Zipper and zipper arrangements and methods of manufacturing the same

RELATED APPLICATIONS

0001The Applicants note that application Ser. No. 13/184,010 was filed on Jul. 15, 2011. Application Ser. No. 13/184,010 is a continuation reissue application from this application (application Ser. No. 10/652,572).

0002This application is a reissue application of U.S. Pat. No. 6,286,189 (application Ser. No. 09/307,937); U.S. Pat. No. 6,286,189 is related to an application entitled “Assembly And Accumulation Of Sliders For Profiled Zippers” Ser. No. 09/307,893 filed May 10, 1999, and to an application entitled “Fastener With Slider Thereon For Use In Manufacturing Recloseable Bags” Ser. No. 09/302,843 filed May 10, 1999. Both applications are filed concurrently with this application, and are assigned to the same assignee as the assignee of this application. Both applications and their disclosures are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

0003The present invention is directed to zippers, zipper arrangements, and methods of manufacturing the same. Specifically, the present invention is directed towards zipper arrangements having a notched zipper and at least one slider for use in manufacturing thermoplastic bags and methods of manufacturing the same.

BACKGROUND OF THE INVENTION

0004Plastic bags are popular for storing food and other items. Zippered plastic bags that can be securely closed and reopened are particularly popular due to their perceived ability to maintain freshness of the food stored in the bags and/or to minimize or eliminate leakage into and out of the bag. These bags are used one at a time by consumers. These bags are also used by businesses to package items that are then sold to consumers. For example, nuts, candy, snacks, ingredients, salt, cheese, and other food and non-food products are packed in these bags by form, fill and seal machines.

0005Slider bags have become popular with customers for a variety of reasons, including difficulty in opening and closing a zippered bag without a slider. Product manufacturers have not, however, used zippers with sliders in their form, fill and seal machines for a variety of reasons. Some of these reasons include the difficulty in having a reliable assembly of sliders to zipper at form, fill and seal manufacturing rates, supplying zipper with sliders that are not prone to machine jamming and excessive downtime, and installing sliders in tight and constraining areas in form, fill and seal machine footprints.

0006Accordingly, a need exists to address the above-noted problems by supplying zippers in a convenient configuration and having methods of easily placing sliders onto zippers.

SUMMARY OF THE INVENTION

0007According to one embodiment of the present invention, a zipper arrangement for use in manufacturing bags includes a zipper and at least one slider. The zipper includes first and second opposing tracks. The first track has a first profile and the second track has a second profile. The first and second profiles are releasably engageable to each other. The first track has one or more spaced primary notches interrupting the first profile. The slider is inserted onto the first profile via a respective one of the primary notches. The slider is adapted to engage and disengage the first and second profiles in response to movement along the zipper.

0008According to another embodiment of the present invention, the second track has a second profile and one or more spaced primary notches interrupting the second profile. The second primary notches are generally aligned with respective ones of the first primary notches to form aligned pairs of primary notches. The slider is inserted onto the first profile via a respective one of the aligned pairs of primary notches.

0009According to yet another embodiment of the present invention, a folded zipper includes first and second opposing tracks that each have one or more primary notches interrupting respective profiles. The primary notches are generally aligned to respective ones of the first primary notches to form aligned pairs of primary notches. The zipper includes a plurality of fold areas generally transverse to a length of the zipper and the zipper is folded along the fold areas.

0010According to a further embodiment, a folded zipper has a first track having one or more primary notches and a second track having one or more spaced slits interrupting the second profile. The slits are generally aligned to respective ones of the primary notches. The zipper includes a plurality of fold areas generally transverse to a length of the zipper and the zipper is folded along the fold areas.

0011According to one method of the present invention, a zipper and at least one slider are provided. The first track has one or more spaced primary notches interrupting the first profile. The slider is mounted onto a second profile and into a respective one of the primary notches. The slider is slid onto the first profile via a respective one the primary notches.

0012According to another method, a zipper and at least one slider are provided. The slider is positioned in a respective one of the aligned pairs of primary notches. Each of the first and second opposing tracks has one or more primary notches interrupting respective profiles. The slider is slid onto the first and second profiles via a respective one of the aligned pairs of primary notches.

BRIEF DESCRIPTION OF THE DRAWINGS

0013Other objects and advantages of the invention will become apparent upon reading the flowing detailed description and upon reference to the drawings.

0014<figref idref="DRAWINGS">FIG. 1</figref> is a perspective view of a zipper having spaced primary notches to be used in one embodiment of the present invention.

0015<figref idref="DRAWINGS">FIG. 2</figref> is a perspective view of a portion of a recloseable package including a zipper and a slider according to one embodiment of the present invention.

0016<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view of the zipper taken across line <b>3</b>-<b>3</b> of <figref idref="DRAWINGS">FIG. 2</figref> prior to opening the tamper evident feature.

0017<figref idref="DRAWINGS">FIG. 4</figref> is a perspective view of a zipper arrangement including a zipper and a plurality of sliders according to another embodiment of the present invention.

0018<figref idref="DRAWINGS">FIG. 5</figref> is a perspective view of a zipper having spaced primary notches according to yet another embodiment of the present invention.

0019FIG. 5a is a perspective view of a zipper having spaced primary notches according to one embodiment.

0020<figref idref="DRAWINGS">FIG. 6</figref> is a diagram of basic components of a form, fill and seal machine.

0021<figref idref="DRAWINGS">FIG. 7a</figref> is a perspective view of a zipper arrangement to be folded according to a further embodiment of the present invention.

0022<figref idref="DRAWINGS">FIG. 7b</figref> is a perspective view of a folded zipper arrangement according to another embodiment of the present invention.

0023<figref idref="DRAWINGS">FIG. 7c</figref> is a top view of the folded zipper arrangement of <figref idref="DRAWINGS">FIG. 7b</figref>.

0024FIG. 7d is a perspective view of a folded zipper arrangement according to one embodiment.

0025<figref idref="DRAWINGS">FIG. 8</figref> is a perspective view of a punching apparatus for forming spaced primary notches in a zipper according to one embodiment of the present invention.

0026<figref idref="DRAWINGS">FIGS. 9-11</figref> epict an operational sequence using an escapement mechanism for placing sliders onto a zipper according to one method of the present invention.

0027While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed but, on the contrary, to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

0028Turning now to the drawings, <figref idref="DRAWINGS">FIG. 1</figref> illustrates a zipper or fastener <b>10</b> having a plurality of generally aligned pairs of primary notches <b>12</b> according to one embodiment of the present invention. The primary notches <b>12</b> are shown as being spaced at a distance W that generally corresponds to a width of a thermoplastic bag. The primary notches <b>12</b> each have a distance D<b>1</b> extending from a top surface of the zipper <b>10</b>. <figref idref="DRAWINGS">FIG. 2</figref> illustrates a mouth portion of a recloseable package or bag <b>14</b> having a slider <b>16</b> on the zipper <b>10</b>, while <figref idref="DRAWINGS">FIG. 3</figref> illustrates the zipper <b>10</b> of the mouth portion of the recloseable package <b>14</b> taken along line <b>3</b>-<b>3</b> of <figref idref="DRAWINGS">FIG. 2</figref>.

0029Referring to <figref idref="DRAWINGS">FIGS. 2 and 3</figref>, the mouth portion of the recloseable package <b>14</b> includes a pair of opposing wall panels <b>18</b> and <b>20</b> made of polymeric film, multi-layer and multi-component laminates, or co-extrusions. The pair of opposing wall panels <b>18</b> and <b>20</b> make up a package body <b>22</b> and define a receptacle space <b>24</b>. Connected to the wall panel <b>18</b> is a male track <b>26</b> having a male profile <b>28</b> and a first fin portion <b>30</b> extending downward from the male profile <b>28</b>. Connected to the other wall panel <b>20</b> is a female track <b>32</b> having a female profile <b>34</b> and a second fin portion <b>36</b> extending downward from the female profile <b>34</b>.

0030The male and female profiles <b>28</b>, <b>34</b> are releasably engageable with each other to provide a recloseable seal to the package. In the illustrated embodiment of <figref idref="DRAWINGS">FIG. 3</figref>, the lower edges of the first and second fin portions <b>30</b>, <b>36</b> are joined to each other along a one time breakable preferential area of weakness or preferential tear area <b>38</b> to form a one time openable tamper evident feature <b>40</b>. The fins may also be formed from one piece that has an area of weakness or preferential tear area. The joined first and second fin portions <b>30</b>, <b>36</b> have a generally U-shaped or V-shaped cross-sectional configuration. The tamper evident feature <b>40</b> is described in detail in U.S. application Ser. No. 08/950,535, filed Oct. 15, 1997, and entitled “Reclosable Fastener Strip With Tamper Evident Feature,” now U.S. Pat. No. 5,964,532 which is incorporated herein by reference in its entirety.

0031It is not necessary that the first and second fin <b>30</b>, <b>36</b> be releasably engaged to each other by a one time breakable preferential area of weakness. For example, the first fin <b>30</b> may be separate from the second fin <b>36</b> according to another embodiment of the present invention.

0032The recloseable package <b>14</b> has the slider <b>16</b> (<figref idref="DRAWINGS">FIG. 2</figref>) slidably mounted to the zipper <b>10</b> for movement between a closed and open position. The male and female profiles <b>28</b>, <b>34</b> are engaged to each other, while the slider <b>16</b> is in the closed position, and movement of the slider <b>16</b> from the closed position to the open position disengages the male and female profiles <b>28</b>, <b>34</b> from each other. The manner of operation of this zipper and slider arrangement is described in detail in U.S. Pat. No. 5,063,644 to Herrington, Jr. et. al., which is incorporated herein by reference in its entirety.

0033The sliders to be used in the present invention may include various sliders that are adapted to move and disengage the male and female profiles <b>28</b>, <b>34</b> from each other. One such slider (slider <b>16</b>) is depicted in <figref idref="DRAWINGS">FIG. 2</figref>. The slider <b>16</b> of <figref idref="DRAWINGS">FIG. 2</figref> is generally U-shaped and includes a transverse support member <b>42</b> with two depending legs <b>44</b>, <b>46</b> therefrom. A separator finger <b>48</b> depends from the transverse support member <b>42</b> and is disposed between the depending legs <b>44</b>, <b>46</b>. The separator finger <b>48</b> extends at least partially between the male and female profiles <b>28</b>, <b>34</b> to aid in disengaging the male and female profiles <b>28</b>, <b>34</b> as the slider <b>16</b> is moved along the zipper <b>10</b>.

0034<figref idref="DRAWINGS">FIG. 4</figref> illustrates a zipper arrangement <b>50</b> comprising a zipper <b>52</b> and a plurality of the sliders <b>16</b>. A slider <b>16</b>a is located in a spaced primary notch <b>12</b>, while the slider <b>16</b>b is shown in a position straddling the male and female profiles. Referring to <figref idref="DRAWINGS">FIGS. 1</figref>, <b>3</b> and <b>4</b>, the male track <b>26</b> has a plurality of spaced first primary notches <b>12</b>a interrupting the male profile <b>28</b>, while the female track <b>32</b> has a plurality of second primary notches <b>12</b>b interrupting the female profile <b>34</b>. The first primary notches <b>12</b>a are generally aligned with the second primary notches <b>12</b>b to form the aligned pairs of primary notches <b>12</b>. The sliders <b>16</b> are adapted to slide onto the male and female profiles <b>28</b>, <b>34</b> via the respective aligned pairs of primary notches <b>12</b>. At least one of the first and second primary notches <b>12</b>a, <b>12</b>b may interrupt a portion of the first fin <b>30</b> and/or the second fin <b>36</b>, respectively.

0035According to another embodiment of the present invention, the zipper may have one slider instead of the plurality of sliders described in the zipper arrangement of <figref idref="DRAWINGS">FIG. 4</figref>. According to another embodiment of the present invention, the zipper may have one first primary notch and/or one second primary notch. Likewise, the zipper may have one secondary notch.

0036The plurality of primary notches <b>12</b> are preferably located near the ends of the recloseable package <b>14</b> for a variety of reasons. For example, locating the primary notches <b>12</b> near the ends of the package <b>14</b> is generally more aesthetically pleasing to customers. In addition, this location allows the slider <b>16</b> to move and open the package <b>14</b> across a greater distance, resulting in a wider mouth of the package <b>14</b>. Locating the primary notches <b>12</b> near the ends of the package <b>14</b> may also assist in forming the side seals of the package <b>14</b> since the profiles do not need to be flattened. Side seals of the package <b>14</b> may be formed more easily and/or efficiently because of the reduction or elimination in temperatures, pressures, and times associated with fusing the male and female profiles <b>28</b>, <b>34</b> together near the ends of the package <b>14</b>. Locating the primary notches near the ends of the package <b>14</b> may eliminate the need to fuse the male and females profiles <b>28</b>, <b>34</b> together if the male and female profiles <b>28</b>, <b>34</b> are cut away at the areas where the side sealing occurs.

0037The relationship between the notch <b>12</b> and the slider <b>16</b> will be discussed with respect to <figref idref="DRAWINGS">FIG. 4</figref>. A distance D<b>1</b> of the notch preferably is less than a distance D<b>3</b> (the internal opening of the slider <b>16</b>) so that the slider may be placed more easily onto the profiles. As shown in <figref idref="DRAWINGS">FIG. 4</figref>, the sliders <b>16</b>a, <b>16</b>b overlap a portion of the fins to assist in aligning the position of the sliders <b>16</b>a, <b>16</b>b prior to threading onto the profiles. Specifically, the opening of the sliders <b>16</b>a, <b>16</b>b between the slider wings falls between the fins. The aligned primary notch <b>12</b> preferably has a width that is greater than a length L of the slider <b>16</b>. The aligned primary notches <b>12</b> of <figref idref="DRAWINGS">FIGS. 1 and 4</figref> are shown as extending through the respective male and female profiles in a direction generally transverse to a length of the zipper <b>16</b>. The primary notches <b>12</b> do not, however, extend entirely through the first fin <b>30</b> and the second fin <b>36</b>, respectively, in <figref idref="DRAWINGS">FIG. 4</figref>.

0038According to another embodiment of the present invention, the zipper may include a plurality of secondary notches. Referring specifically to <figref idref="DRAWINGS">FIG. 4</figref>, the male track <b>26</b> of the zipper arrangement <b>50</b> is further interrupted by a plurality of optional first secondary notches <b>54</b>a, while the female track <b>32</b> is further interrupted by a plurality of optional second secondary notches <b>54</b>b according to another embodiment of the invention. The first secondary notches <b>54</b>a are generally aligned with the second secondary notches <b>54</b>b to form generally aligned pairs of secondary notches <b>54</b>. The aligned notches <b>54</b> have a distance D<b>2</b> extending from a top surface of the zipper <b>52</b>.

0039The secondary notches <b>54</b> are not adapted to engage the separator finger <b>48</b> of the zipper <b>16</b> which inhibits or prevents the slider <b>16</b> from disengaging the male and female profiles <b>28</b>, <b>34</b>. In other words, the separator <b>48</b> is ineffective to force a top portion (the ears) of the male and female profiles <b>28</b>, <b>34</b> apart so as open the package <b>14</b>. The slider is considered to be “parked” when it is in this condition. The secondary notches <b>54</b> also give a user of the package <b>14</b> the feel of a secure closure and assurance that the bag is closed with certainty. The secondary notches are described in detail in U.S. Pat. No. 5,067,208, which is incorporated herein by reference in its entirety.

0040The secondary notches <b>54</b> are preferably located at the closed end of the bag. As shown in <figref idref="DRAWINGS">FIG. 4</figref>, the first and second secondary notches <b>54</b>a, <b>54</b>b extend at least partially into the respective male and female profiles <b>28</b>, <b>34</b>. The aligned secondary notches <b>54</b> may be merged into respective aligned primary notches <b>12</b> as shown in <figref idref="DRAWINGS">FIG. 4</figref>.

0041According to another embodiment (<figref idref="DRAWINGS">FIG. 5</figref>) to be used in the present invention, a zipper <b>60</b> comprises a male track <b>62</b> and a female track <b>64</b>. The male track includes a male profile <b>66</b> and a first fin <b>68</b>. The male track <b>62</b> has a plurality of spaced primary notches <b>70</b> interrupting the male profile <b>66</b>. The female track is shown in <figref idref="DRAWINGS">FIG. 5</figref> as being continuous, and includes a female profile <b>72</b> and a second fin <b>74</b>. A slider (e.g., the slider in <figref idref="DRAWINGS">FIG. 4</figref>) is adapted to be placed onto the female profile <b>72</b> in an area where the primary notch <b>70</b> has been formed. The slider is slid onto the male profile <b>66</b> via the primary notch <b>70</b>. The zipper <b>60</b> may include one slider or a plurality of sliders. Likewise, according to yet another embodiment, a slider may be placed onto a continuous male track (not shown) in an area where the female track has been interrupted by a primary notch. Then, the slider is slid onto the female profile via the primary notch.

0042According to yet another embodiment of the present invention, a zipper (not shown) comprises a male track and a female track. The male track includes a male profile and the female track includes a female profile. Neither the male track nor the female track comprises a first fin or a second fin, respectively, according to this embodiment. The zipper includes a plurality of generally aligned primary notches formed in the zipper. According to one embodiment of the present invention, a slider may be placed in a respective one of the plurality of aligned primary notches. A slider is then slid onto the male and female profiles via a respective one of the aligned primary notches. Alternatively, a plurality of sliders are slid onto the male and female profiles via respective ones of the aligned primary notches. Alternatively, a primary notch may interrupt only one of the profiles, as described above with respect to <figref idref="DRAWINGS">FIG. 5</figref>.

0043A filled and sealed food or storage bag may be formed by a form, fill and seal machine. The zipper arrangement of <figref idref="DRAWINGS">FIG. 6</figref> includes a zipper <b>10</b> and a plurality of sliders <b>16</b>. Bag film or web <b>82</b>, zippers <b>10</b>, and sliders <b>16</b> are components for assembling into a complete bag. A schematic illustration of a form, fill and seal machine <b>80</b> is provided in <figref idref="DRAWINGS">FIG. 6</figref>. As depicted at the left side of <figref idref="DRAWINGS">FIG. 6</figref>, the plastic film or web <b>82</b> and a zipper <b>10</b> with sliders <b>16</b> thereon are fed into the form, fill and seal machine <b>80</b>. The web <b>82</b> has already been formed into a generally U-shape to define a first side wall <b>84</b>, a second side wall <b>86</b>, and an open top <b>88</b> that will become finished individual bags <b>90</b>. In <figref idref="DRAWINGS">FIG. 6</figref>, the sliders <b>16</b> are shown as mounted on the zipper <b>10</b>, but the sliders <b>16</b> may be first assembled and accumulated, and then mounted on the zipper <b>10</b> by the form, fill and seal machine <b>80</b>.

0044The zipper <b>10</b> with the sliders <b>16</b> of <figref idref="DRAWINGS">FIG. 6</figref> is attached to the first side wall <b>84</b> of the web <b>82</b> by a heated seal bar <b>92</b>. Side seals <b>94</b> are then formed in the web <b>82</b> by a second heated seal bar <b>96</b>, leaving the open top <b>88</b> as the only access to the interior of the formed bag <b>90</b>. Another second heated seal bar (hidden in <figref idref="DRAWINGS">FIG. 6</figref>) is typically located on the opposite side of the second heated seal bar <b>96</b> and works in conjunction with the seal bar <b>96</b> in forming the side seals <b>94</b>. The bag <b>90</b> is then moved under a fill spout <b>98</b> through which a product <b>100</b> is deposited into the interior of each bag <b>90</b>. As discussed above, product <b>100</b> may be nuts, candy, snacks, ingredients, salt, cheese, and other food and non-food products. After the bag <b>90</b> is filled, the second side wall <b>86</b> of the bag <b>90</b> is sealed to the zipper <b>10</b> by a third heated seal bar <b>102</b>. The individual bags <b>90</b> are then separated from each other by a knife <b>104</b> that cuts the web <b>82</b> at the side seals <b>94</b>. The filled bags <b>90</b> can then be shipped to retailers for sale to consumers.

0045The bag <b>90</b> may have an end termination or stop (not shown) for inhibiting or preventing the slider <b>16</b> from going past the ends of the zipper. The end terminations also hold the male and female profiles together to resist stresses applied to the profiles during normal use of the plastic bag. One type of end termination is in the form of a strap/clip that wraps over the top of a zipper. Further information concerning such an end termination may be found in U.S. Pat. No. 5,067,208, which is incorporated herein by reference in its entirety. One end of the strap is provided with a rivet-like member that penetrates through the zipper fins and into a cooperating opening at the other end of the strap. Other types of end termination are disclosed in U.S. Pat. Nos. 5,482,375, 5,448,807, 5,442,837, 5,405,478, 5,161,286, 5,131,121 and 5,088,971, which are each incorporated herein by reference in their entireties.

0046The bag <b>90</b> may also have an end termination formed from first and second upstanding panels (not shown) extending upwardly from the respective first and second body panels. The opposing ends of the first upstanding panels are connected to the respective opposing ends of the second upstanding panel to form an open pocket in which the slider and zipper are captured. This is discussed in further detail in U.S. Pat. No. 5,713,669, which is incorporated herein by reference in its entirety.

0047The form, fill and seal machines may produce the bags in a different manner than as described in <figref idref="DRAWINGS">FIG. 6</figref>. For example, the individual bags <b>90</b> may be separated from each other by the knife <b>104</b> after side seals <b>94</b> are formed in the bags by the seal bar <b>96</b>, but before the individual bags <b>90</b> are filled with product <b>100</b> and sealed with top seal <b>102</b>. The zipper <b>10</b> with sliders <b>16</b> may be located at the bottom or c-fold of the web <b>82</b>, opposite the open top <b>88</b>. Other variations of the described form, fill and seal process of <figref idref="DRAWINGS">FIG. 6</figref> are contemplated, such as, for example, having the zipper <b>10</b> sealed on the bag <b>90</b> after it has been filled with product <b>100</b>. It is contemplated that the zipper and zipper arrangements of the present invention may be used in other bag making/packaging processes.

0048Prior to being used in, for example, a form, fill and seal machine, a zipper may be stored by a variety of methods, including being folded in a box. One example of a folded zipper arrangement <b>120</b> is shown in <figref idref="DRAWINGS">FIGS. 7b and 7c</figref>. The folded zipper arrangement <b>120</b> may, for example, have a similar shape as shown in <figref idref="DRAWINGS">FIG. 1</figref>. The folded zipper arrangement <b>120</b> includes first and second opposing tracks where the first track has a plurality of first primary notches interrupting the male profile and the second track has a plurality of spaced second primary notches interrupting the second profile. The second primary notches are generally aligned with respective ones of the first primary notches to form aligned pairs of primary notches <b>124</b>.

0049Referring to <figref idref="DRAWINGS">FIGS. 7a-c</figref>, the zipper <b>120</b> also includes a plurality of fold regions or areas <b>122</b> to assist in folding the zipper <b>120</b>. The plurality of fold areas <b>122</b> are generally transverse to a length of the zipper <b>10</b> and are aligned with respective ones of the aligned pairs of primary notches <b>124</b>. The fold areas <b>122</b> divide the zipper <b>120</b> into a plurality of zipper segments. The zipper segments of the folded zipper <b>120</b> are generally parallel to each other and generally correspond to a width of a thermoplastic bag. The zipper <b>120</b> may also include fold lines that assist in folding the zipper <b>120</b>, such as, for example, score lines. The zipper may also include a breakable line of weakness or an area of weakness (not shown)121 (see FIG. 7d) located in the fold areas to assist in separating portions of the zipper from the remainder thereof. These perforation lines may be used in a method where the bag has been filled with product and the zipper is later added to the filled bag. The zipper <b>120</b> of <figref idref="DRAWINGS">FIGS. 7a-c</figref> is shown as being folded in a general shape of an accordion or z-fold along the fold areas <b>122</b>.

0050In another embodiment, a zipper includes a plurality of fold areas or regions to assist in folding the zipper along the fold areas. The zipper has a first track with a plurality of spaced primary notches interrupting the first profile and a second track with a plurality of spaced slits (not shown)75 (see FIG. 5a) interrupting the second profile. The slits are generally aligned with respective ones of the primary notches. The plurality of fold areas are generally aligned with respective ones of the aligned slits and primary notches. The zipper may include a breakable line of weakness or an area of weakness (not shown) located in the fold areas to assist in separating portions of the zipper from the remainder thereof.

0051It is contemplated, however, that the zipper may be folded in other shapes, such as being rolled or packed. The zipper <b>120</b> of one box may be spliced to a zipper arrangement (not shown) of a second box. The zipper may also be folded without the sliders <b>16</b> (not shown).

0052The zipper arrangement and sliders of the present invention may be made from a variety of suitable materials. Some examples of materials that may be used in forming the profiles, tracks, and fins include the following resins: high density polyethylene (HDPE), linear low density polyethylene (LLDPE), metallocenecatalyzed LLDPE, polypropylene (PP), ethylene-propylene copolymer (E-P copolymer), ethylene vinyl acetate copolymer (EVA), low density polyethylene (LDPE), very low density polyethylene (VLDPE), and nylon.

0053The fins may be comprised of a plurality of layers where the outer layer is made of a lower melting temperature material and the inner layer is made of a higher melting temperature material to assist in inhibiting fusion of the fins. Similarly, one fin may be made of a plurality of layers where the outer layer is made of a lower melting temperature material and the inner layer is made of a higher melting temperature material. For example, the lower melting temperature materials may include EVA, LDPE, VLDPE, LLDPE, and metallocene-catalyzed LLDPE.

0054The slider may be molded from any suitable plastic, such as, for example, nylon, polypropylene, polystyrene, Delrin, or ABS. The opposing wall panels may be made from any suitable thermoplastic film such as, for example, polyethylene, polypropylene, polyester, copolyester, or mixtures thereof. Furthermore, the wall panels of the present invention can have multiple layers joined by coextrusion or lamination. Thus, one skilled in the art can design and coextrude multi-layered polymeric bags which will incorporate the various properties inherent in differing polyethylene and polypropylene compositions. It is further possible to incorporate pigments, metallic components, paper, and/or paper/plastic composites into or on the layer or layers of the polymeric bags of the instant invention.

0000Methods of Forming Notches

0055The primary notches and optional secondary notches may be formed by a variety of methods. For example, one method of forming the primary notches in a zipper is shown in <figref idref="DRAWINGS">FIG. 8</figref>. <figref idref="DRAWINGS">FIG. 8</figref> illustrates a punching apparatus <b>160</b> that forms aligned primary notches. The punching apparatus <b>160</b> includes a movable member <b>162</b> and an air cylinder mechanism <b>163</b>. The air cylinder mechanism <b>163</b> controls the movement of the moveable member <b>162</b>.

0056The moveable member <b>162</b> is shown in <figref idref="DRAWINGS">FIG. 8</figref> as punching aligned primary notches that extend through the male and female profiles. The moveable member <b>162</b> preferably leaves at least a portion of the first and second fins so as to allow a slider to be placed onto a cut edge of the fins. A portion <b>164</b> from the zipper <b>10</b> is shown as being discharged from the zipper <b>10</b> by the moveable member <b>162</b>. The moveable member <b>162</b> notches the zipper <b>10</b> at desired intervals, such as intervals being about a bag distance apart.

0057The punching apparatus <b>160</b> may also contain a second moveable member (not shown) that can form a plurality of secondary notches in a similar manner as described above for the moveable member <b>162</b>. Alternatively, the punching apparatus may comprise a tiered moveable member (not shown) that simultaneously punches a plurality of aligned primary and secondary notches. According to another embodiment, a punching apparatus (not shown) may be designed to punch a first track without punching a second track. One such punching apparatus would include a moveable member located vertically above the zipper and adapted to move in a downward direction for punching a first track without punching a second track. This embodiment may be employed without first separating the male and female profiles.

0000Method of Placing at Least One Slider onto a Zipper

0058One method of placing at least one slider onto a zipper is shown in <figref idref="DRAWINGS">FIGS. 9-11</figref>. Referring to <figref idref="DRAWINGS">FIG. 9</figref>, an escapement mechanism <b>180</b> drops the sliders <b>16</b> one at a time in respective ones of the aligned pairs of the primary notches of the zipper <b>10</b>. The escapement mechanism <b>180</b> is located downstream from the punching apparatus <b>160</b> of <figref idref="DRAWINGS">FIG. 8</figref>. The escapement mechanism <b>180</b> is preferably one bag repeat downstream from the punching apparatus <b>160</b>. The escapement mechanism <b>180</b> may be located upstream from the form, fill and seal machine discussed above in <figref idref="DRAWINGS">FIG. 6</figref>.

0059The escapement mechanism <b>180</b> comprises a slider holder <b>182</b>, a threader or slider finger <b>184</b>, and a restraining finger <b>186</b>. The slider holder <b>182</b> is designed to be compatible with an assembly of sliders <b>16</b> or individual sliders. The slider holder <b>182</b> includes a vertical column with a channel sized to hold the sliders <b>16</b>. The channel of the slider holder <b>182</b> includes an open top and an open bottom. It is contemplated that the slider holder <b>182</b> may be shaped in a different manner than shown in <figref idref="DRAWINGS">FIG. 9</figref>. For example, the slider holder may be rectangular or square. Additional examples are shown in the application entitled “Assembly And Accumulation Of Sliders For Profiled Zippers”, Ser. No. <b>09</b>/<b>307</b>,<b>893</b> which has been filed concurrently with this application, and is incorporated herein be reference in its entirety. The shape of the slider holder generally corresponds to the shape of the assembly of the sliders or individual sliders. The slider holder <b>182</b> is preferably designed to allow one slider <b>16</b> at a time to be placed in a primary notch of the zipper <b>10</b>.

0060As shown in <figref idref="DRAWINGS">FIG. 9</figref>, a zipper <b>10</b> is advanced toward the escapement mechanism <b>180</b> in a direction of the arrow. The zipper <b>10</b> may be pushed or pulled through the escapement mechanism <b>180</b>. At a time when one of the aligned pairs of primary notches is generally located below the open bottom of the channel of the slider holder <b>182</b>, a slider <b>16</b>c is dropped in the aligned pair of primary notches (hidden in <figref idref="DRAWINGS">FIG. 9</figref>) of the zipper <b>10</b>. The slider <b>16</b>c may be placed in the notches by gravity and driven mechanically or electro-mechanically. The zipper <b>10</b> continues to move forward through the escapement mechanism <b>180</b>. The threader finger <b>184</b> engages the dropped slider <b>16</b>c and holds it in place as the zipper <b>10</b> is either pushed or pulled such that the slider <b>16</b>c is threaded onto the profiles. An edge of the slider <b>16</b>c abuts the threader finger <b>184</b> and is prevented from moving forward with the zipper <b>10</b>. Thus, the aligned pair of primary notches is moving away from the slider <b>16</b>c, while the slider <b>16</b>c is being moved along the male and female profiles.

0061Referring to <figref idref="DRAWINGS">FIG. 10</figref>, the threader finger <b>184</b> is then moved away from the path of the slider <b>16</b>c, resulting in the slider <b>16</b>c moving forward with the zipper <b>10</b>. The movement of the threader finger <b>184</b> from the path of the slider <b>16</b>c corresponds to the desired placement of the slider <b>16</b>c relative to a primary notch <b>12</b>c. If a greater distance is desired between the slider <b>16</b>c and the notch <b>12</b>c, then the threader finger <b>184</b> remains abutting the slider <b>16</b>c for a longer period of time. At the same time that the threader finger <b>184</b> is moved from the path of the slider <b>16</b>c, the restraining finger <b>186</b> is moved toward the sliders <b>16</b>. The restraining finger <b>186</b> holds the next slider (<b>16</b>d) in place as the zipper <b>10</b> is being advanced through the escapement mechanism <b>180</b>.

0062According to this embodiment, the threader finger <b>184</b> and the restraining finger <b>186</b> are powered by independent pistons. Internal air passages allow only one of the threader finger <b>184</b> and the restraining finger <b>186</b> to be fully retracted when the other is completely extended. Referring to <figref idref="DRAWINGS">FIG. 11</figref>, the threader finger <b>184</b> is returned to the same position shown in <figref idref="DRAWINGS">FIG. 9</figref> after the slider <b>16</b>c has advanced past the threader finger <b>184</b>. At the same time, the restraining finger <b>186</b> returns to a position away from the assembly of sliders <b>16</b>. The next slider (<b>16</b>d) will be placed into an aligned pair of primary notches <b>12</b>d as the zipper <b>10</b> is advanced forward.

0063According to one embodiment, the slider to be used in the method described above may be of the type described above in <figref idref="DRAWINGS">FIG. 2</figref>. A separator finger of the slider may extend at least partially between the male and female profiles so as to disengage the male and female profiles in response to movement along the zipper. It is preferable that the slider be positioned in the primary notch so that the separator finger of the slider remains between the male and female profiles.

0064According to another method of the present invention, a slider may be placed on a zipper as described above. The zipper may be of a length generally corresponding to a width of the bag after the slider is placed on the zipper.

0065According to yet another method of the present invention, a slider may be placed onto a zipper where only a first track has a plurality of spaced primary notches interrupting a first profile. In this method, the sliders are pushed downward onto a second profile and into respective ones of the primary notches. The sliders are slid onto the first profile via the respective primary notches. This method may use a similar type of escapement mechanism <b>180</b> that would allow the sliders to be pushed downward onto a second profile. The sliders of the type described above in <figref idref="DRAWINGS">FIG. 2</figref> are preferably positioned so that a separator finger of the slider remains between the male and female profiles. Additional, a slider may be placed on a zipper having a length generally corresponding to a width of the bag after the slider is placed on the zipper.

0066While the present invention has been described with reference to the particular embodiments illustrated, those skilled in the art will recognize that many changes and variations may be made thereto without departing from the spirit and scope of the present invention. The embodiments and obvious variations thereof are contemplated as falling within the scope and spirit of the claimed invention, which is set forth in the following claims.