Abstract:
Reclosable gusseted packages or bags have improved resistance to leaking or spilling through the gussets by sealing the gussets together through apertures in the gusset walls, by sealing the zipper flanges together through apertures passing through the gussets in the package or bag, by folding portions of the gussets, or by sewing the gussets shut in areas proximate to the zipper.

Description:
[0001]    This application is a continuation-in-part of application Ser. No. 11/789,262 filed on Apr. 24, 2007, the contents of which are hereby incorporated by reference, and further claims priority under 35 U.S.C. §119(e) of provisional application Ser. No. 61/044,681 filed on Apr. 14, 2008 and provisional application Ser. No. 61/057,036 filed on May 29, 2008, the contents of both provisional applications are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to improving the leak-proof or spill-resistant quality, as well as the breakage-resistant quality, of gussets in reclosable packages, particularly those made with multi-wall paper or woven polypropylene. This is achieved by sealing the gussets together through apertures in the gusset walls, by sealing the zipper flanges together through apertures passing through the gussets, by sewing the gusset shut, by folding the gussets or by similar methods. 
         [0004]    2. Description of the Prior Art 
         [0005]    In the prior art of reclosable packages or bags, it is well known to use gussets between the front and rear walls to increase the capacity of the package or bag with only a small increase in the packaging material, such as multi-wall paper or polypropylene. 
         [0006]    However, the use of gussets can increase the tendency for the contents of the reclosable package or bag to leak from the gusset area proximate to the intersection of the package or bag walls and the zipper. More specifically, the contents can travel up the center of the package or bag, between the zipper profiles and out the gusset. 
         [0007]    Additionally, particularly with packages or bags with heavier capacities (e.g., 15 pounds or more), it is important for the packages or bags to maintain their integrity during routine impacts or environmental changes, typically as tested as described in application Ser. No. 11/728,477 entitled “High Burst Zipper Assembly for Large Reclosable Packages” filed on Mar. 26, 2007, the contents of which are hereby incorporated by reference. 
       OBJECTS AND SUMMARY OF THE INVENTION 
       [0008]    It is therefore an object of the present invention to eliminate or reduce the leakage of contents of a gusseted reclosable package or bag through the gussets proximate to the intersection of the zipper profiles and the package or bag walls, as well as to eliminate or reduce the breakage or tearing of the reclosable package or bag. 
         [0009]    This and other objects are attained by sealing the gussets together through apertures in the gusset walls, by sealing the zipper flanges together through apertures passing through the gussets, by sewing the gussets shut in areas proximate to the zipper, or by similar methods. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0010]    Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings, wherein: 
           [0011]      FIG. 1  is a plan view, partially in phantom, of a prior art gusseted package or bag, showing the route through which contents may inadvertently escape. 
           [0012]      FIG. 2  is a cross-sectional view along plane  2 - 2  of  FIG. 1 . 
           [0013]      FIG. 3  is a cross-sectional view along plane  3 - 3  of  FIG. 1 . 
           [0014]      FIG. 4  is a perspective view of the expanded walls of the package or bag of the first embodiment of the present invention prior to the installation of the reclosable zipper. 
           [0015]      FIG. 5  is a perspective view, partially in phantom, of the collapsed walls of the package or bag of the first embodiment of the present invention prior to the installation of the reclosable zipper. 
           [0016]      FIG. 6  is a plan view, partially in phantom, of the package or bag of the first embodiment of the present invention after installation of the reclosable zipper. This plan view is likewise applicable to the second embodiment of the present invention. 
           [0017]      FIG. 6   a  is a more detailed plan view of  FIG. 6 . 
           [0018]      FIG. 6   b  is a cross-sectional view along plane  6   b - 6   b  of  FIG. 6   a.    
           [0019]      FIG. 6   c  is an alternative cross-sectional view along plane  6   b - 6   b  of  FIG. 6   a , in the absence of gussets. 
           [0020]      FIG. 7  is a perspective view, partially in phantom, of the expanded walls of the package or bag of the second embodiment of the present invention prior to the installation of the reclosable zipper. 
           [0021]      FIG. 8  is a perspective view, partially in phantom, of the collapsed walls of the package or bag of the second embodiment of the present invention prior to the installation of the reclosable zipper. 
           [0022]      FIG. 9  is a perspective view of the expanded walls of the package or bag of the third embodiment of the present invention prior to the installation of the reclosable zipper. 
           [0023]      FIG. 10  is a perspective view, partially in phantom, of the collapsed walls of the package or bag of the third embodiment of the present invention prior to the installation of the reclosable zipper. 
           [0024]      FIG. 11  is a plan view, partially in phantom, of the package or bag of the third embodiment of the present invention after installation of the reclosable zipper. 
           [0025]      FIG. 12  is a perspective view of a first step in the manufacture of a fourth embodiment of the present invention. 
           [0026]      FIG. 13  is a perspective view of a second step in the manufacture of a fourth embodiment of the present invention. 
           [0027]      FIG. 14  is a perspective view of a third step in the manufacture of a fourth embodiment of the present invention. 
           [0028]      FIG. 15  is a perspective view of a fourth step in the manufacture of a fourth embodiment of the present invention. 
           [0029]      FIG. 16  is a perspective view of a fifth step in the manufacture of a fourth embodiment of the present invention, showing the finished product. 
           [0030]      FIG. 17  is a perspective view of a first step in the manufacture of a fifth embodiment of the present invention. 
           [0031]      FIG. 18  is a perspective view of a second step in the manufacture of a fifth embodiment of the present invention. 
           [0032]      FIG. 19  is a perspective view of a third step in the manufacture of a fifth embodiment of the present invention. 
           [0033]      FIG. 20  is a perspective view of a fourth step in the manufacture of a fifth embodiment of the present invention. 
           [0034]      FIG. 21  is a perspective view of a fifth step in the manufacture of a fifth embodiment of the present invention. 
           [0035]      FIG. 22  is a perspective view of a first step in the manufacture of a sixth embodiment of the present invention. 
           [0036]      FIG. 23  is a perspective view of a second step in the manufacture of a sixth embodiment of the present invention. 
           [0037]      FIG. 24  is a perspective view of a third step in the manufacture of a sixth embodiment of the present invention. 
           [0038]      FIG. 25  is a perspective view of a step in the manufacture of a seventh embodiment of the present invention. 
           [0039]      FIG. 26  is a perspective view of a further step in the manufacture of a seventh embodiment of the present invention. 
           [0040]      FIG. 27  is a plan view of an eighth embodiment of the present invention, with the folded gussets shown in phantom. 
           [0041]      FIG. 28  is a plan view of the zipper inserted into the folded gusset of an eighth embodiment of the present invention. 
           [0042]      FIG. 29  is a perspective view of a ninth embodiment of the present invention. 
           [0043]      FIG. 30  is a perspective view of a tenth embodiment of the present invention. 
           [0044]      FIG. 31  is a plan view of an eleventh embodiment of the present invention. 
           [0045]      FIG. 32  is a perspective view of a twelfth embodiment of the present invention. 
           [0046]      FIG. 33  is a perspective view of a variation of the twelfth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0047]    Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that  FIG. 1  is a plan view, partially in phantom, of a prior art reclosable package or bag  100  and that  FIGS. 2 and 3  are cross-sectional views thereof. The package or bag  100  is formed from co-extensive front wall  102  and rear wall  104  which are typically formed from polymeric materials (such as, but not limited to, polyethylene or polypropylene, including woven polypropylene), multi-wall paper or laminates. Gussets  106 ,  108  (illustrated in phantom in  FIG. 1  and in cross section in  FIG. 2 ) are formed as inwardly pointing folds between the side edges of front and rear walls  102 ,  104 , typically integral with, or at least of the same material as, front and rear walls  102 ,  104 . Gusset  106  is formed from gusset walls  106   a ,  106   b  in an inwardly pointing V-shaped configuration while gusset  108  is formed from gusset walls  108   a ,  108   b  in an inwardly pointing V-shaped configuration. The bottom edges of front and rear walls  102 ,  104  are sealed or otherwise closed or joined to form bottom  110  or attached to a panel or bottom gusset (not shown). Mouth  112  is formed between the top edges of front and rear walls  102 ,  104 . Zipper assembly  200  is sealed, glued or otherwise secured to the upper exterior of front and rear walls  102 ,  104 . As shown best in  FIG. 3 , zipper assembly  200  includes first profile  202  and second profile  204 . First profile  202  includes first interlocking element  206  and first flange  210 . Second profile  204  includes second interlocking element  208  and second flange  212 . First and second flanges  210 ,  212  are sealed, glue or otherwise secured to the upper exterior of front and rear walls  102 ,  104 , respectively. Typically, zipper assembly  200  includes slider  214  mounted on first and second profiles  202 ,  204 . Slider  214  operates in a conventional manner of interlocking first and second interlocking elements  206 ,  208  with each other when moved in a first direction and separating first and second interlocking elements  206 ,  208  when moved in a second direction. However, alternatively, first and second interlocking elements  206 ,  208  may have a “press-to-close” configuration in which no slider is required. 
         [0048]    As shown by the circuitous path indicated by the arrow in  FIG. 1 , this design is susceptible to contents within package or bag  100  traveling up the center of the package or bag  100 , between the first and second flanges  210 ,  212  and out of the top of the gussets  106 ,  108 . This leakage or spillage is illustrated for the first gusset  106  but is equally applicable to the second gusset  108 . 
         [0049]    This deficiency can be minimized or eliminated by closing the gussets  106 ,  108  proximate to the zipper assembly  200  as illustrated in the embodiments of the present invention. 
         [0050]      FIG. 4  illustrates a first embodiment of the present invention wherein apertures  120 ,  122 ,  130 ,  132  are formed in gusset walls,  106   a ,  106   b ,  108   a ,  108   b , respectively. When the gussets  106 ,  108  are collapsed as shown in  FIG. 5 , apertures  120 ,  122  align with each other so that a portion of front wall  102  contacts a portion of rear wall  104  through the aligned apertures  120 ,  122 . Similarly, apertures  130 ,  132  align with each other so that a portion of front wall  102  contacts a portion of rear wall  104  through the aligned apertures  130 ,  132 . When the first and second flanges  210 ,  212  of zipper assembly  200  are placed over front and rear walls  102 ,  104  and sealed thereto, front wall  102  is sealed to rear wall  104  through aligned apertures  120 ,  122  and through aligned apertures  130 ,  132  thereby closing the upper ends of the gussets  106 ,  108  and eliminating or reducing the spillage described above. The sealing can be heat sealing by ultrasonic or conduction, or can be by adhesive. Alternatively, grommets (not shown) can pass through aligned apertures  120 ,  122  and  130 ,  132 . The resulting package or bag  100  is illustrated in  FIG. 6 . The parenthetical notations to numerals  118 ,  124 ,  128 ,  134  apply to the extent that  FIG. 6  likewise illustrates the second embodiment of the present invention.  FIGS. 6   a - 6   c  include further detail or alternatives regarding  FIG. 6 . 
         [0051]      FIG. 7  illustrates a second embodiment of the present invention wherein apertures  118 ,  124  (in phantom) are formed in front and rear walls  102 ,  104  respectively, so as to align with apertures  120 ,  122 . Likewise, apertures  128 ,  134  are formed in front and rear walls  102 ,  104 , respectively so as to align with apertures  130 ,  132 . When the gussets  106 ,  108  are collapsed as shown in  FIG. 8 , apertures  118 ,  120 ,  122 ,  124  align with each other. Similarly, apertures  128 ,  130 ,  132 ,  134  align with each other. When the first and second flanges  210 ,  212  of zipper assembly  200  are placed over front and rear walls  102 ,  104  and sealed thereto, portions of first flange  210  are sealed to portions of second flange  212  through aligned apertures  118 ,  120 ,  122 ,  124  and through aligned apertures  128 ,  130 ,  132 ,  134  thereby closing the upper ends of the gussets  106 ,  108  and eliminating or reducing the spillage described above. The resulting package or bag  100  is illustrated in  FIG. 6 , as is the first previously described first embodiment. Alternatively, grommets (not shown) can pass through aligned apertures  118 ,  120 ,  122 ,  124  and  128 ,  130 ,  132 ,  134 . 
         [0052]    Additionally, a subset of the apertures illustrated in  FIG. 7  can be formed. For instance, as shown in  FIG. 4 , some embodiments may include only apertures  120 ,  122 ,  130 ,  132  as formed in gusset walls,  106   a ,  106   b ,  108   a ,  108   b  without apertures formed on the front and rear walls  102 ,  104 . Likewise, some embodiments may include only apertures  118 ,  124 ,  128 ,  134 , on the front and rear walls  102 ,  104  without apertures formed on gusset walls  106   a ,  106   b ,  108   a ,  108   b . Additionally, various apertures illustrated in  FIG. 7  can be omitted, such as  118  and  128  on front wall  102  (or substantially equivalently,  124  and  134  on rear wall  104 , see  FIG. 30 ). Similarly, apertures  122 ,  124 ,  132 ,  134  can be omitted as shown in  FIG. 32 , wherein apertures  118 ,  120 ,  128 ,  130  are shown, or, inversely, apertures  118 ,  120 ,  128 ,  130  can be omitted as shown in  FIG. 33 , wherein apertures  122 ,  124 ,  132 ,  134  are shown. Moreover, as shown in  FIG. 29 , apertures  122 ,  124  can be horizontally (likewise, and/or vertically) offset from apertures  118 ,  120  (alternatively, one pair of apertures can be omitted). This causes a portion of an exterior zipper flange to extend through apertures  122 ,  124  and be sealed to a portion of gusset wall  106   a  and, likewise, a portion of the opposing exterior zipper flange to extend through apertures  118 ,  120  and be sealed to a portion of gusset wall  106   b.    
         [0053]    Similarly, as shown in  FIG. 30 , aligned apertures  118 ,  120 ,  122  can be formed in front wall  102 , and gusset walls  106   a ,  106   b , respectively, while aperture  124  can be omitted, so that no apertures are formed in rear wall  104 . 
         [0054]    Similarly, as shown in  FIG. 31 , first slot  230  can be formed on front wall  102  and gusset wall  106   a  and second slot  232  can be formed on gusset wall  106   b  and rear wall  104 . First and second slots  230 ,  232  are vertically offset from each other to so that portions of the exterior zipper flanges can be sealed through the slots to the opposite gusset walls. In most or all of these embodiments, glue is typically inserted within the gussets. 
         [0055]    The embodiments shown in  FIGS. 29-33  are particularly well adapted to the use of flanged zippers with sliders, with the flanges extending over the various apertures, similar to the configuration shown in  FIG. 7 . 
         [0056]      FIGS. 9 and 10  illustrate a third embodiment of the present invention wherein thread or similar material is used to form first and second stitched seams  150 ,  152 . First stitched seam  150  stitches together gusset walls  106   a ,  106   b  with the portions of front and rear walls  102 ,  104  which contact the gusset walls  106   a ,  106   b . Likewise, second stitched seam  152  stitches together gusset walls  108   a ,  108   b  with the portions of front and rear walls  102 ,  104  which contact the gusset walls  108   a ,  108   b . Stitched seams  150 ,  152  close the upper ends of the gussets  106 ,  108  thereby eliminating or reducing the leakage described above. As shown in phantom in  FIG. 11 , typically, stitched seams  150 ,  152  are formed in an area of front and rear walls  102 ,  104  which is covered by the zipper flanges  210 ,  212 . 
         [0057]      FIGS. 12-16  illustrate the manufacturing process for a fourth embodiment of the present invention. As shown in  FIG. 12 , gussets  106 ,  108  are lower than the top of the package or bag  100 , so that the top portions of front and rear walls  102 ,  104  extend above gussets  106 ,  108 . As shown in  FIGS. 13 and 14 , gusset  106  is folded thereby bringing gusset walls  106   a  and  106   b  together (similarly unillustrated gusset  108  is folded inwardly thereby bringing gusset walls  108   a ,  108   b  together) and tape loop  300  secures or seals the top edges of gusset walls  106   a ,  106   b  together (a second tape loop securing or sealing the top edges of unillustrated gusset walls  108   a ,  108   b  together). The tape loops  300  could be made from the same material as the package walls  102 ,  104 , possibly from the material that was removed to make the gussets  106 ,  108  shorter than the package walls  102 ,  104 . A rigid clip could be substituted for tape loop  300 . As shown in  FIG. 15 , zipper  200  is then inserted and sealed (such as by heat or ultrasonic energy or by other joining methods such as adhesives or rivets) to the interior of the top edges (or glued to the exterior) of front and rear walls  102 ,  104 , immediately above gussets  106 ,  108  thereby forming the package or bag  100  illustrated in  FIG. 16 . For bottom fill or fill-through-the-zipper applications, zipper  200  would be sealed to both front and rear walls  102 ,  104 . However, for fill-behind-the-zipper applications, zipper  200  would be sealed to only one wall, with the subsequent sealing of the zipper to the second wall after the package or bag  100  is filled with contents. The zipper  200  typically includes end seals between the ends of the respective first and second profiles  202 ,  204 . These end seals may be formed before or after zipper  200  is inserted. 
         [0058]      FIGS. 17-21  illustrate the manufacturing process for a fifth embodiment of the present invention. Initially, as shown in  FIG. 17 , the front wall  102 , rear wall  104  and unfolded gussets  106 ,  108  form a rectangular shape. As shown in  FIG. 18 , three vertical slits  310 ,  312 , and  314  are formed on each gusset—slit  310  being formed at the intersection or fold between the front wall  102  and the respective gusset  106  or  108 , slit  312  being formed in the middle of respective gusset  106  or  108  and slit  314  being formed at the intersection or fold between the rear wall  104  and the respective gusset  106  or  108 , thereby forming upper flaps  106   c ,  106   d  at the top of gusset  106  and upper flaps  108   c ,  108   d  at the top of gusset  108 . As shown in  FIG. 19 , upper flaps  106   c ,  106   d ,  108   c ,  108   d  are then folded down 180 degrees to abut the exterior of the respective gusset  106 ,  108 . As shown in  FIG. 20 , as gussets  106 ,  108  are folded, the faces of upper flaps  106   c  and  106   d  (shown as outwardly facing in  FIG. 19 ) are brought together and sealed together, and the faces of upper flaps  108   c ,  108   d  are likewise brought together and sealed together. As shown in  FIG. 21 , zipper  200  is then inserted and sealed (or otherwise secured, such as by gluing) to the interior of the top edges (or glued to the exterior) of front and rear walls  102 ,  104 , immediately above gussets  106 ,  108 . 
         [0059]      FIGS. 22-24  illustrate the first three steps of the manufacture of a sixth embodiment of the present invention, which substitute for  FIGS. 17-19  of the fifth embodiment. Initially, as shown in  FIG. 22  (similar to  FIG. 17 ), the front wall  102 , rear wall  104  and unfolded gussets  106 ,  108  form a rectangular shape. As shown in  FIG. 23 , two vertical slits  310  and  314  are formed on each gusset—slit  310  being formed at the intersection or fold between the front wall  102  and the respective gusset  106  or  108 , and slit  314  being formed at the intersection or fold between the rear wall  104  and the respective gusset  106  or  108 , thereby forming upper flap  106   e  at the top of gusset  106  and upper flap  108   e  at the top of gusset  108 . As shown in  FIG. 24 , upper flaps  106   e  and  108   e  are then folded outwardly and down 180 degrees into the gusseted area of the package or bag  100 , so that the sealing layer of the bag film is facing itself. The gussets  106 ,  108  are collapsed so that the halves of the flaps  106   e  or  108   e  (folded about the center fold of the respective gusset  106 ,  108 ) are facing each other, putting the halves in a position to be sealed together. The zipper  200  can then be placed into the package or bag  100  above the folded down gussets. The folded down gussets can be sealed to themselves to form a robust seal along the zipper  200 , while the zipper  200  will only need to be sealed through one layer of film along the whole top of the package or bag. After filling, making the last seal is simplified again due to the gusset material all being below the zipper  200 . 
         [0060]      FIGS. 25 and 26  illustrate steps in the manufacture of a seventh embodiment of the present invention. As shown in  FIG. 25 , vertical slits  310 ,  314  are formed on each gusset similar to the embodiment illustrated in  FIG. 23 . However, horizontal slits  316 ,  318  extend inwardly from the lower portions of respective vertical slits  310 ,  314 . Vertical slits  310 ,  314  do not join each other and neck  320  is formed thereby retaining upper flaps  106   e ,  108   e  on respective gussets  106 ,  108 . As gussets  106 ,  108  are folded inwardly, upper flaps  106   e ,  108   e  are pushed inwardly and downwardly so as to fold over the top edges of the respective gussets  106 ,  108  and are then sealed to respective gussets  106 ,  108 . 
         [0061]      FIGS. 27 and 28  illustrate steps in the manufacture of an eighth embodiment of the present invention. As shown in  FIG. 27 , gussets  106 ,  108  are folded at the top so that the fold between gusset walls  106   a ,  106   b  is redirected to fold portion  106   f  which is parallel with the upper edge of package  100  and, likewise, the fold between gusset walls  108   a ,  108   b  is redirected to fold portion  108   f  which is parallel to the upper edge of package  100 . Areas  106   g ,  108   g  are open thereby forming a pocket to receive the zipper  200  as shown in  FIG. 28 . Lines  106   h ,  108   h  show the folding of the gussets  106 ,  108 , respectively. The gussets  106 ,  108  are illustrated as being folded at forty-five degrees, but other angles, such as sixty degrees, are envisioned within this embodiment. 
         [0062]    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.