Reclosable pouches or bags having front panel containment zipper

Abstract

Flexible containers that are hermetically resealable after initial opening. The resealable containers are of a type that comprises front and rear panels forming an interior volume that is accessible by means of a resealable plastic zipper attached to the front panel only. Each zipper comprises a pair of extruded plastic zipper strips. The zipper strips are flattened and joined to each other at the ends and are further joined to each other, without substantial deformation of the closure profiles, in respective transition areas substantially contiguous with the flattened ends. These transition areas of zipper strip joinder assist in providing a leakproof transition from the openable section of the zipper to where the closure profiles have been fused and flattened (i.e., crushed).

1 . A reclosable package comprising: 
 a zipper comprising first and second zipper strips that have respective portions fused together in first and second zipper end seals, said first zipper strip comprising a length of a first closure profile having at least two projecting elements and first and second flanges extending in opposite directions and connected to said first closure profile, respective portions of said first and second flanges being flattened within the boundaries of said first and second zipper end seals, and said second zipper strip comprising a length of a second closure profile having at least one projecting element that fits between said at least two projecting elements of said first closure profile and a third flange connected to said second closure profile, respective portions of said third flange being flattened within the boundaries of said first and second zipper end seals, said first and second zipper end seals respectively comprising first and second substantially flat portions and first and second transition areas respectively connected to said first and second substantially flat portions on first, second and third sides, wherein along said first and third sides of each of said first and second transition areas, each of the two projecting elements of said first and second closure profiles that are furthest apart from each other is fused to some portion of the one of said first and second zipper strips of which said respective one of said furthest-apart projecting elements does not form a part; and wherein along a second side of and within each of said first and second transition areas, said first and second closure profiles are deformed and fused together but not flattened, the respective ends of the fused material along said second side being integrally connected to the fused material of said first and third sides, respectively, said third flange being longer than said first flange and extending beyond said first and second zipper end seals in an elevational direction; and    a receptacle comprising top and bottom seals, a first panel connected to and extending between said top and bottom seals, and a second panel connected to and extending between said top and bottom seals, said first and second panels bounding an interior volume of said receptacle,    wherein each of said first through third flanges is joined to said first panel and not joined to said second panel.    
   
   
       2 . The reclosable package as recited in  claim 1 , wherein said first and second closure profiles have a contact area in the range of 33 to 76%.  
   
   
       3 . The reclosable package as recited in  claim 1 , wherein each of said first and second closure profiles comprises two hooked projecting elements and a hookless projecting element.  
   
   
       4 . The reclosable package as recited in  claim 1 , further comprising a peel seal joined to said first and third flanges along their length.  
   
   
       5 . The reclosable package as recited in  claim 1 , further comprising a line of weakness formed in a portion of said first panel that connects the respective portions of said first panel that are joined to said first and third flanges.  
   
   
       6 . The reclosable package as recited in  claim 5 , further comprising a racetrack-shaped zone in which said first panel is joined to said first and third flanges by means of sealant material having a melting point lower than the melting point of the zipper material.  
   
   
       7 . The reclosable package as recited in  claim 6 , wherein each of said first and second zipper end seals extends from an elevation lower than said first and second closure profiles to an elevation higher than a top edge of said first flange, and overlaps a respective portion of said racetrack-shaped zone of joinder.  
   
   
       8 . The reclosable package as recited in  claim 1 , further comprising food product inside said receptacle.  
   
   
       9 . The reclosable package as recited in  claim 1 , further comprising liquid inside said receptacle.  
   
   
       10 . The reclosable package as recited in  claim 1 , further comprising pressurized gas inside said receptacle.  
   
   
       11 . The reclosable package as recited in  claim 1 , further comprising a vacuum inside said receptacle.  
   
   
       12 . A reclosable package comprising: 
 a zipper comprising first and second zipper strips that have respective portions fused together in first and second zipper end seals, said first zipper strip comprising a length of a first closure profile and first and second flanges extending in opposite directions and connected to said first closure profile, respective portions of said first and second flanges being flattened within the boundaries of said first and second zipper end seals, and said second zipper strip comprising a length of a second closure profile interlockable with said first closure profile and a third flange connected to said second closure profile, respective portions of said third flange being flattened within the boundaries of said first and second zipper end seals, said first and second zipper end seals respectively comprising first and second transition areas disposed at opposite ends of said first and second closure profiles, and first and second substantially flat portions that respectively border said first and second transition areas on three sides thereof, said first transition area comprising first sections of said first and second closure profiles that have been deformed and at least partially fused together but not flattened, and said second transition area comprising second sections of said first and second closure profiles that have been deformed and at least partially fused together but not flattened, said third flange being longer than said first flange and extending beyond said first and second zipper end seals in an elevational direction; and    a receptacle comprising top and bottom seals, a first panel connected to and extending between said top and bottom seals, and a second panel connected to and extending between said top and bottom seals, said first and second panels bounding an interior volume of said receptacle,    wherein each of said first through third flanges is joined to said first panel and not joined to said second panel.    
   
   
       13 . The reclosable package as recited in  claim 12 , wherein said first and second closure profiles have a contact area in the range of 33 to 76%.  
   
   
       14 . The reclosable package as recited in  claim 12 , further comprising a peel seal joined to said first and third flanges along their length.  
   
   
       15 . The reclosable package as recited in  claim 12 , further comprising a line of weakness formed in a portion of said first panel that connects the respective portions of said first panel that are joined to said first and third flanges.  
   
   
       16 . The reclosable package as recited in  claim 15 , further comprising a racetrack-shaped zone in which said first panel is joined to said first and third flanges by means of sealant material having a melting point lower than the melting point of the zipper material.  
   
   
       17 . The reclosable package as recited in  claim 16 , wherein each of said first and second zipper end seals extends from an elevation lower than said first and second closure profiles to an elevation higher than a top edge of said first flange, and overlaps a respective portion of said racetrack-shaped zone of joinder.  
   
   
       18 . A reclosable package comprising: 
 a zipper comprising first and second zipper strips that have respective portions fused together in first and second zipper end seals, said first zipper strip comprising a length of a first closure profile and first and second flanges extending in opposite directions and connected to said first closure profile, respective portions of said first and second flanges being flattened within the boundaries of said first and second zipper end seals, and said second zipper strip comprising a length of a second closure profile interlockable with said first closure profile and a third flange connected to said second closure profile, respective portions of said third flange being flattened within the boundaries of said first and second zipper end seals, said first and second zipper end seals respectively comprising first and second transition areas disposed and connected to opposite ends of said first and second closure profiles, and first and second substantially flat portions that respectively border said first and second transition areas on three sides thereof, said first transition area comprising first sections of said first and second closure profiles that have been deformed and at least partially fused together but not flattened, and said second transition area comprising second sections of said first and second closure profiles that have been deformed and at least partially fused together but not flattened, wherein third and fourth sections of said first and second closure profiles that are respectively adjacent said first and second sections form channels therebetween, said channels within said third section being either sealed at one end thereof by said first transition area or communicating with channels formed by said first section that are sealed except where they communicate with said channels formed by said third section, and said channels within said fourth section being either sealed at one end thereof by said second transition area or communicating with channels formed by said second section that are sealed except where they communicate with said channels formed by said fourth section, said third flange being longer than said first flange and extending beyond said first and second zipper end seals in an elevational direction; and    a receptacle comprising top and bottom seals, a first panel connected to and extending between said top and bottom seals, and a second panel connected to and extending between said top and bottom seals, said first and second panels bounding an interior volume of said receptacle,    wherein each of said first through third flanges is joined to said first panel and not joined to said second panel.    
   
   
       19 . A method of manufacture comprising the following steps: 
 (a) interlocking first and second zipper strips of a plastic zipper tape, said first zipper strip comprising a first closure profile and first and second flange extending from said first closure profile in opposite directions, said second zipper strip comprising a second closure profile and a third flange extending further from said second closure profile than said first flange extends from said first closure profile, said first and second closure profiles in combination comprising at least three projecting elements;    (b) applying heat and pressure or ultrasonic vibrations and pressure in first and second zones of said interlocked zipper strips, each of said first and second zones extending from an elevation lower than said first and second closure profiles to an elevation higher than a top edge of said first flange, and having a predetermined dimension in first and second areas of overlap with said interlocked first and second closure profiles, whereby said first and second closure profiles are flattened in first and second sections having a length equal to said predetermined dimension, the midpoints of said first and second sections being separated by one zipper length, said first and third flanges are flattened at least in respective areas directly above said first and second sections of said first and second closure profiles, and said second flange is flattened at least in respective areas directly below said first and second sections of said first and second closure profiles;    (c) before step (b) is performed, applying heat and pressure or ultrasonic vibrations and pressure in first and second transition regions having intermediate portions that will be respectively overlapped by said first and second zones in step (b), heat and pressure or ultrasonic vibrations and pressure being applied to an extent that upon completion of step (c), the projecting elements of said first and second closure profiles that are furthest apart from each other will become fused to respective portions of the other zipper strip in said first and second transition regions, and said first and second closure profiles will be heated but not flattened in said first and second transition regions,    wherein upon completion of steps (b) and (c), said unflattened portions of said first and second closure profiles in said first transition region form first and second transition areas on opposite sides of a first flattened section of said first and second closure profiles, and said unflattened portions of said first and second closure profiles in said second transition region form third and fourth transition areas on opposite sides of a second flattened section of said first and second closure profiles;    (d) after step (b) has been performed, applying pressure in said first and second transition regions to an extent that surface irregularities formed on said first through third flanges during step (b) are flattened without flattening said first through fourth transition areas; and    (e) cutting said first and second zipper strips along first and second lines that respectively intersect said first and second zones to create an individual zipper.    
   
   
       20 . The method as recited in  claim 19 , further comprising the following step: 
 (f) attaching said individual to a web of packaging material in a transverse direction,    wherein steps (a) through (f) are repeated to form a zipper-carrying web having a multiplicity of zippers attached thereto, said zippers being spaced apart at regular intervals along the length of said web.    
   
   
       21 . The method as recited in  claim 20 , further comprising the steps of forming, filling and sealing said zipper-carrying web on a form-fill-seal machine to make filled packages.