Patent Description:
This disclosure relates to a method and apparatus for securing a zipper closure to polymeric film. More specifically, this disclosure relates to an apparatus and method for securing the zipper closure to the film using minimal tension.

<CIT>, describes a flexible pouch-type bag (package) having a reclosable closure and a method of making it. In many typical recloseable bags, the zipper closure is pre-made by an extrusion process and then secured to a bag film. The zipper closure can be a "press to close" type of closure having a protruding male member that is received by a female groove. These are known as the zipper interlocking members. Other types of closures can also be used, including, e.g., closures having slider devices.

The zipper closures are pre-made into a continuous strip and stored by coiling around a roll. The packages are made by feeding a continuous web or sheet of polymeric film from a roll and folded so that half the sheet forms a front panel and the other half forms a rear panel. The continuous strip of zipper closure is fed between the panels and then bonded, typically by heat, to the opposing panels. Side seals are formed by heat between the opposing panels transverse to the direction of the zipper closure. The packages are separated along parting lines by a cutting process along the side seals.

In existing technologies, a dancer mechanism is used that has only a crude control of the tension on the strip of zipper closure. This can result in packages in which the film is wrinkled or deformed. Improvements are desirable. <CIT> discloses an apparatus for forming a plurality of flexible pouches from a continuous web of film having a plurality of registration marks spaced a predetermined distance apart. The apparatus includes a film displacement mechanism, a registration mark sensor, and a controller. The film displacement mechanism includes at least one vertically oriented roller that rollingly engages with the continuous web of film. The film displacement mechanism adjusts the tension in the film by horizontally displacing the vertically oriented roller. The registration mark sensor is positioned upstream of the film displacement mechanism and is configured to detect the registration marks. The controller controls the film displacement mechanism to horizontally displace the film upon receipt of a signal from the registration mark sensor.

In one aspect of the invention, a method of securing a zipper closure to polymeric film using minimal tension on the zipper closure is provided, the method comprising the features according to independent claim <NUM>. The method includes paying out a continuous strip of plastic zipper closure from a roll of zipper closure; paying out polymeric film from a film roll, the polymeric film having periodic eyemarks thereon; passing the strip of zipper closure through a tension control mechanism; passing the strip of zipper closure through a first tension control loop; advancing the film toward a sealing station and past an eyemark detection to detect an eyemark on the film; after detection of the eyemark on the film, punching a hole into the strip of zipper closure upon detection of the eyemark on the film; passing the strip of zipper closure with a punched hole through a second tension loop; applying the strip of zipper closure to the sealing station while simultaneously supplying the film to the sealing station at the same speed as the strip of zipper closure; aligning the hole in the strip of zipper closure with the eyemark on the film; and sealing the strip of zipper closure to the film.

In some embodiments, the step of sealing includes sandwiching the strip of zipper closure between two walls of the film and using heated sealing bars to transfer heat to the strip of zipper closure and the film.

The step of sealing can include using three sets of opposing sealing bars.

In some implementations, the step of sealing includes using opposing sealing bars, with a first of the opposing sealing bars controlling sealing pressure and a second of the opposing sealing bars controlling distance between the sealing bars.

In some methods, there are steps of detecting a position of the eyemark; detecting a position of the hole; comparing a distance between the detected eyemark and the detected hole to a predetermined target value; and if distance is not equal to the target value, adjusting a length of an index distance so that the distance becomes equal to the target value.

In some methods, the step of passing the strip of zipper closure through a first tension control loop includes threading the strip of zipper closure under a weighted disk movable up and down by gravity to provide constant tension to the strip of zipper closure.

In some methods, the step of passing the strip of zipper closure through a second tension loop includes threading the strip of zipper closure under a weighted disk movable up and down by gravity to provide constant tension to the strip of zipper closure.

The method can include, after the step of detecting an eyemark on the film, a step of folding the film.

The step of sealing can include using multiple sets of opposing guide rollers to guide the position of the strip of zipper closure relative to the film.

In a further aspect of the invention, an apparatus for securing a zipper closure to polymeric film using minimal tension on the zipper closure is provided, the apparatus comprising the features according to independent claim <NUM>. The apparatus includes a tension control mechanism to provide at least some tension to a strip of zipper closure. A first tension control loop is downstream of the dancer mechanism. An eyemark detector is positioned to detect an eyemark on the film. A hole punch is downstream of the first tension control loop and programed to punch a hole in a strip of zipper closure upon detection of an eyemark on the film. A second tension control loop is downstream of the hole punch. A sealing station is downstream of the second control loop and of the eyemark detector and constructed and arranged to seal a strip of zipper closure to the film.

In one or more embodiments, the first tension control loop includes a weighted disk movable up and down by gravity.

In some embodiments, the second control loop can include a weighted disk movable up and down by gravity.

The apparatus can further include an aperture detector downstream of the second control loop and upstream of the sealing station. The apparatus can also include a controller to compare a distance between the detected eyemark and the detected hole.

In some embodiments, the sealing station includes at least a first set of opposing sealing bars, with a first of the opposing sealing bars controlling sealing pressure and a second of the opposing sealing bars controlling distance between the sealing bars.

The sealing station can include three sets of opposing sealing bars, in some embodiments.

A variety of examples of desirable product features or methods are set forth in the description that follows, and in part, will be apparent from the description, or may be learned by practicing various aspects of this disclosure. The aspects of this disclosure may relate to individual features, as well as combinations of features. It is to be understood that both the foregoing general description and the following detailed description are explanatory only, and are not restrictive of the claimed inventions.

A method and apparatus according to the invention are described below, which results in improvements over the prior art. For example, the aesthetics of the packages, or bags, are improved, as the polymeric film does not wrinkle or deform. The zipper closure has a periodic mass of material removed from it, which needs to be aligned with eyemarks on the film indicating the position of the parting lines of the bags. The mass of material removed corresponds to the interlocking elements of the press-to-close zipper. The interlocking elements are much thicker than the rest of the zipper flange. In prior art processes, when the side seals of the bags are made, these thick interlocking members are flattened out by the sealing bars, and this delays the sealing process. By punching out the interlocking members, the sealing time is reduced. The method and apparatus described below ensures precise alignment of the removed mass of material in the zipper closure with the eyemarks, while maintaining the same minimal tension in the zipper closure and bag film to result in advantages. Other advantages that result include reducing instances of overheating or underheating film and a zipper closure, when the zipper closure is sealed to the film. This advantage is achieved by ensuring that the sealing perimeters, including pressure, sealing time, and the gap between opposing sealing bars, are controlled.

Reference is made to <FIG> shows an apparatus <NUM> for securing a zipper closure <NUM> to polymeric film <NUM>.

A roll <NUM> having a continuous strip of the plastic zipper closure <NUM> coiled therearound is provided. The method includes a step of paying out the continuous strip of zipper closure <NUM> from the roll <NUM> and passing the strip of zipper closure <NUM> through a tension control mechanism, embodied herein as a dancer mechanism <NUM>.

The dancer mechanism <NUM> provides at least some tension to the strip of zipper closure <NUM>. The dancer mechanism <NUM> includes a plurality of guiding rollers <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM>. The guiding mechanism <NUM> further includes a carriage bar <NUM> and carriage guide <NUM>.

The dancer mechanism <NUM> can be the type of tensioning mechanism that is described in <CIT>, incorporated herein by reference. The guiding rollers <NUM>, <NUM>, <NUM> and <NUM> are stationary and are fixed permanently to a frame of the apparatus <NUM>. The guiding rollers <NUM> and <NUM> are mounted on the carriage bar <NUM>, which moves up and down along the carriage guide <NUM>. A sensor <NUM>, which is fixed, continuously detects the position of the carriage bar <NUM>. If the carriage bar <NUM> goes up beyond a certain height, the detector sends a signal to the controller <NUM> so that the motor controlling the roll <NUM> causes rotation of the roll <NUM> to an unwind further zipper closure <NUM>. Unwinding of further zipper closure <NUM> causes the carriage bar <NUM> to go downward. Once the carriage bar <NUM> has reached a minimum height, another signal is sent to the controller <NUM> to stop rotation and dispensing zipper closure <NUM>. This cycle is continuously repeated while apparatus <NUM> is in operation.

The method further includes a step of passing the strip of zipper closure <NUM> through a first tension control loop <NUM>. The first tension control loop <NUM> is located downstream of the dancer mechanism <NUM>. The first tension control loop <NUM> is provided to result in a minimum tension needed to keep the zipper closure <NUM> linear and to prevent entanglement. A weighted disk <NUM> is provided, and the zipper closure <NUM> is threaded under the weighted disk <NUM>. The weighted disk <NUM> is movable up and down by gravity to provide a constant tension to the zipper closure <NUM>. The zipper closure <NUM> and the weighted disk <NUM> are contained within a loop box <NUM>. A sensor <NUM> provides feedback to the controller <NUM> to keep the zipper closure <NUM> inside the loop box <NUM>.

Still in reference to <FIG>, it can be seen how the zipper closure <NUM> is threaded around guide roller <NUM> and into nip <NUM> between guide rollers <NUM> and <NUM>. After nip <NUM>, the zipper closure enters the loop box <NUM> and is threaded around the weighted disk <NUM>.

As can be appreciated by comparing the tension loop <NUM> with the dancer mechanism <NUM>, in the tension loop <NUM>, there are no rotating arms or sliding members that have frictional force affecting the tension of the zipper closure <NUM>. This helps to result in better control of the tension than the in the dancer mechanism <NUM>.

The apparatus <NUM> and method includes a step of paying out polymeric film <NUM> from a film roll <NUM>. The film <NUM> has periodic eyemarks thereon. The eyemarks are for indicating parting lines where the side seals and cutting will be to create the individual bags or packages. The eyemarks <NUM> appear at a regular pitch P. In general, the pitch distance P is constant throughout the roll of film <NUM>, but the placement accuracy of the eyemarks <NUM> can vary within the roll <NUM>.

The film <NUM> is advanced toward a sealing station <NUM>. While it is being advanced, an eyemark detector <NUM> is provided to detect the eyemark <NUM> on the film <NUM>. The eyemark detector <NUM> sends a signal to the controller <NUM> to indicate that the eyemark <NUM> has been detected.

After the eyemark <NUM> is detected on the film <NUM>, the film <NUM> is guided around a triangle board <NUM> to be folded into a desired shape. Typically, this will involve forming the film <NUM> to have a U-shape, and result in opposing panels with a fold between the opposing panels. At an open side of the folded film <NUM> is where the zipper closure <NUM> will be provided.

As mentioned previously, the eyemark detector <NUM> sends a signal to the controller <NUM>, which captures the position of the nip <NUM>. The nip <NUM> is servo-controlled and has a rotational encoder for keeping track of the position of the film <NUM>. After the eyemark <NUM> has been detected, an aperture or hole <NUM> is punched into the zipper closure <NUM> at the hole punch <NUM>. The hole punch <NUM> is located downstream of the first tension control loop <NUM>. <FIG> illustrates the zipper closure <NUM> having periodic holes <NUM> therein, separated by distance P2 and interlocking members <NUM>.

Once the zipper closure <NUM> passes the punching operation, the zipper closure <NUM> is passed on to the second tension control loop <NUM>. The second tension control loop <NUM> helps to ensure that the zipper closure <NUM> that has been punched with hole <NUM> is maintained with minimal tension, such that the zipper closure <NUM> is straight and untangled. The second tension control loop <NUM> also allows for the stopping of the zipper which is necessary for actuating hole punch <NUM>. The second tension loop <NUM> is preceded by a driven nip <NUM> to introduce the punched zipper closure <NUM> into a loop box <NUM>. The nip <NUM> includes a pair of rollers <NUM>, <NUM>.

Nip <NUM> runs in an index and dwell repeat sequence. The controller <NUM> controls nip <NUM>, and during the index portion of the sequence, the nip <NUM> runs for a given distance generally close to, or equal to, the pitch distance P (<FIG>). The distance that the nip <NUM> runs in a given index will vary when the system is making adjustments to align the eyemark <NUM> to the detected hole <NUM>. Nip <NUM> stops in a dwell between indexes to allow for the actuation of hole punch <NUM>.

The second tension control loop <NUM> is constructed similarly as the first tension control loop <NUM>. A weighted disk <NUM> moves up and down by force of gravity, and the punched zipper closure <NUM> is threaded under the weighted disk <NUM>. The disk <NUM> provides the punched zipper closure <NUM> at a constant tension. A detector <NUM> monitors the level of the punched zipper closure <NUM> within the loop box <NUM> and is used as an indication that nip <NUM> needs to run to keep a loop. Both the loop box <NUM> and <NUM> are open in the bottom.

After passing through the second tension control loop <NUM>, the punched zipper closure <NUM> proceeds through the guide <NUM> and around guiding roller <NUM>.

An aperture detector <NUM> is provided downstream of the second tension control loop <NUM>, and in this embodiment, downstream of the guide <NUM> and roller <NUM>. The aperture detector <NUM> detects the aperture or hole <NUM> in the zipper closure <NUM>. After the eyemark <NUM> is detected by the eyemark detector <NUM>, the position of film nip <NUM> is captured by controller <NUM>. Then the aperture detector <NUM> detects hole <NUM>, and the controller <NUM> captures this position of film nip <NUM>. The controller <NUM> is able to calculate the distance between the detected eyemark <NUM> and the detected hole <NUM>. The controller <NUM> compares this distance to the target value that has been entered into controller <NUM> by the operator. If the compared distances are not equal, controller <NUM> will adjust the length of the index distance by nip <NUM> so that they will become equal. If the compared distances are equal, but the hole <NUM> is not lined up with the eyemark <NUM>, then the operator is able to perform a step of calibrating the apparatus <NUM> and provide a correction. The correction can be performed by adjusting the target value entered into controller <NUM>.

By having eyemark detector <NUM> and aperture detector <NUM>, in addition to controller <NUM> that receives the position of both the locations and then automatically adjusts the distance between the holes <NUM> by changing the index distance from nip <NUM>, advantages are realized. The advantages include being able to accurately line up the holes <NUM> in the zipper closure <NUM> with the film eyemarks <NUM>, in spite of variations and tension on the zipper closure <NUM> on the roll <NUM>, variations in the tension of the film <NUM>, or variations in the distance between printed eyemarks <NUM> on the film <NUM>.

The method includes the step of supplying the strip of zipper closure <NUM> to the sealing station <NUM>, while simultaneously supplying the film <NUM> to the sealing station <NUM> at the same speed as the strip of zipper closure <NUM>. The sealing station <NUM> is downstream of the second tension control loop <NUM> and aperture detector <NUM>, as well as being downstream of the eyemark detector <NUM>.

Although the zipper closure <NUM> is stopped intermittently for punching the holes <NUM>, the accumulation of a sufficient length of zipper closure <NUM> in the dancer mechanism <NUM> and tension control loops <NUM>, <NUM> allows the zipper closure <NUM> to be supplied continuously to the sealing station <NUM> at the same net speed that the film <NUM> is supplied. The holes <NUM> in the zipper closure <NUM> are lined up with the eyemarks <NUM> with the zipper closure <NUM> at minimal tension, so that minimum wrinkles are formed after the bag is made.

The method further includes sealing the strip of zipper closure <NUM> to the film <NUM>. The sealing step is done while the hole <NUM> is aligned with the eyemark <NUM>.

During the step of sealing, the strip of zipper closure <NUM> is sandwiched between two opposing walls of the film <NUM>, and heated sealing bars transfer heat to the film <NUM> and zipper closure <NUM>. In this embodiment, there are three pairs of opposed heating sealing bars, shown at 11a and 11b; 12a and 12b; and 13a and 13b. The sealing bars 11a, 12a, and 13a extend and retract by actuation of air cylinders <NUM>, <NUM>, and <NUM>. The air cylinders <NUM>, <NUM>, <NUM> are controlled by electro-pneumatic regulators, which accurately control sealing pressure. The controller <NUM> sends signals to the air cylinders <NUM>, <NUM>, <NUM> to extend and retract the sealing bars 11a, 12a, and 13a.

The sealing bars 11b, 12b, and 13b are mounted on rod-type electric actuators <NUM>, <NUM>, <NUM> that accurately control the amount of extension and retraction. All of the sealing bars <NUM>, <NUM>, <NUM> includes electric heaters and thermocouples to control the temperature of the sealing bars by way of a programmable controller having an operator interface.

Sealing of the zipper closure <NUM> to the film <NUM> is accomplished by extending the heating sealing bars <NUM>, <NUM>, <NUM> toward the moving film <NUM> and applying pressure on Teflon belts <NUM>, <NUM> disposed between the film <NUM> and the opposing sealing bars. The belts <NUM>, <NUM> rotate continuously in their respective loops. The belts <NUM>, <NUM> move synchronously with the film <NUM> and zipper closure <NUM> and are in contact with opposing edges of the film <NUM>.

Depending on the linear speed of the film <NUM>, a selected number of the sealing bars will be actuated for sealing. That is, only a single set of the opposed sealing bars, two sets of the opposed sealing bars, or all three sets of the opposed sealing bars can be used. At lower film speeds, only one pair of the opposing sealing bars may be actuated. At intermediate film speeds, two sets of the sealing bars may be actuated. At the highest speed, all three sets of sealing bars can be actuated. This results in advantages in that less film <NUM> and zipper closure <NUM> is wasted, as there are fewer instances of overheating or underheating.

As can be appreciated from the above, by having independent control of single sets of opposed sealing bars, any unsealed film <NUM> and zipper closure <NUM> located between sealing bars 11a & 11b and 13a & 13b which did not get sealed together during normal line stops will be sealed completely during the process startup. During process startup, sealing bars 11a & 11b extend towards the moving film <NUM> and apply pressure on the Teflon belts <NUM> & <NUM> sealing film <NUM> and zipper closure <NUM> together. At the same time, controller <NUM> instructs sealing bars 13a & 13b to extend towards the moving film <NUM> and apply pressure on the Teflon belts <NUM> & <NUM> sealing film <NUM> and zipper closure <NUM> together. Depending on the linear speed of the film <NUM>, controller <NUM> will retract 13a & 13b so as not to overheat film <NUM> and zipper closure <NUM>. Sealing bars 11a & 11b will remain in the extended position to seal film <NUM> and zipper closure <NUM> together. This operation is helpful to a reduction, or in many cases, elimination of wasted film <NUM> and zipper closure <NUM> not sealing together and being rejected by the downstream processing equipment.

After the film <NUM> and zipper closure <NUM> are processed through the sealing station <NUM>, they are advanced to a bag machine for product filling and for final bag sealing. Because the holes <NUM> remove the interlocking members of the zipper <NUM> at the parting lines between the bags, the amount of heat required to make the final seals is lower as compared to if the holes <NUM> were not provided.

As can be appreciated from the above, the first and second tension control loops <NUM>, <NUM> help to deliver the zipper closure <NUM> with minimal tension at the time of attachment of the zipper closure <NUM> to the film <NUM>, while ensuring accurate alignment of the holes <NUM> with the film eyemarks <NUM>. This results in individual bags that are wrinkle free. The minimal tension is a tension less than <NUM> lbs, and is typically between <NUM> lbs and <NUM> lbs (<NUM>,<NUM> and <NUM>,<NUM>). In many preferred systems and methods, the tension is less than <NUM> lbs (<NUM>,<NUM>), indeed often less than <NUM> lbs (<NUM>,<NUM>). In an example system, the tension is about <NUM> lbs (<NUM>,<NUM>).

Modifications can be made to this process and still result in the above advantages. For example, three tension control loops can be used instead of a dancer mechanism and two tension control loops. Alternatively, only one tension control loop can be used.

Claim 1:
A method of securing a zipper closure (<NUM>) to polymeric film (<NUM>) using minimal tension on the zipper closure; the method comprising:
(a) paying out a continuous strip of plastic zipper closure (<NUM>) from a roll (<NUM>) of zipper closure; (<NUM>)
(b) paying out polymeric film (<NUM>) from a film roll (<NUM>), the polymeric film (<NUM>) having periodic eyemarks thereon;
(c) passing the strip of zipper closure (<NUM>) through a tension control mechanism;
(d) passing the strip of zipper closure (<NUM>) through a first tension control loop (<NUM>);
(e) advancing the film (<NUM>) toward a sealing station (<NUM>) and past an eyemark detector (<NUM>) to detect an eyemark (<NUM>) on the film (<NUM>);
(f) after detection of the eyemark (<NUM>) on the film (<NUM>), punching a hole (<NUM>) into the strip of zipper closure (<NUM>) upon detection of the eyemark (<NUM>) on the film (<NUM>);
(g) passing the strip of zipper closure (<NUM>) with a punched hole (<NUM>) through a second tension loop (<NUM>);
(h) supplying the strip of zipper closure (<NUM>) to the sealing station (<NUM>) while simultaneously supplying the film (<NUM>) to the sealing station (<NUM>) at the same speed as the strip of zipper closure (<NUM>);
(i) aligning the hole (<NUM>) in the strip of zipper closure (<NUM>) with the eyemark (<NUM>) on the film (<NUM>); and
(j) sealing the strip of zipper closure (<NUM>) to the film (<NUM>).