Abstract:
A double gusseted, tamper evident, reclosable container  120  of plastic film. The container can be stored in a flat condition but is capable of receiving a bulky item such as a loaf of bread or a stack of paper napkins with the bag assuming a squared off condition. The container  120  has two gussets  185  and  191.

Description:
BACKGROUND OF THE INVENTION  
       [0001]    This application claims priority to U.S. Provisional Patent Application Serial No. 60/368,243 filed Mar. 28, 2002. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention pertains to flexible reclosable containers and in particular to flexible reclosable containers including sliders, tamper evident seals, and a top gusset.  
         SUMMARY OF THE INVENTION  
         [0003]    The present invention relates to flexible reclosable containers, especially those containers incorporating a pair of top gussets.  
           [0004]    One embodiment of the invention might involve a plastic film including a pair of side walls which are secured to one another and which define a mouth of the bag. A first gusset and a second gusset are joined to one another and extend across the mouth of the bag. The first gusset includes a tamper evident seal. There are also provided fastener strips mounted on the bag for closing off access to the interior of the bag through the tamper evident seal. The fastener strips allow access when they are disconnected from one another and prevent access when they are connected to one another. The second gusset is adapted to extend across and close off the mouth of the bag when the fastener strips are connected to one another.  
           [0005]    In one aspect of the present invention, each container includes a first top gusset and a second top gusset, the first top gusset being expandable to a greater extent than the second top gusset.  
           [0006]    In yet another aspect of the present invention, there is a pair of top gussets, one of the top gussets incorporating a pair of opposing fastener strips and a slider for repeatedly closing and opening the fastener strips.  
           [0007]    In yet another aspect of the present invention, the container includes a pair of top gussets, with one of the gussets incorporating a tamper evident seal.  
           [0008]    In yet other embodiments, the first wall and second wall of one of the gussets are affixed to one another by opposing surfaces forming a peelable seal.  
           [0009]    These and other embodiments of the present invention will be apparent from the drawings and description of preferred embodiments that follow.  
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a plan side view of a container according to one embodiment of the present invention.  
         [0011]    [0011]FIG. 2 is a cross-sectional view of the container of FIG. 1 as taken along line  2 - 2  of FIG. 1.  
         [0012]    [0012]FIG. 3 is a cross-sectional view of a container according another embodiment of the present invention.  
         [0013]    [0013]FIG. 4 is a side view of another embodiment of the present invention.  
         [0014]    [0014]FIG. 5 is side view of a partially constructed container according to another embodiment of the present invention.  
         [0015]    [0015]FIG. 6 is a plan side view of a container according to another embodiment of the present invention.  
         [0016]    [0016]FIG. 7 is a side elevational view of a portion of the container of FIG. 6 as taken along line  7 - 7  of FIG. 6, and in an expanded state.  
         [0017]    [0017]FIG. 8 is a top perspective view of the container of FIG. 6 filled with a product.  
         [0018]    [0018]FIG. 9 is a plan side view of a container according to another embodiment of the present invention.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated devices, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.  
         [0020]    The present invention relates to improvements in flexible reclosable containers, particularly containers which include a header strip for convenient mounting of the container until it is used, and further including a slider for convenient closing of the container while it is used. The header strip is preferably a single-ply flexible material which extends from the mouth of the container. Preferably, the container or the header strip includes a line of weakness, such as by mechanical perforation or laser scoring, to enable a user to easily separate the container from the header strip. In some embodiments, the header strip includes one or more holes through which the header strip and container assembly can be hung from a stand.  
         [0021]    In another embodiment, the header strip extends from the mouth of the bag. Further, the mouth of the bag preferably includes a fastener strip along each of the edges of the mouth, each of the fastener strips including an interlockable profile element. A slider is mounted to the fastener strips for easy interlocking and unlocking of the profile elements.  
         [0022]    Preferably, the slider and profile elements are arranged and configured such that the mouth of the bag is substantially open. In this manner, it is most convenient for a user of the bag to place his or her hand between the fastener strips and into the bag, tear the bag off of the header strip, and hold the bag for subsequent filling of the container with a product.  
         [0023]    As one example, the bag is particularly useful in situations such as a deli counter in a food store, where the store employee uses one hand to tear off the bag from the header strip, and uses the other hand to place a deli counter product in the container with the other hand. This particular arrangement of the header strip extending from an open mouth, preferably with a slider, reduces the motion and time of the store employee to fill the customer&#39;s order.  
         [0024]    [0024]FIG. 1 shows a flexible reclosable container  20  for containing a product. Container  20  is useful for embodiments in which the container is sold to a consumer in the empty state, although the present invention also contemplates embodiments in which the container includes a product stored therein. Further, some embodiments of the present invention are suitable for use with a form, fill, and seal method of construction, examples of methods for forming, filling, and sealing the flexible reclosable container being found in U.S. Pat. No. 5,956,924, issued Nov. 7, 1997, and incorporated herein by reference.  
         [0025]    Container  20  comprises first and second side walls  22  and  24 , respectively, which may be made from any suitable thermoplastic film such as, for example, low density polyethylene, linear low density polyethylene, or similar materials. Side walls  22  and  24  include first left transverse side seal  28  and second right transverse side seal  30 . Seals  28  and  30  can be formed by any method, including ultrasonic welding and heat fusion methods. Container  20  also includes a bottom edge  26  generally opposite a pair of interlocking fastener strips  32  and  34 . Bottom edge  26  may include a fold between side walls  22  and  24 , or alternatively edge  26  may include a seal between side walls  22  and  24 .  
         [0026]    [0026]FIG. 2 is an enlarged cross section of the container of FIG. 1 as taken along line  2 - 2  of FIG. 1 with side wall  22  spaced apart from side wall  24 . As shown in both FIGS. 1 and 2, interlocking fastener strips  32  and  34  including one or more interlockable profiles  50 , and  52   a  and  52   b , respectively, run along the top edge or mouth of container  20 . Preferably, fastener strips  32  and  34  are fabricated by an extrusion method, although the present invention contemplates any method of fabrication. Fastener strips  32  and  34  can be attached to side walls  22  and  24  in any manner, including ultrasonic welding, fusion by heat, or adhesive methods. Strips  32  and  34  are sealed together at endstops  36  and  38 . Strips  32  and  34  are sealed to each other and also to side walls  22  and  24  at corner seals  40  and  42 . Corner seals  40  and  42  are located along their respective edges of container  20 . Seals  40  and  42  are generally located below shoulders  45  and  47  of fastener strips  32  and  34 , respectively, and above lower edges  45   a  and  47   a  of inner flanges  44  and  46  of fastener strips  32  and  34 , respectively.  
         [0027]    In some embodiments of the present invention profiles  50  and  52  are comprised of at least one uppermost and bottommost profile elements. Preferably, one profile element terminates in a shape that can be securely grasped by a complementary-shaped profile element coupled to the opposing side wall. Referring to FIGS. 2 and 3, apparatus  20  includes a male profile element  50  which interlocks between female profile elements  52   a  and  52   b  of fastener strip  34 . These fastener strips and profile elements are further described in U.S. Provisional Patent Application No. 60/330,140, filed Oct. 17, 2001, entitled SLIDERS FOR RECLOSEABLE CONTAINERS, incorporated herein by reference. However, the present invention contemplates the use of any type of profile elements compatible with a slider. When fastener strips  32  and  34  are interlocked, cover flanges  49   a  and  49   b  are disposed in overlapping relationship and provide a secondary seal of container  20 . Of course, the primary seal is provided by the coupling of fastener strips  32  and  34 . As best seen in FIG. 1, a slider  48  straddles and is slidable upon fastener strips  32  and  34 . Slider  48  includes a pair of feet (not shown) which retain slider  48  on the interlocking fastener strips by way of shoulders  45  and  47 . Further, slider  48  includes a closing end (not shown) which includes a reduced-width aperture which presses the profile elements into interlocking relationship. Slider  48  further includes a separator (not shown) near an opening end which spreads apart and unlocks the profile elements. Movement of slider  48  along the fastener profiles results in either an interlocking of profile elements  50  and  52 , or an unlocking of profiles  50  and  52 . The present invention contemplates any configuration of slider which locks and unlocks the profile elements, including the sliders, endstops, profiles, docking stations, and other features of a reclosable container disclosed in U.S. patent application Ser. No. 09/794,592, filed Feb. 27, 2001, and incorporated herein by reference.  
         [0028]    Some embodiments of the present invention further include a docking station  39  located near endstop  38  and or endstop  36 . The docking station provides a location which accommodates the separator element of a slider, and relieves the forces from the separator which would otherwise tend to separate the fastener strips. As one example, the docking station may be formed by placement of the slider adjacent to a heat-fused endstop before the endstop cools. In yet other embodiments, the docking station may be one of a vertical slit, horizontal slit, notch, or window placed in the fastener strips near the corner seals. Additional examples of flexible reclosable containers contemplated by the present invention can be found in U.S. Provisional Patent Application No. 60/330,140, filed Oct. 17, 2001, entitled SLIDERS FOR RECLOSABLE CONTAINERS, incorporated herein by reference.  
         [0029]    In one embodiment of the present invention, container  20  does not include a tamper evident seal. However, in some embodiments of the present invention, containers  20  and  120  include a tamper-evident seal  143  between side walls  22  and  24 . This seal may be an extension of flanges  46  and  44  that extends internally across the opening of container  20 . However, the present invention contemplates other configurations of tamper evident seal, including external seals that cover portions of the fastener profiles and slider. The seal may be integrally molded with flanges  44  and  46 , or may be attached separately. Further, the seal may be integrally molded with side walls  22  and  24  or attached separately. The broken or unbroken state of the seal provides evidence to the user of whether or not the container has been previously opened. A tamper evident seal is especially useful with a form, fill, and seal machine that inserts an edible product into container  20 . Further examples of tamper evident seals can be found in U.S. Pat. No. 6,257,763, issued Jul. 10, 2001, and incorporated herein by reference. Yet other forms of laser-scored tamper evident elements are contemplated by the present invention and can be found in U.S. Provisional Patent Application No. 60/314,787, filed Aug. 24, 2001, entitled SCORED TAMPER EVIDENT ZIPPER SLIDER, and incorporated herein by reference.  
         [0030]    [0030]FIG. 2 is a close-up cross-sectional view according to one embodiment of the present invention. A header strip  70  extends outwardly from one side of mouth  23 . One or more apertures or holes  74  are defined in the upper portion of header  70 . Header strip  70  is preferably an integral portion of container side  24 , and in one embodiment extends about three inches beyond the end of shorter container side  22 . Container side  24  is preferably fused to flange  46  of fastener strip  34  at a location intermediate of fastener strip shoulder  47  and fastener strip bottom edge  47   a . By locating the attachment below the shoulder 47 , the attachment feet (not shown) of slider  48  are free to move over shoulder  47  without interference by the container side wall or header strip.  
         [0031]    Preferably, a tear line or line of weakness  72  is created along the length of header strip  70  in a direction generally parallel to the edge of mouth  23 . This line of weakness can be located along header strip  70  anywhere from hole  74  of header strip  70 , to the location where container sidewall  24  is fused to fastener strip  34 . The line of weakness  72  can be implemented in any manner, including mechanical scoring or perforation, laser scoring, or any other method.  
         [0032]    [0032]FIG. 3 depicts a cross-sectional view of another embodiment according to the present invention. The use of a prime (′) suffix with an element number (XX′) denotes an element that is the same as the element previously cited (XX), except for those changes shown or described hereafter. Header strip  70 ′ is separately attached to profile element  34 ′. Header strip  70 ′ includes one or more apertures or holes  74 ′. Header strip  70 ′ preferably includes a line of weakness  72 ′ along the length of header strip  70 ′ in a direction generally parallel of the edge of mouth  23 ′. Header strip  70 ′ is preferably attached by fusion or adhesion at a location below shoulder  47 ′ so as to not interfere with sliding operation of slider  48 . Further, the present invention also contemplates those embodiments in which the header strip is integrally extruded with the fastener strip.  
         [0033]    [0033]FIG. 4 is a side view of an apparatus  80  according to another embodiment of the present invention. Apparatus  80  includes a plurality of containers  20  which have been attached together into a group  81  by fusing together adjacent portions of the corresponding header strips  70 . The header strips are fused or adhered together such that adjacent through holes  74  line up in a manner suitable for mounting container group  81  from a wicket  82 . Wicket  82  is preferably supported by a stand  84  such that containers  20  extend downward vertically from wicket  82 . Stand  84  is preferably located near the products to be stored in the containers. In yet other embodiments of the present invention, apparatus  80  includes a plurality of containers  20  which have not been attached together into a group, and which instead hang individually from wicket  82 .  
         [0034]    [0034]FIG. 5 is a side view of a partially constructed container  21  according to another embodiment of the present invention. In this embodiment of the present invention, a sheet is fabricated starting with blown low density polyethylene (LDPE) material, or other material suitable for fabrication of flexible reclosable container. Using a bag machine such as an Amplas MS 1400 Servo machine, the film sheet  21  is folded to include a center fold  27 , with one side  24  being about three inches longer than shorter side  22 . Line of weakness  72  is created in second side  24  in a manner as previously discussed. Preferably, line of weakness  72  is located approximately opposite free edge  22   a  of shorter side  22 . In this embodiment, the length from bottom fold  27  to line of weakness  72  is about the same as the length from bottom fold  27  to free edge  22   a  of shorter side  22 . However, the present invention also contemplates those embodiments in which these lengths differ significantly.  
         [0035]    After installing line of weakness  72 , a folding device folds back a portion  70 . This configuration of sheet  21  then enters a fastener attachment machine where a fastener strip is attached along free edge  72 , and a second fastener strip is applied proximate to line of weakness  72 . Following application of the fastener to sheet  21 , slider endstops  40  and  42  are formed, sealed side edges  28  and  30  are formed, and slider  48  is attached to the interlockable fastener strips. However, the present invention can be fabricated using a different sequence of processing. For example, line of weakness  72  can be incorporated after attachment of the fastener strips. Further, slider  48  can be attached to the fastener strips prior to their attachment to sheet  21 .  
         [0036]    Preferably following attachment of the slider and fastener strips, the folded portion  70  of sheet  21  is folded back out to facilitate the punching of one or more holes  74 . In some embodiments, multiple containers  20  are attached together by fusing together adjacent portions of header strips  70 . The plurality  81  of fused together containers  20  can then be hung from a wicket  82 . Preferably, each slider of a container is placed in a position such that the mouth of the container is substantially open. By having the mouth open, it is convenient for a user to place his or her fingers within the container, tear the container from the wicket along the tear line, and since the container is substantially open, readily place an object in the container.  
         [0037]    [0037]FIGS. 6, 7 and  8  depict various views of a gusseted bag according to another embodiment of the present invention. The use of a one hundred series prefix with an element number (1XX) denotes an element that is the same as the previously cited element (XX) except for those changes shown or described herein. This application incorporates by reference the following applications and issued patents, all owned by the same assignee: METHOD AND APPARATUS FOR PLACING A PRODUCT IN A FLEXIBLE RECLOSEABLE CONTAINER, Ser. No. 09/794,592, filed Feb. 27, 2001; TAMPER EVIDENT ZIPPER SLIDER, Ser. No. 09/866,457, filed May 25, 2001; SCORED TAMPER EVIDENT ZIPPER SLIDER, Ser. No. 60/314,787, filed Aug. 24, 2001; SLIDERS FOR RECLOSABLE CONTAINERS, Ser. No. 60/330,140, filed Oct. 17, 2001; METHOD AND APPARATUS FOR PLACING A PRODUCT IN A FLEXIBLE RECLOSABLE CONTAINER, Ser. No. 10/022,451, filed Dec. 17, 2001; and EXTENDED LIP WICKET SLIDER DELI BAG, filed Mar. 27, 2002.  
         [0038]    [0038]FIG. 8 shows a flexible reclosable container  120  incorporating a pair of top gussets. These gussets are best viewed in FIG. 7, which is an expanded view of a container of FIG. 6 as taken along line  7 - 7  of FIG. 6 in the direction of the arrows.  
         [0039]    In one embodiment according to the present invention, container  120  includes a first top gusset  185  and a second top gusset  191 . In one embodiment, first top gusset  185  is deeper, and therefore more expandable, than second top gusset  191 . However, the present invention also contemplates those embodiments in which both gussets are of a similar depth and capable of similar expansion.  
         [0040]    Referring to FIG. 7, first top gusset  185  is connected to side wall  124  from topmost fold  186  to bottommost fold  187 , and further extends toward a third fold  188 . 2 . Third fold  188 . 2  is preferably fusion bonded to one side of fastener strip  134 . The fastener strip  134  is part of a reclosable closure which also includes fastener strip  132 . First top gusset  185  includes a first gusset wall  188 . 15  extending between folds  186  and  187 , and a second gusset wall  188 . 10  extending from fold  187  to fold  188 . 2 .  
         [0041]    Second top gusset  191  is connected to side wall  122  and extends from a first fold  190 . 1  to tamper evident seal  143 . First fold  190 . 1  is fusion bonded to a side of fastener strip  132 . A gusset wall  190 . 2  may be an extension of side wall  122  extending from first fold  190 . 1  along flange  144  to tamper evident seal  143 . The opposing gusset wall  188 . 3  of second top gusset  191  extends from fold  188 . 2  and along a side of flange  146  toward tamper evident seal  143 .  
         [0042]    In some embodiments of the present invention, tamper evident seal  143  is a peelable seal, such that surfaces of gusset walls  188 . 3  and  190 . 2  are coated or co-extruded with materials sufficient to adhere together facing surfaces of gusset walls  188 . 3  and  190 . 2 .  
         [0043]    In other embodiments of the present invention, gusset walls  109 . 2  and  188 . 3  are joined together in a fusion seal to form tamper evident seal  143 . In these embodiments, tamper evident seal  143  can include a laser scored or mechanically scored line of weakness. In yet other embodiments of the present invention, second top gusset  191  includes first and second gusset walls  190 . 2  and  188 . 3  that are integral, such that the top portion of container  120  is continuous through fold  190 . 1 , tamper evident seal  143 , fold  188 . 2 , fold  187 , and fold  186 .  
         [0044]    The present invention lends itself to other methods of construction. For example, as has been described, the topmost free edges of the plastic film from which container  120  is fabricated are joined together at tamper evident seal  143  in a peel seal. Further, a method of fabrication has been described in which the free edges of the web of plastic film are along the bottom of container  120 , such that the pair of top gussets are continuous. However, it is to be appreciated that the present invention contemplates still other methods of fabrication, in which the free edges of the web of plastic film are joined together and joined to fastener strip  132  in place of fold  190 . 1 . In yet other embodiments, the free edges of the plastic film are joined together and joined to fastener strip  134  at a location replacing fold  188 . 2 . In yet other embodiments, the free edges are joined together replacing fold  187 . In yet other embodiments, the free edges are joined together replacing fold  186 .  
         [0045]    [0045]FIG. 8 shows container  120  containing product such as napkins. In one embodiment, these napkins are loaded from the bottom of container  120 , by either splitting bottom edge  126 , or separating the free edges during filling in those embodiments in which the free edges of the web of plastic film are provided at the bottom of the container.  
         [0046]    As best seen in FIG. 8, the top gussets of the present invention permit container  120  to be filled with a bulky item, yet also permit container  120  to be substantially flat when not filled. When filled with a bulky product, the top of container  120  expands. Bottom fold  187  moves to a location along the top of container  120 . Gusset walls  188 . 10  and  188 . 15  extend across the top of container  120 . As shown in FIG. 8, the gusset  185  extends across and closes off the mouth of the bag when the fastener strips are connected to one another. Further, the slider  148  and the fastener strips  132  and  134  are squared off and out of the way along the side of the container  120 .  
         [0047]    The side walls  122  and  124  are sealed or fused together at  128  in similar fashion to the above described embodiment of FIGS.  1 - 5 . It should also be noted that in the embodiment of FIG. 8 the side walls  122  and  124  are also sealed or fused to the gussets with the fusion or attachment extending to the corners  128 A and  130 A of the container as viewed in FIG. 6.  
         [0048]    As shown in FIG. 8, fastener strips  132  and  134  extend half way around container  120 , and preferably around the top edge of the filled container. Second gusset  191  remains unexpanded when the profiles of the fastener strips are interlocked. In order to open container  120 , the consumer moves slider  148  in an unlocking direction, such that fastener strips  132  and  134  are released from one another. The user can then pull apart gusset walls  190 . 2  and  188 . 3 , and thereby separate tamper evident seal  143 . The user can then reach into container  120 , remove the product, and then reseal the fastener strips by moving slider  148  in an interlocking direction.  
         [0049]    Referring to FIG. 9, another embodiment of the present invention is shown and described. Container  120 ′ is the same as the various embodiments of container  120  previously described, except that top fold  186 ′ is lower than top fold  188 . 2 .  
         [0050]    The type of reclosable features discussed as shown in FIGS. 6, 7,  8 , and  9  allow products to be presented on a shelf with the bags squared out and opened. As an example, a stack of paper napkins of a square folded shape can be displayed on a grocer&#39;s or homeowner&#39;s shelf with the reclosable closure squared off and out of the way. As another example of the use of the invention, it can be used to package bread. The bread is easily visible through the clear plastic film of the container. Also the container can be easily resealed by the reclosable closure operated by the slider keeping the bread fresh. In some embodiments the fastener profiles are sealed to the outside to the plastic film so that the integrity of the package is not interfered with by the addition of fastener profiles and a slider. The tamper evident feature is achieved in some embodiments of the present invention by sealing the fastener profiles onto the outside of the second gusset.  
         [0051]    In some embodiments of the present invention, bottom  126  includes an internal gusset (not shown). In other embodiments, bottom  126  is a fold of the web of plastic film. In yet other embodiments, bottom  126  comprises free edges of side walls  122  and  124  that are fused together.  
         [0052]    Referring to FIG. 6, preferably sides  128  and  130  are fused together from top fold  186  to bottom edge  126 , referring to FIG. 6. In these embodiments, the side edges of first gusset  185  and second gusset  191  are fused together, and fused to the edges of side walls  122  and  124 . In yet other embodiments, the side edges of the first and second gussets are not fused to the edges of side walls  122  and  124 .  
         [0053]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.