Zipper Flange Tear Line Creation via Peel Seal Resin
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Solution Overview
Problem
Existing reclosable packages with multiple-track self-locking zippers lack a direct tearing feature in the zipper flange and fail to balance manufacturing costs, hermeticity, and ease of opening effectively.
Innovation Solution
The integration of a tear line in the zipper flange using polymer resin, foaming agents, or coextrusion of peel seal resin with perforations to create a linear tearing mechanism, allowing the package to be opened by tearing the film and zipper flange in a straight line, while maintaining hermeticity and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tear features such as laser scoring, perforation, or tear beads are formed on the package film, then ease of opening is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts the tear feature directly from the zipper flange itself rather than adding separate tear elements to the package film. By creating the tear line within the flange material through methods like laser scoring, perforation, or thinning during the extrusion process, the patent eliminates the need for separate tear beads, stickers, or other added components, thereby reducing manufacturing complexity while maintaining ease of opening
Solution Approach 2:
The tear line is created in advance during the flange manufacturing process itself, before the zipper is assembled into the final package. Methods such as laser scoring, perforation, or material thinning are applied to the flange during extrusion or forming, so that when the consumer opens the package, the tear feature is already prepared and ready to function, eliminating the need for additional manufacturing steps
2Reliability
If multiple-track self-locking zippers are used, then reclosability and hermeticity are improved, but ease of opening deteriorates due to lack of integrated tear feature
Solution Approach 1:
The invention merges the tear feature directly into the zipper flange structure, combining two previously separate functions (zipper closure and tear opening) into a single integrated component. The flange now serves dual purposes: providing the self-locking zipper mechanism for reclosability and containing the tear line for easy opening, thereby maintaining hermeticity while improving ease of opening
Solution Approach 2:
The invention applies local quality changes to specific portions of the flange to create the tear line, while the rest of the flange maintains its full strength and hermetic properties. Methods such as laser scoring, perforation, or localized thinning create a weakened path only where needed for tearing, preserving the integrity and sealing capability of the surrounding flange material
3Ease of operation
If traditional tear features are added separately to the package, then ease of opening is improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts the tear feature creation process from separate post-manufacturing steps and integrates it directly into the flange manufacturing process. By using methods like laser scoring, perforation, or material thinning during extrusion, the patent eliminates the need for separate addition of tear beads, stickers, or other elements, thereby reducing material costs and manufacturing steps
Solution Approach 2:
The flange material itself serves the dual function of providing structural integrity for the zipper and containing the tear feature, eliminating the need for separate tear-promoting materials. The flange's own structure is modified to provide the tear line, so no additional materials or components are required, reducing both material and manufacturing costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables a robust and easy-to-open package with reduced manufacturing costs and increased hermeticity by allowing the package to be opened along a straight line, enhancing the user experience and maintaining the integrity of the contents.
Implementation Method 1
applying polymer resin of the type normally used as a peel seal in order to create a tear line on the flanges
Implementation Method 2
providing a foaming agent to achieve a density reduction in a portion of the flange
Implementation Method 3
The action of drawing down the zipper flange orients the polymer and the entrained gas bubbles, which causes the flange material to tear in a linear fashion
Data Source
AI summary
The disclosure pertains to various embodiments of zippers with a tear flange for use in a reclosable flexible package or bag. A line of weakness can be introduced into the tear flange by application of a peel seal polymer resin or of a foaming agent. The disclosure includes further embodiments wherein lines of weakness are introduced into the flange of zippers in reclosable packages or bags.