System and method for applying a fastening material to a substrate

Abstract

A system for applying a fastening material to a substrate is provided.SOLUTION: The system may include a first material source including a substrate. The substrate may define a first length extending from the first edge to the second edge, and the first material source may feed the substrate in a first direction transverse to the first length. The system may additionally comprise a second material source comprising a fastening material. The fastening material may define a second length extending from the third edge to the fourth edge, wherein the second length is substantially equal to the first length, and wherein the second material source dispenses the fastening material in a second direction transverse to the second length. The system may also include an applicator system for applying the fastening material to a substrate.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 330,390, filed May 2, 2016, the entirety of which is incorporated herein by reference.

[0002] Field FIELD OF THE DISCLOSURE The present disclosure relates generally to systems and methods for applying fastener material to substrates, and more particularly to systems and methods for applying reclosable fastener material to packaging substrates. [Background technology]

[0003] background This section provides background information that is relevant to the present disclosure, but is not necessarily prior art.

[0004] Packages and containers, such as bags and pouches, often utilize fastener systems located along one or more edges of the package to allow an end user to access the package. For example, various food packages often utilize reclosable fastener systems located along an edge of the package to allow an end user to access and reclose the package.

[0005] While such fastener systems adequately allow a user to access and reclose the package, applying such fastener systems to the package can be time-consuming and, as a result, costly. For example, systems and methods for applying conventional fastener systems to a substrate often require measuring an amount of fastener material equal to the length of the opening in the package. Furthermore, such fastener material typically also includes flanges located on either side of the working portion of the fastener system to allow machines to grip and dispense the fastener material into the desired location during package manufacturing. The added manufacturing steps and increased material required to form the flanges increase the processing time required to manufacture the package, thereby increasing the overall cost of the product. Summary of the Invention [Means for solving the problem]

[0006] overview This section provides a general overview of the disclosure, but is not an all-inclusive disclosure of its entire scope or all of its features.

[0007] In one configuration, a system for applying fastener material to a substrate is provided. The system may include a first material source including the substrate. The substrate may define a first length extending from a first edge to a second edge, and the first material source may supply the substrate in a first direction transverse to the first length. Additionally, the system may include a second material source including the fastener material. The fastener material may define a second length extending from a third edge to a fourth edge, the second length being substantially equal to the first length, and the second material source supplies the fastener material in the second direction transverse to the second length. The system may also include an applicator system having a cutting block and a sealing head. The cutting block may have a cutting mechanism defining a third length substantially equal to the first length, and the sealing head may define a fourth length substantially equal to the first length. The cutting block and sealing head may define a first length. The fastener material may be attached to the substrate such that the edge is aligned with the third edge and the second edge is aligned with the fourth edge.

[0008] In one configuration, the first material source includes a first axis of rotation and the second material source includes a second axis of rotation, the first length can extend in a direction substantially parallel to the first axis of rotation, and the second length can extend in a direction substantially parallel to the second axis of rotation.

[0009] The fastener material may define a width extending perpendicular to the second length, the width being less than or equal to the second length. Specifically, the width may be between 1% and 10% of the second length.

[0010] In one configuration, the fastener material includes a first portion of a self-engaging fastener portion. For example, the self-engaging fastener portion may include one of a hook-type fastener portion and a loop-type fastener portion.

[0011] The cutting block and seal head may attach the fastener material to the substrate using at least one of ultrasonic welding and adhesive.

[0012] A method of applying fastener material to a substrate is provided and may include feeding the substrate in a first direction, the substrate defining a first length extending perpendicular to the first direction from a first edge to a second edge. The method may additionally include feeding the fastener material in a second direction substantially parallel to the first direction, the fastener material defining a second length extending perpendicular to the second direction and substantially equal to the first length. A portion of the fastener material defining a length substantially equal to the first length may be removed. The portion of the fastener material may be attached to the substrate such that the portion extends from the first edge to the second edge.

[0013] In one configuration, feeding the substrate in a first direction may include rotating a first material source about a first axis of rotation, and feeding the fastener material in a second direction includes rotating a second material source about a second axis of rotation substantially parallel to the first axis.

[0014] Removing the portion of the fastener material may include cutting the fastener material with a cutting mechanism having a length that is greater than or equal to the first length of the substrate.

[0015] In one configuration, attaching the portion of fastener material to the substrate may include ultrasonically welding the fastener material to the substrate.

[0016] Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0017] drawing The drawings described herein illustrate only selected configurations, not all possible embodiments, and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a perspective view of a system for applying fastener material to a substrate in accordance with the principles of the present disclosure; [Figure 2] FIG. 2 is a top view of the system of FIG. 1. [Figure 3A] FIG. 2 is a side view of the system of FIG. 1 in a first operational stage. [Figure 3B] FIG. 2 is a side view of the system of FIG. 1 in a second operational stage. [Figure 3C] FIG. 2 is a side view of the system of FIG. 1 in a third operational stage. [Figure 3D] FIG. 2 is a side view of the system of FIG. 1 in a fourth operational stage. [Figure 4] FIG. 2 is a perspective view of a package formed by the system of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION

[0019] Corresponding reference characters indicate corresponding parts throughout the drawings. Detailed Description The exemplary configurations are more fully described with reference to the accompanying drawings. The exemplary configurations are provided so that the disclosure will be thorough and will fully convey the scope of the disclosure to those skilled in the art. The detailed description is set forth, including examples of specific components, devices, and methods, to provide a thorough understanding of the disclosed configurations. It will be apparent to those skilled in the art that the detailed description is not necessary, that the exemplary configurations can be embodied in any number of different forms, and that the detailed description and exemplary configurations do not limit the scope of the disclosure.

[0020] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles "a," "an," and "the" are intended to include the plural unless the context clearly dictates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and thus identify the presence of features, steps, operations, elements, and / or components, but do not exclude one or more other features, steps, operations, elements, components, and / or groups thereof. The steps, processes, and operations of methods described herein should not be construed as necessarily requiring performance in the particular order described or illustrated, unless specifically identified as such order of performance. Additional or alternative steps may be employed.

[0021] When an element or layer is referred to as "overlying," "engaging," "connected," "attached," or "coupled" to another element or layer, it may be directly overlying, engaging, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "directly overlying," "directly engaging," "directly connected," "directly attached," or "directly coupled" to another element or layer, no intervening elements or layers are present. Other terms used to describe relationships between elements (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.) should be interpreted similarly. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0022] Terms such as first, second, and third may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first," "second," and other numerical terms do not imply an order or sequence unless clearly indicated by context. Thus, a first element, component, region, layer, or section discussed below could also be referred to as a second element, component, region, layer, or section without departing from the teachings of the example configurations.

[0023] 1-3D, a package assembly system 10 is provided, which may include a first material source 12, a second material source 14, and an applicator system 16. As described in more detail below, package assembly system 10 may be configured to produce packages 18 (FIG. 4) from first material source 12 and second material source 14. For example, packages 18 may be used to store various items, such as food products. The package 18 may be a container, such as a plastic bag or pouch, used for storing and dispensing materials. In this regard, the package 18 may include an opening 20 extending along a width W1 of the package 18. In this regard, the width W1 may extend from a first sealed seam 22 to a second sealed seam 23 that extends opposite and / or substantially parallel to the first sealed seam 22. In some configurations, the package 18 may be a reclosable package such that an end user can selectively open and close the opening 20. For example, material from the second material source 14 may be applied along the width W1 of the package 18 proximate to the opening 20 such that the end user can open and reclose the opening 20 by engaging the material from the second material source 14 with at least one of the material from the first material source 12 and a material from a third material source (not shown). In some configurations, material from the second material source 12 may be combined with a mating material from a third material source to close and reclose the opening 20 .

[0024] The first material source 12 may include a first material 24 forming a polymeric substrate. For example, in some configurations, the first material 24 may include a polyolefin substrate. The first material 24 may define a length L1 extending from a first lateral edge 25 to a second lateral edge 27 opposite the first lateral edge 25. The length L1 may correspond to a width W1 of the package 18. For example, the length L1 of the first material 24 may be substantially equal to the width W1 of the package 18. In this regard, the first lateral edge 25 of the first material 24 may correspond to a first sealed seam 22 of the package 18, and the second lateral edge 27 of the first material 24 may correspond to a second sealed seam 23 of the package 18, such that the opening 20 of the package 18 extends in a direction corresponding to the length L1 of the first material 24.

[0025] The first material 24 may be disposed on or within the first material source 12 in a variety of configurations. For example, in some configurations, the first material source 12 may include a roll 26 of the first material 24. In this regard, the length L1 of the first material 24 may correspond to the length of the roll 26. In other configurations, the first material source 12 may include a stack, pile, or other suitable configuration of the first material 24, such that the length L1 of the first material 24 corresponds to the length of the configuration of the first material 24 within the first material source 12 (i.e., the stack of the first material 24 has the length L1).

[0026] As described, the first material source 12 may supply the first material 24 from the first material source 12 in a first feed direction FD1. As illustrated in FIG. 2, the first feed direction FD1 may be transverse to the length L1 of the first material 24. For example, the first feed direction FD1 may be substantially perpendicular (+ / - 5 degrees) to the length L1. As described above, in some configurations, the first material 24 may be disposed on a roll 26. Thus, the first material 24 may be supplied by rotating the roll 26 about a first axis of rotation A1 in the first feed direction FD1. As illustrated in FIG. 2, the first axis of rotation A1 may be generally parallel (+ / - 5 degrees) to the length L1 of the first material 24 and generally perpendicular (+ / - 5 degrees) to the first feed direction FD1.

[0027] The second material source 14 may include a second material 30. The second material 30 may include any of a variety of suitable fastener materials. In some configurations, the second material 30 may include self-engaging fastener portions 32 configured to mate with self-engaging fastener portions of the same type (not shown). While the second material 30 is shown and described herein as including hook-shaped self-engaging fastener portions 32 configured to mate with self-engaging fastener portions that are also hook-shaped, the second material 30 may include other types of self-engaging fastener portions within the scope of the present disclosure. For example, the second material 30 may include loop-shaped self-engaging fastener portions, mushroom-shaped self-engaging fastener portions, or the like. In this regard, in some configurations, the second material 30 may include any form of VELCRO® self-engaging fastener portion sold by Velcro® USA Inc.

[0028] The second material 30 may define a length L2 extending from a first lateral edge 31 to a second lateral edge 33 opposite the first lateral edge 31. The length L2 may correspond to the width W1 of the package 18. For example, the length L2 of the second material 30 may be substantially equal to the width W1 of the package 18. In this regard, the length L2 of the second material 30 may be substantially the same (+ / −10%) as the length L1 of the first material 24. The opening 20 of the package 18 may extend in a direction corresponding to the length L2 of the second material 30.

[0029] The second material 30 may be disposed on or within the second material source 14 in various configurations. For example, in some configurations, the second material source 14 may include a roll 34 of the second material 30. In this regard, the length L2 of the second material 30 may correspond to the length of the roll 34. Thus, the length of the roll 34 of the second material 30 may be substantially equal to the length of the roll 26 of the first material 24. In other configurations, the second material source 14 may include a stack, pile, or other suitable configuration of the second material 30 such that the length L2 of the second material 30 corresponds to the length of the configuration of the second material 30 within the second material source 14 (i.e., the stack of the second material 30 has the length L2).

[0030] As will be described, the second material source 14 may supply the second material 30 from the second material source 14 in a second feed direction FD2. As illustrated in FIG. 2, the second feed direction FD2 may be transverse to the length L2 of the second material 26. For example, the second feed direction FD2 may be substantially orthogonal (+ / - 5 degrees) to the length L2. In this regard, the second feed direction FD2 may be substantially parallel to the first feed direction FD1. As mentioned above, in some configurations, the second material 30 may be disposed on a roll 34. Thus, the second material 30 may be supplied in the second feed direction FD2 by rotating the roll 34 about a second axis of rotation A2. As illustrated in FIG. 2, the second axis of rotation A2 may be generally parallel (+ / - 5 degrees) to the length L2 of the second material 30 and generally orthogonal (+ / - 5 degrees) to the second feed direction FD2.

[0031] Applicator system 16 may include a cutting block 40, a sealing head 42, and a drive mechanism 44. As described in more detail below, applicator system 16 may be configured to remove portion 46 of second material 30 (FIGS. 3B-4) and apply portion 46 of second material 30 to first material 24.

[0032] The cutting block 40 may include a coupling mechanism 48 and a cutting mechanism 50. The coupling mechanism 48 may include any of a variety of mechanisms configured to engage and selectively attach the second material 30. For example, the attachment mechanism 48 may include an adhesive, a suction source, or mechanical fastener(s) that engage and attach the second material 30 to the cutting block 40. In some configurations, the coupling mechanism 48 may include self-engaging fastener portions (not shown) that engage the self-engaging fastener portions 32 of the second material 30.

[0033] The cutting mechanism 50 may include a blade 54 that selectively engages and cuts the second material 30. As shown in FIG. 2 , the blade 54 may define a length L3 extending from a proximal end 56 to a distal end 58. In this regard, the blade 54 may extend in a direction substantially perpendicular to the first and second lateral edges 25, 27 of the first material 24 and in a direction generally parallel to the opening 20 of the package 18. The length L3 may be greater than or equal to the length L1 of the first material 24 and the length L2 of the second material 30.

[0034] The seal head 42 may selectively engage the first material 24. As shown in FIG. 2 , the seal head 42 may define a length L4 extending from the proximal end 57 to the distal end 59. In this regard, the seal head 42 may extend in a direction substantially perpendicular to the first and second lateral edges 25, 27 of the first material 24 and in a direction generally parallel to the opening 20 of the package 18. The length L4 may be greater than or equal to the length L1 of the first material 24 and the length L2 of the second material 30.

[0035] 3A-3D , the drive mechanism 44 may include any of a variety of mechanisms for moving the cutting block 40 in the first direction D1 and / or the second direction D2. Additionally or alternatively, the drive mechanism 44 may move the sealing head 42 in the first direction D1 and / or the third direction D3. For example, the drive mechanism 44 may include a gear train, a belt drive system, or a hydraulic drive mechanism (not shown) for moving the cutting block 40 and / or the sealing head 42 in one or more of the first, second, and third directions D1, D2, D2. In particular, the drive mechanism 44 may move the cutting block 40 and / or the sealing head 42 toward the first material 24 and / or the second material 30. In this regard, the first direction D1 may be substantially parallel to the first and second feed directions FD1, FD2, and the second and third directions D2, D3 may be substantially perpendicular to the first and second feed directions FD1, FD2.

[0036] 3A-3D, a method of applying a second material 30 to a first material 24 will now be described. As illustrated in FIG. 3A, the method may include feeding the first material and / or the second material 24, 30 in first and second feed directions FD1, FD2, respectively. In this regard, a first operational stage may include rotating a first roll 26 about a first axis of rotation A1 and / or rotating a second roll 34 about a second axis of rotation A2.

[0037] 3B , the method may also include moving the cutting block 40 relative to the second material 30 and / or moving the sealing head 42 relative to the first material 30. For example, the method may include moving the cutting block 40 in a first direction and / or a second direction D1, D2 and / or moving the sealing head 42 in a first direction and / or a third direction D1, D3. In particular, the method may include moving the cutting block 40 in the second direction D2 such that the blade 54 engages and cuts the second material 30 and the coupling mechanism 48 engages and attaches the second material 30. In this regard, the coupling mechanism 48 may engage and attach a portion 46 of the second material 30. As illustrated in FIG. 2 , portion 46 may include a length L5 extending from a first lateral edge 60 to a second lateral edge 62 opposite the first lateral edge 60, and a width W2 extending from a proximal end 64 to a distal end 66 opposite the proximal end 64. With respect to package 18, width W2 may extend in a direction substantially perpendicular to the opening 20 of package 18 and substantially parallel to the first and second sealed seams 22, 23 of package 18. Length L5 may be substantially equal to length L1 of first material 24. In this regard, length L5 may be substantially equal to width W1 of opening 20 of package 18. Width W2 of portion 46 may be between 1% and 10% of length L5 of the portion. In some configurations, width W2 may be substantially equal to 5% of length L5.

[0038] 3C, the method may also include moving the cutting block 40 including the portion 46 of the second material 30 relative to the first material 24. For example, the method may include moving the cutting block 40 in a first direction and / or a second direction D1, D2, and may further include positioning the portion 46 of the second material 30 into engagement with the first material 24. In this regard, the method may include moving the portion 46 on a first side 70 of the first material 24. The method may include engaging the first material 24 with the sealing head 42 at a second side 72 of the first material 24, the first side 70 being opposite the second side 72. Thus, the first material 24 and the portion 46 of the second material 30 may be clamped by and disposed between the cutting block 40 and the sealing head 42.

[0039] The method may also include attaching the portion 46 of the second material 30 to the first material 24. For example, the method may include securing the portion 46 to the first material 24 using one or more of a variety of techniques. In some configurations, the method may include transmitting ultrasonic energy to one or both of the portion 46 and the first material 24 through one or both of the cutting block 40 and the sealing head 42 to ultrasonically weld the first material 24 to the portion 46. In other configurations, the method may include activating an adhesive by heating one or both of the portion 46 and the first material 24 through one or both of the cutting block 40 and the sealing head 42 to secure the first material 24 to the portion 46.

[0040] 3D , when attaching portion 46 to the first material, the method may include moving cutting block 40 relative to second material 30 and / or moving sealing head 42 relative to first material 30. For example, the method may include moving cutting block 40 in a direction opposite to first direction and / or second direction D1, D2 and / or moving sealing head 42 in a direction opposite to first direction and / or third direction D1, D3. In particular, the method may include moving cutting block 40 toward second material source 14 and / or moving sealing head 42 toward first material source 12.

[0041] 4 , the method may also include attaching a third material 76 to the first material 24. For example, the method may include attaching the third material 76 to the first material 24 along one or more of the first lateral edge 25, the second lateral edge 27, and the bottom edge 78 of the first material 24 to form the first sealed seam 22, the second sealed seam 23, and the third sealed seam 80, respectively, of the package 18. In this regard, the width W2 of the opening 20 of the package 18 and the portion 46 of the second material 30 may extend in a direction substantially parallel to the third sealed seam 80 and in a direction substantially perpendicular to the first sealed seam 22, the second sealed seam 23. Although not specifically shown, the third material 76 may similarly receive the portion of the fastener portion that mates with the second material 30. For example, if the second material 30 is a hook-type fastener portion, the loop-type fastener portion may be applied to the third material 76 to allow the loop-type fastener portion to engage the hook-type fastener portion so that a user can selectively reclose the opening 20 of the package 18. The loop-type fastener portion may be applied to the third material 76 using the process described above for attaching a hook-type fastener portion (i.e., the second material 30) to the first material 24. Although the first material 24 is described as a receiving hook-type fastener portion and the third material 76 is described as a receiving loop-type fastener portion, the first material 24 could alternatively be a receiving loop-type fastener portion and the third material 76 could be a receiving hook-type fastener portion.

[0042] By cutting second material 32 so that portion 46 has width W2 and length L5 extending in each direction and having the described ratios, the system 10 and method described herein can significantly reduce the time required to manufacture package 18. For example, by measuring width W2 of portion 46, which is equal to or less than length L5 and extends in a direction substantially parallel to first and second lateral edges 25, 27 of first material 24, system 10 and corresponding method can rapidly manufacture package 18. That is, for example, the present method and system can rapidly manufacture package 18 by cutting second material 32 from second material source 14 that is width W2 of portion 46. The system defines a marker or measurement length in direction FD2 of fastener material 30. In some approaches, this measurement length is about 0.25 to about 1 inch long, and in other approaches, about 0.25 to about 0.5 inch long. This contrasts with prior systems that require the overall length L2 of the fastener member to be measured transverse to the feed direction of the packaging substrate. In other approaches, systems and materials allow for fastener material 32 to be flangeless, i.e., not having any flanges (or other areas of non-fastener material, e.g., material without hook-and-loop type fastener portions), opposite fastener portion portion 46 cut here.

[0043] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration and, where applicable, may be interchangeable and used in selected configurations even if not specifically shown or described. The same may also be modified in various ways. These modifications should not be considered departures from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. 1. A system for applying fastener material to a substrate, the system comprising: a first material source including the substrate, the substrate defining a first length extending from a first edge to a second edge, the first material source configured to supply the substrate in a first direction transverse to the first length, the system further comprising: a second material source including the fastener material, the fastener material defining a second length extending from a third edge to a fourth edge, the second length being substantially equal to the first length, the second material source configured to supply the fastener material in a second direction transverse to the second length, the system further comprising:

1. An applicator system comprising: a cutting block and a sealing head, the cutting block having a cutting mechanism defining a third length substantially equal to the first length; the sealing head defining a fourth length substantially equal to the first length; and the cutting block and the sealing head configured to apply the fastener material to the substrate such that the first edge is aligned with the third edge and the second edge is aligned with the fourth edge.

2. 2. The system of claim 1, wherein the first material source includes a first axis of rotation, the second material source includes a second axis of rotation, the first length extends in a direction substantially parallel to the first axis of rotation, and the second length extends in a direction substantially parallel to the second axis of rotation.

3. The system of claim 1 , wherein the fastener material defines a width extending perpendicular to the second length, the width being less than or equal to the second length.

4. The system of claim 3 , wherein the width is between 1% and 10% of the second length.

5. The system of claim 1 , wherein the fastener material comprises a first portion of a self-engaging fastener portion.

6. The system of claim 5 , wherein the self-engaging fastener portion comprises one of a hook-type fastener portion and a loop-type fastener portion.

7. The system of claim 1 , wherein the cutting block and the seal head are configured to attach the fastener material to the substrate using at least one of ultrasonic welding and an adhesive.

8. 1. A method for applying fastener material to a substrate, the method comprising: The method includes providing the substrate in a first direction, the substrate defining a first length extending perpendicular to the first direction from a first edge to a second edge, the method further comprising: feeding the fastener material in a second direction substantially parallel to the first direction, the fastener material defining a second length extending perpendicular to the second direction, the second length being substantially equal to the first length, the method further comprising: removing a portion of the fastener material, the portion defining a length substantially equal to the first length, the method further comprising: attaching the portion of the fastener material to the substrate such that the portion extends from the first edge to the second edge.

9. Supplying the substrate in the first direction includes rotating a first material source about a first axis of rotation, and supplying the fastener material in the second direction includes rotating a second material source. The method of claim 8 , comprising rotating about a second axis of rotation, the second axis being substantially parallel to the first axis.

10. The method of claim 8 , wherein removing the portion of the fastener material includes severing the fastener material with a cutting mechanism, the cutting mechanism having a length greater than or equal to the first length of the substrate.

11. The method of claim 8 , wherein attaching the portion of the fastener material to the substrate comprises ultrasonically welding the fastener material to the substrate.

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