Abstract:
A fastener profile assembly and method of forming a fastener profile assembly is provided. The assembly includes a continuous supply of two interlocking profiles which are sealed at either end with a compression molded segment seal. The compression molded segment seal is formed through the application of heat and pressure to the interlocking profiles, thereby fusing the area and forming one end of the profile. Advancement of the profiles and application of heat and pressure to a second area forms the second end of the profile assembly. Manufacture of a fastener in such a manner allows for highly automated profile production with precise, accurate registration of the fastener profile.

Description:
This is a continuation-in-part of patent application Ser. No. 09/415,696, which was filed on Oct. 12, 1999, now abandoned, and a continuation-in-part of patent application Ser. No. 10/337,139, which as filed on Jan. 7, 2003, now U.S. Pat. No. 7,041,249, and which is incorporated herewith by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates generally to reclosable fasteners and a method of forming a reclosable fastener profile assembly which allows for fast, automated production and accurate, seal registration. In particular, the invention relates to a seal arrangement for a reclosable zipper profile strip, which is created through the application of heat and pressure to a male and female profile to form a ‘compression molded segment’ seal, and to a method of producing such a seal. 
     The popularity of reclosable zipper fasteners has created a demand for a large number and wide variety of reclosable bag sizes and types. It is commonly known in the art to form a reclosable bag through the addition of a zipper profile to a pair of bag walls in order to form a bag with a reclosable, airtight seal. However, improper registration may cause the seal to weaken and fail over time or become permeable to the air. In many reclosable bag applications, an airtight seal is necessary to maintain the freshness of articles placed in the bag. Further, such seals must be suitable for high-speed automated production in order to make the production of reclosable bags commercially viable. 
     In the case of zipper profiles, commonly known methods of construction and seal formation often cause inaccurate, commercially unacceptable seals which cannot be produced on an economically practical scale. Commonly known profile formation methods in the art require multiple sealing devices, precise machinery or extensive retooling to alter the size and type of reclosable fastener. Exemplary devices are shown and described in U.S. Pat. Nos. 5,601,368 (Bodolay); 3,847,711 (Howard); 5,461,845 (Yeager); 5,823,933 (Yeager); 4,241,865 (Ferrell); 4,335,817 (Bahr); 4,909,017 (McMahon); and 5,024,537 (Tilman). As such, none of the devices referenced above satisfy the need for a multi-purpose reclosable zipper profile, which can be accurately and economically manufactured. 
     Therefore, an unfulfilled need remains for a zipper profile which can be accurately manufactured at a high rate of speed and which can be adapted to a wide range of reclosable zipper bag applications. 
     SUMMARY OF THE INVENTION 
     The present invention provides a reclosable fastener profile seal and a disclosed method of forming a fastener profile assembly. In particular, the preferred embodiment of the method of forming a fastener assembly includes a first profile strip, a second profile strip and a compression molded segment seal fusing the first and second profiles together to provide a reclosable faster having fused ends which form the opening for a reclosable bag. To manufacture the assembly, the first profile strip and second profile strip are fed by at least one motorized roller from a web or roll of respective profile strips. Interlocking ribs are included on the profiles to create an airtight reclosable seal which is suitable for a wide range of applications. 
     Those of ordinary skill in the art might construe the term “air tight” differently. Webster&#39;s Collegiate Dictionary, Tenth Edition, copyright 1997 by Merriam-Webster, Inc., defines “air tight” to mean “impermeable to air, or nearly so.” Under such as definition for “air tight,” those of ordinary skill in the art might construe an “air tight” seal on a plastic bag to mean a seal that is actually impermeable, or only nearly impermeable to air. Alternatively, persons of ordinary skill might construe an “air tight” reclosable seal to be defined by an industry standard air leak test known as ASTM D3078-02. Under this standard, a bag is submersed in water above which a pressure is applied. Leaks in the bags seal are manifested as air bubbles. As used herein, an “air tight” seal means a seal that will prohibit the transfer or movement of air molecules at atmospheric pressure and room temperature, across or through the seal structure for a substantially long time. In other words, an airtight seal should prohibit the transfer of air molecules from the inside to the outside and vice versa. For example, an “air tight” seal should be able to keep air molecules in a bag prior to the seal&#39;s closure and air molecules outside the bag after the seal&#39;s closure, for as long as the product contained within the bag is expected to be kept reasonably fresh. 
     The first and second profile strips are engaged to form a reclosable profile assembly. After the first and second profiles are interconnected, a portion of the first and second profile are sealed together. The interconnected first profile and second profiles are advanced and staggered applications of a compression molded segment seal are applied to the end portions of each profile assembly. This allows the profile assembly to be formed at a high rate with good accuracy. While being fused, the first and second profiles are cut to provide for individual reclosable fasteners. 
     In an alternative embodiment, the individual reclosable fastener profiles are not cut, thereby providing a continuous linear strip of fully formed reclosable bag profiles. In such an embodiment, the completed reclosable fasteners may be wound onto a roll for later separation and addition to bag walls. 
     It is a principal advantage of the invention to provide a reclosable fastener profile seal and method of forming a fastener profile assembly that can be produced quickly and precisely to form a zipper profile suitable for use in a wide range of reclosable bag applications. 
     It is another advantage of the invention to provide a reclosable profile assembly and a method of forming a reclosable fastener profile assembly, which is easily adjustable to provide a reclosable fastener profile of any commercially desirous length. 
     It is another advantage of the present invention to provide a reclosable profile assembly and a method of forming a reclosable fastener profile assembly, which is readily adaptable to seal and form reclosable fasteners and profiles of various sizes and styles. 
     It is yet another advantage of the invention to provide a reclosable profile assembly, which is suitable for attachment to a wide range of bag wall sizes and types. 
     Various other features and advantages of the invention are set forth in the following detailed description, drawings and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front elevational view of a portion of the profile assembly embodying the invention including the compression molded segment seal. 
         FIG. 2  is a front elevational view of a portion of the first profile and second profile prior to engagement and fusion. 
         FIG. 3  is a side elevational view of the first profile of  FIGS. 1 and 2 . 
         FIG. 4  is a side elevational view of the second profile of  FIGS. 1 and 2 . 
         FIG. 5  is a perspective view of the first and second profiles including the sealing apparatus that forms the compression molded segment seal and a single compression molded segment seal. 
         FIG. 6  is a perspective view of the first and second profiles including the compression molded segment seal formed in  FIG. 5  and the formation of a second compression molded segment seal. 
         FIG. 7  is a front elevational view of a reclosable bag including the profile seal disclosed in  FIGS. 1 through 6 . 
         FIG. 8  is a perspective view of a reclosable bag including the profile seal disclosed in  FIGS. 1 through 6 . 
         FIG. 9  is a flowchart of the method of forming a reclosable fastener profile assembly disclosed in  FIGS. 1 through 6 . 
         FIG. 10  is a flowchart of an alternative method of forming a reclosable fastener profile assembly also disclosed in  FIGS. 1 through 6 . 
     
    
    
     While the specification and claims herein may refer to specific fastener or rib structures, it will be understood and fully appreciated that the principles of the present invention refer to closures generally and incorporate any compatible closure type or style. As such, before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As seen in  FIGS. 1 through 4 , the reclosable profile  10  assembly as disclosed in the present embodiment includes a first profile  14 , a second profile  18  and a compression molded segment seal  22 . The profile assembly  10  has a length, which may be reduced or enlarged in accordance with the present application to accommodate any length required by a particular industry application. 
     The profile assembly  10  includes a first profile  14 . The first profile  14  is flat, thin piece of packaging material preferably manufactured from polyethylene. As most clearly depicted in  FIGS. 1 ,  2 ,  3  and  4 , the first profile  14  includes a first profile surface  26  including an end  28 , a first rib  30 , second rib  34  and third rib  38 . The first rib  30 , second rib  34  and third rib  38  are in a location offset from the center of the first profile  14 , thereby defining a profile adherence surface  42  between ribs  30 ,  34 ,  38  and the edge  44  of the first profile strip  14 . As seen in  FIGS. 1 through 4 , the first rib  30 , second rib  34  and third rib  38  of the first profile  14  extend the entire length of the first profile surface  26 . 
     The second profile  18  is preferably manufactured from the same material and with the same dimensions as the first profile  14 . As best depicted in  FIG. 2 , the second profile  18  includes a second profile surface  46  including an end  48 , first rib  50 , second rib  54  and third rib  58 . As best depicted in  FIG. 4 , the first rib  30 , second rib  34  and third rib  38  are located along one edge  40  of the second profile  18 . As seen in  FIGS. 1 through 4 , the first rib  30 , second rib  34  and third rib  38  of the second profile  18  extend the entire length of the second profile surface  46 . 
     As seen in  FIG. 1 , the completed profile assembly  10  also includes a compression molded segment seal  22  portion. “Compression molding” is well known. In general, compression molding entails placing a predetermined amount of material between mold halves. The mold halves are closed, causing the enclosed material to become heated, and in turn, causing it to liquefy, filling voids in the molds. Various embellishments to compression molding have been disclosed in various patents. For example, U.S. Pat. No. 4,309,379, which issued Jan. 5, 1982, discloses a “Method and Apparatus for Runnerless Injection-Compression Molding Thermosetting Materials.” In this patent, a thermosetting molding material is heated and passed through a heated nozzle into a heated manifold. The heated material is passed from the manifold into a heated mold. The mold is closed to press and cure the material enclosed within it. The cured, finished article is removed from the mold and the process repeated. 
     In the preferred embodiment of the present invention, the “mold” is a die and anvil. Heat and pressure applied to the seal material causes the seal material to liquefy. When it liquefies, it flows into voids between the two film layers. The sealed areas are gradually cooled, causing the material in the mold to cool and solidify, taking the shape of the mold. In a preferred embodiment of the invention, the cooling time in the mold is increased and the amount of heat is reduced in order to cure the finished product more slowly. In so doing, the segment seal  22  retains its cross section better than it would if the mold were opened quickly or at a relatively higher temperature, and gaps between the film layers which would otherwise allow the passage of air across the seal, are eliminated. 
     The compression molded segment seal  22  of  FIG. 1  comprises the profile adherence surface  42  of the first profile surface  26  fused to the portion of the second profile surface  46 , which engages the profile adherence surface  42  and a portion of the first  30 , second  34  and third  38  ribs of the first profile surface  14  and the corresponding engaged portion of the first  50 , second  54  and third ribs  58  of the second profile surface  46 . In the embodiment depicted, the compression molded segment seal  22  portion has a thickness less than the combined thickness of the individual first profile  14  and second profile  18 . 
     The formation of the profile assembly  10  and compression molded segment seal  22 , as depicted in  FIGS. 5 and 6 , is accomplished by providing a continuous supply of an interconnected first profile  14  and second profile  18  where the ribs  30 ,  34 ,  38  of the first profile  14  are engaged with the ribs  50 ,  54 ,  58  of the second profile  18 . 
     As seen in  FIG. 5 , the engaged first profile  14  and second profile  18  are fed or otherwise positioned in proximity to the compression molded segment sealer  62 . The compression molded segment sealer  62  provides heat and pressure to the profile assembly to form the compression molded segment seal  22 . In one embodiment of the invention, multiple compression molded segment sealers  62  may be utilized in order to reduce the amount of heat and/or pressure applied at each segment sealer  62 . 
     As seen in  FIG. 6 , the engaged first profile  14  and second profile  18  are repositioned  82  with the first compression molded segment seal  22  advanced  82  past compression molded segment sealer  62 . The second compression molded segment seal  24  is formed, defining the second compression molded segment seal  24  of the completed profile assembly  70  and the first seal  22  of a second incomplete profile assembly  78 . While the second compression molded segment seal  24  is being formed, the first profile  14  and second profile  18  are simultaneously cut  60  by the compression molded segment sealer  62  to define the completed profile assembly  70  and form a portion of the first compression molded segment seal  22  for a second incomplete profile  78 . The area between the first compression molded segment seal  22  and second compression molded segment seal  24  defines the opening  80  of the reclosable bag profile  70  (as seen in  FIG. 8 ). The second incomplete profile  78  depicted in  FIG. 4  is advanced  82  and the process (as depicted in  FIGS. 9 and 10 ) is repeated to form an additional completed profile assembly  70  (as shown in  FIGS. 7 and 8 ). 
     As seen in  FIGS. 7 and 8 , a reclosable storage bag  84  is created by fusing or otherwise affixing a completed profile assembly  70  to a first bag wall  72  and second bag wall  74 . The completed reclosable storage bag  84  includes a first bag wall  72 , a second bag wall  74  and the reclosable fastener profile assembly  70  depicted in  FIG. 6 . As depicted in  FIG. 8 , the reclosable fastener profile and first  72  and second bag walls  74  combine to define a storage bag  84  with a reclosable opening  80 . 
       FIGS. 9 and 10  represent graphically the method of forming a fastener profile assembly  70  disclosed herein. As seen in  FIG. 9 , the following steps are performed in sequence: first  82 , an interconnected profile strip  10  is provided; second  84 , heat and pressure is applied by the compression molded segment sealer  62  to the interconnected profile strip  10  to form a compression molded segment seal  22 ; and third  86 , the profile strip  10  is advanced  82 . The second  84  and third  86  steps are then repeated to form additional completed profile assemblies  70 . 
     Alternatively, as seen in  FIG. 10 , the steps  82 ,  84 ,  84  depicted in  FIG. 9  are duplicated, however, a cutting step  88  is applied after the interconnected first  14  and second  18  profiles are fused  22  during the second step  84 . The cutting step  88  cuts  60  the compression molded segment seal  22 , thereby defining a second compression molded segment seal  24 . The second step  82 , cutting step  88  and third step  86  are then repeated sequentially to form additional individual profile assemblies  70 . 
     In other embodiments (not shown), the reclosable profile assembly  10  may include a peel seal, a frangible seal or other means for detecting tampering. Such means may include any type of known frangible seal which, when broken, is easily detected by the user. 
     Various features and advantages of the invention are set forth in the following claims.