Methods of making a gusset style pouch in a reclosable bag

Abstract

A method for making a reclosable bag ( 56 ) with gussets ( 36, 38 ) in which a zipper profile ( 16 ) is attached to bag-making film ( 10 ), while leaving side margins ( 20, 22 ) of the film. The film ( 10 ) is folded as a tube ( 26 ). Gusset-forming wheels ( 34, 35 ) indent the tube ( 26 ) to form the side gussets ( 36, 38 ). The side gussets ( 36, 38 ) are sealed to the tube ( 26 ) and/or the zipper profile ( 18 ) with the profile sealed to the tube. The tube ( 26 ) is sealed and cross-cut to form the bag ( 56 ). In an alternative method, lengths of tubular gusset material ( 112 ) are positioned on a lower web ( 110 ) of film ( 101 ) transverse to a bag-forming direction. A zipper ( 124 ) is sealed in the bag-forming direction to the webs ( 108, 110 ), and the gusset material ( 112 ). The webs ( 108, 110 ) and the material ( 112 ) are sealed to each other to form an end seal ( 140 ) as well as cross-cut and sealed to form the gussets ( 144, 148 ) of a reclosable bag ( 147 ). The webs ( 108, 110 ) may be sealed above the zipper ( 124 ) to form a tamper-evident feature ( 166 ).

1 - 11 . (canceled)  
   
   
       12 . A reclosable plastic bag formed from a bag-making film and having a front wall and a rear wall, a first end and a second end and opposed sides; at least one side gusset in each said side; and a zipper having first and second interlockable profiles Joined by their interlocking elements extending across said bag between opposed sides, said first profile sealed to the front wall and said second profile sealed to a face of said at least one side gusset with the remaining portion of said second profile and an opposite face of said at least one side gusset sealed to the rear wall of said reclosable plastic bag.  
   
   
       13 . The reclosable bag in accordance with  claim 12 , wherein said zipper is sealed to at least one side gusset on a bag interior side of the interlocking elements of said zipper.  
   
   
       14 . The reclosable bag in accordance with  claim 13 , wherein said zipper further includes a slider for opening and closing said zipper.  
   
   
       15 . The reclosable bag in accordance with  claim 14 , wherein said reclosable bag further includes a consumer product; and wherein the front and rear walls of bag-making film are sealed to each other at said first end adjacent said zipper with said bag-making film forming a tamper-evident section encompassing said zipper.  
   
   
       16 . The reclosable bag in accordance with  claim 15 , wherein said tamper-evident section further includes a weakness area to assist in the removal of said section.  
   
   
       17 . The reclosable bag in accordance with  claim 16 , wherein a bottom gusset forms the second end of said reclosable bag.  
   
   
       18 . A reclosable plastic bag formed from a bag-making film and having a front wall and a rear wall, a first end and a second end and opposed sides; at least one side gusset in each said side; and a zipper having first and second interlockable profiles joined by their interlocking elements extending across said bag between opposed sides, a flange of said first profile sealed to the front wall and a face of said at least one side gusset and a flange of said second profile sealed to an opposite face of said at least one side gusset and to the rear wall of said reclosable plastic bag.  
   
   
       19 . An apparatus for making a reclosable gusseted bag comprising: a first sealing section for sealing the first profile of a length of zipper having first and second interlockable profiles joined by their interlocking elements to a length of bag-making film having opposite longitudinal edges; a tube for folding said film so as to bring said longitudinal edges into an adjacent relationship to form a fin with side margins between said fin and the ends of said zipper; a second sealing section for forming a seal at said fin; at least one retractable wedge for indenting said sealed side margins toward said zipper ends to form at least one side gusset, a base of said at least one side gusset bordering a rear wall of said tube; a third sealing section for sealing the second profile of said zipper to a face of said at least one side gusset and to a surface of said rear wall facing the interior of said tube and for sealing an opposite face of said at least one side gusset in alignment with said zipper to said surface of said rear wall; a fourth sealing section for sealing across said tube at spaced intervals to form a first end seal of said reclosable bag; and a first cutter for cutting across said tube at spaced intervals to separate said tube as said reclosable bag.  
   
   
       20 . The apparatus in accordance with  claim 19  further including a consumer product feeder for filling said reclosable bag.  
   
   
       21 . The apparatus in accordance with  claim 20  wherein said apparatus further comprises a fifth sealing section for sealing on an opposite side of the zipper from said first end seal to form a second end seal as the top of said reclosable bag and a second cutter for forming a weakness area in said film between said second end seal and said at least one side gusset.  
   
   
       22 . The apparatus in accordance with  claim 19  wherein said retractable wedge is a rotating wheel in which the circumference of the wheel indents said side margins.  
   
   
       23 . An apparatus for making a reclosable gusseted bag comprising: a first sealing section for sealing a section of a face of a first tubular length of gusset material and for sealing a section of a face of a second tubular length of gusset material at a bag width interval from said first length of gusset material to a lower web of bag-making film transverse to a bag-forming direction; a second sealing section for sealing a length of zipper in said bag-forming direction to an opposite face of each of said lengths of gusset material in alignment with the sections of the faces of said first and second lengths of gusset material and for sealing said length of zipper to said lower web and an upper web of bag-making film; a third sealing section for sealing said upper and lower webs together and to said lengths of gusset material to form a first end seal of said reclosable bag; a cutter for cutting said length of zipper, said lengths of gusset material and said webs transverse to said bag-forming direction at said bag-width interval and a fourth sealing section for sealing said face of said lengths of gusset material at the transverse cut of each to said lower web and for sealing said opposite face of said lengths of gusset material at the transverse cut of each to said upper web.  
   
   
       24 . An apparatus for making a reclosable gusseted bag comprising: a first sealing section for sealing a section of a face of a first tubular length of gusset material and for sealing a section of a face of a second tubular length of gusset material at a bag width interval from said first length of gusset material to a lower web of bag-making film transverse to a bag-forming direction; a second sealing section for sealing a length of zipper in said bag-forming direction to an opposite face of each of said lengths of gusset material in alignment with the sections of the faces of said first and second lengths of gusset material and for sealing said length of zipper to said lower web; a third sealing section for sealing said upper and lower webs together and to said lengths of gusset material to form a first end seal of said reclosable bag; a cutter for cutting said length of zipper, said lengths of gusset material and said webs transverse to said bag-forming direction at said bag width interval; and a fourth sealing section for sealing said face of said lengths of gusset material at the transverse cut of each to said lower web and for sealing said opposite face of said lengths of gusset material at the transverse cut of each to said upper web; and a fifth sealing station for sealing said length of zipper to said upper web.  
   
   
       25 . The apparatus in accordance with  claim 24  wherein said apparatus further comprises a consumer product filling station for filling said reclosable bag.  
   
   
       26 . The apparatus in accordance with  claim 25 , wherein said fifth sealing section seals said upper and lower webs together to form a second end seal on an opposite side of said zipper from said gusset material; and wherein said apparatus further comprises a second cutter for forming a weakness area in said upper and lower webs between said second end seal and said gusset material.  
   
   
       27 . The apparatus in accordance with  claim 24  wherein said apparatus further comprises a second cutter for slitting an end of each of said tubular length of gusset material; and wherein said third sealing section seals a semi-elliptical length of gusset material between said upper and lower webs and in the slit area of said tubular lengths of gusset material.  
   
   
       28 . The apparatus in accordance with  claim 24  wherein said apparatus further includes a wedge for separating a first flange from a second flange of said zipper; and wherein said second sealing section seals the first flange to said lower web and to said section of face of each of the first and second lengths of gusset material; and wherein said fifth sealing section seals the second flange to the upper web and an opposite face of each of the first and second lengths of tubular material.