Patent Abstract:
A method of making a reclosable plastic bag ( 38 ) having a fin seal ( 35 ) which provides a weakness area ( 23, 80, 81, 84, 86 ) that extends into at least one side of the fin seal ( 35 ). Perforation axes ( 19, 20 ) for opening the reclosable plastic bag ( 38 ) may be aligned with the weakness area ( 23, 80, 81, 84, 86 ). A reclosable bag ( 38 ) made in accordance with the method is also disclosed.

Full Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to reclosable plastic bags of the type in which perishable food products and other goods are packaged for sale to consumers in retail outlets. More specifically, the present invention relates to a method of producing plastic bags which are concurrently manufactured to include a fin seal, and the manner of producing such bags so that they may more readily be tom open through the fin seal.  
       DESCRIPTION OF THE PRIOR ART  
       [0002]     The present invention relates to improvements in the package-making art and may be practiced in the manufacture of reclosable thermoplastic bags and packages of the type that may be used for various consumer products. Such packages often include a form of peel-seal to render the package moisture-tight and/or airtight prior to the initial opening, and/or a tamper-evident seal. A zipper means protects any remainder of the product therein after the initial opening.  
         [0003]     The indicated art is fairly well developed but nevertheless remains open to improvements contributing to increased efficiency and cost-effectiveness. In the prior art, McMahon et al. (U.S. Pat. No. 4,909,017) discloses a method of making a form-fill and seal bag having a reclosable fastener. Prior to entering the form-fill and seal machine, fastener strips are attached to the surface of the film transverse to the running direction at bag length intervals. The fastener strips contain pre-joined interlocked rib and groove strips. Only one of the strips is attached to a top surface of the film with the other strip facing upwardly or, in other words, inwardly toward the interior of the bag to be formed. The attached strips are secured in one form at the center of the film and each strip is less than half of the film width. The film is then advanced to the form-fill and seal machine and is drawn down over a forming collar and about the filling tube, with the longitudinal side edge margins of the film brought together and seamed with a fin seal to form a tube. Cross-seals are made across the tube to join the unattached fastener strip to the film to form the closure and to form the bottom of the following bags. A further seal may be provided above the fastener to provide tamper-evident sealing. In such case, an easy-open feature such as a line of weakness in the form of a line of perforations or a score line would be provided for the bag between the top seal and the fastener strip.  
         [0004]     A potential problem with the above method is that the bag walls contain layers which will be doubled or tripled in the area of the fin seal which must be tom through to open the bag. While the line of weakness aids in starting the tear through the bag walls, tearing through multiple layers of the fin seal and the underlying bag may be difficult for the consumer to achieve. A significant step would involve reducing the amount of layers of bag film in the fin seal or weakening the layers of bag film in the fin seal area. When opening the bag by tearing along provided perforations or a score line in the bag, the fin area would be a reduced impediment, thus providing the bag with an easy-open feature.  
       SUMMARY OF THE INVENTION  
       [0005]     Accordingly, the present invention relates to a method for producing a reclosable plastic bag with an easy-open feature in which a length of bag making film is advanced in a bag forming direction. A length of fastener having first and second mateable profile strips is attached to a mid-portion of the bag making film transverse to the bag forming direction, while leaving sides of film on opposite ends of the length of fastener. A weakness area is created in at least one of the sides with the weakness area comprising either an aperture, multi-line perforations of the bag film, scoring of the bag film, or any other weakening method known to those skilled in the art. The weakness area aligns with a flange portion of one of the profile strips or with an area of film adjacent the flange portion.  
         [0006]     In a later stage of manufacture, the weakness area extends into a side margin that runs to an edge of one of the sides. The side margin of one side, together with a side margin of an opposite side, is sealed in a fin seal to form a tube. The unattached length of fastener is sealed to the inner surface of the tube that includes the fin seal. When the fin seal is formed, and if the weakness area comprises an aperture aligning with the flange portion, a portion of the opposite side margin of the fin seal is sealed to the flange portion of the fastener through the aperture. If the weakness area comprises an aperture aligning with an area of film adjacent the flange portion, a portion of the opposite side margin of the fin seal is sealed to the bag making film of the front bag wall through the aperture. Alternatively, a weakness area other than an aperture can be created when the fin seal is formed, instead of at the stage of manufacturing described earlier. In the last stage of manufacturing, the tube is cross-sealed at spaced intervals to form a bag. An opening notch is provided to create a tear line that will run through the weakness area. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     Further objects and advantages of the invention will become apparent from the following description and claims taken in conjunction with the accompanying drawings, in which:  
         [0008]      FIG. 1  is a plan view depicting a first embodiment of the present invention wherein a perforated fastener with an adjacent elliptical aperture is formed on a section of thermoplastic film;  
         [0009]      FIG. 2A  is a side view depicting the first embodiment of the present invention wherein the thermoplastic film is folded to provide a fin seal area;  
         [0010]      FIG. 2B  is a sectional view depicting the first embodiment of the present invention taken from reference line  2 B- 2 B of  FIG. 2A ;  
         [0011]      FIG. 3A  is a side view depicting the first embodiment of the present invention wherein a fin seal has been formed at a cross-jaw section of a form-fill and seal machine;  
         [0012]      FIG. 3B  is a sectional view depicting the first embodiment of the present invention taken from reference line  3 B- 3 B of  FIG. 3A ;  
         [0013]      FIG. 4  is a side view depicting the first embodiment of the present invention wherein the fin seal has been sealed to a wall of the reclosable bag;  
         [0014]      FIG. 5  is a side view depicting the first embodiment of the present invention with a reclosable bag shown in an opening condition;  
         [0015]      FIG. 6  is a plan view depicting a second embodiment of the present invention wherein a perforated fastener with adjacent multi-line perforated areas of weakness is formed on a section of thermoplastic film;  
         [0016]      FIG. 7A  is a side view depicting the second embodiment of the present invention wherein a fin seal has been formed at a cross-jaw section of a form-fill and seal machine;  
         [0017]      FIG. 7B  is a sectional view depicting the second embodiment of the present invention taken from reference line  7 B- 7 B of  FIG. 7A ;  
         [0018]      FIG. 8  is a side view depicting the second embodiment of the present invention wherein a reclosable bag has been formed;  
         [0019]      FIG. 9  is a side view depicting the second embodiment of the present invention with the reclosable bag shown in an opening condition;  
         [0020]      FIG. 10  is a plan view depicting a third embodiment of the present invention wherein a perforated fastener with adjacent multi-line perforated areas of weakness is formed on a section of thermoplastic film;  
         [0021]      FIG. 11  is a side view depicting the third embodiment of the present invention wherein a fin seal has been formed at a cross-jaw section of a form-fill and seal machine;  
         [0022]      FIG. 12  is a side view depicting the third embodiment of the present invention wherein a reclosable bag has been formed;  
         [0023]      FIG. 13  is a side view depicting the third embodiment of the present invention with the reclosable bag shown in an opening condition;  
         [0024]      FIG. 14  is a plan view depicting a fourth embodiment of the present invention wherein a fastener with an adjacent elliptical aperture is formed on a section of thermoplastic film;  
         [0025]      FIG. 15  is a side view depicting the fourth embodiment of the present invention wherein a fin seal has been formed at a cross-jaw section of a form-fill and seal machine;  
         [0026]      FIG. 16  is a side view depicting the fourth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch on the edge of the reclosable bag;  
         [0027]      FIG. 17  is a side view depicting the fourth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch formed in the cross-seal of the reclosable bag;  
         [0028]      FIG. 18  is a side view depicting the fourth embodiment of the present invention with the reclosable bag shown in an opening condition;  
         [0029]      FIG. 19  is a side view depicting the fourth embodiment of the present invention with the reclosable bag shown in an alternative opening condition;  
         [0030]      FIG. 20  is a plan view depicting a fifth embodiment of the present invention wherein a fastener with adjacent multi-line perforated areas of weakness is formed on a section of thermoplastic film;  
         [0031]      FIG. 21  is a side view depicting the fifth embodiment of the present invention wherein a fin seal has been formed at a cross jaw section of a form-fill and seal machine;  
         [0032]      FIG. 22  is a side view depicting the fifth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch on the edge of the reclosable bag;  
         [0033]      FIG. 23  is a side view depicting the fifth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch formed in the cross-seal of the reclosable bag;  
         [0034]      FIG. 24  is a side view depicting the fifth embodiment of the present invention with the reclosable bag shown in an opening condition;  
         [0035]      FIG. 25  is a side view depicting the fifth embodiment of the present invention with the reclosable bag shown in an alternative opening condition;  
         [0036]      FIG. 26  is a plan view depicting a sixth embodiment of the present invention wherein a fastener with adjacent multi-line perforated areas of weakness is formed on a section of thermoplastic film;  
         [0037]      FIG. 27  is a side view depicting the sixth embodiment of the present invention wherein a fin seal has been formed at a cross-jaw section of a form-fill and seal machine;  
         [0038]      FIG. 28  is a side view depicting the sixth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch on the edge of the reclosable bag;  
         [0039]      FIG. 29  is a side view depicting the sixth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch formed in the cross-seal of the reclosable bag;  
         [0040]      FIG. 30  is a side view depicting the sixth embodiment of the present invention with the reclosable bag shown in an opening condition;  
         [0041]      FIG. 31  is a side view depicting the sixth embodiment of the present invention with the reclosable bag shown in an alternative opening condition;  
         [0042]      FIG. 32  is a side view depicting the sixth embodiment of the present invention wherein a reclosable bag has been formed with a tear notch formed in an alternative position in the cross-seal of the reclosable bag; and  
         [0043]      FIG. 33  is a side view of the sixth embodiment of the present invention with the reclosable bag shown in an alternative opening condition. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0044]     Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, a continuous length of thermoplastic packaging film  10  is shown in  FIG. 1  prior to sealing, where the film would be fed to a form-fill and seal machine in movement direction  12 .  
         [0045]     In accordance with the present method, a fastener strip  14  with male and female profiles joined by their interlocking elements is attached to the midsection of the film  10  extending in a direction transverse to movement direction  12 . Only profile  16  that sits on the thermoplastic film  10  is attached to the film. The other profile  18 , as depicted in  FIG. 2B , is secured only by the engagement of the interlocking elements.  
         [0046]     In  FIG. 1 , a line of weakness is set along perforation axis  19  on a flange of the profile  16  prior to its attachment to the film. Alternatively, a line of weakness may also be set along perforation axis  20  prior to its attachment to the film, with the positioning of the perforation axis  20  illustrated in  FIG. 2A . The lines of weakness may be perforations, dimples, scoring of the film, or any other tearing axes known to those skilled in the art. The positioning of the lines of weakness will hereinafter be referred to as on perforation axis  19 , since perforation axis  20  is preferably collinear with perforation axis  19 . Also, any tearing action or dimensioning regarding the present invention similarly affects perforation axis  20  as well as perforation axis  19 . As such, perforation axes  19  and  20  are parallel to the interlocking profiles and end short of the longitudinal ends of the fastener strip, thereby protecting the lines of weakness from prematurely tearing open during the manufacturing process.  
         [0047]     Sides  21  and  22  of thermoplastic film extending to the longitudinal film edges are provided on opposite sides of the fastener strip  14 . In this regard the combined length of sides  21  and  22  is greater than that of the fastener strip to allow proper sealing, as will be discussed later. An area of weakness is created on the side  21  to align with the perforation axis  19  or to be to the right of and parallel with the fastener strip  14 . The area of weakness may comprise an aperture  23 , as shown in  FIGS. 1-5 ,  14 - 18 , or lines of weakness  80 ,  81 ,  84 ,  86 , as shown in  FIGS. 6-13 ,  20 - 33 .  
         [0048]     As shown in  FIG. 1  the aperture  23 , preferably elliptical, is cut or punched through the thermoplastic film  10  such that the longitudinal axis of the aperture  23  aligns with the perforation axis  19 . The outer edge of aperture  23  should be in proximity to a longitudinal edge  24  of the thermoplastic film, but should also allow a sufficient buffer between the longitudinal edge to prevent the film from tearing to the aperture  23  from the longitudinal edge during the manufacturing process.  
         [0049]     As shown in  FIGS. 2A and 2B , during the bag forming process the thermoplastic film  10  is folded on the form-fill and seal machine to bring side margins  25  and  26 , respectively adjacent the longitudinal edges of the film, together in a fin to thereby form the thermoplastic film into a tube. The wall sections  28  and  30 , corresponding to sides  21  and  22  that extend from the opposite ends  32  and  34  of the zipper strip, are joined by the fin to define a rear surface of the tube that faces the fastener strip  14 . In  FIG. 3A  the side margins  25  and  26  are seamed together to form a fin seal  35 , and a cross-jaw sealing section is used to seal wall sections  28  and  30  to the profile  18 . When folding the film to form the fin seal  35 , more than half of the aperture  23  should be on the side margin  25  with the remainder of the aperture on the adjacent wall section  28 .  
         [0050]     As shown in  FIG. 3B , the use of the cross-jaw sealing section of a form-fill and seal machine (not shown) seals wall sections  28 ,  30  to an upper flange  36  of profile strip  18  of the fastener strip  14  while preferably avoiding pressure on the perforation axes  19  and  20 . In  FIG. 4 , the thermoplastic film is folded into a tube with the fin seal  35  sealed to wall section  28 . Because of the removed layers of the wall section  28  created by the aperture  23 , the fin seal side margin  26  now seals directly to the upper flange  36  of the profile strip  18 . The thermoplastic film is now formed as a reclosable bag  38  by forming a bottom cross-seal and a top cross-seal  39  above the profiles.  
         [0051]     To assist in reaching the perforation axes  19 ,  20  of the reclosable bag  38  during an opening operation, a tear notch  50  is formed by cutting or melting away material from an edge of the reclosable bag  38 . For the tear notch  50 , the edge selected should be closer to the fold line  52  in the aperture than to the folded-over ends  54  and  55  of the aperture.  
         [0052]     If a hermetic seal is necessary for the notch  50 , a melting operation is used to form the notch. A peripheral melt zone  56  would join the front and rear walls of the package around the notch and hence would seal the contents of the interior of the reclosable bag from exposure via the notch.  
         [0053]      FIG. 5  depicts the reclosable bag  38  in an opening condition. The notch  50  is separated by a tearing force produced by the user, thereby allowing the tearing force to continue to a resultant perforation  57  of the bag. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced by exposed sealing areas  59  since the tearing force is exposed to only the side margin  26  of the fin seal.  
         [0054]     A second embodiment of the present invention is shown in  FIG. 6 . In the figure, the weakness area comprises a line of weakness  80  instead of the aperture  23 . An opposing line of weakness  81  is positioned on the opposite side of the fastener  14 . The lines of weakness  80 ,  81  may be a plurality of perforated lines on the film used to form the reclosable bag, a dimpling of the film, a scoring of the film, or any other tearing axis known to those skilled in the art. Shown as a plurality of perforated lines, the lines of weakness  80 ,  81  align with the perforation axis  19 . The outer edge of the lines of weakness  80 ,  81  should be in proximity to the longitudinal edges  24 ,  82  of the film, but should also allow a sufficient buffer between the longitudinal edges to prevent the film from tearing to the lines of weakness from the longitudinal edges during the manufacturing process.  
         [0055]     Using the bag forming process described in  FIGS. 2A and 3A , a bag with the fin seal  35  is shown in  FIGS. 7A and 7B . When the wall sections  28  and  30  are folded to form the fin seal  35 , more than half of the lines of weakness  80  should be on the side margin  25  with any remainder on the adjacent wall section  28 . Similarly, more than half of the line of weakness  81  should be on the side margin  26  preferably in alignment with the line of weakness  80 .  
         [0056]     In  FIG. 8 , the thermoplastic film is formed into a reclosable bag by the form-fill and seal machine. The wall sections  28  and  30  are sealed to the upper flange  36  while preferably avoiding pressure on the perforation axes  19  and  20 . Alternatively, the line of weakness  81  can be applied on the wall section  30  and the side margin  26  after the fin seal is formed, instead of at the stage of manufacturing described earlier. The bottom cross-seal and the top cross-seal  39  are then formed, thereby creating the reclosable bag  38 .  
         [0057]     To assist in reaching the perforations of the reclosable bag  38  during an opening operation, the tear notch  50  is formed by cutting or melting away material from an edge of the reclosable bag  38 . If a seal is necessary for the notch  50 , a melting operation is used to form the notch. The peripheral melt zone  56  would join the front and rear walls of the package around the notch.  
         [0058]      FIG. 9  depicts the reclosable bag  38  in an opening condition. The notch  50  is separated by a tearing force produced by the user, allowing the tearing force to continue to a resultant perforation  57  of the bag. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced by the lines of weakness  80 ,  81 , since the lines of weakness produce a weakened layer of the fin seal  35 .  
         [0059]     A third embodiment of the present invention is shown in  FIG. 10 . In the figure, a line of weakness  84  is created on side  21  of the film  10  with the line of weakness  84  less than half the length of the line of weakness  80 . Additionally, a line of weakness  86  with a length less than half the length of the line of weakness  81  is created on side  22  of the film  10 . Similar to the placements of lines of weakness  80 ,  81 , the lines of weakness  84 ,  86  align with the perforation axes  19  and  20 .  
         [0060]     Using the bag forming process described for  FIGS. 2A and 3A , a bag with the fin seal is shown in  FIG. 11 . When the wall sections are folded to form the fin seal  35 , lines of weakness  84 ,  86  should be fully on the fin seal with the lines of weakness ending short of the fold line  52  and with the lines of weakness preferably in alignment with each other. This positioning of the lines of weakness  84 ,  86  allows the resultant reclosable bag to be hermetically sealed since the lines of weakness are not on any bag wall.  
         [0061]     In  FIG. 12 , the thermoplastic film for forming the bag is folded into a tube by the form-fill and seal machine. The wall sections  28  and  30  are sealed to the upper flange  36  while preferably avoiding pressure on the perforation axes  19 ,  20 . Alternatively, the line of weakness  86  can be applied in the side margin  26  after the fin seal is formed, instead of at the stage of manufacturing described earlier. The bottom cross-seal and the top cross-seal  39  are then formed, thereby creating the reclosable bag  38 . To assist in reaching the perforations, the tear notch  50  is formed by cutting or by melting away material from an edge of the reclosable bag  38 . A melting operation is used to form a hermetic seal for the notch. The peripheral melt zone  56  joins the front and rear walls of the package around the notch and hence seals the contents of the interior of the reclosable bag  38  from exposure via the notch.  
         [0062]      FIG. 13  depicts the reclosable bag  38  in an opening condition. The notch  50  is separated by a tearing force produced by the user, allowing the tearing force to continue to the resultant perforation  57  of the bag. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced by the lines of weakness  84 ,  86  as the tearing force encounters the weakened layers of the fin seal  35 .  
         [0063]     A fourth embodiment of the present invention is shown in  FIG. 14 . In the figure, the aperture  23  is cut or punched through the thermoplastic film  10  on the side  21  such that the longitudinal axis of the aperture aligns to an area to the right of and parallel with the fastener strip  14 . The outer edge of the aperture  23  should be in proximity to the longitudinal edge  24  of the film, but should allow a sufficient buffer between the longitudinal edge to prevent the film from tearing to the aperture  23  from the longitudinal edge during the manufacturing process.  
         [0064]     Using the bag forming process described in  FIGS. 2A and 3A , a bag with the fin seal  35  is shown in  FIG. 15 . When the wall sections  28 ,  30  are folded to form the fin seal  35 , more than half of the aperture  23  should be on the side margin  25  with the remainder on the adjacent wall section  28 . A cross-jaw sealing section of a form-fill and seal machine (not shown) seals the wall sections  28 ,  30  to an upper flange  36  of profile strip  18  of the fastener strip  14 .  
         [0065]     In  FIG. 16 , the thermoplastic film for forming the bag is folded into a tube with the fin seal  35  sealed to wall section  28 . Because of the removed layers of the wall section  28  created by the aperture  23 , the fin seal margin  26  now seals directly to the thermoplastic film  10  of the interior bag wall  87  above the fastener strip  14 . The thermoplastic film is now formed as a reclosable bag  38  by forming the bottom seal and the top cross-seal  39 .  
         [0066]     To assist in reaching the perforations of the reclosable bag  38  during an opening operation, the tear notch  50  is formed by cutting or melting away material from an edge of the reclosable bag  38 . If a seal is necessary for the notch  50 , a melting operation is used to form the notch. A peripheral melt zone  56  would join the front and rear walls of the package around the notch and hence would seal the contents of the interior of the reclosable bag from exposure via the notch. As shown in  FIG. 17 , the alternative tear notch  51  may be formed by cutting or melting away material from the top cross-seal  39 . For the tear notches  50  and  51 , the edge selected should be closest to the fold line  52 .  
         [0067]      FIG. 18  depicts the reclosable bag  38  in an opening condition. The notch  50  is separated by a tearing force produced by the user, thereby allowing the tearing force along the top of the fastener  14  to the aperture  23 . The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and thereby prevents the package from being destroyed. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced since the tearing force is exposed to only the side margin  26  of the fin seal. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0068]      FIG. 19  depicts the reclosable bag  38  in an alternative opening condition using the tear notch  51 . The notch  51  is separated by a tearing force produced by the user, thereby allowing the tearing force to proceed along the top of the fastener  14  to the aperture  23 . The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and prevents the package from being destroyed. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced since the tearing force is exposed to only the side margin  26  of the fin seal. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0069]     A fifth embodiment of the present invention is shown in  FIG. 20 . In the figure, the lines of weakness  80 ,  81  align to an area to the right of and parallel with the fastener strip  14 . The lines of weakness  80 ,  81  should be in proximity to the longitudinal edges  24 ,  82  of the film, but should also allow a sufficient buffer between the longitudinal edges to prevent the film from tearing to the lines of weakness from the longitudinal edges during manufacture.  
         [0070]     Using the bag forming process described in  FIGS. 2A and 3A , a-bag with the fin seal  35  is shown in  FIG. 21 . When the wall sections  28  and  30  are folded to form the fin seal  35 , more than half of the line of weakness  80  should be on the side margin  25  with the remainder on the adjacent wall section  28 . Similarly, more than half of the line of weakness  81  should be on the side margin  26  preferably in alignment with the line of weakness  80 .  
         [0071]     In  FIG. 22 , the thermoplastic film for forming the bag is folded into a tube with a fin seal  35  by the form-fill and seal machine. The wall sections  28  and  30  are sealed to the upper flange  36 . Alternatively the line of weakness  81  can be applied in the side margin  26  after the fin seal  35  is formed, instead of at the stage of manufacturing described earlier. The bottom cross-seal and the top cross-seal  39  are formed, thereby creating the reclosable bag  38 .  
         [0072]     To assist in reaching the perforations of the reclosable bag  38  during an opening operation, the tear notch  50  is formed by cutting or melting away material from an edge of the reclosable bag  38 . If a seal is necessary for the notch  50 , a melting operation is used to form the notch. A peripheral melt zone  56  would join the front and rear walls of the package around the notch  50  and hence would seal the contents of the interior of the reclosable bag from exposure via the notch. As shown in  FIG. 23 , the alternative tear notch  51  may be formed by cutting or melting away material from the top cross-seal  39 .  
         [0073]      FIG. 24  depicts the reclosable bag  38  in an opening condition. The notch  50  is separated by a tearing force produced by the user, thereby allowing the tearing force along the top of the fastener  14  to the lines of weakness  80 ,  81 . The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and thereby prevents the package from being destroyed. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced since the tearing force is exposed to the lines of weakness. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0074]      FIG. 25  depicts the reclosable bag  38  in an alternative opening condition using the tear notch  51 . The notch  51  is separated by a tearing force produced by the user, thereby allowing the tearing force along the top of the fastener  14  to the lines of weakness  80 ,  81 . The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and thereby prevents the package from being destroyed. As the tearing force proceeds, the hindrance of the fin seal  35  is reduced since the tearing force is exposed to the lines of weakness  80 ,  81  on the fin seal. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0075]     A sixth embodiment of the present invention is shown in  FIG. 26 . In the figure, a line of weakness  84  is created on side  21  of the film  10  with the line of weakness less than half the length of the line of weakness  80 . Additionally, a line of weakness  86  with a length less than half the length of the line of weakness  81  is created on side  22  of the film  10 . Similar to the lines of weakness  80 ,  81  in  FIG. 20 , the lines of weakness  84 ,  86  in  FIG. 26  align to an area to the right of and parallel with the fastener strip  14 .  
         [0076]     Using the bag forming process described for  FIGS. 2A and 3A , a bag with the fin seal  35  is shown in  FIG. 27 . When the wall sections are folded to form the fin seal  35 , lines of weakness  84 ,  86  should be fully on the fin seal with the lines of weakness ending short of the fold line  52  and preferably in alignment with each other. This allows the resultant reclosable bag to be hermetically sealed since the lines of weakness  84 ,  86  are not on any bag wall.  
         [0077]     In  FIG. 28 , the thermoplastic film for forming the bag is folded into a tube by the form-fill and seal machine. The wall sections  28  and  30  are sealed to the upper flange  36 . The bottom cross-seal and the top cross-seal  39  are formed, thereby creating the reclosable bag  38 . Alternatively, the line of weakness  86  can be applied on the side margin  26  after the fin seal is formed instead of at the stage of manufacturing described earlier.  
         [0078]     To assist in reaching the perforations, the tear notch  50  is formed by cutting or melting away material from an edge of the reclosable bag  38 . If a hermetic seal is necessary for the notch  50 , a melting operation is used to form the notch. The peripheral melt zone  56  would join the front and rear walls of the package around the notch and hence would seal the contents of the interior of the reclosable bag from exposure via the notch. As shown in  FIG. 29 , the alternative tear notch  51  may be formed by cutting or melting away material from the top cross-seal  39 .  
         [0079]      FIG. 30  depicts the reclosable bag  38  in an opening condition. The notch  50  is separated by a tearing force produced by the user, allowing the tearing force to continue to the fin seal  35  of the bag along the top of fastener strip  14 . As the tearing force proceeds, the hindrance of the fin seal  35  is reduced by the lines of weakness  84 ,  86  since the tearing force encounters a weakened layer of the fin seal  35 . The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and prevents the package from being destroyed. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0080]      FIG. 31  depicts the reclosable bag  38  in an alternative opening condition using the tear notch  51 . The notch  51  is separated by a tearing force produced by the user, thereby allowing the tearing force to continue along the top of the fastener  14  to the lines of weakness  84 ,  86 . As the tearing force proceeds, the hindrance of the fin seal  35  is reduced since the tearing force encounters a weakened layer of the fin seal. The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and prevents the package from being destroyed. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0081]      FIG. 32  depicts another alternative tear notch  100  formed in the top cross-seal  39  by cutting or melting away material in the cross-seal.  FIG. 33  depicts the reclosable bag  38  in another alternative opening condition using the tear notch  100 . The notch  51  is separated by a tearing force produced by the user, thereby allowing the tearing force to continue along the top of the fastener  14  to the lines of weakness  84 ,  86 . As the tearing force proceeds, the hindrance of the fin seal  35  is reduced since the tearing force encounters a weakened layer of the fin seal. The fastener  14  prevents the tear pattern from continuing down the length of the reclosable bag  38  and prevents the package from being destroyed. Once the tearing is complete, the flanges of the fastener strip  14  can be gripped by the user to open to the interior of the reclosable bag  38 .  
         [0082]     Although the tear notch  100  is shown for the sixth embodiment of the present invention, the tear notch may be formed in the cross-seal  39  for the fourth and fifth embodiments of the present invention. The separation of the notch  100 , as described for  FIG. 33 , would be similar for the areas of weakness described for the fourth and fifth embodiments.  
         [0083]     Thus, the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.

Technology Classification (CPC): 1