Methods of manufacturing reclosable packages using transverse application of zipper closure

Abstract

A method of making packages having a reclosable zipper closure on a vertical form, fill and seal process. The method includes providing a length of the zipper closure having a length same as the width of the resulting package. The ends of the length of zipper closure are sealed together prior to applying the zipper closure to the film web. The zipper construction is first applied and adhered to one half of the film web and then to the other half. A tamper-evident structure encasing the zipper closure may be included.

What is claimed:  
     
         1 . A method of manufacturing a reclosable package comprising a zipper closure construction, the reclosable package having a width and the zipper closure extending the width of the package, the method comprising: 
 (a) providing a zipper closure having a length approximately equal to the package width, the length defined by a first end and a second end, the zipper closure having a first mating profile and a second mating profile;    (b) sealing the first mating profile to the second mating profile at the first end and at the second end to provide first and second end seals;    (c) after the step of providing the zipper closure having a length approximately equal to the package width and after the step of sealing the first mating profile to the second mating profile, attaching the first mating profile to a first portion of a film web;    (d) attaching the second mating profile to a second portion of the film web;    (e) joining a first side edge and a second side edge of the film web approximately perpendicular to the zipper closure to form a casement;    (f) forming a bottom edge to provide an interior defined by the casement and the bottom edge; and    (g) forming a top edge.    
     
     
         2 . The method according to  claim 1 , further comprising, between the step of forming a bottom edge to provide an interior defined by the casement and the bottom edge and the step of forming a top edge: 
 (a) filling the package interior.    
     
     
         3 . The method according to  claim 1 , wherein the step of forming a top edge is done before the step of forming a bottom edge to provide an interior defined by the casement and the bottom edge.  
     
     
         4 . The method according to  claim 3 , further comprising, between the step of forming a top edge and the step of forming a bottom edge to provide an interior defined by the casement and the bottom edge: 
 (a) filling the interior.    
     
     
         5 . The method according to  claim 1 , wherein the step of providing a closure construction having a length approximately equal to the package width comprises: 
 (a) cutting an extended length of closure construction to a length approximately equal to the package width.    
     
     
         6 . The method according to  claim 1 , wherein the step of sealing the first mating profile to the second mating profile at the first end and at the second end to provide first and second end seals is done before the step of providing a zipper closure having a length approximately equal to the package width, the length defined by a first end and a second end.  
     
     
         7 . The method according to  claim 6 , wherein the step of providing a closure construction having a length approximately equal to the package width comprises: 
 (a) cutting at least partially through the first and second end seals.    
     
     
         8 . The method according to  claim 7 , wherein the step of cutting at least partially through the first and second end seals comprises: 
 (a) cutting through the first and second end seals with a blade.    
     
     
         9 . The method according to  claim 7 , wherein the step of cutting at least partially through the first and second end seals is accomplished by a sealing bar used to provide at least one of first and second end seals.  
     
     
         10 . The method according to  claim 1 , wherein the step of attaching the first mating profile to a first portion of a film web comprises: 
 (a) attaching the first mating profile to a first portion of the film web equally between the first side edge and the second side edge of the film.    
     
     
         11 . The method according to  claim 1 , wherein the step of forming a top edge comprises: 
 (a) providing a tamper-evident structure over the zipper closure to indicate whether access has been gained to the zipper closure.    
     
     
         12 . The method according to  claim 11 , wherein the step of providing a tamper-evident structure over the zipper closure to indicate whether access has been gained to the zipper closure comprises: 
 (a) providing a tamper-evident structure comprising a perforation.    
     
     
         13 . The method according to  claim 1 , wherein the step of joining a first side edge and a second side edge of the film web to form a casement is done before the step of attaching the second mating profile to a second portion of the film web.  
     
     
         14 . A method of making and filling a reclosable package comprising a zipper closure construction, the reclosable package having a width and the zipper closure extending the width of the package, the method comprising: 
 (a) providing a zipper closure segment having: 
 (i) a first mating profile and a second mating profile;  
 (ii) a length approximately equal to the package width, the length defined by a first end and a second end;  
 (iii) the first mating profile being sealed to the second mating profile at the first end and at the second end at first and second end seals, respectively;  
   (b) attaching the first mating profile of the zipper closure segment to a first portion of a film web;    (c) after the step of attaching the first mating profile to a first portion of a film web, joining first and second edges of the film web approximately perpendicular to the zipper closure segment to form a casement;    (d) attaching the second mating profile of the zipper closure segment to a second portion of the film web;    (e) forming a top edge to provide an interior defined by the casement and the bottom edge; the top edge comprising a tamper-evident structure encasing the zipper closure;    (f) filling the package interior; and    (g) forming a bottom edge.    
     
     
         15 . The method according to  claim 14  wherein the step of providing a zipper closure segment having a length approximately equal to the package width, the length defined by a first end and a second end, comprises: 
 (a) cutting an extended length of zipper closure to a length approximately equal to the package width to provide a zipper closure segment.  
 
     
     
         16 . A reclosable package made according to  claim 14 .  
     
     
         17 . The reclosable package according to  claim 16 , the package comprising: 
 (a) first and second side panel sections, the first and second side panel sections having first and second side edges and a bottom edge, the side edges and bottom edge defining an interior;    (b) a zipper closure sealed to the first and second side panel sections along a top edge of the side panel sections; and    (c) a tamper-evident structure encasing the zipper closure.    
     
     
         18 . The reclosable package according to  claim 17 , further comprising an internal tamper-evident structure extending between the first and second side panel sections and positioned between the zipper closure and the package interior.