Method for manufacturing a sealable bag having an integrated timer/sensor for use in vacuum packaging

Abstract

A method for manufacturing a bag for use in vacuum packaging comprises forming a first panel having an embedded timer and/or sensor for communicating information to a user and a second panel. Each panel comprises a gas-impermeable base layer and a heat-sealable inner layer molded from melt-extruded resin. The timer and/or can be encapsulated in the resin, or alternatively impregnated into the resin. The first panel is overlapped with the second panel, and three of four edges of the panels are heated such that the inner layers bond at the heated edges. This description is not intended to be a complete description of, or limit the scope of, the invention. Other features, aspects, and objects of the invention can be obtained from a review of the specification, the figures, and the claims.

1 . A method for forming a panel for use in a sealable bag; comprising: 
 flowing a material onto a backing film, such that the flowing material is molded to form a structure;    wherein at least one of a timer and a sensor is formed in the structure;    cooling the flowing material such that the flowing material solidifies to form an inner layer having the structure; and    wherein the inner layer adheres to the backing film.    
   
   
       2 . A method for forming a bag adapted to receive an article, the bag being partially formed between a laminating roll and a cooling roll having at least one cavity for positioning an implant including at least one of a timer and a sensor, comprising: 
 positioning the implant in the at least one cavity of the cooling roll;    feeding a gas-impermeable film to a nip formed by the cooling roll and the laminating roll;    extruding resin such that the resin fills the nip and the at least one cavity exposed to the nip;    pressing the resin between the cooling roll and the laminating roll;    cooling the resin such that the resin forms a structure and adheres to the gas-impermeable film, forming a panel;    wherein the structure includes the implant;    folding the panel such that a first portion of the panel overlaps a second portion of the panel; and    applying heat to a portion of a periphery of the first and second portions such that an envelope is formed.    
   
   
       3 . A method for manufacturing a bag adapted to receive an article, comprising: 
 positioning an implant including at least one of a timer and a sensor in at least one cavity of a first cooling roll;    feeding a first gas-impermeable film to a first nip formed by the first cooling roll and a first laminating roll;    extruding resin such that the resin fills the first nip and the at least one cavity exposed to the first nip;    pressing the resin between the first cooling roll and the first laminating roll;    cooling the resin such that a first inner layer having the implant is formed;    wherein the first inner layer adheres to the first gas-impermeable film, thereby forming a first panel;    feeding a second gas-impermeable film to a second nip formed by a second cooling roll and a second laminating roll;    extruding resin such that the resin fills the second nip and the plurality of cavities exposed to the second nip;    pressing the resin between the second cooling roll and the second laminating roll;    cooling the resin such that a second inner layer having the second structure is formed;    wherein the second inner layer adheres to the first gas-impermeable film, thereby forming a second panel;    overlapping the first panel with the second panel; and    applying heat to a first, second, and third side of the first and second panels.    
   
   
       4 . A method for manufacturing a bag adapted to receive an article, comprising: 
 rotating a first cooling roll at a first rate, the first cooling roll including at least one cavity for forming a structure;    positioning an implant including at least one of a timer and a sensor in the at least one cavity;    rotating a first laminating roll at a second rate;    introducing a first film to a first nip between the first cooling roll and the first laminating roll;    extruding molten material to the first nip;    pressing the molten material between the first cooling roll and the first film such that the molten material fills the at least one cavity exposed to the first nip;    cooling the molten material such that a first inner layer is formed;    wherein the first inner layer includes the structure, the structure including the implant;    wherein the first inner layer adheres to the first film, thereby forming a first panel;    rotating a second cooling roll at a third rate;    rotating a second laminating roll at a fourth rate;    introducing a second film to a second nip between the second cooling roll and the second laminating roll;    extruding molten material to the second nip;    pressing the molten material between the second cooling roll and the second film;    cooling the molten material such that a second inner layer is formed;    wherein the second inner layer adheres to the second film, thereby forming a second panel;    overlapping the first panel with the second panel; and    applying heat to a portion of a periphery of the first and second panels such that the first panel and the second panel form an envelope.    
   
   
       5 . The method of  claim 4 , wherein the second rate is an integer multiple of the first rate and the fourth rate is an integer multiple of the third rate.  
   
   
       6 . The method of  claim 4 , wherein the first film and the second film comprise at least one layer.  
   
   
       7 . The method of  claim 6 , wherein the at least one layer comprises a gas-impermeable material.  
   
   
       8 . The method of  claim 7 , wherein the gas-impermeable material is one of polyester, polyamide, ethylene vinyl alcohol, and nylon.  
   
   
       9 . The method of  claim 4 , wherein the molten material is polyethylene.  
   
   
       10 . The method of  claim 4 , wherein a thickness of the first inner layer is determined by the size of the first nip and the thickness of the second inner layer is determined by the size of the second nip.  
   
   
       11 . The method of  claim 4 , wherein the implant includes at least one timer.  
   
   
       12 . The method of  claim 11 , wherein the at least one timer is an active radio frequency identification tag.  
   
   
       13 . The method of  claim 4 , wherein the implant includes at least one sensor.  
   
   
       14 . The method of  claim 13 , wherein the at least one sensor is a temperature sensor.  
   
   
       15 . The method of  claim 13 , wherein the at least one sensor is a temperature sensor.  
   
   
       16 . The method of  claim 4 , wherein the first inner layer includes UV activated chemicals.  
   
   
       17 . The method of  claim 16 , wherein the UV activated chemical is one or both of silver chloride and silver halide.  
   
   
       18 . The method of  claim 4 , wherein the first inner layer includes at least one chemical for preserving the article.  
   
   
       19 . The bag of  claim 18 , wherein the chemical is potassium permanganate.  
   
   
       20 . A method of manufacturing a bag adapted to receive an article, comprising: 
 rotating a first roller having one or both of a plurality of recesses that can define at least one structure;    positioning an implant including at least one of a timer and a sensor in the plurality of recesses;    rotating a second roller adjacent to the first roller, said second roller can feed a first film adjacent to the first roller;    applying a molten material between the first roller and the first film;    said molten material filling the plurality of recesses of the first roller and said molten material and film moving between the first roller and the second roller forming a first panel with the structure having the implant;    forming a second panel; and    mating the first panel to the second panel in order to form a bag.    
   
   
       21 . The method of  claim 20  further comprising: 
 using a gas impermeable material for the film; and    using a heat sealable material for the molten material.    
   
   
       22 . The method of  claim 20 , wherein said second panel is formed with the first roller and the second roller.  
   
   
       23 . The method of  claim 20 , wherein said second panel is formed with the first roller and the second roller, and the mating step includes folding the first panel over the second panel.  
   
   
       24 . The method of  claim 20 , wherein the implant includes at least one timer.  
   
   
       25 . The method of  claim 24 , wherein the at least one timer is an active radio frequency identification tag.  
   
   
       26 . The method of  claim 20 , wherein the implant includes at least one sensor.  
   
   
       27 . The method of  claim 26 , wherein the at least one sensor is a temperature sensor.  
   
   
       28 . The method of  claim 26 , wherein the at least one sensor is a temperature sensor.  
   
   
       29 . The method of  claim 20 , wherein the first inner layer includes UV activated chemicals.  
   
   
       30 . The method of  claim 29 , wherein the UV activated chemical is one or both of silver chloride and silver halide.  
   
   
       31 . The method of  claim 20 , wherein the first inner layer includes at least one chemical for preserving the article.  
   
   
       32 . The bag of  claim 31 , wherein the chemical is potassium permanganate.  
   
   
       33 . A method for manufacturing a bag adapted to receive an article, comprising: 
 feeding a first gas-impermeable film to a first nip formed by a first cooling roll and a first laminating roll, the first cooling roll having a plurality of cavities and protuberances for forming a first structure and a second structure;    wherein the first structure is one of a receiving feature and an insertion feature;    wherein the second structure is a valve;    extruding resin such that the resin fills the first nip and the plurality of cavities exposed to the first nip;    pressing the resin between the first cooling roll and the first laminating roll;    cooling the resin such that a first inner layer having the first structure and the second structure is formed;    wherein the first inner layer adheres to the first gas-impermeable film, thereby forming a first panel;    feeding a second gas-impermeable film to a second nip formed by a second cooling roll and a second laminating roll, the second cooling roll having a plurality of cavities and protuberances for forming a third structure;    wherein the third structure is the other of the receiving feature and the insertion feature;    extruding resin such that the resin fills the second nip and the plurality of cavities exposed to the second nip;    pressing the resin between the second cooling roll and the second laminating roll;    cooling the resin such that a second inner layer having the third structure is formed;    wherein the second inner layer adheres to the first gas-impermeable film, thereby forming a second panel;    overlapping the first panel with the second panel; and    applying heat to a first, second, and third side of the first and second panels.