System and method for applying fastener material to a substrate

Abstract

A system for applying reclosable fastener material to a packaging substrate is provided. The system includes a first material source (12) comprising a substrate. The substrate defines a first length extending from a first edge to a second edge, and the first material source (12) supplies the substrate in a first direction transverse to the first length. The system additionally includes a second material source (14) comprising fastener material (30). The fastener material (30) defines 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 (14) supplies the fastener material (30) in a second direction transverse to the second length. The system also includes an applicator system (16) that applies the fastener material (30) to the substrate.

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 on May 2, 2016, which is hereby incorporated herein by reference in its entirety.

[0002] Field The present disclosure relates generally to systems and methods for applying fasteners to a substrate, and more particularly, to systems and methods for applying re - closable fasteners to a package substrate.

Background Art

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

[0004] Packages and containers such as bags and pouches often utilize a fastener system disposed along the edge of one or more packages to enable an end - user to access the package. For example, various food packages often utilize a re - closable fastener system disposed along the edge of the package to enable an end - user to access and re - close the package.

[0005] While such fastener systems allow users to properly access and re-close the package, their application to the package can be time-consuming and consequently 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 positioned on both sides of the working portion of the fastener system to allow a machine to grip and feed the fastener material into the desired position during the manufacturing of the package. The additional manufacturing steps and increased material required to form the flanges increase the processing time required to manufacture the package, and thus increase the overall cost of the product. [Overview of the project] [Means for solving the problem]

[0006] overview This chapter provides a general overview of the disclosure, but does not constitute a comprehensive disclosure of its entire scope or all of its characteristics.

[0007] In one configuration, a system is provided for applying fastener material to a substrate. The system may include a first material source containing 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 across the first length. Additionally, the system may include a second material source containing 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 supplying the fastener material in a second direction across 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 the sealing head are first The fastener material may be attached to the base material such that its edge is aligned with the third edge and its 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 may extend in a direction substantially parallel to the first axis of rotation, and the second length may extend in a direction substantially parallel to the second axis of rotation.

[0009] The fastener material may have a defined width extending perpendicular to the second length, and the width is 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 section. For example, the self-engaging fastener section may include one of a hook-type fastener section and a loop-type fastener section.

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

[0012] A method is provided for applying fastener material to a substrate, which may include supplying the substrate in a first direction, defining a first length extending perpendicular to the first direction from a first edge to a second edge. The method may further include supplying the fastener material in a second direction substantially parallel to the first direction, defining a second length extending perpendicular to the second direction and substantially equal to the first length. The portion of the fastener material defining the 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, supplying the substrate in a first direction may include rotating the first material source around a first axis of rotation, and supplying the fastener material in a second direction may include rotating the second material source around a second axis of rotation that is substantially parallel to the first axis.

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

[0015] In one configuration, attaching the fastener portion to the base material may include ultrasonic welding the fastener to the base material.

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

[0017] drawing The drawings described herein illustrate only selected configurations and do not represent all possible embodiments, nor are they intended to limit the scope of this disclosure. [Brief explanation of the drawing]

[0018] [Figure 1] This is a perspective view of a system for applying fastener material to a substrate, in accordance with the principles of this disclosure. [Figure 2] Figure 1 is a top view of the system. [Figure 3A] This is a side view of the system in Figure 1 during the first operational phase. [Figure 3B] This is a side view of the system in Figure 1 during the second operational phase. [Figure 3C] This is a side view of the system in Figure 1 during the third operational phase. [Figure 3D] This is a side view of the system in Figure 1 during the fourth operational stage. [Figure 4] Figure 1 is a perspective view of the package formed by the system.

Best Mode for Carrying Out the Invention

[0019] Corresponding reference numerals indicate corresponding parts throughout the drawings. Detailed Description Exemplary configurations are described more fully with reference to the accompanying drawings. The exemplary configurations are provided so that this disclosure will be sufficient and will convey the scope of this disclosure to those skilled in the art. The detailed description is set forth such as examples of particular components, devices, and methods to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that the detailed description is not essential to adopt, that the exemplary configurations can be implemented in any different forms, and that the detailed description and the exemplary configurations do not limit the scope of this disclosure.

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

[0021] When an element or layer is referred to as being "above", "engaging", "connected", "attached", or "coupled" to another element or layer, it may be directly above, 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 being "directly above", "directly engaging", "directly connected", "directly attached", or "directly coupled" to another element or layer, no intervening element or layer is present. Other terms used to describe relationships between elements (e.g., "between" versus "directly between", "adjacent" versus "directly adjacent", etc.) should be interpreted in a similar manner. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0022] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or portions. These elements, components, regions, layers, and / or portions should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or portion from another region, layer, or portion. The terms "first", "second", etc. and other numerical terms do not imply an ordering or sequence unless clearly indicated by the context. Thus, a first element, component, region, layer, or portion discussed below could be termed a second element, component, region, layer, or portion without departing from the teachings of the exemplary configuration.

[0023] Referring to Figures 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 will be described in more detail below, the package assembly system 10 may be configured to manufacture a package 18 (Figure 4) from the first material source 12 and the second material source 14. For example, the package 18 may be a container such as a plastic bag or pouch used to store various items, such as food. In this regard, the package 18 may include an opening 20 extending along the 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 to and / or substantially parallel to the first sealed seam 22. In some configurations, the package 18 may be a resealable package, such that an end user can selectively open and close the opening 20. For example, the material from the second material source 14 may be applied along the width W1 of the package 18, close to the opening 20, so that the end user can open and close 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 the material from the third material source (not shown). In some configurations, the second material source 14 is used to close and reclose the opening 20. 4 The material from one source may be combined with a mating material from a third material source.

[0024] The first material source 12 may include a first material 24 that forms a polymer substrate. For example, in some configurations, the first material 24 may include a polyolefin substrate. The first material 24 may have a defined length L1 extending from a first transverse edge 25 to a second transverse edge 27 opposite to the first transverse edge 25. The length L1 may correspond to the 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 transverse edge 25 of the first material 24 may correspond to a first sealed seam 22 of the package 18, and the second transverse 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 the direction corresponding to the length L1 of the first material 24.

[0025] The first material 24 may be placed on or inside the first material source 12 in various 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 a 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 supply direction FD1. As shown in Figure 2, the first supply direction FD1 may traverse the length L1 of the first material 24. For example, the first supply direction FD1 may be substantially perpendicular (+ / - 5 degrees) to the length L1. As described above, in some configurations, the first material 24 may be placed on a roll 26. Thus, the first material 24 may be supplied by rotating the roll 26 around a first rotation axis A1 in the first supply direction FD1. As shown in Figure 2, the first rotation axis A1 may generally be parallel (+ / - 5 degrees) to the length L1 of the first material 24 and generally perpendicular (+ / - 5 degrees) to the first supply direction FD1.

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

[0028] The second material 30 may have a defined length L2 extending from the first lateral edge 31 to the second lateral edge 33 opposite to 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 the direction corresponding to the length L2 of the second material 30.

[0029] The second material 30 may be arranged on or inside 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 a length L2).

[0030] As described, the second material source 14 may supply the second material 30 from the second material source 14 in a second supply direction FD2. As shown in Figure 2, the second supply direction FD2 may cross the length L2 of the second material 26. For example, the second supply direction FD2 may be substantially perpendicular (+ / - 5 degrees) to the length L2. In this regard, the second supply direction FD2 may be substantially parallel to the first supply direction FD1. As described above, in some configurations, the second material 30 may be placed on a roll 34. Thus, the second material 30 may be supplied in the second supply direction FD2 by rotating the roll 34 around a second rotation axis A2. As shown in Figure 2, the second rotation axis A2 may generally be parallel (+ / - 5 degrees) to the length L2 of the second material 30 and generally perpendicular (+ / - 5 degrees) to the second supply direction FD2.

[0031] The applicator system 16 may include a cutting block 40, a sealing head 42, and a drive mechanism 44. As will be described in more detail below, the applicator system 16 may be configured to remove a portion 46 (Figures 3B to 4) of the second material 30 and to apply the portion 46 of the second material 30 to the 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 various mechanisms configured to engage and selectively attach the second material 30. For example, the attachment mechanism 48 may include an adhesive, suction source, or mechanical fastener(s) for engaging and attaching the second material 30 to the cutting block 40. In some configurations, the coupling mechanism 48 may include a self-engaging fastener(s) for engaging the self-engaging fastener(s) 32 of the second material 30.

[0033] The cutting mechanism 50 may include a blade 54 for selectively engaging and cutting the second material 30. As shown in Figure 2, the blade 54 may have a defined 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 transverse 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 with the first material 24. As shown in Figure 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] As shown in Figures 3A to 3D, the drive mechanism 44 may include various arbitrary mechanisms for moving the cutting block 40 in a first direction D1 and / or a second direction D2. Additionally or alternatively, the drive mechanism 44 may move the seal head 42 in a first direction D1 and / or a third direction D3. For example, the drive mechanism 44 may move the cutting block 40 and / or the seal head 42 in the first, second, and third directions D1, D2, D3. 3 The system may include a gear train, a belt drive system, or a hydraulic drive mechanism (not shown) that moves in one or more of the following directions. In particular, the drive mechanism 44 may move the cutting block 40 and / or the seal head 42 toward the first material and / or the second material 24, 30. In this regard, the first direction D1 may be substantially parallel to the first and second supply directions FD1, FD2, and the second and third directions D2, D3 may be substantially perpendicular to the first and second supply directions FD1, FD2.

[0036] Referring to Figures 3A to 3D, a method for applying the second material 30 to the first material 24 will now be described. As shown in Figure 3A, the method may include supplying the first material and / or the second materials 24, 30 in a first supply direction and a second supply direction FD1, FD2, respectively. In this regard, the first operating step may include rotating the first roll 26 around a first rotation axis A1 and / or rotating the second roll 34 around a second rotation axis A2.

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

[0038] As shown in Figure 3C, the method may also include moving a cutting block 40, which includes a 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 further include positioning the portion 46 of the second material 30 to engage with the first material 24. In this regard, the method may include positioning the portion 46 on the first side 70 of the first material 24 This may include engaging and engaging the seal head 42 with the second side 72 of the first material 24, where the first side 70 is opposite to the second side 72. Thus, the first material 24 and the portion 46 of the second material 30 may be clamped and positioned between the cutting block 40 and the seal head 42.

[0039] The method may also include attaching a portion 46 of the second material 30 to the first material 24. For example, the method may include fixing the portion 46 to the first material 24 using one or more different 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 in order to ultrasonically weld the first material 24 to the portion 46. In other configurations, the method may include activating the 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 in order to fix the first material 24 to the portion 46.

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

[0041] Referring to Figure 4, the method may also include attaching the 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, second lateral edge 27, and bottom edge 78 of the first material 24 to form the first sealed seam 22, second sealed seam 23, and third sealed seam 80 of the package 18, respectively. In this regard, the opening 20 of the package 18 and the width W2 of 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 and second sealed seams 22, 23. Although not specifically shown, the third material 76 may similarly receive portions of fasteners that mate 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 in order to allow the loop-type fastener portion to engage with the hook-type fastener portion so that the user can selectively re-close 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 the hook-type fastener portion (i.e., the second material 30) to the first material 24. The first material 24 is described as a receptive hook-type fastener portion and the third material 76 is described as a receptive loop-type fastener portion, although the first material 24 can alternatively be a receptive loop-type fastener portion and the third material 76 can be a receptive hook-type fastener portion.

[0042] By cutting the second material 32 such that the portion 46 extends in each direction and has a width W2 and length L5 having the proportions described herein, the system 10 and method described herein can significantly reduce the time required to manufacture the package 18. For example, by measuring the width W2 of the portion 46 which is less than or equal to the length L5 and extends in a direction substantially parallel to the first transverse edge and the second transverse edge 25, 27 of the first material 24, the system 10 and the corresponding method can rapidly manufacture the package 18. That is, for example, the method and system of the present application from a second material source 14 which is the width W2 of the portion 46 This defines an index or measurement length in direction FD2 of the fastener material 30. In some methods, this measurement length is approximately 0.25 to 1 inch, and in other methods, it is approximately 0.25 to 0.5 inches. This is in contrast to earlier systems that require measuring the overall length L2 of the fastener member in a direction transverse to the supply direction of the package substrate. In other methods, the system and material allow the fastener material 32 on the opposite side of the fastener portion 46 cut here to be flangeless, i.e., having no flanges at all (or other areas of non-fastener material, such as material that does not have hook and loop type fastener portions).

[0043] The descriptions provided above are for illustrative and explanatory purposes only. They are 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 are interchangeable where applicable, and may be used in selected configurations even if not specifically illustrated or described. The same thing may also be modified in various ways. These modifications should not be considered deviations from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A system for applying fastener material to a base material of a package having an opening, wherein the system comprises: The system comprises a first material source including the substrate, wherein the substrate defines a first length extending from a first edge to a second edge, and the first material source is configured to supply the substrate in a first direction traversing the first length, and the system further comprises: The system further comprises a second material source including the fastener material, wherein the fastener material defines 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 is configured to supply the fastener material in a second direction traversing the second length, and the system further comprises, An applicator system comprising a cutting block and a sealing head, wherein the cutting block cuts the fastener material and has a cutting mechanism defining a third length, the sealing head defines a fourth length, the cutting block and the sealing head are configured to attach 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, the cutting block is configured to be movable in a first direction and in another direction intersecting the first direction, the other direction being substantially perpendicular to the first and second directions.

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

3. The system according to claim 1, wherein the fastener material defines a width extending in a direction perpendicular to the second length, and the width is less than or equal to the second length.

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

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

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

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

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