each of thediscrete pouches12 can be formed from various materials, described above. Desirably, each of thediscrete pouches12 can be formed from a single, identical material. It should be noted that theclosure system28 can be formed from a different material from the material used to construct the remainder of thediscrete pouch12. Furthermore, each of thediscrete pouches12 can be formed from a laminate having at least two layers. When a laminate is used, at least one of the layers of the laminate can be constructed so as to prevent air, a liquid or a fluid, or a combination thereof, from passing therethrough.
• Each of thediscrete pouches12 includes a firstmajor surface14 having a transverse edge with apredetermined pattern84 formed therein. Thepredetermined pattern84 can be cut out of or be punched out of the material that will form the first and secondmajor surfaces14 and16 respectively, as well as the pair ofsides18 and20. The transverse edge of the firstmajor surface14 has a pair of opposite ends242 and244, seeFIG. 27. Each of thediscrete pouches12 also has a secondmajor surface16 aligned opposite to the firstmajor surface14. The secondmajor surface16 has atransverse edge204, seeFIG. 24, with thepredetermined pattern84 formed therein. Thepredetermined pattern84 formed in both of the first and second major surfaces,14 and16 respectively, has a contiguous boundary, seeFIG. 9. Thebase90 and thelegs92 and94 form the contiguous boundary. In addition, the transverse edges of the first and second major surfaces,14 and16 respectively, can be contiguous with one another. The secondmajor surface16 also has aninner surface206, seeFIG. 24.
• Each of thediscrete pouches12 also has a pair ofsides18 and20 joined to the first and second major surfaces,14 and16 respectively, by at least onelongitudinal bond124, seeFIG. 15, to form atubular structure126′. Desirably, four, spaced apartlongitudinal bonds124,124,124 and124 are present approximate each corner of atubular structure126, seeFIG. 14. Desirably, heat and pressure is use to form the longitudinal bond(s)124. Each of thesides18 and20 can be constructed to contain agusset22 or some other expandable structure.
• Each of thediscrete pouches12 further includes aseal136 which extends transversely across thetubular structure126 or126′ to form a closed bottom24, seeFIG. 16.
• Lastly, each of thediscrete pouches12 includes aclosure system28. Theclosure system28 can vary such that it includes a closure system having a slide mechanism, a press-to-close closure system, a cohesive closure system, a closure system using Velcro®, etc. Referring to the closure system shown inFIGS. 3-6, theclosure system28 includes atrack30 having afirst leg32 and asecond leg34. Each of thelegs32 and34 has anouter surface38 and42 respectively. Theouter surface38 of thefirst leg32 is secured to theinner surface206 of the secondmajor surface16 adjacent to thetransverse edge204, seeFIG. 24. The first and second legs,32 and34 respectively, are joined together by an opening/closing mechanism46 which includes amember52 capable of being manually moved back and forth such that the opening/closing mechanism46 can be sequentially opened and closed. The pair of opposite ends242 and244 of the firstmajor surface14 is secured to theouter surface42 of thesecond leg34 to form an open top26 located adjacent to the transverse edge of the firstmajor surface14, seeFIG. 28. The open top26 is aligned opposite to theseal136 and is spaced apart therefrom. The open top26 is located horizontally between the pair of opposite ends242 and244.
• It should be understood that theopen top26 of each of thediscrete pouches12 is designed to be sealed after each of thediscrete pouches12 is filled with items, articles or products.
• While the invention has been described in conjunction with several specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims.

Claims (20)

1. A discrete pouch comprising:

a) a first major surface having a transverse edge with a predetermined pattern formed therein, said transverse edge having a pair of opposite ends;

b) a second major surface aligned opposite to said first major surface, said second major surface having a transverse edge with said predetermined pattern formed therein, said predetermined pattern in said first and second major surfaces having a contiguous boundary, and said second major surface having an inner surface;

c) a pair of sides joined to said first and second major surfaces to form a tubular structure;

d) a seal extending transversely across said tubular structure to form a closed bottom; and

e) a closure system including a track having a first leg and a second leg, each leg having an outer surface, said outer surface of said first leg being secured to said inner surface of said second major surface adjacent to said transverse edge, said first and second legs being joined together by an opening/closing mechanism which includes a member capable of being manually moved back and forth such that said opening/closing mechanism can be sequentially opened and closed, and said pair of opposite ends of said first major surface being secured to said outer surface of said second leg to form an open top located adjacent to said transverse edge of said first major surface, said open top being aligned opposite to said seal and being spaced apart therefrom.

2. The discrete pouch ofclaim 1 wherein each of said pair of sides contains a gusset.

3. The discrete pouch ofclaim 1 wherein said seal is a K-shaped seal.

4. The discrete pouch ofclaim 3 wherein said K-shaped seal includes an elongated segment that extends between said pair of sides and two spaced apart shorter segments that angle outward from said elongated segment, and each of said shorter segments intersects with one of said pair of sides.

5. The discrete pouch ofclaim 4 wherein said two shorter segments extend away from said closed bottom.

6. The discrete pouch ofclaim 1 wherein said discrete pouch is formed from a laminate having at least two layers and at least one of said layers can prevent a liquid from passing therethrough.

7. The discrete pouch ofclaim 1 wherein said pair of sides is joined to said first and second major surfaces by four, spaced apart longitudinal bonds to form said tubular structure.

8. The discrete pouch ofclaim 1 wherein said discrete pouch is formed from a thermoplastic material and said predetermined pattern is cut from said first and second major surfaces.

9. The discrete pouch ofclaim 1 wherein said predetermined pattern comprises a pair of spaced apart, approximately C-shaped configurations, and each of said pair of approximately C-shaped configurations has a base member with two legs extending outward from said base member.

10. A discrete pouch comprising:

a) a first major surface having a transverse edge with a predetermined pattern formed therein, said transverse edge having a pair of opposite ends;

b) a second major surface aligned opposite to said first major surface, said second major surface having a transverse edge with said predetermined pattern formed therein, said predetermined pattern in said first and second major surfaces having a contiguous boundary, and said second major surface having an inner surface;

c) a pair of sides joined to said first and second major surfaces by at least one longitudinal bond to form a tubular structure, each of said pair of sides containing a gusset, and said first and second major surfaces and said pair of sides being formed from an identical material;

d) a seal extending transversely across said tubular structure to form a closed bottom; and

e) a closure system including a track having a first leg and a second leg, each leg having an outer surface, said outer surface of said first leg being secured to said inner surface of said second major surface adjacent to said transverse edge, said first and second legs being joined together by an opening/closing mechanism which includes a member capable of being manually moved back and forth such that said opening/closing mechanism can be sequentially opened and closed, and said pair of opposite ends of said first major surface being secured to said outer surface of said second leg to form an open top located adjacent to said transverse edge of said first major surface, said open top being aligned opposite to said seal and being spaced apart therefrom.

11. The discrete pouch ofclaim 10 wherein said at least one longitudinal bond and said seal are formed using heat and pressure.

12. The discrete pouch ofclaim 10 wherein said first and second major surfaces and said pair of sides are formed from a laminate having at least two layers, and at least one of said layers can prevent air from passing therethrough.

13. The discrete pouch ofclaim 10 wherein said seal is K-shaped and includes an elongated segment that extends between said pair of sides and two spaced apart shorter segments that angle outward from said elongated segment, and each of said shorter segments intersects with one of said pair of sides.

14. The discrete pouch ofclaim 10 wherein said closure system is a zipper.

15. The discrete pouch ofclaim 10 wherein said open top of said closure system is designed to be sealed after said discrete pouch is filled with articles.

16. A discrete pouch comprising:

a) a first major surface having a transverse edge with a predetermined pattern formed therein, said transverse edge having a pair of opposite ends;

b) a second major surface aligned opposite to said first major surface, said second major surface having a transverse edge with said predetermined pattern formed therein, said transverse edges of said first and second major surfaces being contiguous, said predetermined pattern being cut into both said first and second major surfaces and having a contiguous boundary, and said second major surface having an inner surface;

c) a pair of sides joined to said first and second major surfaces by at least one longitudinal bond to form a tubular structure, and each of said pair of sides containing a gusset;

d) a seal extending transversely across said tubular structure to form a closed bottom; and

e) a closure system including a track having a first leg and a second leg, each leg having an outer surface, said outer surface of said first leg being secured to said inner surface of said second major surface adjacent to said transverse edge, said first and second legs being joined together by an opening/closing mechanism which includes a member capable of being manually moved back and forth such that said opening/closing mechanism can be sequentially opened and closed, and said pair of opposite ends of said first major surface being secured to said outer surface of said second leg to form an open top located adjacent to said transverse edge of said first major surface, said open top being aligned opposite to said seal and being spaced apart therefrom.

17. The discrete pouch ofclaim 16 wherein said open top is located between said pair of opposite ends of said first major surface.

18. The discrete pouch ofclaim 17 wherein said first major surface has a width and said open top extends across at least 75% of said width.

19. The discrete pouch ofclaim 16 wherein said closure system is a zipper.

20. The discrete pouch ofclaim 16 wherein said open top of said closure system is designed to be sealed after said discrete pouch is filled with articles.

Images