Form fill seal packaging method and apparatus for compressible goods

Abstract

The disclosure relates to a method and apparatus for compressing woven material or other compressible material, such as, but not limited to, a comforter set or bedding set. The bedding set or other woven material is placed into a reclosable storage bag through the open bottom thereof. The bag is compressed by a compression apparatus and the open bottom of the storage bag is sealed shut. The result is a package with reduced volume, which reduces shipping and display costs, and is more aesthetically attractive to the consumer.

1 . A method, including the steps of:
 providing a package with a first end and a second end, including a closure at the first end and an opening at the second end;   placing compressible material within the package through the opening;   compressing the package thereby expelling a portion of air from the package; and   sealing the opening.   
     
     
         2 . The method of  claim 1 , wherein the closure is a reclosable zipper. 
     
     
         3 . The method of  claim 2  wherein the compressible material includes woven material. 
     
     
         4 . The method of  claim 1  wherein the compressible material includes textile or cloth. 
     
     
         5 . The method of  claim 4  wherein the step of compressing the package is performed in the absence of a vacuum being applied to the package. 
     
     
         6 . The method of  claim 4  wherein the step of compressing the package is performed with vacuum being applied to the package. 
     
     
         7 . The method of  claim 5  wherein the step of compressing is performed with at least 2.5 pounds per square inch of force applied to the package. 
     
     
         8 . The method of  claim 5  wherein the step of compressing is performed with at least 3.5 pounds per square inch of force applied to the package. 
     
     
         9 . The method of  claim 5  wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak-resistant seal. 
     
     
         10 . The method of  claim 9  wherein a peel seal is provided adjacent to the reclosable zipper. 
     
     
         11 . The method of  claim 1  wherein the step of providing a package includes the step of providing a series of packages. 
     
     
         12 . The method of  claim 11  wherein the step of providing a series of packages includes the step of providing a stack of packages include apertures through which at least one pin passes. 
     
     
         13 . The method of  claim 12  wherein the step of providing a stack of packages includes provided a wicketed stack of packages. 
     
     
         14 . The method of  claim 11  wherein the step of providing a series of packages includes the step of providing a sequential chain of packages, wherein packages are attached to adjacent packages. 
     
     
         15 . The method of  claim 14  wherein the sequential chain of packages is provided in a stack. 
     
     
         16 . The method of  claim 11  including the step of providing the packages in an inverted vertical configuration. 
     
     
         17 . The method of  claim 16  wherein the step of placing compressible material within the package through the opening is performed vertically. 
     
     
         18 . The method of  claim 11  including the step of providing the packages a horizontal configuration. 
     
     
         19 . The method of  claim 18  wherein the step of placing compressible material within the package through the opening is performed horizontally. 
     
     
         20 . The method of  claim 1  further including the step of extruding first and second zipper profiles onto a single sheet of web and folding the web align the first and second zipper profiles with each other and to form walls of the package. 
     
     
         21 . The method of  claim 1  wherein the packages and the compressible material are provided horizontally in a first direction, and wherein the step of placing compressible material within the package through the opening is performed horizontally in a second direction, perpendicular to the first direction. 
     
     
         22 . The method of  claim 21  further including a preliminary compression step prior to the step of placing compressible material within the package through the opening. 
     
     
         23 . The method of  claim 21  wherein the preliminary compression step is performed by a funnel shaped apparatus. 
     
     
         24 . A packaging of compressible material, comprising:
 a package including front and rear walls, a mouth with a reclosable zipper; and a sealed bottom;   compressible material contained within the package, the compressible material being in a compressed state resulting from a compressive force of at least 2.5 pounds per square inch, and the package being at least partially evacuated of air, the compressible material having been inserted into the package prior to sealing of the bottom;   wherein the packaging is sold in a retail establishment.   
     
     
         25 . The packaging of  claim 24  wherein the compressible material includes woven material. 
     
     
         26 . The packaging of  claim 24  wherein the compressible material includes textile or cloth. 
     
     
         27 . The packaging of  claim 25  wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak resistant seal.