Patent Publication Number: US-2004058039-A1

Title: Resealable bag for filling with food product(s) and method

Description:
RELATED APPLICATIONS  
     [0001] This application is a divisional of co-pending U.S. patent application Ser. No. 09/751,290 filed on Dec. 28, 2000, which is a continuation of international patent application Serial No. PCT/US00/25393 filed on Sep. 15, 2000 which is a continuation-in-part of U.S. patent application Ser. No. 09/474,493 filed on Dec. 29, 1999 (abandoned), which is a continuation-in-part of U.S. patent application Ser. No. 09/431,732 filed on Nov. 1, 1999 (now U.S. Pat. No. 6,360,513), which claims the benefit of provisional patent application Serial No. 60/133,810 filed on May 11, 1999. 
    
    
     
       BACKGROUND OF THE INVENTION  
       [0002] The present invention relates generally to the field of reclosable bags and more specifically to reclosable bags that use or incorporate tamper evident, hermetic seal, and reclosable fastener assemblies or mechanisms of the slider, zipper, or press-to-close type. The present invention is particularly concerned with a reclosable bag that may be filled with a food product at a factory or food processing plant and then sealed to protect the food product until such time as a customer purchases the reclosable bag and opens it to access the protect the food product until such time as a customer purchases the reclosable bag and opens it to access the food product within.  
       [0003] Reclosable, typically flexible, containers are well known in the art. Such containers normally comprise a bag-like structure made from a folded web of material, like thermoplastic film. These types of containers may also include reclosable zipper structures, as well as interlocking male and female zipper elements fused, extruded, or attached to the bag sidewalls. Alternatively, the reclosable zipper structures, mechanisms, or assemblies may also be identified as slider closure systems, i.e., a closure system for slider bags and form, fill and seal technology that contain two tracks that can be interlocked and a separate part (a slider) that rides on the tracks and is used to open and/or close the tracks. The bag-like structure is created when the thermoplastic film is folded, sealed, and severed along its exposed edges.  
       [0004] Reclosable bags are a great convenience to the consumer. This is especially true where the food product or material contained within the bag is of a type that may not all be consumed at once, for example, shredded cheese, sliced cheese, cheese, processed cheese, deli meats, snack foods, vegetables, fruits, sweets, etc. A problem with these types of bags is achieving a design in which the food product is hermetically sealed against oxygen, atmospheric intrusion or transmission, bacteria, molds, and/or other sources of contamination, while also providing features that help to disclose to the consumer evidence of tampering without substantially interfering with the ease of use of the bag.  
       [0005] In addressing this problem it is also desired to achieve a design that is easy to manufacture and may be used in combination with known types of packaging machinery that use form, fill, and seal technology such as Horizontal Form Fill and Seal (HFFS) machines or Vertical Form Fill and Seal (VFFS) machines. It is also desired to achieve a design that may optionally be used in combination with Horizontal Flow Wrapper (HFW) machines; e.g., J-WRAP machines presently available from Jones Automation Company, Inc. of Beloit, Wis.  
       [0006] Tamper evident packaging may also require the use of several pieces of film, which must then be connected to each other. This can make manufacturing of the reclosable bag more complicated.  
       [0007] Gusseted style packages are additionally greatly convenient to the consumer. Gusseted style packages allow the package to stand upright due to their wider base. This is true when it is desirable to stand a package upright by itself. Further, the wider base of the gusseted style package enables them to hold a greater volume of product than a conventional four-sided seal package of similar dimensions. The challenge has been to combine the convenience of a zippered packaged in one gusseted, reclosable bag.  
       [0008] With a “press to close” type zipper, the gusset style package is typically formed with the gusset at the bottom and the zipper at the top. This type of package is filled through the opened zipper. Several problems have arisen during production and filling of this type package. For example, in the package making process, it is necessary for the “press to close” zipper to be closed (i.e. the male and female profiles need to be engaged), when the zipper profiles are fused together at the side seal. If the male and female profiles are not engaged, they are subject to misalignment. If they are mis-aligned at the side seal station, the resulting package will have a zipper that does not close completely, specifically adjacent to the side seal, and a leaky package results. Furthermore, after the side seal is added, the usually simple process of opening the zipper for filling using a stationary blade to plow the zipper open, is no longer a reasonable option. Rather, the zipper must be opened, by either pulling the sides of the package that the zipper is attached to apart, or by holding the sides securely while a plunger lowers into the upper portion of the package, forcing the zipper open. Regardless of the method chosen, an unacceptable percentage of unopened packages or damaged zippers results.  
       [0009] An additional problem encountered by usual top filling of the zippered, gusseted bag, is product waste and contamination of zipper profiles. As a solution to this problem, some filling processes lower a fill tube into the package and past the zipper profiles area in an attempt to protect the profiles from the product. This technique reduces profile contamination, but does not eliminate it. This is because clearance must be maintained between the fill tube and the package walls to ensure consistency of tube insertion and to provide an exit passage for the air of the package that the product is displacing. In the stream of air exiting the package to make room for the product, some product is inevitably included, and profile contamination results.  
       [0010] A further problem associated with traditional top filling of zippered, gusseted packages occurs when the zipper is closed after the package has been filled with product. The usual method forces the zipper closed by applying force to both sides of the zipper and in a direction tangent to the sides of the package. This process may not consistently close the zipper and those that do close may have product pushed into the zipper profiles.  
       [0011] Gusseted packages using a slider type zipper encounter additional filling problems. In filling a package of this type, the slider portion of the zipper must be slid from one side of the package to the other in order to open the profiles. Once the package is filled, the sliding of the slider portion must be reversed to close the top. This process is difficult and expensive, rendering top filling through slider type zippered packages to be commercially impractical.  
       [0012] The closest gusseted package references are believed to be U.S. Pat. No. 5,938,337 issued on Aug. 17, 1999, U.S. Pat. No. 5,529,394 issued on Jun. 25, 1996, and U.S. Pat. No. 5,417,040 issued on May 23, 1995. Although these patents disclose advantageous methods, they fail to fully utilize the benefits of a gusseted type package. Namely, because of the wider base provided in a gusseted bag, they are able to hold a greater volume than conventional four sided seal packages of the same height and width. The above-mentioned patents provide methods for filling the gusseted bag from the gusset side of the package and opposite the closure mechanism. However, when a gusseted bag is filled from the bottom, gusseted side, product stacks upward in the package similarly to filling a conventional four sided package. The result is the inability to fully utilize the added volume benefit that the gusset provides.  
       [0013] It is one of the objectives of the present invention to provide a reclosable bag that may be manufactured using known packaging machinery. As previously, noted, such known machinery includes HFFS machines, VFFS machines, and HFW machines. Additionally, as will be apparent to a person of skill in the art after reading the present disclosure contained herein thermoform type machines like the one disclosed in U.S. Pat. No. 4,240,241 could also be used to practice the present invention disclosed herein, after appropriate modification as the disclosure herein will make apparent. It is also an objective to perform the manufacturing task using only one piece of parent film in combination with a reclosable zipper assembly.  
       [0014] Further, it is an objective of the invention to provide the manufacturer with the option of including some or all the features of tamper resistance or evidence, hermetic seal, and ease of use in the reclosable bag that is produced.  
       [0015] Another objective, especially with slider or zipper type structures or sliding type zippers or fasteners is ease of use. While a sliding type zipper structure is itself relatively easy to use, the bag structures include sidewalls or fin portions that extend up past the sliding type zipper structure. This interferes with the consumer&#39;s access to the food, makes it difficult to see the zipper structure, and also makes it more difficult to easily operate the zipper mechanism. This is especially true if the person opening and closing the bag is disabled, has arthritis, or another aliment, which limits the manual dexterity of that person.  
       [0016] Additionally, increased ease of access to the food product is an objective because the larger the zipper structure and its associated elements the smaller the opening left to the consumer to access the food product.  
       [0017] It is a further objective to provide a reclosable gusseted package that may be side filled with product.  
       [0018] It is another objective to provide a reclosable gusseted package that may be side filled and avoid zipper profile contamination.  
       [0019] It is another objective to provide a reclosable, gusseted package that may be side filled to ensure optimal volumetric filling of the gusseted portion.  
       [0020] It is one of the objectives of the present invention to provide a gusseted reclosable bag that may be manufactured using known packaging machinery, such known machinery includes HFFS machines.  
       [0021] The present invention is believed to address these and other objectives by the unique and simple structures and methods disclosed herein.  
       SUMMARY OF THE INVENTION  
       [0022] The present invention may generally be described as a reclosable bag for filling with at least one food product. The reclosable bag includes at least one sheet of web material. The sheet of web material has at least two areas of structural weakness and at least one fold structure located between and defined by the two areas of structural weakness. The reclosable bag includes an opening located generally opposite the fold structure. (Please note that fold structure as used in the specification and claims herein is to be interpreted as broadly as possible and should include not only structures that are a fold but also any structure that has the same or similar characteristics to a fold even though said structure may be formed by non-folding means or methods such as the result of joining or fusing the edges of two or more sheets of film.) In addition, the reclosable bag includes a sliding fastener structure having a skirt structure of web material extending therefrom and located within the fold structure. The skirt structure or skirt material may be either integral to the slider fastener structure or it may be coupled, e.g., sealed or adhered, to the slider fastener structure. The skirt structure includes a distal margin that is coupled to the sheet of web material at a location between the areas of structural weakness and the opening. The web material of the reclosable fastener structure extending past the areas of structural weakness so that the reclosable fastener structure is located within the fold structure. The reclosable bag is capable of being filled with at least one food product through the opening.  
       [0023] The reclosable bag structure of the present invention may optionally include other features. For example, but not by way of limitation, the skirt may include an outside surface and an inside surface. The distal margin is located on the outside surface. The inside surface may include a predetermined area having a releasable adhesive material. This allows for the option of having a peelable seal, which may be used to aid in making the reclosable bag initially hermetic and may also add another reclosable/resealable feature to the bag. (Please note that the terms reclosable, resealable, and releasable, in addition to their normal meaning, are used herein, interchangeably, to describe a closed or sealed opening that may be re-opened at a predetermined time to aid in providing access to at least a portion of the contents of the bag, and then closed or sealed to allow the remaining contents to be stored in the bag for later use and/or provide evidence of tampering.)  
       [0024] Additionally, and more typically, the web material of the reclosable bag is substantially comprised of a predetermined portion of a roll of a parent film material. The predetermined portion having predetermined dimensions from which a reclosable bag of predetermined dimensions may be constructed. The parent film material may be manufactured to a specification which determines the shape and location of the areas of structural weakness and which makes the areas of structural weakness an integral part of the parent film. Presently, it is believed to be commercially preferred to do so. Alternatively, the areas of structural weakness could be applied to the parent film at a predetermined step of the construction or manufacturing process of the resealable bag.  
       [0025] Further, the areas of structural weakness may extend intermittently, continuously, and linearly, non-linearly, or in some other predetermined pattern across a predetermined dimension of the sheet of web material. The predetermined dimension where the area of structural weakness is located may be either the length or the width of the reclosable bag, which is usually rectangular in shape, depending on whether or not it is desired to use the long edge or side of the bag or the short edge or side of the bag with the slider closure system. Use of the long edge of the bag provides for a larger opening and thus enhances the ease of access to the food material or other materials contained within the reclosable bag.  
       [0026] The term structural weakness is generally used to describe that area of the reclosable bag that is intentionally designed to be easily torn by the consumer to provide for evidence of tampering and to allow for easy exposure of the zipper mechanism or assembly. Nonetheless, it should be understood that use of the term structural weakness should include, without limiting its meaning, structures such as perforation, scores, microperforations, and multiple laminate materials which include a layer having an area of material or materials which are specifically designed to be easily torn. Accordingly, it should be understood that the areas of structural weakness are intentionally designed to create a predetermined tear path, which may or may not be hermetic.  
       [0027] Also, opening of the bag may be facilitated by the application of a tear strip (e.g., tear tape or tear string) along a predetermined surface or surfaces of the parent film. The tear strip may or may not be used in combination with a predetermined area of structural weakness.  
       [0028] Alternatively, the present invention may be described as a reclosable bag for filling with at least one food product and comprising at least one sheet of a web material. The sheet of web material includes a first area of structural weakness and a second area of structural weakness. (Alternatively, the areas of structural weakness may be tear areas or areas having a propensity to tear in a predetermined direction.) The sheet of web material including at least one fold structure, located between and defined by the first and second areas of structural weakness, and a fill opening. The sheet of web material further comprising a first panel coupled to the fold structure at the first area of structural weakness and a second panel coupled to the fold structure at the second area of structural weakness. A reclosable fastener structure including a male track structure and a female track structure. The male track structure including a first fin structure of web material extending therefrom and the female track structure including a second fin structure of web material extending therefrom. Each fin structure including a predetermined coupling portion. The coupling portion of the first fin structure being coupled to the first panel and the coupling portion of the second fin structure being coupled to the second panel. (please note that the seal, when it is formed, may be adjacent or near but should not be on the area of structural weakness). The reclosable fastener structure extending past the areas of structural weakness and into the fold structure. The areas of structural weakness being located below the reclosable fastener structure. The alternative reclosable bags are also capable of being filled with at least one food product through the fill opening, which is subsequently sealed.  
       [0029] The present invention allows the fold structure to be easily removed from the reclosable bag. More importantly the present invention allows the consumer to substantially expose the reclosable fastener structure so that it is easily accessible and the consumer does not have to be impeded by bag sidewalls or bag fin portions that extend up past the zipper structure. Finally, the present invention accomplishes this using but not limited to substantially one piece of film material.  
       [0030] Alternatively, the present invention may be described as a reclosable bag for filling with at least one food product. The reclosable bag may include at least one sheet of web material, at least one tear tape structure, at least one fold structure, and an opening located generally opposite the fold structure. A reclosable fastener structure including at least one integral skirt structure of skirt web material extending therefrom. The integral skirt structure including at least one distal margin. The distal margin being coupled to the web material at, at least one location between the tear tape structure and the opening. The reclosable fastener structure extending past the tear tape structure and into the fold structure. The reclosable bag capable of being filled with at least one food product.  
       [0031] Additionally, the reclosable bag for filling with at least one food product, may also be described as a reclosable bag including at least one sheet of web material having at least one fold structure presenting at least two sidewall structures having inside surfaces, and an opening located generally opposite the fold structure. A reclosable fastener structure including an integral skirt structure comprising a web material extending therefrom and including opposed distal margin structures. The web material of the integral skirt structure being sealed to the inside surfaces of the sidewall structures at a plurality of predetermined sealing areas. The reclosable bag may also include a barrier web material extending between and coupled to the distal margin structures.  
       [0032] The barrier web material of the alternative bag may alternatively extend between and be coupled to the sidewall structures. Alternatively, the barrier web material may also be coupled to predetermined sealing areas by at least one peelable seal. Alternatively, the barrier web material may include at least one area of structural weakness that extends through it along a direction generally parallel to the predetermined sealing areas.  
       [0033] Alternatively, the reclosable bag for filling with at least one food product of the present invention may include at least one sheet of web material having at least one predetermined tear area, at least one fold structure, and an opening located generally opposite the fold structure. A reclosable fastener structure including at least one integral skirt structure of skirt web material extending therefrom. The integral skirt structure including at least one distal margin. The distal margin being coupled to the web material at, at least one location between the tear area and the opening. The reclosable fastener structure extending past the tear area and into the fold structure. The reclosable bag capable of being filled with at least one food product.  
       [0034] This alternative reclosable bag structure may further include at least one piece of a header material located in a predetermined area of the fold structure. The header material may include at least one edge structure adjacent the tear area. The reclosable bag of this alternative structure may further include at least one tear tape structure coupled to the web material and adjacent to the tear area.  
       [0035] Alternatively, the present invention may be described as a reclosable bag for filling with at least one food product. The reclosable bag may include at least one sheet of web material, at least one tear tape structure, at least one fold structure, and an opening. A reclosable fastener structure including at least one integral skirt structure of skirt web material extending therefrom. The integral skirt structure including at least one distal margin. The distal margin being coupled to the web material at, at least one location between the tear tape structure and the opening. The reclosable fastener structure extending past the tear tape structure and around and over the fold structure. The reclosable bag capable of being filled with at least one food product.  
       [0036] Additionally, the reclosable bag for filling with at least one food product, may also be described as a reclosable bag including at least one sheet of web material having at least one fold structure, and an opening. A reclosable fastener structure including an integral skirt structure comprising a web material extending therefrom and including opposed distal margin structures. The web material of the integral skirt structure being sealed to the outside surfaces of the sidewall structures at a plurality of predetermined sealing areas. The inside surface of the reclosable bag may also include a predetermined area having a releasable adhesive material. This allows for the option of having a peelable seal, which may be used to aid in making the bag initially hermetic and may also add another reclosable/resealable feature to the bag.  
       [0037] Additionally, the present invention may be described as a method of construction using known form-fill-and-seal machinery including but not limited to HFFS, VFFS, and HFW machines. The steps of the method of construction include 1. Folding the sheet of web material along a predetermined folding area located between the areas of structural weakness to form the fold structure. 2. Inserting the reclosable fastener into the fold structure. 3. Coupling the distal margin of the integral skirt structure to the web material. 4. Sealing the web material along at least two predetermined linear areas located generally perpendicular to the fold structure. 5. Filling the reclosable bag with at least one food product through an opening. 6. Sealing the opening. Please note that in an HFW application it is presently believed that the step four should occur last.  
       [0038] The method may also include a step of inserting either a tear tape or a tear string at least prior to step four. Further, a header strip could also be introduced prior to step four.  
       [0039] Alternatively, the web material may be slit along the fold line and the reclosable fastener assembly inserted and sealed to result in an exposed zipper structure assembly at one end of the bag.  
       [0040] Also, alternatively, if the reclosable bag is designed to have a gusset opposite the zipper opening then the fill opening may be sealed and the bag may be filled with product through the zipper opening.  
       [0041] Alternatively, the present invention may generally be described as a gusseted, reclosable bag for filling with at least one food product. The gusseted, reclosable bag includes at least one sheet of web material. The sheet of web material has at least two areas of structural weakness, a gusseted portion, at least one fold structure and an opening located generally between the fold structure and the gusseted portion.  
       [0042] In addition, the reclosable bag includes a sliding fastener structure having a skirt structure of web material extending therefrom. The skirt structure or skirt material may be either integral to the slider fastener structure or it may be coupled, e.g., sealed or adhered, to the slider fastener structure. The skirt structure includes a distal margin that is coupled to the sheet of web material at a location between the fold and the opening. The reclosable bag is capable of being filled with at least one food product through a fill opening located between the skirt structure and the gusseted portion.  
       [0043] A backing or barrier strip structure is inserted between and extending below the zipper skirts along the side fill opening. The backing or barrier strip structure may be made out of any suitable material but is preferably two-ply and composed of a laminate film such as Curwood&#39;s 7182 barrier film. One side of the barrier strip structure to be used in the present invention is nylon, or any other suitable material such as polypropylene, which will not bond to the parent film. The opposite side of the barrier strip structure may be provided with a sealant such as polyethylene, polyethylene blend, or a polyethylene co-extrusion. The sealant side is sealed or tacked to the inside surface of the top (or front side) zipper skirt prior to insertion into an upper fold (i.e. fold structure). Once inserted into the upper fold, the front side of each zipper skirt is sealed to the parent film. The parent film then passes over folding boards to form a bottom gusset. The remaining unsealed edge of parent film extends upward to meet the other edge located at zipper skirt. After filling with product, the final sealing bar seals the parent film to the zipper skirt and a portion of the barrier strip structure to make a hermetic package. With the barrier strip structure inserted between and extending below the zipper skirts, the zipper skirts will not seal to each other and the nylon side of the barrier strip structure will not seal to the opposite inside surface of the parent film.  
       [0044] The gusseted, reclosable bag structure of the present invention may optionally include other features. For example, but not by way of limitation, the skirt may include an outside surface and an inside surface. The distal margin is located on the outside surface. The inside surface may include a predetermined area having a releasable adhesive material. This allows for the option of having a peelable seal, which may be used to aid in making the reclosable bag initially hermetic and may also add another reclosable/resealable feature to the bag.  
       [0045] Alternatively, if the reclosable bag is designed to have a gusset opposite the zipper opening, the bag may be filled with product through a fill opening located between the zipper skirt and the gusseted portion.  
       [0046] Alternatively, the present invention may be described as a gusseted, reclosable bag for side filling with at least one food product and comprising at least one sheet of a web material. The sheet of web material includes a first area of structural weakness and a second area of structural weakness. (Alternatively, the areas of structural weakness may be tear areas or areas having a propensity to tear in a predetermined direction.) The sheet of web material including at least one fold structure, located between and defined by the first and second areas of structural weakness, a fill opening, a backing or barrier strip structure, and a gusseted portion. A reclosable fastener structure including a male track structure and a female track structure. The male track structure including a first fin or skirt structure of web material extending therefrom and the female track structure including a second fin or skirt structure of web material extending therefrom. Each fin structure including a predetermined coupling portion. (Please note that the seal, when it is formed, may be adjacent or near but should not be on the area of structural weakness). The reclosable fastener structure extending past the areas of structural weakness and into the fold structure. The areas of structural weakness being located below the reclosable fastener structure.  
       [0047] The backing or barrier strip structure is inserted between and extending below the fin or skirt structures along the side fill opening. As in the previous embodiment, one side of the barrier strip structure to be used is nylon, or any other suitable material such as polypropylene, which will not bond to the parent film. The opposite side of the barrier strip structure may be provided with a sealant such as polyethylene, polyethylene blend, or a polyethylene co-extrusion. The sealant side of the backing or barrier strip of this alternative embodiment may be sealed or tacked to the inside surface of the top (or front side) zipper skirt prior to insertion into an upper fold (i.e. fold structure). Once inserted into the upper fold, the front side of each zipper skirt is sealed to the parent film, as discussed with regard to the reclosable gusseted bag with sliding fastener structure. Alternatively, an anti-seal agent may be brush applied to the inside surface of the zipper skirt prior to insertion into an upper fold.  
       [0048] Alternatively, the present invention may be described as a gusseted, reclosable bag for side filling with at least one food product. The reclosable bag may include at least one sheet of web material, at least one fold structure, at least one gusset structure, a side fill opening having a backing or barrier strip structure, located generally between the fold structure and the gusset structure. A reclosable fastener structure including at least one integral skirt structure of skirt web material extending therefrom. The integral skirt structure including at least one distal margin. The distal margin being coupled to the web material at, at least one location between the fold structure and the opening. The reclosable bag capable of being filled with at least one food product.  
       [0049] This alternative reclosable bag structure may further include at least one piece of a header material located in a predetermined area of the fold structure. The header material may include at least one edge structure adjacent the tear area.  
       [0050] Additionally, the present invention may be described as a method of construction using known form-fill-and-seal machinery including but not limited to HFFS, VFFS, and HFW machines. The steps of the method of construction include 1. Placing a backing or barrier strip structure in registration with the side seal. 2. Punching out the strip in the area that is both in the side seal and adjacent to the skirt of the zipper to which the backing or barrier strip will be attached. 3. Attaching the backing or barrier strip to the inside face of one of the skirts of a zipper track with sealant side of the strip facing the inside surface of the skirt. 4. Heat sealing a portion of the remaining strip adjacent the zipper skirt to the zipper skirt. 5. Folding the sheet of web material along a predetermined folding area located between areas of structural weakness to form a fold structure. 6. Inserting the reclosable fastener and attached backing strip structure into the fold structure. 7. Attaching the zipper track to the web in a location relative to the areas of structural weakness by heat sealing the web to the skirt portions of the zipper track. 8. Positioning the edge of the web such that it is attached to, but not covering the entire portion of, the skirt having the barrier strip attached. 9. Passing the remaining web across folding boards such that a gusset is formed at the bottom of the package. 10. Folding the other edge of web material upward to the remaining exposed zipper skirt having the backing or barrier strip attached, and adjacent to the first edge of the web. 11. Sealing the web material along at least two predetermined linear areas located generally perpendicular to the fold structure. 12. Filling the reclosable bag with at least one food product through the side opening. 13. Sealing the opening.  
       [0051] The method may also include a step of introducing a header strip prior to step ten.  
       [0052] Alternatively, the process and structure of the present invention could include a reclosable fastener assembly having two skirts or flaps of web material. The first skirt could be coupled or sealed to the parent film prior to folding the parent film. (Additionally, the first skirt could be tack or partially sealed prior to folding and then subsequently a full seal applied in the HFFS, VFFS, or HFW machine.) After folding the parent film the second skirt or flap would be sealed to the film sidewall located opposite the sidewall to which the first skirt is sealed or coupled. Construction of the bag could then be completed as disclosed herein. 
     
    
    
     DESCRIPTION OF THE DRAWINGS  
     [0053]FIG. 1 is a top plan view of a predetermined portion of parent film comprising a sheet of web material including at least two areas of structural weakness.  
     [0054]FIG. 2 is an, edge elevational view of a portion of the sheet of web material of FIG. 1 and shows the location of the areas of structural weakness.  
     [0055]FIG. 3 is a side elevational view of the fold structure of a reclosable bag of the present invention showing the position of the slider or zipper structure in the fold structure relative to the predetermined position of the areas of structural weakness.  
     [0056]FIG. 4 is a perspective view of the embodiment shown in FIG. 3.  
     [0057]FIG. 5 is a front plan view of a first embodiment of the present invention.  
     [0058]FIG. 6 is a front plan view of an alternative to the first embodiment of the present invention disclosing sealed track mass  23   b.    
     [0059]FIG. 7 is a front plan view of an alternative embodiment of the present invention.  
     [0060]FIG. 8 is a view taken from line  8 - 8  of FIGS. 5 and 6.  
     [0061]FIG. 9 is an alternative to the embodiment of the present invention shown in FIG. 8.  
     [0062]FIG. 10 is another alternative to the embodiment shown in FIG. 8.  
     [0063]FIG. 11 is an alternative to the embodiment shown in FIG. 10 wherein a peal seal tape with a releasable adhesive located on one side of the tape is used.  
     [0064]FIG. 12 is a view from line  12 - 12  of FIG. 11, the header material  15  that is shown, along with other structures, is optional.  
     [0065]FIG. 13 is another alternative to the embodiment shown in FIG. 8.  
     [0066]FIG. 14 is a front plan view of another alternative embodiment of the present invention.  
     [0067]FIG. 15 is a view taken from line  15 - 15  of FIG. 14.  
     [0068]FIG. 16 is an alternative to the embodiment of the present invention shown in FIG. 15.  
     [0069]FIG. 17 is another alternative to the embodiment shown in FIG. 15.  
     [0070]FIG. 18 is another alternative to the embodiment shown in FIG. 15.  
     [0071]FIG. 19 is a front plan view of an alternative embodiment of the present invention.  
     [0072]FIG. 20 is a view from line  20 - 20  of FIG. 19.  
     [0073]FIG. 21 is a plan view of an alternative embodiment of the present invention illustrating various features of the invention including die cutting of the track mass of the zipper assembly and the use of a tear structure like a tear tape or a tear string.  
     [0074]FIG. 22 is a view from line  22 - 22  of FIG. 21.  
     [0075]FIG. 23 is a view of an alternative to the embodiment shown in FIG. 22 wherein tear tape is applied to both the inside and outside surface of the bag.  
     [0076]FIG. 24 is a cut-away view of an alternative to the embodiment shown in FIG. 22 wherein the tear tape includes a tear bead.  
     [0077]FIG. 25 is a perspective view of the embodiment shown in FIG. 24.  
     [0078]FIG. 26 is a cut-away view of a predetermined portion of the embodiment shown in FIG. 24 illustrating the tear tape and tear bead&#39;s relationship to the film and the area of structural weakness created as a result of the presence of the tear bead.  
     [0079]FIG. 27 is an alternative embodiment to the structure disclosed in FIG. 22.  
     [0080]FIG. 28 is a plan view of an alternative embodiment of the present invention illustrating various features of the invention including the use of an optional header strip and the use of an optional opening to assist in removal of the hood and exposure of the zipper assembly.  
     [0081]FIG. 29 is a view from line  29 - 29  of FIG. 28.  
     [0082]FIG. 30 is a schematic diagram showing the components of another alternative embodiment of the present invention being fed into a machine suitable for adaptation to perform the process and make at least one of the products disclosed herein before the plow structure of the machine.  
     [0083]FIG. 31 is a schematic diagram showing the components of another alternative embodiment of the present invention being fed into a machine suitable for adaptation to perform the process and make at least one of the products disclosed herein before the plow structure of the machine.  
     [0084]FIG. 32 is a schematic top plan view illustrating at least one method by which the components of the alternative embodiment disclosed in FIG. 30 are introduced prior to the plow mechanism of the form fill and seal machine.  
     [0085]FIG. 33 is a schematic top plan view illustrating at least one method by which the components of the alternative embodiment disclosed in FIG. 31 are introduced prior to the plow mechanism of the form fill and seal machine.  
     [0086]FIG. 34 is a perspective view generally showing the general relationship of the components for making the various embodiments disclosed herein. Specifically, the embodiment having the peel seal tape is disclosed although after review of this disclosure it will be apparent to a person of ordinary skill in the art how the machinery may be modified to produce the various embodiments disclosed, described, and claimed herein.  
     [0087]FIG. 35 is side elevational schematic view illustrating the steps of construction of the alternative embodiment disclosed in FIG. 30 subsequent to folding the parent film on the plow structure.  
     [0088]FIG. 36 is side elevational schematic view illustrating the steps of construction of the alternative embodiment disclosed in FIG. 31 subsequent to folding the parent film on the plow structure.  
     [0089]FIG. 37 is an alternative embodiment of the present invention illustrating various features of the invention including the use of tear string and a diamond shaped opening as opposed to a circular opening for assisting in the removal of the hood and exposing the zipper assembly.  
     [0090]FIG. 38 is a schematic diagram showing the components of another alternative embodiment of the present invention being fed into a machine suitable for adaptation to perform the process and make the product disclosed herein, wherein either a tear string or the zipper assembly are introduced to the parent film after the plow.  
     [0091]FIG. 39 is a side elevational schematic view illustrating the steps of construction of the alternative embodiment disclosed in FIG. 38 wherein the tear string or slider or zipper assembly is introduced after the plow structure.  
     [0092]FIG. 40 is a front plan view of an alternative embodiment of the present invention.  
     [0093]FIG. 40 a  is a front plan view of the alternative embodiment of FIG. 40, but showing a peel seal area.  
     [0094]FIG. 41 is a view taken from line  41 - 41  of FIG. 40 a  and showing the reclosable fastener structure extending over the fold structure and peel seal.  
     [0095]FIG. 41 a  is an enlarged view of the structure shown in FIG. 41 and showing the position of the slider or zipper structure over the fold structure relative to the predetermined position of the areas of structural weakness.  
     [0096]FIG. 42 is a front plan view of an alternative embodiment of the present invention.  
     [0097]FIG. 43 is a view taken from line  43 - 43  of FIG. 42 and showing a gusset portion, a slider fastener, and barrier strip and fill opening therebetween.  
     [0098]FIG. 44 is a view similar to that shown in FIG. 43 but with the gusset portion open and showing a flattened bottom.  
     [0099]FIG. 45 is a side elevational view of the fold structure of the reclosable bag shown in FIGS.  42 - 44  showing the position of the slider or zipper structure in the fold structure relative to the barrier strip and fill opening, and showing side  36  in phantom in position for filling through side opening, and side  36  in solid line illustrating the closed opening after filling.  
     [0100]FIG. 45 a  is a partially cut-away perspective view of the alternative embodiment shown in FIG. 45.  
     [0101]FIG. 46 is a schematic diagram illustrating at least one method by which the components of the alternative embodiment disclosed in FIGS.  42 - 45  are assembled.  
     [0102]FIG. 47 is a schematic top plan view illustrating at least one method by which the components of the alternative embodiment disclosed in FIGS.  42 - 45  are introduced prior to the plow mechanism of the form fill and seal machine.  
     [0103]FIG. 48 is a side elevational schematic view illustrating the steps of construction of the alternative embodiment disclosed in FIGS.  42 - 45  subsequent to folding the parent film on the plow structure and tucking board.  
     [0104]FIG. 49 is a front plan view of an alternative embodiment of the present invention.  
     [0105]FIG. 50 is a view taken from line  50 - 50  of FIG. 49 and showing a gusset portion, press-to-close fastener with barrier strip, and fill opening between the gusset portion and fastener.  
     [0106]FIG. 51 is a view similar to that shown in FIG. 50 but with the gusset portion open and showing a flattened bottom.  
     [0107]FIG. 52 is a side elevational view of the fold structure of the reclosable bag shown in FIGS.  49 - 51  showing the position of the press-to-close zipper structure in the fold structure relative to the barrier strip and fill opening, and showing side  36  in phantom while in position for filling through the fill opening and side  36  in solid line illustrating the closed and sealed, post-fill position.  
     [0108]FIG. 53 is a schematic diagram illustrating at least one method by which the components of the embodiment disclosed in FIGS.  49 - 52  are assembled.  
     [0109]FIG. 54 is a schematic top plan view illustrating at least one method by which the components of the embodiment disclosed in FIGS.  49 - 52  are introduced prior to the plow mechanism of the form fill and seal machine.  
     [0110]FIG. 54 a  is a cross sectional view taken along lines  54   a - 54   a  of FIG. 54 and showing the press-to-close zipper structure and backing strip.  
     [0111]FIG. 55 is a side elevational schematic view illustrating the steps of construction of the alternative embodiment disclosed in FIGS.  49 - 52  subsequent to folding the parent film on the plow structure and tucking board.  
     [0112]FIG. 55 a  is an enlarged partial view of the area referred generally as  55   a  in FIG. 55.  
     [0113]FIG. 56 is a perspective view generally showing the general relationship of the components for making the gusseted embodiments shown in FIGS.  42 - 55   a.    
     [0114]FIG. 57 is a perspective view generally showing the relationship of the components for making a prior art gusseted bag.  
     [0115]FIG. 58 is a perspective view of a prior art, top filled gusseted bag.  
     [0116]FIG. 59 is a perspective view of a side fill gusseted bag of the present invention and showing a slider type zipper and a backing strip. 
    
    
     DETAILED DESCRIPTION  
     [0117] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures or methods. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.  
     [0118] The present invention is both a method and a structure resulting from the method. The present invention generally relates to reclosable plastic bags  100  and, more particularly, to a reclosable plastic bags  100  having a slider or zipper assembly  20 , which cooperates with a tamper-evident feature. The tamper-evident feature may also be a hermetic seal feature. The method of the present invention, while unique and fully described herein, may be used on known machinery such as, by way of illustration and not by way of limitation, the rpm  100  packaging machine manufactured by Klockner Packaging Machinery of Sarasota, Fla., U.S.A. The modifications necessary to the machinery used to practice the present invention will be apparent to a person of ordinary skill in the art after reading this disclosure.  
     [0119] Reclosable plastic bags using various zippers and sealing mechanisms are well known. However, the advantages of the present invention are believed not to be apparent from the known zippers and sealing mechanism of the prior art. The zipper assembly  20  typically includes a zipper structure  20   a  and an integral skirt  16 . In the present invention, the skirt  16  is bonded to the parent film  10  at a predetermined seal location  14 . See FIG. 3.  
     [0120] Referring to FIGS.  1 - 5 , the method and structure of the present invention may begin to be generally described. Referring to FIG. 1 a predetermined portion of the parent film  10  is illustrated. The parent film  10 , at predetermined locations, is structurally weakened, e.g., by the use of presently known laser scoring technology.  
     [0121] Referring to FIG. 2, an elevational edge view of the parent film  10  including the score lines  12  may be seen. The weakened area  12  may also be imperforate and hermetic. The weakened areas  12  define an integral tear off portion or fold structure  11 .  
     [0122] Referring to FIG. 3, the film  10  is folded over, as shown, to form the fold structure  11  and a zipper assembly  20  is inserted. Weakened areas  12  are preferably positioned below the zipper structure  20   a  so that when fold structure or hood  11  is removed the zipper structure  20   a  is exposed sufficiently above the resulting fin structures  19  to allow the user access to the zipper structure  20   a . Zipper skirts  16  are shown bonded to the film  10 . However, it is presently believed preferable, prior to insertion of the zipper assembly  20 , that the uncut ends  23  (see FIG. 5) of each zipper assembly  20  be punched out or cut to form a radiused notch  22   a , as shown in FIG. 7. The cut zipper assembly ends  22  are sealed together (the sealed mass  22   b  of FIG. 7) which will later function to retain the contents of the bag  100  such as food.  
     [0123] Referring back to FIG. 3, the skirt(s)  16  remain intact so that the zipper assembly  20  is kept continuous for ease of handling. Once inserted the skirt(s)  16  of the zipper assembly  20  is bonded to the inside surface  10   a  of the parent film  10  at seal location(s)  14 .  
     [0124] Next sides  30  and  32  are sealed, along margin  10   c  illustrated in FIG. 5 or  7 , using a known mechanism such as a heat-sealing bar of a form fill and seal machine by advancing the folded film  10  to the heat sealing bar portion of the machine used; creating a seal  30   a  across the length and width of margin  10   c . The resulting bag  100  is then filled with a predetermined foodstuff or other desired material through the opening  33  located, opposite the zipper assembly  20 , at bottom edge  34  shown in FIG. 5 or  7 . Then bottom edge  34  is subsequently sealed, forming seal  34   a.    
     [0125] This results in the zipper assembly  20  being hermetically sealed within the tear off portion  11 . Tear off portion  11  is integral to the parent film  10 . Integral tear off portion  11  may be easily removed by tearing along the score lines  12 , leaving the zipper structure  20   a  fully exposed and easily accessible for the use desired.  
     [0126] The above noted process and mechanism may also be performed so that the zipper assembly  20  is located along one of the long sides  30  or  32  of the bag  100  rather than the short side of the rectangle, which is defined by the bag  100 .  
     [0127] Referring to FIG. 5, a second embodiment of the present invention  1  is illustrated. As may be seen from FIG. 5 two bags  100  are shown prior to their being separated along seam  101 . This embodiment includes score lines  12  laid out in an alternative pattern that includes curve or arcuate section  13  and tear notch  24 . As further disclosed in FIG. 5 the parent film  10  is sealed at section  26  to either its opposing sides  35  and  36  or the structure of the zipper assembly  20 . The tear notch  24  provides a starting point for removing the fold structure  11 , which is located above the zipper assembly  20 . The fold structure  11  being defined by the location of the score lines  12 . The score lines  12  extending along curve  13  to a predetermined area below the zipper assembly  20  for substantially the entire width of the reclosable bag  100  facilitating removal of the hood or fold structure  11  and exposure of the zipper structure  20   a . The embodiment of FIG. 5 further including a hermetic seal  40 .  
     [0128] Referring now to FIG. 8, a cross-sectional view of the embodiment of FIGS. 5 and 6 may be seen. In particular, the integral skirt  16 , usually comprised of two strips on pieces of plastic film or a one-piece unit of continuous film, may be seen to have its outside surface  19  sealed hermetically to the inside surfaces  36   a  and  35   a  at respective hermetic seals  40   a  and  40 . Additionally, a peelable seal  50  is located at the bottom of the skirt  16 . Any standard commercially known resealable adhesive  51  may be used to make the peel seal  50 . The peel seal  50  may also be a hermetic seal  40   b.    
     [0129] Referring now to FIG. 9 an alternative to the embodiment of FIG. 8 is shown. In this embodiment the zipper skirt  16  is heat sealed to the side panels  36  and  35  respectively of the parent film  10 . The inside surfaces  17  of the zipper skirt  16  are peelable sealed to one another, using a known releasable adhesive  51 , to provide a releasable hermetic or gas tight seal  50  therebetween. It should be noted that the terms resealable adhesive or releasable adhesive as used herein should be construed interchangeably as well as given their common meaning.  
     [0130] Referring now to FIG. 10 another alternative embodiment of FIG. 8 is shown. In this embodiment the parent film  10  is sealed along a predetermined portion  42  of inside surface  35   a  and  36   a . A known releasable adhesive  51  is used to form a peelable seal  50  between inside surfaces  35   a  and  36   a  at predetermined portion  42 . U.S. Pat. No. 4,944,409 contains an example of such an adhesive. Presently, CUREX brand grade 4482-0, supplied by Curwood of Oshkosh, Wis. is considered an acceptable adhesive for use with this embodiment of the present invention.  
     [0131] Referring now to FIGS. 11 and 12 another alternative embodiment is illustrated wherein the peelable seal  50  is comprised of a peel seal tape  53  having a permanent sealant like a metallocene catalyzed polyethylene located on one side and a releasable seal material like the aforesaid CUREX brand material on the other side (side  54 ).  
     [0132] One possible method for achieving the structure of FIGS. 11 and 12 is the use of a form fill and seal machine system in which the peel seal tape  53  would be tacked onto a predetermined location of the parent film  10  prior to the plow  200 . (See FIGS. 31, 33, and  34  for a general illustration of the location of the plow  200  in relationship to the other components of a form fill and seal machine. Please note with reference to FIG. 33 that it is presently believed preferable for heat sealer bar  208  to be enlarged sufficiently so that in addition to sealing the tear tape  120  is place it also seals the permanent seal side of the peal seal tape  53  in place at the same time. Accordingly, while one sealer bar  208  is believed preferable for these separate functions multiple bars could be used, each having a dedicated function or a combination of functions). After the plow  200  the peelable sealant side  54  would be sealed to the parent film  10  by heat sealer bars  55 . Use of sealer bars  208  and  55  as disclosed herein allows independent temperatures and pressures to be used for each seal and it is believed that more consistent peel seals will result.  
     [0133] Additionally, the zipper skirt  16  may be sealed in place subsequent to the plow  200  by sealer bar  56  and the header seal  206   a  may be made by sealer bar  57  as illustrated generally in FIGS. 34 and 36.  
     [0134] Referring now to FIG. 13 another alternative embodiment of FIG. 10 is shown. In this embodiment, the zipper skirt  16  includes an elongated section  16   a . End  21  of elongated section  16   a  is positioned between the inside surfaces  36   a  and  35   a  of the side panels  36  and  35  of the parent film  10 . The elongated section  16   a  is heat sealed to the parent film  10  on inside surface  35   a  and peelable sealed using a known releasable adhesive  51  to inside surface  36   a  to form peel seal  50 .  
     [0135] Referring now to FIG. 14 a third embodiment of the present invention is disclosed. Again, two bags  100  are shown prior to their being separated along seam  101 . The invention of the third embodiment is comprised of parent film  10 , which is used to form the bag  100  that is to be filled. The bag  100  includes a first side seal  30 , a second side seal  32 , and a fill opening  33 . Side panel  35  forms the front side of the bag  100 . The fill opening  33 , after the bag  100  is formed and filled with a predetermined type of food material, is heat sealed to form bottom edge or seal  34 . The bag  100  further includes a fold structure  11 , header  15 , integral zipper skirt  16 , a zipper assembly  20  including a zipper structure  20   a , at least one hermetic seal  40 , an unsealed area  60 , and a section  62  where the zipper skirt  16  and the ends  23  of the zipper assembly  20  are heat sealed together (see sealed mass  23   b  in FIG. 14) prior to their insertion between the front side  35  and the back side  36  of the film  10 . This forms sealed mass  23   b . The formation of sealed mass  23   b  may take place at sealer  216 , which is illustrated in FIG. 30.  
     [0136] Sealing zipper skirt(s)  16  to the parent film  10  forms the hermetic or gas tight seal  40 . The zipper skirts  16  may have a predetermined portion or portions that extend past seal  40  and which may be held together with a peel seal  50 . See for example, FIG. 15.  
     [0137] Since, within the unsealed area  60 , the side panels  35  and  36  are not attached to the zipper assembly  20 , the hood structure  11  (which may be defined by the score lines  12 ) may be easily removed to expose zipper structure  20   a . The sealed mass  23   b  provides for containment of product when the peelable seal  50  is opened.  
     [0138] Referring to FIG. 15 a view from line  15 - 15  of FIG. 14 may be seen. This may be seen to be identical to the embodiment of FIG. 8, except as explained above with reference to FIG. 14.  
     [0139] Referring now to FIG. 16 an alternative structure to the one shown in FIG. 15 may be seen. In this alternative, the zipper skirt  16  is made of one piece of material. It is heat sealed to the inside surfaces  35   a  and  36   a  to form hermetic seals  40  and  40   a . The skirt  16  is provided with a structural weakness  45  which extends linearly and generally parallel to hermetic seals  40  and  40   a  along the zipper skirt  16 . The structural weakness  45  is designed to fracture or tear relatively easily when the customer opens the bag  100 .  
     [0140] Referring now to FIG. 17, an alternative to the embodiment shown in FIG. 16 may be seen. In this embodiment the zipper skirt  16  includes a barrier film section  16   b . The barrier film  16   b  is applied (preferably by heat sealing although other methods could be used, e.g., Adhesive coupling, ultrasonic or high frequency sealing technology) to the inside surface  16   d  of the zipper skirt  16 . The zipper skirt  16  is heat sealed along a predetermined portion of its outside surface  16   e  to parent film  10  to form a hermetic seal  40 . The barrier film section  16   b  is releasably sealed to the inside surface  16   d  to form at least one peel type seal  50 . Note that it is presently believed that section  16   b  must have a surface  16   c  that is resistant to heat sealing.  
     [0141] Referring now to FIG. 18 an alternative to the embodiment shown in FIG. 17 may be seen. In this embodiment barrier film section  16   b  is heat sealed to a separate predetermined portion of the inside surfaces  35   a  and  36   a  of the parent film  10 . To form two additional hermetic seals  40  located below the hermetic seals  40  of the zipper skirt  16 . The barrier film  16   b  is provided with a structural weakness at  45  which extends linearly and generally parallel to hermetic seals  40 . The structural weakness is designed to fracture or tear relatively easily when the customer opens the bag  100 . Alternatively, the structure of FIG. 17 could be provided with a structural weakness  45  as described with reference to FIG. 18. In such a case peel seal  50  would be replaced with a permanent seal.  
     [0142] Referring to FIGS. 19 and 20, header strip  206 , located between the front side  35  and back side  36  of the parent film material  10 , of a predetermined size have sufficient width to extend down to, preferably just above, a tear line  132  (area of structural weakness). The header strip  206  terminates at edge(s)  131 . This tear line  132  has the predetermined propensity to tear in predetermined way. The extension of the header strip material  206  extends down so that it is adjacent to the tear line  132 . This facilitates tearing off the hood structure  11  from the bag  100  along the tear line  132 . The optional tear notch  134  facilitates initiation of the tear, the tear line  132  (the oriented parent film  10  or film  10  with the propensity to tear) directs the tear, and the header material  206 , which is bonded or sealed to the front side  35  and back side  36  of the parent film  10 , controls the tear so that the zipper structure  20   a  is consistently clear of the parent film material  10  after the removal of the hood structure  11 .  
     [0143] Alternatively, if the header material  206  is made of an oriented polypropylene having at least one side with a heat sealable sealant then the parent film  10  would not need to be oriented or have the tear line  132  or propensity to tear. Presently, it is believed preferable that if the header material  206  is made of an oriented polypropylene then the oriented polypropylene should have both its sides coated with a heat sealable sealant. Also, alternatively, a plurality of header strips  206  could be used instead of a single integral header strip  206 . In either case, the parent film  10  would not necessarily need to be oriented or have a tear line  132  or a propensity to tear.  
     [0144] Referring to FIGS. 21 and 22, at least one but preferably two pieces of tear tape  120 , located between the front side  35  and back side  36  of the parent film material  10  on film surfaces  35   a  and  36   a , of a predetermined size are bonded or sealed to the parent film  10  of the hood structure  11  adjacent, preferably just above, a tear line  132  (area of structural weakness). This tear line  132  has the predetermined propensity to tear in predetermined way. The tear tape material  120  adjacent the tear line  132  facilitates tearing off the hood structure  11  from the bag  100  along the tear line  132  in a controlled manner. The optional tear notch  134  facilitates initiation of the tear, the tear line  132  (the oriented parent film or film with the propensity to tear) directs the tear, and the tear tape  120 , which is bonded or sealed to the front side  35  and back side  36  of the parent film  10 , controls the tear so that the zipper structure  20   a  is consistently clear of the parent film material  10  after the removal of the hood structure  11 . Alternatively, if the tear tape material  120  is made of an oriented polypropylene having at least one side with a heat sealable sealant then the parent film  10  would not necessarily need to be oriented or have the tear line  132  or propensity to tear.  
     [0145] With respect to facilitating removal of hood or fold  11  it should be understood that instead of score lines  12  the parent film  10  may be weakened in predetermined areas using other procedures as well, including but not limited to scoring or the use of multiply laminate film having a predetermined weakened area or the addition of a tear assistance structure, e.g., Tear tape  120  or tear string  120   a . The tear assistance structure may be added for use by itself or in conjunction with a predetermined area of structural weakness  12  to aid in the tearing of the film  10 . See FIGS. 28 and 29.  
     [0146] Referring to FIG. 23 another alternative to the embodiment disclosed in FIG. 22 is disclosed. In this embodiment tear tape  120  is applied to both the inside surfaces  36   a  and  35   a  and the outside surfaces  36  and  35  of the bag  100 . In this embodiment no score line or weakening  132  is believed necessary (although such an area of structural weakness could be used) since the tear tape  120  located on both the inside and outside surfaces of the bag  100  will act as an effective tear guide.  
     [0147] Referring to FIGS. 24, 25, and  26  another alternative to the embodiment shown in FIG. 22 is illustrated. In this embodiment a modified tear tape  120   b  having a tear bead  120   c  is used.  
     [0148] As FIGS.  24 - 26  illustrate, when the film  10  is sealed to the tear tape  120   b  the bead  120   c  is depressed into the film  10  creating an area of structural weakness  12  without requiring pre-scoring or other modification of the parent film  10  prior to the application of the tear tape  120   b . This structure is believed beneficial because the tear tape  120   b  is always in alignment with the area of structural weakness  12 .  
     [0149] Referring to FIG. 27 another alternative to the embodiment disclosed in FIG. 22 is disclosed. In this embodiment tear tape  120  is applied to both the inside surfaces  36   a  and  35   a  and the outside surfaces  36  and  35  of the bag  100 . The tear tape  120  is applied to border both sides of the score line or weakening  132 . Since the tear tape  120  is located on both sides of the score line  132  and on the inside and outside surfaces of the bag  100  a very consistent controlled or guided will be achieved.  
     [0150] Tear tape  120  is interchangeable with tear string  120   a . Accordingly, a tear string  120   a  could be substituted for the tear tape  120 . See, e.g., FIGS. 38 and 39. Preferably, the tear tape  120  or the tear string  120   a  used is made from a material, e.g., Thermoplastic material, that is compatible with the film  10  and which may be sealed, coupled, or bonded to the film  10 . For example, the tear tape  120  or tear string  120   a  may be formed of polyethylene or may be encased in polyethylene. It is understood in the art that a tear string, such as tear string  120   a , may have various cross-sectional shapes, e.g., Round, square, triangular, etc., which may be used to enhance its ability to tear the parent film material  10 .  
     [0151] In particular, referring to FIGS. 30, 32, and  35 , the process by which the alternative embodiment having tear tape  120  is presently believed to be manufacturable is illustrated using an rpm  100  machine. The parent film  10  is fed over a predetermined number of rollers and toward the plow structure  200 . The parent film  10  after passing over dancer roller  203   a  is die punched by die  210  to present parallel openings  121 . It is presently believed that the film  10  must pass over the dancer rollers  203   a  so that they are kept sufficiently taut thus allowing openings  121  to be punched out accurately at predetermined positions, by die  210 , such that the positions of the openings  121  are always at the same or a uniform distance from each other. In addition to the parent film  10  two rolls of tear tape  120  are fed over the parent film  10  and in parallel alignment with the parallel openings  121  such that the tear tape  120  preferably, but not necessarily, bisects each the parallel opening  121 . Tear string  120   a  could be substituted for tear tape  120 . See, e.g., FIGS. 38 and 39.  
     [0152] In addition, referring back to FIGS. 30, 32, and  35 , optionally a header material  206  may be fed over the parent film  10 . Further, the zipper or slider assembly  20  is also fed over the parent film  10 . Prior to being fed over the parent film  10  the zipper assembly  20  has a notch  22   a  die punched, by die  214  and heat sealed by sealer  216 , at a predetermined position that is also designed to be in general alignment with the parallel openings  121 . Once the tear tape  120  is presented over the parent film  10  but before it is passed over the plow  200  it passes over a tear tape sealer mechanism  208  so that the tear tape  120  is sealed to the parent film  10 . Alternatively, the tear tape  120  could be tacked in place and subsequently sealed to the parent film  10  either before or after the plow  200 .  
     [0153] The parallel openings  121  may be of any shape although circular is the shape that is presently preferred. Diamond shaped cuts could be used to further enhance initiation of the tear in the parent film  10 . See FIG. 37.  
     [0154] Additionally, the notch  22   a  as generally illustrated herein may be of an arcuate or radiused shape but the notch  22   a  could also be made at a sharp angle such as a 90° angle. See FIG. 37. The sharper angle is presently believed to add more stress to the structure of the zipper assembly  20  and therefore a radiused structure is presently considered to be preferred. However, the present invention should not be interpreted as being limited to solely a radiused notch  22   a  as generally illustrated herein.  
     [0155] After the parent film  10  is folded the remaining manufacturing process is carried out as generally illustrated in FIG. 35. The zipper skirts  16  are sealed to the respective sides of the parent film  10  at seal  14 . The header strip  206 , if used, is sealed to the parent film  10  at seal  206   a . The side seal  30   a  is made, which also seals the perimeter or edge  121   a  of opening  121 . (note, if no tear tape  120  or tear string  120   a  is used then it is presently considered best to add a tear notch  24  to the opening  121  to facilitate removal of the hood  11 .) An opening  123  is die punched in the package  100  to provide a point where the package  100  may be easily hung for display purposes. The package  100  is then cut along seam  101  from the V-fold portion of the form fill and seal machine and transferred to the fill and seal stations where fill opening  33  is opened and the package  100  is filled and gas is flushed through the fill opening  33 . Opening  33  is then hermetically sealed at seal  34   a.    
     [0156] Alternatively, referring to FIG. 38 and FIG. 39 the zipper assembly  20  may be introduced subsequent to the plow structure  200 . The parent film  10 , prior to being fed over the rollers  202  is still die punched by die  210  to present parallel openings  121 . Also, alternatively, the tear tape  120  or tear string  120   a  may be feed over the parent film  10  and in parallel alignment with the parallel openings  121  subsequent to the plow  200 . See FIGS. 38 and 39. Again, the tear tape  120  or tear string  120   a  preferably, but not necessarily, bisects each parallel opening  121 . Also, while FIG. 39 shows both the tear string  120   a  and skirts  16  of the zipper assembly  20  being introduced to the parent film  10  subsequent to the plow  200  and respectively sealed by sealer bars  208  and  209  it should be understood that either the tear string  120   a  or the zipper assembly  20  could be introduced before the plow  200 . For example, the zipper assembly  20  could be introduced after the plow  200  and the tear string  120   a  prior to the plow  200 . Since tear tape  120  is interchangeable with the tear string  120   a  it will be apparent to a person of ordinary skill in the art reading this disclosure that the tear tape  120  could also be introduced after the plow  200  and used in essentially the same manner as the tear string  120   a.    
     [0157] The openings  121  are provided, at a minimum, to facilitate access to the tear tape  120  or the tear string  120   a  and to facilitate tearing and removal of the hood  11  to expose the zipper assembly  20 .  
     [0158] Additionally, the present invention may be used in combination with other VFFS and HFFS machines. The present invention could also be used with HFW machines. However, in using either VFFS machines or HFFS machines the method of the present invention is presently believed to require post-compression (commonly called post-squashing) of a predetermined portion of the track structures  20   b , with respect to the embodiment shown in FIG. 6. (sometimes also referred to as track mass  20   b , herein) of the slider closure assembly  20  located within a margin or line  10   b  of the parent film  10  where a seal  30   a , especially a hermetic seal, is desired. Alternatively, the track mass  20   b  may have a pre-compressed portion located with margin  10   b . Neither pre-compression nor post-compression are believed to be required where a notch, e.g.,  22   a  of FIG. 7, has been punched out or cut from the zipper assembly  20 . However, if pre-compression is desired then this is accomplished in the present invention at sealer  216  shown in FIG. 30. This is so that when, on either a HFFS or VFFS machine, the track mass  20   b  (with the slider or zipper structure  20   a  avoided) passes through the package side seal zone portion of either the machine a consistent hermetic seal  30   a  is produced by the application of the heater bars of the machine used. As will be apparent to a person of ordinary skill in the art from this disclosure, if a notch, e.g., notch  22   a  of FIG. 7, is cut from the zipper assembly  20  then there is no structure or mass for sealer  216  to pre-compress and sealer  216  will then only provide seal  22   b  of the cut end  22 , as shown in FIG. 7.  
     [0159] In applications using HFW machines for the manufacture of the embodiment shown in FIG. 5, such as Jones Automation Company machines, it is not believed necessary to pre-compress, post-compress, or squash a predetermined portion of the track mass  20   b . HFW machines have a rotary jaw assembly, which includes a hinged side. The jaw assembly provides at least two advantages, either of which, separately or in combination, eliminates the need for pre-compression of the track mass  20   b . First, the jaw assembly provides a relatively long time, longer than the time provided by either VFFS or HFFS machines, for the application of heat and pressure sufficient to form the desired seal  30   a . Second, the portion of the track mass  20   b  that is targeted to be fused or sealed (generally located within the boundary of margin  10   b ) is placed or fed into the jaw assembly so that it is placed toward and near the hinged portion of the jaw assembly and thus maximum mechanical advantage and force may be applied to the predetermined portion of the track mass  20   b.    
     [0160] If either the longer seal time or the mechanical advantage of the jaw assembly of the HFW machine was not available then, referring to FIG. 6, since there is generally insufficient room on an HFW machine to pre-compress the track mass  20   b , the track mass  20   b  may be pre-punched with a die at the predetermined location  22   a  (where the seal  30   a  is also to be applied or created) prior to insertion into the fold  11  of the parent film  10 . Since the pre-punched area or notch  22   a  would be synchronized to be in registration with the portion of the folded parent film  10  that is to be sealed, less energy (time, temperature, and/or pressure), due to the reduced mass to be sealed is required to consistently obtain the type of seal  30   a  desired. (note, pre-punching rather than pre-compression could also be used with HFFS or VFFS machines.)  
     [0161] Referring now to FIGS. 40, 40 a ,  41  and  41   a , an alternate embodiment of the present invention may be seen. The film  10  is folded over, as shown, to form the fold structure  11 , and a zipper assembly  20  is positioned over the fold structure  11 . Weakened areas  12  are preferably positioned below the zipper structure  20   a , so that when the zipper structure  20   a  is in the open position the fold structure  11  and its weakened areas  12  are exposed to allow the user access to the fold structure  11 . Seen particularly in FIG. 41, the overlaying zipper skirt  16 , of the alternate embodiment may be viewed. Zipper skirt  16  is usually comprised of two strips of pieces of plastic film or a one-piece unit of continuous film, and is seen to have its inside surfaces  17  sealed hermetically to the outside surfaces  35   b ,  36   b  of the film  10  at respective hermetic seals  40   c ,  40   d . The fold structure  11  is preferably designed to act as an imperforate hermetic barrier to protect the contents of bag  100 . Tearing the fold structure  11  allows the user access to the contents and also provides visual evidence that the hermetic seal is broken. Seen particularly in FIGS. 40 a  and  41 , the inside surfaces  35   a ,  36   a  of the parent film  10  may also be peelably sealed to one another, using a known releasable adhesive  51 , to provide a releasable hermetic or gas tight seal  50  therebetween. The seal  50  is located adjacent, perferably just below, the weakened areas  12 .  
     [0162] As best seen in FIGS. 40 and 40 a , two bags  100  are shown prior to their being separated along seam  101 . The alternate embodiment seen in these views is comprised of parent film  10 , which is used to form the bag  100  to be filled. The bag  100  further includes a header  15 , and a peg hole  15   a , seen in this embodiment at the end opposite the fold  11 . It is presently believed preferable, after the folding and sealing of parent film  10  that the parent film  10  be punched out to form a tear area  24   a . The parent film is then sealed around the perimeter of the punched out tear area  24   a  and a tear notch  24  is added, as seen in FIG. 40. These steps are preferably performed before the attachment of the zipper assembly  20  and zipper skirt(s)  16 . Following this, the zipper assembly  20  is positioned and bonded to the outside surfaces  35   b ,  36   b , of the parent film  10 , and over the fold  11 . Alternately, the parent film  10  may be sealed around the perimeter to include the sealed perimeter of the punched out tear area  24   a  so that after the punching step which forms tear area  24   a , the sealed perimeter remains. The tear notch  24  provides a starting point for removing the fold structure  11 , which is surrounded by the zipper assembly  20  and attached zipper skirt  16 . Further, at least one piece of tear tape  120 , located between the front side  35  and back side  36  of the parent film  10  on film surfaces  35   a ,  36   a , of a predetermined size may be bonded or sealed to the parent film  10  at the fold  11 . The tear tape  120  is located adjacent, preferably just above, a tear line  132  (area of structural weakness). This tear line  132  has the predetermined propensity to tear in a predetermined way. The tear tape material  120  adjacent the tear line  132  facilitates tearing off the fold structure  11  from the bag  100 . The aforementioned tear notch  24  facilitated initiation of the tear.  
     [0163] Referring to FIGS. 41 and 41 a , the skirt(s)  16  remain intact so that the zipper assembly  20  is kept continuous for ease of handling. Once positioned over the punched fold structure  11 , the skirt(s)  16  of the zipper assembly  20  is bonded to the outside surfaces  35   b ,  36   b  of the parent film  10  at seal location(s)  40   c ,  40   d . Next, sides  30  and  32  are sealed, along margin  10   c  illustrated in FIG. 40, using a known mechanism such as a heatsealing bar of a form fill and seal machine (as described earlier in the present application) by advancing the film  10  to the heat sealing bar portion of the machine to be used.  
     [0164] It will be apparent to the person of ordinary skill in the art after reading this disclosure that the present alternative embodiment shown in FIGS. 40, 40 a , and  41 ,  41   a  may be manufactured using the methodology previously disclosed herein with the necessary modifications, which this specification makes apparent to a person of skill in the art.  
     [0165] With reference to FIGS.  42 - 45   a , an alternative embodiment reclosable bag  100 ′ including a gusseted portion  310  and side fill opening  300  is shown.  
     [0166] The gusseted, reclosable bag  100 ′ includes at least one sheet of web material  10  having at least two areas of structural weakness  12 . The areas of structural weakness  12  may be micro perforations, scoring or any other structural weakness that will allow facile tearing of the web material  10 . The weakened areas  12  define an integral tear off portion or fold structure  11 . The gusseted, reclosable bag  100 ′ is further defined by a gusseted portion  310  and a sealable fill opening  300 . The sealable fill opening  300  is located generally between the fold structure  11  and gusseted portion  310 . A backing or barrier strip  320  is inserted between the zipper skirts  16 . The backing or barrier strip  320  is preferably two-ply material and may be composed of laminent film such as Curwood&#39;s 7182 barrier film. A first or inner side  328 , may be composed of Nylon, polypropylene, or any other suitable material that will not bond to the parent film  10  during sealing. A second or outer side  329  of the strip  320  may be provided with a sealant, such as a polyethylene, polyethylene blend, or a polyethylene co-extrusion. The backing or barrier strip  320  is preferably notched at  326  and  326   a  (best seen in FIG. 47) to allow proper sealing of side seal  30   a . A zipper assembly  20  having attached zipper skirts  16  is inserted in the fold structure  11 . When the zipper assembly  20  and skirt(s)  16  are bonded to the inside surface  36   a  of parent film  10  at  14 , the inner resistant side  328  of strip  320  prevents the skirt(s)  16  from sealing together along their respective inner surface  17 , seen particularly in FIG. 45. The skirts  16  are bonded at  14  to the inside surface of the parent film  10 .  
     [0167] As may be seen from FIG. 42, two bags  100 ′ are shown prior to their being separated along seam  101 . This embodiment includes score lines  12  laid out in a pattern that includes a tear notch  24 . The tear notch  24  provides a starting point for removing the fold structure  11 , which is located above the zipper assembly  20 . The parent film  10  is sealed at section  26  to either its opposing sides  35  and  36  or the structure of the zipper assembly  20 . For ease of illustration, it is to be noted that seal  30   a  extends across notches  326 ,  326   a  in strip  320  and area  26   a  refers to the general area of the hermetic side seal  30   a  adjacent the notches  326 ,  326   a . The fold structure being defined by the location of the score lines  12 . The score lines  12  extend below the zipper assembly  20  for substantially the entire width of the reclosable gusseted bag  100 ′, facilitating removal of the fold structure  11  and exposure of the zipper structure  20   a . The embodiment of FIG. 42 further includes a sealable fill opening  300  located below the zipper assembly and above the bottom gusset  310 .  
     [0168] Referring now to FIGS. 43 and 44, a cross-sectional view of the embodiment of FIG. 42 may be seen. In particular, the backing or barrier strip  320  is seen with an upper portion  324  thereof attached to the inside surface  17  of the zipper skirt  16 . As may be further seen, a lower portion  322  of the barrier strip  320  is attached to the inside surface  32   a  of the bag  100 ′ at a point just below the fill opening  300 . As illustrated particularly in FIG. 44, the lower portion  322  is seen prior to attachment to inside surface  32   a , with the fill opening  300  in the open position. For illustration purposes, when opening  300  is shown in the closed position the web edges  400  are seen as not completely abutting. It is to be understood that while it is preferred that the edges  400  abut, it is within the scope of the present invention to include a closed opening  300  wherein the web edges  400  are not completely abutted.  
     [0169] Referring to FIG. 45, the film  10  is folded over, as shown to form the fold structure  11  and a zipper assembly  20  is inserted. Weakened areas  12  are preferably positioned below the zipper structure  20   a  so that when the fold structure  11  is removed, the zipper structure  20   a  is exposed sufficiently above the resulting fin structures  19  to allow the user access to the zipper structure  20   a . Zipper skirts  16  are shown bonded to the film  10 . However, it is presently believed preferable, prior to insertion of the zipper assembly  20 , that the uncut ends (not seen in these views) of each zipper assembly  20  be punched out or cut to form a radiused notch  22   a , as shown in FIG. 42. As seen in FIG. 45, an upper portion  324  of a backing or barrier strip  320  is attached to the inside surface  17  of one of the zipper skirts  16 . A lower portion  322  of the strip  320  extends beyond the distal margin  342  of the zipper skirt  16  and is bonded to the inside surface  36   a  of side  36 . It is presently believed preferable, prior to attachment to the zipper skirt  16 , that the backing or barrier strip  320  be punched out or cut to form notch  326  (seen in FIG. 47). As may be further seen in FIG. 47, barrier strip  320  is further punched prior to insertion into fold structure  11 , to form notch  326   a , also in register with side seal  30   a . Notches  326  and  326   a  are positioned to be in register with radiused notch  22   a  of zipper assembly  20 , all of which are positioned to be in register with side seal  30   a , seen in FIGS. 42 and 48. Consecutive notches  326 ,  326   a  in barrier strip  320  alleviate the presence of barrier strip  320  at side seal  30   a , thus facilitating a hermetic seal at area  26   a  (best seen in FIG. 42). The hermetic seal is obtained by sealing inside opposing surfaces  35   a ,  36   a  at  26   a  and  30   a . The inside surface  10   a  of parent film  10  is simultaneously sealed to the zipper skirts  16  at area  14 , as seen in FIG. 45, and simultaneously, inside surfaces  17  of skirts  16  (FIG. 45) are sealed to each other in the notched out areas  326  and  326   a  at  26   a , where the barrier strip is not present (seen best in FIG. 42).  
     [0170] As illustrated in FIGS. 45 and 47, the skirt(s)  16  remain intact so that the zipper assembly  20  is kept continuous for ease of handling. Once inserted, the skirt(s) of the zipper assembly  20  is bonded to the inside surface  10   a  of the parent film  10  at seal location(s)  14 .  
     [0171] Referring to FIGS. 46, 47, and  48 , the process by which the alternative embodiment gusseted, side fill bag  100 ′ (seen in FIGS.  42 - 45 ) is presently believed to be manufacturable is illustrated using an rpm  100  machine. The parent film  10  is fed over a predetermined number of rollers and toward the trapezoidal plow structure  200   a . In addition to the parent film  10 , the zipper assembly  20  and backing strip  320  are fed over the parent film  10 . It is presently believed that the zipper assembly  20  and backing strip  320  must pass over the dancer rollers  203   a  so that they are kept sufficiently taut thus allowing notches  22   a ,  326 , and  326   a  to be punched out accurately at predetermined positions such that the notches  22   a  and  326  will be in register with each other when the backing strip  320  is inserted between zipper skirts  16 . Prior to being fed over the parent film  10 , the zipper assembly  20  has a notch  22   a  die punched, by die  214 ′ and heat sealed by sealer  216 ′, at a predetermined position at seal  22   b  that is also designed to be in general alignment with the notch  326  in strip  320 , formed by die  214 ″ and  326   a  formed by die  214 ′. It is to be noted that notch  326  is preferably formed such that the distal margin  342  of skirt  16  extends into the notch  326 . This configuration allows notch  326   a  to be formed by die  214 ′ with minimal chance of skirt  16  being inadvertently notched by die  214 ′. Die  214 ′ simultaneously forms notches  326   a  and  22   a . The parent film  10  is folded over the zipper assembly  20  to form the fold structure  11 . Before the parent film  10  is passed over the trapezoidal plow  200   a  it passes over a zipper sealer mechanism  216  whereby the zipper skirts  16  are sealed to the parent film  10  at the inside surfaces  35   a ,  36   a  of opposing sides  35 ,  36  respectively. Unlike prior embodiments, no blade between the skirts  16  is needed during sealing since, as seen in FIG. 45, the inner side  328  of strip  320  will not seal to the inside surface  17  of opposite zipper skirt  16 . Further, gusset holes  344  are die punched by die  344   a  at a predetermined position designed to be in general alignment with side seal  30   a . The gusset holes  344  allow gusset folds to be attached to each other at side seal  30   a  thereby adding rigidity to the gusset portion  310  of the gusseted bag  100 ′. This added rigidity enables the gusseted bag  100 ′ to stand up by itself when placed on a flat surface such as a table or refrigerator shelf (not seen in these views). Further, with reference to the prior art gusseted bags  460  seen in FIG. 57, additional seals  470  may be included for additional rigidity and containment as would be desired with liquid products.  
     [0172] In addition, referring to FIGS. 46 and 47, optionally a header material  206  may be fed over the parent film  10 . The header strip  206 , if used, is sealed to the parent film  10  at seal  206   a , seen particularly in FIG. 47. As seen in FIG. 46, seal  206   a  is formed by heat sealer  216 . Heat sealer  216  simultaneously seals the zipper skirt(a)  16  to the parent film  10  at  14 . The parent film  10 , attached zipper assembly  20 , and strip  320  are passed over roller  350 . After the parent film  10  is folded and the zipper assembly  20  is inserted, the remaining manufacturing process is carried out as generally illustrated in FIG. 48. The parent film  10  and attached zipper assembly  20  passes over a trapezoidal folding board or plow  200   a . The folding step leaves a flat bottom prior to the parent film  10  being passed over a tucking board  334 . The tucking board  334  reverse folds the previously formed flat bottom of the parent film  10  into a gusset  310 . The side seal  30   a  is made. It is to be noted that the barrier strip  320  preferably marginally enters the area of side seal  30   a  at seal area  26   a . Notches  326  and  326   a  preferably remove a majority of the barrier strip  320  in the seal  30   a  area to provide hermetic seal  30   a . Although it is preferred that the barrier strip  320  minimally enter the side seal  30   a  area at seal area  26   a , it is within the province of the present invention to provide a barrier strip  320  which ends before, at, or beyond the side seal  30   a  area. Further, it is to be understood that the present invention may be practiced using a barrier strip  320  having longitudinally-spaced sealable areas whereby the notches  326  and  326   a  are not necessary and the sealable areas are arranged to be in alignment with the seal area  30   a . Tear notch  24  is added to facilitate removal of the fold  11 . An opening  123  is die punched in the package  100 ′ to provide a point where the package  100 ′ may be easily hung for display purposes. The package  100 ′ is then cut along seam  101  from the bag making portion of the form fill and seal machine and transferred to the fill and seal stations where the side fill opening  300  is opened and the package  100 ′ is filled through side fill opening  300 . The opening  300 , seen in FIG. 48, is then hermetically sealed at seal  340 , as seen in FIG. 48. The presence of the backing or barrier strip  320  permits the seal  340  to be formed while the inside surfaces  17  of zipper skirts  16  are not sealed to one another (see FIG. 45). As previously described with reference to FIGS.  42 - 45 , the inner side  328  of strip  320  will not seal to inside surface  35   a  or zipper skirt  16  during sealing, thus permitting a seal without the need for a blade between the skirts  16 .  
     [0173] Referring now to FIGS.  49 - 52 , an alternative embodiment gusseted, side fill bag  100 ′ is illustrated. As may be seen, a press-to-close zipper assembly  20 ′ having lower skirt(s)  16  and upper skirts  16   a  may be inserted in the fold structure  11 . As in the embodiment shown in FIGS.  42 - 45   a , the gusseted, reclosable bag  100 ′ with press-to-close zipper assembly  20 ′ seen in FIGS.  49 - 52  includes at least one sheet of web material  10  having at least two areas of structural weakness  12 . The weakened areas  12  define an integral tear off portion or fold structure  11 . The gusseted, reclosable bag  100 ′ is further defined by a gusseted portion  310  and a sealable fill opening  300  which is located between the fold structure  11  and gusseted portion  310 . As best seen in FIG. 52, the press-to-close zipper assembly  20 ′ typically includes a male track structure  330  and a female track structure  331 . The male track structure  330  and the female track structure  331  each include an upper zipper skirt  16   a  of web material extending therefrom and a lower zipper skirt  16  extending therefrom. Each zipper skirt  16 ,  16   a  includes a predetermined coupling area arranged to be sealed to the parent film  10  at sealing location  14 .  
     [0174] As may be further seen in FIG. 52, the zipper skirt(s)  16  is heat sealed to the inside surface  35   a ,  35   b  of side panels,  35  and  36  respectively, of the parent film  10 . A backing or barrier strip  320  is located between, and extends below the zipper skirts  16 . As discussed with reference to the embodiment shown in FIGS.  42 - 45 , the backing or barrier strip  320  is preferably two-ply and composed of a laminate film such as Curwood&#39;s 7182 barrier film. As such, the strip includes a first side  328  and a second side  329 . The first side  328  is preferably composed of Nylon, polypropylene, or any other substance known in the art that will not bond to the zipper skirt  16  or parent film  10  during heat sealing. The second side  329  may be provided with a sealant, such as a polyethylene, polyethylene blend, or a polyethylene co-extrusion. The second or sealant side  329  of the strip  320  is sealed or tacked to the inside surface  17  of a zipper skirt  16  prior to insertion in the fold structure  11  at a location adjacent the sealable side fill opening  300  at seal  335 . The inner, resistant side  328  of strip  320  prevents the skirt(s)  16  from sealing together along their respective inner surface  17  during sealing of the side fill opening  300 . The backing or barrier strip  320  is preferably notched at  326  and  326   a , as seen in FIG. 54, to allow proper sealing of side seal  30   a.    
     [0175] As may be seen from FIG. 49, two bags  100 ′ having press-to-close zipper assembly  20 ′ are shown prior to their being separated along seam  101 . The score lines  12  are seen to be laid out in a portion that includes a tear notch  24 . The tear notch  24  provides a starting point for removing the fold structure  11 , which is located above the press-to-close zipper assembly  20 ′. The fold structure  11  being defined by the location of the score lines  12 . The parent film  10  is sealed at area  26   a  to either its opposing sides  35  and  36  or the structure of the press-to-close zipper assembly  20 ′. For ease of illustration, it is noted that the seal  30   a  extends down across notches  326 ,  326   a  in strip  320 . Reference numeral  26   a  refers to this general area of hermetic side seal  30   a . The embodiment seen in FIG. 49 further includes a sealable fill opening  300  located below the fold structure  11  and above the bottom gusset  310 .  
     [0176] Referring now to FIGS. 50 and 51, a cross sectional view of the embodiment of FIG. 49 may be seen. The backing or barrier strip  320  is particularly seen, with the upper portion  324  thereof attached to the inside surface  17  of zipper skirt  16 . The lower portion  322  of the barrier strip  320  is attached to the inside surface  36   a  of the parent film  10  at a point below the fill opening  300 . As illustrated particularly in FIG. 51, the lower portion  322  is seen prior to attachment to inside surface  36   a , with the fill opening  300  in the open position. For illustration purposes, when opening  300  is shown in the closed position, as in FIG. 52, for example, web edges  400  are seen as not completely abutting. It is to be understood that while it is preferred that web edges  400  completely abut when opening  300  is in the closed and sealed position, it is within the scope of the present invention to include a closed opening  300  having non-abutting web edges  400 .  
     [0177] Referring now to FIGS.  53 - 55   a , the process by which the alternative embodiment, gusseted, side fill bag  100 ′ (seen in FIGS.  49 - 52 ) is illustrated. Seen particularly in FIG. 54, a press-to-close zipper assembly  20 ′ may be introduced prior to the trapezoidal plow structure  200   a . The parent film  10  is fed over a predetermined number of rollers and toward the plow  200   a . The press-to-close zipper assembly  20 ′ and backing strip  320  are fed over the parent film  10 . It is presently believed that the press-to-close zipper assembly  20 ′ and backing strip  320  must pass over the dancer rollers  203   a  so that they are kept sufficiently taut to allow notches  326 , and  326   a  to be punched out accurately at predetermined positions such that the notches  326  and  326   a  will be in register with each other when the backing strip  320  is inserted between zipper skirts  16 . As seen in FIG. 54, notch  326  is punched out prior to insertion of the strip  320  between skirt(s)  16 , whereas notch  326   a  is punched out prior to insertion of press-to-close zipper assembly  20 ′ into fold structure  11 . It may be further seen that notch  326  is preferably formed such that the distal margin  342  of skirt  16  extends into the notch  326 . This configuration allows notch  326   a  to be formed by die  214 ′ while preventing skirt  16  from inadvertent notching by die  214 ′. Die  214 ″ punches notch  326 . FIG. 55 a  illustrates the position of notches  326 ,  326   a  relative the backing strip  320  and distal margin  342  of zipper skirts  16 . The press-to-close zipper assembly  20 ′ is heat sealed by sealer  216  to strip  320  at seal  335 .  
     [0178] The parent film  10  is folded over the press-to-close zipper assembly  20 ′ to form the fold structure  11 . As seen in FIG. 53, prior to being passed over the trapezoidal plow  200   a , the parent film  10  it passes over a zipper sealer mechanism  216  whereby the zipper skirts  16  are sealed to the parent film  10  at the inside surfaces  35   a ,  35   b  of opposing sides  35 ,  36  respectively. As is further seen in FIG. 53, the press-to-close zipper assembly  20 ′ and backing strip  320  further passes over a blade  450  which allows the skirts  16  and  16   a  to be heat sealed to the web  10  while preventing the inner surfaces  17  of the skirts  16 ,  16   a  from sealing together. Further, gusset holes  344  are die punched by die  344   a  at a predetermined position designed to be in general alignment with side seal  30   a . The gusset holes  344  allow gusset folds to be attached to each other at side seal  30   a  thereby adding rigidity to the gusset portion  310  of the gusseted bag  100 ′. This added rigidity enables the gusseted bag  100 ′ to stand up by itself when placed on a flat surface, such as a table or refrigerator shelf (not seen in these views).  
     [0179] Again referring to FIGS. 53 and 54, optionally a header material  206  may be fed over the parent film  10 . The header strip  206 , if used, is sealed to the parent film  10  at seal  206   a , seen particularly in FIG. 54. After the parent film  10  is folded and the press-to-close zipper assembly  20 ′ and strip  320  are inserted, the remaining manufacturing process is carried out as generally illustrated in FIG. 55. The parent film  10  with attached press-to-close zipper assembly  20 ′ and strip  320  passes over a trapezoidal folding board or plow  200   a . The folding step leaves a flat bottom prior to the parent film  10  being passed over a tucking board  334 . As is also illustrated in the manufacturing steps of the gusseted bag  100 ′ seen in FIGS.  42 - 45 , the tucking board  334  reverse folds the previously formed flat bottom of the parent film  10  into a gusset  310 . The side seal  30   a  is made and tear notch  24  is added to facilitate removal of the fold structure  11 . It may be seen that the barrier strip  320  preferably marginally enters the area of side seal  30   a  at seal area  26   a . A majority of the strip  320  is removed by notches  326  and  326   a , thereby allowing a hermetic seal to be formed at  30   a . Although it is preferred that the barrier strip  320  minimally enter the side seal  30   a  area, it is to be understood that the barrier strip may end before, at, or beyond the side seal  30   a  at area  26   a . An opening  123  is die punched in the package  100 ′ to provide a point where the package  100 ′ may be easily hung for display purposes. As seen in FIG. 55, the package  100 ′ is then cut along seam  101  from the bag making portion of the form fill and seal machine and transferred to the fill and seal stations where the side fill opening  300  is opened and the package  100 ′ is filled through side fill opening  300 . The opening  300  is then hermetically sealed at seal  340 . The seal  340  is formed without use of a blade between the skirts  16 , due to the presence of strip  320  between the skirts  16  which prevents the inside surfaces  17  of skirts  16  from sealing together while the opening  300  is sealed.  
     [0180] It is to be understood that the gusseted, side fill bags  100  and  100 ′ having a backing or barrier strip  320  may alternatively include any of the features disclosed with reference to the embodiments shown in FIGS.  1 - 42 . Furthermore, although not shown in the Figures, it is within the scope of the present invention to provide a brush applied, anti-seal agent to the inside surface  17  of zipper skirts  16 . A brush applied, anti-seal agent such as nitrocellulose obtained from Amantceh may thereby take the place of the barrier or backing strip  320  and provide a non-bonding function to the inside surface  17  of the zipper skirts  16  during seal of the fill opening  300 .  
     [0181] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described.