Cross-Reference to Related Application

This application claims priority to U.S. Provisional Application No. 63/118,148, filed November 25, 2020, the disclosure of which is incorporated by reference in its entirety herein.

Background

Fasteners are used in a variety of applications, including construction, machinery, medical equipment, automobile assembly, personal care products, and the textile industry. Commonly known fasteners range from rivets, snaps and buttons to hook and loop fasteners, each of which involve joining unlike components (e.g., male and female components) for assembling two articles together. Some fasteners, which are sometimes called self-mating fasteners or hook-and-hook fasteners, are composed of interlocking members that do not include male and female components. For assembling two articles together, each fastening member is attached to a surface of its respective article, and the two articles are joined together when the fastening members are mated.

Certain fasteners have been reported that include different structures on the same fastening member. See, for example, U.S. Pat. Nos. 5,586,372 (Eguchi) and 6,546,604 (Galkiewicz). The different structures may have different shapes, sizes, or abilities to engage.

Reclosable packages can be used as containers for various consumer goods such as dry goods, food such as potato chips and cheese, animal food, lawncare products, etc. Such packages are available in a variety of shapes and sizes. Further, various reclosable packages can be multi-use containers that can maintain storage of consumer goods disposed within the packages for a desired number of openings and closings of the package. For example, a multi-use package can provide access by a user to the contents disposed within the package and then be closed to prevent the contents from spilling out of the package. These multi-use packages can include built-in fasteners that can be repeatedly opened and closed. Further, various multi-use packages can also be resealed after the first opening of the packages to keep the contents fresh and free from intrusion by various external elements such as air, moisture, and various contaminants.

Typically, reclosable packages can be made from one or more sheets or films that include one or more flexible materials. A film can be folded and sealed together to form a pouch having an interior volume and an opening through which consumer goods can be disposed within the volume. A fastener can be disposed adjacent the opening that can be repeatedly manipulated from a closed configuration to an open configuration.

Some reclosable packages having self-mating fasteners have been reported. See, for example, U.S. Pat. Nos. 8,641,278 (Ducauchuis), 9,198,483 (Adams), 4,655,862 (Christoff), U.S. Pat. Appl. Pub. Nos. 2020/0352287 (Gorman et al.).

Summary

The present disclosure provides a fastener that includes alternating rails and ribs on a backing. Typically, and advantageously, the unique structure of the fastener can allow for multiple cycles of fastening and unfastening without excessive plastic (i.e., irreversible) deformation of the engaging rail segments. The rails and ribs can improve the ability of the fastener to seal relative to a comparative fastener that includes rows of rail segments and rows of posts on a backing. The fastener of the present disclosure can be useful, for example, as a self-mating fastener for a reclosable package.

In one aspect, the present disclosure provides a fastener. The fastener includes a backing having opposing first and second major surfaces, a length, a width, a thickness, and rails and ribs protruding perpendicularly from the first major surface of the backing. The rails and ribs alternate. Each of the rails has a continuous base portion attached to the backing and a continuous cap portion distal from the backing. The continuous cap portion has a cap width that is greater than a width of the continuous base portion, and the continuous cap portion overhangs the continuous base portion on opposing sides. Each of the ribs has a continuous proximal portion attached to the backing, a height that is no greater than a height of rails, and a continuous distal portion distal from the backing. The continuous distal portion has a width that is no greater than the width of the continuous proximal portion.

In another aspect, the present disclosure provides a fastening system that includes the fastener.

In another aspect, the present disclosure provides a reclosable package. The reclosable package includes a package defining an interior volume and an opening providing access to the interior volume, a flexible material, a seal region disposed adjacent the opening that is adapted to be broken to allow a first opening of the package; and the fastening system described herein connected to the package. The fastening system further includes an open configuration and a closed configuration. When in the open configuration, the fastening system is adapted to allow access to the interior volume of the package through the opening after the seal region has been broken, and when in the closed configuration the fastening system is adapted to prevent access to the interior volume of the package through the opening. In another aspect, the present disclosure provides the fastener attached to a portion of a package.

In another aspect, the present disclosure provides a process for making package. The process includes a wrapping a fdm around a former to provide a tube of fdm. The fdm comprises first and second opposing longitudinal edges, a distance between the first and second opposing longitudinal edges, and a plurality of fastening strips extending perpendicularly to the first and second longitudinal edges. Each of the fastening strips includes the fastener described herein with the rails and ribs exposed to an interior of the tube of film and the second major surface attached to the film and a first end portion closer to the first longitudinal edge and a second end portion closer to the second longitudinal edge. The process further includes bringing together the first and second longitudinal edges and sealing the first and second longitudinal edges together to form a vertical seal.

In this application:

All headings provided herein are for the convenience of the reader and should not be used to limit the meaning of any text that follows the heading, unless so specified.

The term “comprises” and variations thereof do not have a limiting meaning where these terms appear in the description and claims. Such terms will be understood to imply the inclusion of a stated step or element or group of steps or elements but not the exclusion of any other step or element or group of steps or elements.

Terms such as "a", "an" and "the" are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration. The terms "a", "an", and "the" are used interchangeably with the term "at least one".

The phrase "comprises at least one of' followed by a list refers to comprising any one of the items in the list and any combination of two or more items in the list. The phrase "at least one of' followed by a list refers to any one of the items in the list or any combination of two or more items in the list.

As used herein, the term “or” is generally employed in its usual sense including “and/or” unless the content clearly dictates otherwise.

The term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.

The term "machine direction" (MD) as used herein denotes the direction of a running web of material during a manufacturing process. When a strip is cut from a continuous web, the dimension in the machine direction corresponds to the length "L" of the strip. The terms “machine direction” and “longitudinal direction” may be used interchangeably. The term "cross-machine direction" (CD) as used herein denotes the direction which is essentially perpendicular to the machine direction. When a strip is cut from a continuous web, the dimension in the cross-machine direction corresponds to the width "W" of the strip. Accordingly, the term “width” typically refers to the shorter dimension in the plane of the first surface of the backing, which is the surface bearing the rails and ribs. As used herein, the term “thickness” usually refers to the smallest dimension of the fastener, which is the dimension perpendicular to the first surface of the backing.

The term "alternating" as used herein refers to one rail being disposed between any two adjacent ribs (i.e., the adjacent ribs have only one rail between them) and one rib being disposed between any two adjacent rails (i.e., the adjacent rails have only one rib between them).

The term "perpendicular" as used herein to refer to the relationship between the backing and the rails and/or ribs includes substantially perpendicular. “Substantially perpendicular” means that the planes defined by the backing and a rail or rib can deviate from perpendicular by up to 10 (in some embodiments, up to 7.5 or 5) degrees.

The term “continuous” with reference to the rails and ribs means that for a given length of backing, there is only one rail or rib in a given location along the width of the backing. This is in contrast to rail segments and posts, which are arranged in rows having spaces between individual rail segments and posts in a row. In some embodiments, the continuous rails and/or ribs are continuous for the length of the backing.

As used herein in connection with a measured quantity, the term “about” refers to that variation in the measured quantity as would be expected by the skilled artisan making the measurement and exercising a level of care commensurate with the objective of the measurement and the precision of the measuring equipment used. Herein, “up to” a number (e.g., up to 50) includes the number (e.g., 50).

All numerical ranges are inclusive of their endpoints and nonintegral values between the endpoints unless otherwise stated (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

These and other aspects of the present disclosure will be apparent from the detailed description below. In no event, however, should the above summaries be construed as limitations on the claimed subject matter, which subject matter is defined solely by the attached claims, as may be amended during prosecution.

Brief Description Of The Drawings

The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

FIG. 1 is a schematic perspective view of an embodiment of a fastener of the present disclosure. FIG. 2 is a schematic side view of another embodiment of a fastener of the present disclosure.

FIG. 3 is a schematic side view of an embodiment of a fastening system of the present disclosure in which both fastener members include an embodiment of the fastener of the present disclosure.

FIG. 4A is a schematic side view of an embodiment of fastener of the present disclosure undergoing deformation during fastening, with strain calculated by Finite Element Modeling depicted by shading.

FIG. 4B is a schematic side view of the fastener of FIG. 4A after fastening, with residual strain calculated by Finite Element Modeling depicted by shading.

FIG. 5 is a schematic front plan view of one embodiment of a reclosable package.

FIG. 6 is a schematic rear plan view of the reclosable package of FIG. 5.

FIG. 7 is a schematic top perspective view of the reclosable package of FIG. 5.

FIG. 8 is a schematic cross-section view of a portion of the reclosable package of FIG. 5 with an embodiment of the fastener of the present disclosure disposed in a closed configuration.

FIG. 9 is a schematic cross-section view of a portion of the reclosable package of FIG. 5 with an embodiment of the fastener of the present disclosure disposed in an open configuration with the upper seal region still intact.

FIG. 10 is a schematic cross-section view of a portion of the reclosable package of FIG. 5 with an embodiment of the fastener of the present disclosure disposed in the open configuration.

FIG. 11 is a schematic cross-section view an embodiment of the opening of the reclosable package of FIG. 5 when the fastener is in the closed configuration.

FIG. 12 is a schematic perspective view of another embodiment of a reclosable package.

FIG. 13 is a schematic front plan view of the reclosable package of FIG. 12.

FIG. 14 is a schematic perspective view of another embodiment of a reclosable package.

FIG. 15 is a schematic front plan view of the reclosable package of FIG. 14.

FIG. 16 is a perspective view of one embodiment of an apparatus and method used to form a reclosable package.

FIG. 17 is a schematic plan view of a film useful for making the reclosable package of the present disclosure.

FIG. 18 is a schematic perspective view of an embodiment of an apparatus useful for carrying out the process of the present disclosure. Detailed Description

An embodiment of a fastener of the present disclosure is shown in FIGS. 1, 2, and 3. Fastener 1 includes a backing 2 having a length (L), a width (W), and a thickness (T). Fastener 1 includes rails 4 protruding perpendicularly in the illustrated embodiment from the backing 2. Dimensions of rails 4 are indicated in FIG. 2. Each of the rails 4 has a continuous base portion 10 attached to the backing 2 and a continuous cap portion 8 distal from the backing 2. The continuous cap portion 8 has a cap width X4 that is greater than the width XI of the continuous base portion 10, and the continuous cap portion 8 overhangs the base portion 10 on opposing sides. The ratio of the continuous cap width X4 to the width XI of the continuous base portion 10 is typically at least 1.25: 1, 1.5:1, or 2: 1 and can be up to 3:1, 4: 1, or 5: 1. FIG. 2 illustrates the cap overhang distance X6. Continuous cap portions also have a cap thickness, which, if the cross- sectional cap shape is not rectilinear, is measured as a distance between a line tangent to the highest point on the cap above the backing and a line tangent to lowest point on the cap above the backing. For example, in the embodiment shown in FIG. 2, the cap thickness is Z7.

The continuous base portion 10 of rails 4 may have a variety of cross-sectional shapes.

For example, the cross-sectional shape of the continuous base portion 10 may be a polygon (e.g., rectangle or trapezoid), or the cross-sectional shape of the continuous base portion 10 may be curved (e.g., elliptical). The continuous base portion 10 may taper from its base to its distal portion. In other embodiments, the continuous base portion does not taper and, in some embodiments, has faces that make a 90-degree angle A1 with the backing 2. For embodiments such as the embodiment illustrated in FIG. 2, continuous base portions 10 that taper from their bases to their distal portions have a sloping face and a taper angle A1 between the sloping face and the backing 2. In some embodiments, the taper angle A1 between the sloping face of the continuous base portion 10 and the backing 2 is in a range from 91 degrees to 130 degrees, in some embodiments, in a range from 91 degrees to 125 degrees, 95 degrees to 120 degrees, 95 degrees to 115 degrees, 95 degrees to 110 degrees, 93 degrees to 105 degrees, 95 degrees to 100 degrees, 91 degrees to 105 degrees, 91 degrees to 100 degrees, 91 degrees to 99 degrees, or 91 degrees to 95 degrees.

Referring again to FIG. 2, in some embodiments, the rails 4 have a maximum height Z 1 (above the backing 2) of up to 0.65 millimeter (mm). 0.6 mm, or 0.55 mm and, in some embodiments, a minimum height of at least 0.1 mm or 0.2 mm. The height Z 1 of the rails 4 can be in a range from 0.3 mm to 0.65 mm, 0.3 mm to 0.6 mm, or 0.35 mm to 0.55 mm. The thickness Z7 of the continuous cap portion 8 of rail 4 can be in a range from 0.03 mm to 0.2 mm, 0.04 mm to 0.15 mm, or 0.04 mm to 0.1 mm. In some embodiments, the continuous base portions 10 of the rails 4 have a maximum width XI of up to about 0.5 mm, 0.4 mm, 0.3 mm, or 0.2 mm and a minimum width of at least 0.05 mm, 0.1 mm, or 0.125 mm. Some useful widths XI of the continuous base portions 10 are in a range from 0.05 mm to 0.5 mm, 0.1 mm to 0.2 mm, or 0.125 mm to 0.175 mm. Some useful cap portion widths X4 of the rails 4 are in a range from 0.1 mm to 1.0 mm, 0.3 mm to 0.5 mm, 0.3 mm to 0.45 mm, or 0.3 mm to 0.4 mm. Some useful cap overhang distances X6 of the rails 4 are in a range from 0.025 mm to 0.4 mm, 0.05 mm to 0.3 mm, or 0.1 m to 0.25 mm.

In FIG. 1, 2, and 3, the continuous cap portion 8 of the rails 4 has a shape in which the overhang is turned down toward backing 2 although this is not a requirement. Cap shapes that are rectilinear and not turned down toward backing 2 are also useful. A combination of the cap shapes may also be useful.

As shown in FIG. 1, 2, and 3, fastener 1 of the present disclosure also includes ribs 6 protruding perpendicularly from the backing 2. Ribs 6 are also continuous as shown in FIG. 1. In the embodiment illustrated in FIGS. 1, 2, and 3, the rails 4 and ribs 6 alternate. The fastener 1 can have at least 2, 3, 5, or 10 of the rails 4 alternating with at least 2, 3, 5, or 10 of the ribs 6.

In some embodiments, ribs 6 useful in the fastener 1 have a maximum width X2 of up to about 0.5 mm, 0.4 mm, 0.3 mm, or 0.2 mm and a minimum width of at least 0.05 mm, 0.1 mm, or 0.125 mm. Some useful widths X2 of the ribs 6 are in a range from 0.05 mm to 0.2 mm, 0.1 mm to 0.2 mm, or 0.125 mm to 0.175 mm. Ribs 6 have a continuous proximal portion attached to the backing 2 and continuous distal portions distal from the backing. Continuous distal portions of the ribs have a width that is no greater than a width of the continuous proximal portion. In some embodiments, ribs 6 can taper from their continuous proximal portions to their distal portions and have a taper angle A2 as described above for the continuous base portions of the rails. The ribs 6 may have a variety of cross-sectional shapes. For example, the cross-sectional shape of the ribs 6 may be a polygon (e.g., rectangle or trapezoid) or may be curved (e.g., elliptical). In some embodiments, the ribs do not taper and have faces that make a 90-degree angle A2 with the backing 2.

Since the fastener 1 is useful as a self-mating fastener, the ribs 6 generally have a height that is no greater than a height of the rails 4. In the embodiment illustrated in FIGS. 1, 2, and 3, the height Z3 of the ribs 6 is less than the height of the rails 4. In some embodiments, the height Z3 of ribs 6 is up to 95, 90, 80, 75, or 70 percent of the height Z1 of the rails 4 (shown in FIG. 2). In some embodiments, the ribs 6 have a maximum height Z3 (above the backing 2) of up to 0.6 mm, 0.55 mm, or 0.5 mm and, in some embodiments, a minimum height of at least 0.08 mm or 0.16 mm. The height Z3 of the ribs 6 can be in a range from 0.2 mm to 0.6 mm, 0.3 mm to 0.5 mm, 0.3 mm to 0.4 mm, or 0.35 mm to 0.55 mm. In some embodiments, each of the ribs 6 has a height to width (Z3 to X2) aspect ratio that is at least 1.5: 1, at least 2: 1, or at least 3:1. Continuous distal portions are generally not formed with a series of notches. That is, the height Z3 of the ribs can be substantially uniform along their lengths “L”. Substantially uniform can mean that the height Z3 changes by at most 5, 4, 3, 2, or 1 percent along the length of the rib 6.

Fastener 1 is useful, for example, as a self-mating fastener. As used herein, self-mating refers to fasteners in which fastening is accomplished by interengaging fastening elements of the same type (e.g., fastening rails). In some embodiments, self-mating refers to fasteners in which fastening is accomplished by interengaging fastening elements of identical shape. In some embodiments, self-mating refers to the ability for the fastener to engage with itself when it is in a folded configuration, for example, along an axis parallel to either the length (L) of the fastener, referring to FIGS. 1. Two fastener members (e.g., first and second fastener members (1,5)), each having a structure shown in FIGS. 1 and 2, for example, can be fastened together in a self-mating engagement as shown in FIG. 3. In some embodiments, a first fastener member 1 is a fastener of the present disclosure as described above in any of its embodiments, and a second fastener member may include the rails but not include the ribs. In some embodiments, the first and second fastener members may be different embodiments of the fastener of the present disclosure. For example, the first fastener member 1 may have a cap shape for the rails like that shown in FIGS. 1 and 2 and a second fastener member 5 may have a different cap shape, for example, a rectilinear shape. Since self-mating includes fasteners having fastening elements of the same type, each of these is an example of self-mating.

When the first and second fastener members undergo fastening, the ribs typically bend away from the rails while the continuous cap portions of the rails of the first and second fastener members pass by each other as shown in FIG. 4A. The ribs then return to their original positions after the first and second fastener members are fastened as shown in FIG. 4B.

In some embodiments, the fastening system of the present disclosure is releasably fastenable. As used herein, the term “releasably fastenable” means that the fastener members can alternate between the fastened and unfastened configurations one or more times without destroying the functionality of the fastener. In some embodiments, the unique structure of the fastener of the present disclosure can allow for multiple cycles of fastening and unfastening without excessive plastic (i.e., irreversible) deformation of the engaging rails. As described in detail in U.S. Pat. Appl. Pub. No. 2020/0352287 (Gorman et al.), Finite Element Modeling provides evidence that a comparative fastener that includes rail segments can undergo fastening when the rail segments are pushed against and past one another for interlocking. The cap portions of the rail segments of comparative fastener exhibit a relative high degree of plastic (i.e., irreversible) deformation after such engagement. The plastic deformation can limit the ability of the comparative fastener to be unfastened and refastened since the shape of the fastener is altered by the first and successive engagements. In contrast, in a fastener that includes alternating rail segments and posts, when the first and second fastener members undergo fastening, the posts undergo elastic deformation while the cap portions of the rail segments of the first and second fastener members pass by each other as shown in FIG. 4A. The cap portions of the rail segments of the fastener exhibit a relative low degree of plastic (i.e., irreversible) deformation after engagement as shown in FIG. 4B. While the modeling was carried out with a fastener having rail segments and posts, the fastener in the model and the fastener of the present disclosure have the same cross-sectional shape. Accordingly, the same mechanism providing a low degree of plastic deformation is believed to be operative with the ribs and the continuous cap portions of the rails in the fastener of the present disclosure.

Since fastener 1 illustrated in FIGS. 1, 2, and 3 is useful, for example, as a self-mating fastener, a shortest distance between one of the ribs 6 and the continuous base portion 10 of an adjacent rail 4 is wide enough to allow the insertion of the cap portion 8 of the rails 4 and may be substantially the same as X4, as described above in any of the embodiment for X4. In some embodiments, the distance between one of the ribs 6 and the continuous base portion 10 of an adjacent rail 4 is within about 20, 15, or 10 percent of the cap width X4. In some embodiments, a ratio of this distance to the width XI of the continuous base portion 10 is in a range from 2: 1 to 5: 1 or from 2: 1 to 4: 1, or the ratio may be about 3:1. In FIG. 2, distances X3 and X5 between one of the ribs 6 and the continuous cap portions 8 of an adjacent rail 4 is generally smaller than the distance between one of the ribs 6 and the continuous base portion 10 of an adjacent rail 4 since the cap width X4 is wider than the width of the base portion XL Some useful distances X3 and X5 are in a range from 0.08 mm to 0.8 mm, 0.1 mm to 0.5 mm, 0.2 mm to 0.4 mm, or 0.2 mm to 0.35 mm. Distances X3 and X5 between a rib 6 and two adjacent continuous cap portions 8 of rails 4 need not be equal. A variety of spacings between rails X7, measured as the center-to-center distance of the rails in closest proximity as shown in FIG. 2, may be useful. In some embodiments, the distance X7 between rails is 0.25 mm to 2.5 mm, 0.5 mm to 1.5 mm, or 0.6 mm to 1.2 mm. The spacing of the rails and ribs need not be uniform.

In some embodiments, when the first and second fastener members are fastened, they can slide relative to each other in a direction parallel to the length of the backing. This may be advantageous, for example, if the positioning of the first and second fastener members relative to each is not desirable when the first and second fastener members are initially fastened. To achieve a desirable positioning the first and second fastener members can be slid into place.

The first and second fastener members of a fastening system according to some embodiments of the present disclosure may or may not be connected together. In some embodiments, the first and second fastener members may be connected to two discrete substrates. In some embodiments, the first and second fastener members may be part of the same strip of material in which the first fastener member is folded over to contact the second fastener member.

In the fastener according to the present disclosure, the rails, ribs, and at least the portion of the backing to which they are attached are integral (that is, generally formed at the same time as a unit, unitary). Fastening elements such as rails and ribs on a backing can be made, for example, by feeding a thermoplastic material onto a continuously moving mold surface with grooves having the inverse shape of the ribs and the continuous base portions of the rails, for example. The grooves in the mold surface can have generally a rectangular profile although different shapes can be used to provide a film with differently shaped ribs and rails. The mold may be of any type used for continuous processing, for example, a tape, cylindrical roll, or belt. When making a mold, the grooves may be formed in any suitable manner, such as by drilling, machining, laser drilling, water jet machining, casting, etching, die punching, diamond turning, and engraving knurling. The placement of the grooves determines the spacing and orientation of fastener. The mold can be made of metal, steel, ceramic, polymeric materials, and combinations thereof. In some embodiments, the mold is a roll coated with hard copper.

Grooves can be formed in a mold surface using a variety of other techniques. For example, grooves and higher-profile areas can be formed from a series of plates having different diameters that are stacked together to collectively form a tool roll or rings having different diameters that are stacked together and placed over a cylindrical base roll. Useful materials for making rings include stainless steel SS430, cold rolled steel, and copper. The cylindrical base roll or mandrel can be made out of aluminum wall, steel wall, or stainless steel wall and can be a water pressure vessel through which water can be passed for cooling and heating. The mold surface may also be a wire-wrapped roll, with wires having different profiles helically wound around a base roll. Grooves can also be machined into the surface of a metal master roll made, for example, of electroformed nickel or into screens formed into sleeves to fit over a cylindrical base roll.

In some embodiments, the mold is made by diamond turning on a hard copper surface. Advantageously, as shown in the Examples below, the mold can be readily filled with thermoplastic resins described below to the desired height, and the continuous distal portions can be formed with substantially uniform height, for example, without a series of notches. As described above, substantially uniform can mean that the height Z3 (FIG. 2) changes by at most 5, 4, 3, 2, or 1 percent along the length “L” of the rib 6.

The grooves can have different depths so that ribs of different heights can be formed on a backing. Taller ribs may be preferentially capped using the methods described below to provide the rails. The thermoplastic material can be passed between a nip formed by two rolls or a nip between a die face and roll surface, with at least one of the rolls having the grooves. Pressure provided by the nip forces the resin into the cavities. In some embodiments, a vacuum can be used to evacuate the cavities for easier fdling of the cavities. The nip has a large enough gap such that a coherent backing is formed over the grooves. The backing may be formed with no holes therethrough. The mold surface and grooves can optionally be air or water cooled before stripping the integrally formed backing, ribs, and continuous base portions of the rails from the mold surface such as by a stripper roll.

If rails formed upon exiting the cavities do not have caps, first and second fastener members will not have any closure affinity for each other. Caps can be subsequently formed on the rails by a capping method as described in U.S. Pat. No. 5,077,870 (Melbye et ah). Typically, the capping method includes deforming the continuous distal portions of the rails using heat and/or pressure. The heat and pressure, if both are used, could be applied sequentially or simultaneously. The formation of rails can also include a step in which the shape of the cap is changed, for example, as described in U.S. Pat. No. 6,132,660 (Kampfer) and/or 6,592,800 (Levitt). For example, one or more of these processes can be useful for changing the shape of the continuous cap portion 8 from rectilinear, for example, to the shape shown in FIGS. 1, 2, and 3. The formation of rails can also include a step in which the cap is embossed, for example, as described in U.S. Pat. No. 6,000,106 (Kampfer). After one or more of these capping processes, first and second fastener members in a fastening system of the present disclosure can be closed together.

The amount of force necessary to close and to peel open the first and second fastener members can be adjusted as desired by tailoring the capping process.

Another useful method for forming rails and ribs on a backing is profile extrusion described, for example, in U.S. Pat. No. 4,894,060 (Nestegard). Typically, in this method a thermoplastic flow stream is passed through a patterned die lip (e.g., cut by electron discharge machining) to form a web having downweb ridges. The ridges may be in the final form desired for the ribs and rails described above, or one or more of the capping processes described above may be useful for changing the cap shape.

The backing of the fastener of the present disclosure may have a variety of thicknesses. In some embodiments, including the embodiments illustrated in FIGS. 1 to 3, the thickness Z4 of the backing 2 integral with the rails 4 and ribs 6 may be up to about 200 micrometers (pm), 150 pm, or 100 pm and at least about 50 pm or 75 pm. This thickness does not include the heights of the rails and ribs protruding from the first major surface of the backing. In some embodiments, the thickness of the thermoplastic backing is in a range from 50 pm to about 300 pm, from about 50 pm to about 200 pm, or from about 50 pm to about 150 pm.

In some embodiments, the rails and ribs can each independently be formed on fillets with a fillet thickness above the backing 2 of up to about 100 pm, 75 pm, or 50 pm and at least about 10 mih or 15 mih. This thickness does not include the heights of the rails and ribs protruding from the first major surface of the backing. In some embodiments, the fillet thickness is in a range from 10 mih to about 100 mih, from about 15 mih to about 75 mih, or from about 20 mih to about 50 mih. In some embodiments, the backing, excluding the rails, ribs, and fillets, is substantially uniform in thickness. For a thermoplastic that is substantially uniform in thickness, a difference in thickness between any two points in the backing may be up 5, 2.5, or 1 percent.

In some embodiments, the backing can be monoaxially or biaxially stretched. Stretching in the machine direction can be carried out on a continuous web of the backing, for example, by directing the web over rolls of increasing speed. Stretching in a cross-machine direction can be carried out on a continuous web using, for example, diverging rails or diverging disks. A versatile stretching method that allows for monoaxial and sequential biaxial stretching of the thermoplastic layer employs a flat film tenter apparatus. Such an apparatus grasps the thermoplastic layer using a plurality of clips, grippers, or other film edge-grasping means along opposing edges of the thermoplastic web in such a way that monoaxial and biaxial stretching in the desired direction is obtained by propelling the grasping means at varying speeds along divergent rails. Increasing clip speed in the machine direction generally results in machine-direction stretching. Stretching at angles to the machine direction and cross-direction are also possible with a flat film tenter apparatus. Monoaxial and biaxial stretching can also be accomplished, for example, by the methods and apparatus disclosed in U.S. Pat. No. 7,897,078 (Petersen et al.) and the references cited therein. Flat film tenter stretching apparatuses are commercially available, for example, from Bruckner Maschinenbau GmbH, Siegsdorf, Germany.

In some embodiments, after stretching, the backing has an average thickness of up to 150 pm, 125 pm, 100 pm, 80 pm, or 75 pm. In some embodiments, the average thickness of the backing after stretching is in a range from 30 pm to 150 pm, 50 pm to 150 pm, or 50 pm to 125 pm. In general, the backing has no through-holes before or after stretching. Referring again to FIG. 2, stretching in the cross-direction can increase the distances X3, X5, and X7, for example.

In some embodiments, the backing is not stretched and does not have stretch-induced molecular orientation that is typically detected by standard spectrographic analysis of the birefringent properties of the backing.

The fastener of the present disclosure may be made from a variety of suitable materials, including thermoplastics. Examples of thermoplastic materials suitable for making the fastener using the methods described above include polyolefin homopolymers such as polyethylene and polypropylene, copolymers of ethylene, propylene and/or butylene; copolymers containing ethylene such as ethylene vinyl acetate and ethylene acrylic acid; polyesters such as polyethylene terephthalate), polyethylene butyrate, and polyethylene naphthalate; polyamides such as poly(hexamethylene adipamide); polyurethanes; polycarbonates; poly(vinyl alcohol); ketones such as polyetheretherketone; polyphenylene sulfide; and mixtures thereof. In some embodiments, the thermoplastic useful for making the fastener comprises at least one of a polyolefin, a polyamide, or a polyester. In some embodiments, the thermoplastic useful for making the fastener is a polyolefin (e.g., polyethylene, polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers, and copolymers and blends of these materials). In some embodiments, the fastener comprises polyethylene. In some embodiments, the fastener comprises high density polyethylene. In some embodiments, the fastener of the present disclosure is made from a blend of any of these thermoplastic materials and an elastomer. Examples of elastomers useful in such blends include elastomers such as ABA block copolymers (e.g., in which the A blocks are polystyrenic and formed predominantly of substituted (e.g., alkylated) or unsubstituted moieties and the B blocks are formed predominately from conjugated dienes (e.g., isoprene and 1,3- butadiene), which may be hydrogenated), polyurethane elastomers, polyolefin elastomers (e.g., metallocene polyolefin elastomers), olefin block copolymers, polyamide elastomers, ethylene vinyl acetate elastomers, and polyester elastomers. Examples of useful polyolefin elastomers include a polyethylene elastomer, an ethylene propylene elastomer, an ethylene octene elastomer, an ethylene propylene diene elastomer, an ethylene propylene octene elastomer, polybutadiene, a butadiene copolymer, polybutene, or a combination thereof. Any of these elastomers may be present in a blend with any of the thermoplastics in an amount of up to 20, 15, or 10 percent by weight, based on the total weight of the blend. In some embodiments, the fastener comprises polyethylene and an elastomer comprising polyethylene, including any of those described above.

In some embodiments, the elastomer comprising polyethylene may be present in a blend with polyethylene (in some embodiments, high density polyethylene) in an amount of up to 20, 15, or 10 percent by weight, based on the total weight of the blend.

Many types of elastomers are commercially available, including those from BASF,

Florham Park, N.J., under the trade designation "STYROFLEX", from Kraton Polymers, Houston, Tex., under the trade designation "KRATON", from Dow Chemical, Midland, Mich., under the trade designation "PEEFETHANE", “INFUSE”, VERSIFY”, “NORDEL”, and “ENGAGE”, from DSM, Heerlen, Netherlands, under the trade designation "ARNITEL", from E. I. duPont de Nemours and Company, Wilmington, Del., under the trade designation "HYTREL", from ExxonMobil, Irving, Tex. under the trade designation “VISTAMAXX”, and more.

In some embodiments, the backing includes a multi-layer construction. The multi-layer construction can include from 2 to 10, 2 to 5, or 2 to 3 layers. The multiple layers can include films, adhesives, and tie layers. The multiple layers can be joined together using a variety of methods including coating, adhesive bonding, and extrusion lamination. In some embodiments, the backing having the protruding rails and ribs can be made (e.g., using any of the methods described above) from a multilayer melt stream of thermoplastic materials. This can result in the protruding rails and ribs formed at least partially from a different thermoplastic material than the one predominately forming the backing. Various configurations of upstanding posts made from a multilayer melt stream are shown in U. S. Pat. No. 6,106,922 (Cejka et ah), for example. In some embodiments, the thickness of the backing (including a multi-layer backing) combined with the height of the rails is up to 750, 700, 650, 600, 500, 540, or 400 micrometers. In some embodiments, the thickness of the fastening system according to the present disclosure, in which the first and second fastener members are engaged with each other is up to 750, 700, 650, 600,

500, 540, or 400 micrometers. In some embodiments, the fastener of the present disclosure comprises at least one of a tie layer or adhesive on the second major surface of the backing, opposite the first surface from which the rails and ribs project.

In some embodiments, the fastener of the present disclosure and/or the backing of the fastener includes a tie layer. Tie layers can include elastomeric materials or other materials that have lower melting points than the backing integral with the rail segments and posts. Examples of elastomers useful in such tie layers include any of the elastomers described above. Various elastomeric polymers and other polymers may be blended to have varying degrees of elastomeric properties. For example, in a tie layer, any of the elastomers described above may be present in a range from 50% by weight to 95% by weight in a blend with any of the thermoplastics described above for forming the backing integral with the rails and ribs.

In some embodiments, the fastener of the present disclosure and/or the backing of the fastener includes a layer of a hot melt adhesive. Hot melt adhesives are typically non-tacky at room temperature, and the use of hot melt adhesives can decrease contamination on equipment during the handling of the film and lamination. Suitable hot melt adhesives include those based on ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, polyolefins, polyamides, polyesters, polyurethanes, styrene block copolymers, polycaprolactone, and polycarbonates and may include a variety of tackifying resins, plasticizers, pigments, fillers, and stabilizers. Examples of suitable hot melt adhesives include those available from 3M Company, St. Paul, Minn., under the trade designation “3M SCOTCH-WELD” hot melt adhesives (e.g., products 3731 B and 3764 PG).

In some embodiments, the tie layer or hot melt adhesive will be thermally activated in a temperature range of 90 °C to 125 °C depending on time and pressure and can be useful for making a secure bond to a substrate, such as a film used in a reclosable package. The tie layer or hot melt adhesive layer can have any useful thickness. In some embodiments, the tie layer or hot melt adhesive layer has a thickness of up to 0.1 mm, 0.075 mm, 0.05 mm, or 0.025 mm. Typically, the tie layer or hot melt adhesive layer has a thickness of at least 0.005 mm or 0.01 mm. Useful thicknesses include those in a range from 0.005 mm to 0.1 mm, 0.005 mm to 0.05 mm, and 0.01 mm to 0.025 mm.

We have found that the presence of continuous rails and ribs can improve the air sealing of the reclosable package of the present disclosure relative to fastening elements that are discontinuous in the length direction. Consumers may expect that a reclosable package should remain closed after the fastener is put into a closed configuration and also that the fastener should provide resistance to air flow across the fastener to maintain freshness of the consumer goods inside. If a consumer puts the fastener in a closed configuration is still able to squeeze the air out of the package or smell odor from the package, the consumer may question the effectiveness of the fastener and recloseable package. Inclusion of rails and ribs in the fastener useful for practicing the present disclosure improves the air sealing of the reclosable package when evaluated using the test method described in the Examples below. For example, in a comparison of Example 1 and Illustrative Example 2, replacement of rows of posts and rail segments as described in U.S. Pat. Appl. Pub. No. 2020/0352287 (Gorman et al.) with continuous rails and ribs results in more than doubling the air pressure inside the bag introduced using a continuous stream of air.

Air sealing of the reclosable package may further be improved by the presence of adhesive (e.g., pressure sensitive adhesive) on at least a portion of the first major surface of the fastener members. In some embodiments, at least one of the first fastener member or the second fastener member comprises adhesive (e.g., pressure sensitive adhesive) on at least a portion of its first major surface. Pressure sensitive adhesives (PSAs) are well known to those of ordinary skill in the art to possess properties including the following: (1) aggressive and permanent tack, (2) adherence with no more than finger pressure, (3) sufficient ability to hold onto an adherend, and (4) sufficient cohesive strength to be cleanly removable from the adherend. Materials that have been found to function well as PSAs are polymers designed and formulated to exhibit the requisite viscoelastic properties resulting in a desired balance of tack, peel adhesion, and shear holding power.

One method useful for identifying pressure sensitive adhesives is the Dahlquist criterion. This criterion defines a pressure sensitive adhesive as an adhesive having a 1 second creep compliance of greater than 1 x 10 ⁶ cm ² /dyne as described in Handbook of Pressure Sensitive Adhesive Technology, Donatas Satas (Ed.), 2nd Edition, p. 172, Van Nostrand Reinhold, New York, NY, 1989. Alternatively, since modulus is, to a first approximation, the inverse of creep compliance, pressure sensitive adhesives may be defined as adhesives having a storage modulus of less than about 1 x 10 ⁶ dynes/cm ² .

A variety of PSAs may be useful on the first major surface of at least one of the first or second fastener member in the fastening system of the present disclosure. Examples of suitable PSAs include natural rubber-, acrylic-, block copolymer-, silicone-, polyisobutylene-, polyvinyl ether-, polybutadiene-, or and urea-based pressure sensitive adhesive and combinations thereof. These PSAs can be prepared, for example, as described in Adhesion and Adhesives Technology, Alphonsus V. Pocius, Hanser/Gardner Publications, Inc., Cincinnati, Ohio, 1997, pages 216 to 223, Handbook of Pressure Sensitive Adhesive Technology, Donatas Satas (Ed.), 2nd Edition, Van Nostrand Reinhold, New York, NY, 1989, Chapter 15, and U.S. Pat. No. Re 24,906 (Ulrich).

PSAs can be strip coated onto the first major surface of at least one of the first or second fastener member using conventional techniques. In some embodiments, areas of the backing adjacent ribs may be coated with PSA to engage with the cap portions of the rails when the self-mating fastener is in the closed configuration.

The bending stiffness of the fastener (e.g., at an axis parallel to the width of the fastener) is influenced by the modulus of the material or materials making up the backing, the thickness of the layer or layers making up the backing, the distance between the structures (including rails and ribs) on the backing, and the dimension of the fastener parallel to the bending axis. In general, materials, thicknesses of the layer or layers in the fastener, and distances between structures can be selected to provide the fastener with a desirable bending stiffness. Advantageously, in many embodiments of the fastener of the present disclosure, the bending stiffness of the fastener is low enough such that the fastener does not unintentionally open when the fastener is bent. In some of these embodiments, the bending stiffness of the fastener in a closed configuration is in a range from 100 mN/mm to 1500 mN/mm, 200 mN/mm to 1200 mN/mm, or 300 mN/mm to 1000 mN/mm as measured by a Flexural Stiffness Test Method, for example, as described in the Examples, below.

The fastener of the present disclosure can be useful for joining two articles together for a variety of purposes. For example, the fastener of the present disclosure can be useful as a self mating fastener for a reclosable package. The self-mating fastener can be connected to a package or pouch. The self-mating fastener can include an open configuration and a closed configuration. When in the open configuration, the self-mating fastener is adapted to allow access to an interior volume of the pouch through an opening disposed in the pouch after a first opening of the pouch. Further, when in the closed configuration, the self-mating fastener is adapted to prevent access to the interior volume of the pouch through the opening.

FIGS. 5 to 10 are various views of one embodiment of a reclosable package 100. The reclosable package 100 includes a pouch 120 that defines an interior volume 122 and an opening 124 that provides access to the interior volume. The pouch 120 also includes an upper seal region 140 disposed adjacent the opening 124 that is adapted to be broken to allow a first opening of the pouch. The reclosable package 100 also includes a self-mating fastener 150 connected to the pouch 120. The self-mating fastener 150 can include any suitable fastener, e.g., fastener 1 of FIGS. 1 to 3. The self-mating fastener 150 includes an open configuration (as shown in FIG. 7) and a closed configuration (as shown in FIGS. 5 and 6). When in the open configuration, the self-mating fastener 150 is adapted to allow access to the interior volume 122 of the pouch 120 through the opening 124 after the seal region 140 has been broken. Further, when in the closed configuration, the self-mating fastener 150 is adapted to prevent access to the interior volume 122 of the pouch 120 through the opening 124.

As used herein, the term “allow access” means that a user of the reclosable package 100 can reach into the interior volume 122 of the pouch 120 through the opening 124 and grasp at least a portion of consumer goods disposed within the interior volume. Further, as used herein, the term “prevent access” means that the user of the reclosable package cannot reach into the interior volume 122 of the pouch 120 through the opening 124 to grasp at least a portion of the consumer goods disposed within the interior volume without first manipulating the self-mating fastener 150.

The pouch 120 can include any suitable bag or package that defines the interior volume 122. Further, the pouch 120 can be adapted to contain any suitable items. In some embodiments, the pouch 120 can be adapted to contain any suitable consumer goods, e.g., foodstuffs such as crackers, potato chips, and cheese, bulk granular or powdered products, animal feed, lawn and garden products, etc.

The pouch 120 can be formed using any suitable technique or techniques. In the embodiments illustrated in FIGS. 5 to 10, the pouch 120 is formed from a single piece of material or film that is connected along a rear seal region 138 that extends in a vertical direction that is substantially parallel to first and second side edges 134, 136 of the pouch as shown in FIG. 6. Further, the pouch 120 includes the upper seal region 140 and a lower seal region 142. The rear, upper, and lower seal regions 138, 140, 142 can be formed using any suitable technique or techniques, e.g., ultrasonic welding, adhering (e.g., using a hot melt adhesive as described herein), heat sealing, and combinations thereof. In some embodiments, the seal regions 138, 140, 142 can be formed using the same technique or techniques. In some embodiments, one or more of the seal regions 138, 140, 142 can be formed using a technique that is different from the technique utilized to form the other seal regions.

The pouch 120 can have any suitable dimensions and take any suitable shape or combination of shapes. Further, the pouch 120 includes a front panel 130 and a back panel 132.

The front panel 130 and the back panel 132 can meet at the first and second side edges 134, 136. In some embodiments, the front panel 130 and the back panel 132 are integral such that the pouch 120 does not include seams or seal regions adjacent one or both of the first and second side edges 134, 136. As used herein, the term “adjacent the side edge” means that an element or component of the package 100 is disposed closer to one of the first and second side edges 134, 136 than to the rear seal region 138. In some embodiments, the front and back panels 130, 132 can be connected to each other at side edges 134, 136 using any suitable technique or techniques. For example, in some embodiments, the front panel 130 and the back panel 132 can be made separately and then joined together at the first and second side edges 134, 136 by connecting the front panel to the back panel.

The pouch 120 can include the opening 124 (FIG. 7) that provides access to the interior volume 122. The opening 124 can be disposed in any suitable location on the pouch 120. As shown in FIG. 7, the opening 124 is disposed adjacent a top edge 126 of the pouch 120. As used herein, the term “adjacent the top edge” means that an element or component of the package 100 is disposed closer to the top edge 126 of the pouch 120 than to a bottom edge 128 of the pouch. The opening 124 can take any suitable shape and have any suitable dimensions. In some embodiments, the opening extends between first and second side edges 134, 136 of the pouch. In some embodiments, one or more seal regions may be disposed between edges of the opening 124 and the first and second side edges 134, 136 of the pouch 120 such the opening does not extend to one or both of the first and second side edges of the pouch. In some embodiments, the opening 124 of the pouch 120 can be defined by the top edge 126 of the pouch.

In some embodiments, the pouch 120 can include a seal region disposed adjacent the opening 124 that is adapted to be broken to allow a first opening of the pouch such that the user can access consumer goods disposed within the interior volume 122. As used herein, the term “first opening” refers to the first time that the reclosable package is opened by the user following manufacturing and filling of the package. In the embodiments illustrated in FIGS. 5 to 10, such seal region includes the upper seal region 140. The upper seal region 140 seals the pouch 120 prior to the first opening of the pouch to preserve the consumer goods disposed within the interior volume 122. To access such consumer goods, the user can break the upper seal region 140 using any suitable technique or techniques, e.g., pulling apart, tearing, cutting, etc.

The pouch 120 can be made using any suitable material or materials, e.g., one or more inorganic, polymeric, and metallic materials. In some embodiments, the pouch 120 can include one or more polymeric materials such as a polyolefin (e.g., oriented polypropylene OPP, low density polyethylene (LDPE), and linear low polyethylene (LLDPE)), a polyester (e.g., polyethylene terephthalate) (PET)), a polyacrylate, and ethylene vinyl alcohol (EVOH). Films of these materials are available as single-layer films, for example, and as multiple layer films including functional tie layers. Multiple layer films can be made by coextrusion or stepwise extrusion. The functional tie layer can be made of any of the polymeric materials described for the pouch blended with 5% by weight to 50% by weight of a functional polymer. The multiple layer film is usually configured with the tie layer on the inside of the pouch 120 and can allow for adhesive bonding and hermetic sealing of the pouch. Many functional polymers useful as tie layer resins are commercially available, for example, from Dow Chemical Company under the trade designation “AMPLIFY”. In some embodiments, the pouch 120 can include a flexible material. Tie layers on the pouch may also include any of the elastomeric materials described above in connection with the tie layer on the fastener.

The pouch 120 can include any suitable graphic or graphics (not shown) disposed on one or both of the front and back panels 130, 132 using any suitable technique or techniques, e.g., ink jet printing, laminating, digital printing, flexographic printing, screen printing, ink transfer, and combinations of these. In some embodiments, the graphic (not shown) can be disposed on the front panel of the pouch, where a portion of the graphic is disposed over the self-mating fastener 150 when the fastener is in the closed configuration.

Connected to the pouch 120 is the self-mating fastener 150 of the present disclosure as described above in any of its embodiments. The self-mating fastener 150 can be connected to the pouch 120 in any suitable location. In the embodiment illustrated in FIGS. 5 to 10, the self-mating fastener 150 is connected to the pouch 120 adjacent the top edge 126 of the pouch. In some embodiments, the self-mating fastener 150 is disposed at the top edge 126 of the pouch 120. Further, in some embodiments, the self-mating fastener 150 can be disposed adjacent a center region 146 of the pouch 120. As used herein, the term “adjacent the center region” means that the self-mating fastener 150 is disposed closer to the center region 146 of the pouch 120 than to the top edge 126 or the bottom edge 128 of the pouch.

Further, the self-mating fastener 150 of the present disclosure can be disposed in any suitable location relative to the opening 124 of the pouch 120 such that the fastener when in the open configuration can allow access to the interior volume 122 of the pouch through the opening, after the upper seal region 140 has been broken and that when in the closed configuration the fastener is adapted to prevent access to the interior volume of the pouch through the opening.

For example, as shown in FIG. 7, the self-mating fastener 150 is disposed adjacent the opening 124. As used herein, the term “adjacent the opening” means that the self-mating fastener 150 is disposed such that the fastener can manipulate the opening such that is sufficiently open to allow access to the consumer goods disposed within the pouch 120 and sufficiently closed to prevent access to the consumer goods. In some embodiments, the self-mating fastener 150 can be disposed within the opening 124. In some embodiments, the self-mating fastener 150 can be disposed outside of the opening 124 along an edge of the opening such that the fastener can be manipulated between the open and closed configurations to open and close the opening as is further described herein. The self-mating fastener 150 can have any suitable dimensions and take any suitable shape or shapes. In some embodiments, the self-mating fastener 150 can be connected to the pouch 120 adjacent the top edge 126 of the pouch and extend between the first and second side edges 134,

136 of the pouch as shown in FIGS. 5 and 6. The self-mating fastener 150 can extend to one or both of the first and second side edges 134, 136 of the pouch. In some embodiments, the self mating fastener 150 can be adapted such that one or both of a first side edge 156 and a second side edge 158 of the fastener is spaced apart from the respective first and second side edges 134, 136 of the pouch 120 any suitable distance. In such embodiments, the pouch 120 may also include one or more seal regions disposed between one or both of the first and second side edges 156, 158 of the self-mating fastener 150 and the first and second side edges 134, 136 of the pouch 120 such that the fastener along with the seal regions seal the pouch along a width of the pouch.

As shown in FIG. 8, which is a schematic cross-section view of a portion of the pouch 120 of FIGS. 5 to 7, the self-mating fastener 150 includes a first fastener member 152 and a second fastener member 154. The first fastener member 152 can be the same as the second fastener member 154 or different from the second fastener member. Further, the first and second fastener members 152, 154 can be connected to the pouch 120 in any suitable location. In the embodiment illustrated in FIG. 8, the first fastener member 152 is disposed on an inner surface 131 of the front panel 130 and the second fastener member 154 is disposed on an inner surface 133 of the back panel 132. In some embodiments, the first fastener member 152 can be disposed on the inner surface 131 of the front panel 130 adjacent the top edge 126 of the pouch 120, and the second fastener member 154 can be disposed on the inner surface 133 of the back panel 132 adjacent the top edge of the pouch.

In some embodiments, the first fastener member 152 can overlap with the second fastener member 154 in a direction orthogonal to the front and back panels 130, 132 such that at least a portion of the first fastener member can mate with the second fastener member. In some embodiments, the first fastener member 152 is registered with the second fastener member 154 in the direction orthogonal to the front and back panels 130, 132 as shown, e.g., in FIG. 8.

The self-mating fastener 150 can be connected to the pouch 120 using any suitable technique or techniques. In some embodiments, the fastener 150 is adhered to the pouch 120 using any suitable adhesive or combination of adhesives, including any of the hot melt adhesives described herein. Further, in some embodiments, self-mating fastener 150 can be ultrasonically bonded to the pouch 120. In some embodiments, the fastener 150 can be mechanically attached to the pouch 120 using any suitable technique or techniques. In some embodiments, a tie layer as described herein in any of its embodiments may be disposed between one or both of the first and second fastener members 152, 154 and the front and back panels 130, 132 respectively. When tie layers or hot melt adhesives are used to connect the self-mating fastener 150 of the present disclosure to the pouch 120, heating the adhesive or tie layer can be carried out using high-temperature impingement fluid as described in U.S. Pat. Nos. 9,096,960 (Biegler et al.), 9,126,224 (Biegler et al.), and 8,956,496 (Biegler et al.). In some embodiments, the high- temperature fluid is a high-temperature gas (e.g., air, dehumidified air, nitrogen, an inert gas, a mixture of any of these, or another gas mixture). In some embodiments, the high-temperature fluid is high-temperature air. The high-temperature fluid can be directed toward the tie layer or hot melt adhesive only, or the high-temperature fluid can be directed toward both the tie layer or hot melt adhesive and the film useful for forming the pouch. In some embodiments, high-temperature air is directed toward the tie layer or hot melt adhesive only before it is bonded to the pouch. In some embodiments, connecting the self-mating fastener 150 to the pouch 120 includes impinging high- temperature fluid, including any of those described above, onto a second surface of a web of the self-mating fastener while it is moving, wherein the second surface is the surface opposite the first surface bearing the rails and ribs. In some of these embodiments, the second surface of the web includes a tie layer. In some embodiments, the second surface of the web includes a hot melt adhesive. Optionally, either sequentially or simultaneously, connecting the self-mating fastener 150 to the pouch 120 includes impinging high-temperature fluid, including any of those described above, onto a surface of a web of a film useful for forming the pouch while the web of the film is moving. Connecting the self-mating fastener 150 to the film can then be carried out by contacting the second surface of the web of the self-mating fastener to the web of the film useful for forming the pouch. A heated bar may also be useful for connecting the self-mating fastener to the pouch. The self-mating fastener, tie layer, and/or hot melt adhesive may be contacted with a heated bar one or multiple times to ensure a good bond to the packaging film. Typically, the heated bar is contacted to the non-adhesive-containing side of the packaging film.

Methods for attaching a fastening strip to a package across the package in a direction transverse to the direction of forming the package are described, for example, in U.S. Pat. Nos. 4,372,793 (Herz), 4,655,862 (Christoff et al.), 5,103,546 (Rossini), and 4,931,003 (VanErden) and in Int. Pat. Appl. Pub. No. WO 2021/144690 (Alberg et al.).

As mentioned herein, the self-mating fastener 150 has an open configuration and a closed configuration. For example, as shown in FIG. 8, the self-mating fastener 150 is in the closed configuration such that the user is prevented from accessing the interior volume 122 of the pouch 120 through the opening 124 of the pouch. Further, as shown in FIG. 8, the upper seal region 140 is intact and has not yet been broken upon a first opening of the pouch 120. As a result, the consumer goods disposed within the interior volume 122 of the pouch 120 can be preserved by the seal region 140. In general, the self-mating fastener 150 can be connected to the pouch 120 such that the fastener is in this closed configuration when the bag is manufactured. In some embodiments, self mating fastener 150 can be connected to the pouch 120 during manufacturing such that it is in an open configuration. For example, FIG. 9 is a schematic cross-section view of a portion of the pouch 120 of FIGS. 5 to 7. As shown in FIG. 9, the self-mating fastener 150 is in the open configuration. As used herein, the term “open configuration” means that one or more portions of the self-mating fastener 150 has been separated such that the user may reach into the pouch 120 through the opening 124 and the self-mating fastener to grasp a portion of the consumer goods disposed within the interior volume 122 of the pouch.

As also shown in FIG. 9, the upper seal region 140 is still intact and has not yet been broken upon the first opening of the pouch 120. In embodiments where the self-mating fastener 150 is connected to the pouch 120 such that it is in the open configuration prior to the first opening of the pouch 120, the user may grasp portions of the front and back panels 130, 132 and manipulate the panels in a direction away from each other. During this manipulation by the user, the upper seal region 140 may remain intact while portions of the self-mating fastener 50 may be separated such that it is in the open configuration as shown in FIG. 9. In some embodiments, manipulation by the user upon the first opening of the pouch 120 may instead first separate the upper seal region 140 such that the seal region is at least partially broken prior to manipulation of the self-mating fastener 150 from the closed configuration to the open configuration.

Further shown in FIG. 9, both of the first and second fastener members 152, 154 are provided with flange zones 155 in which the ribs and rails are crushed but may leave raised areas 153 on the backing. Such zones may be useful, for example, for example, for attaching the self mating fastener to the pouch 120. Flange zones can be made, for example, by subjecting the self mating fastener to a roll having high-profile areas and low-profile areas. In some embodiments, the high-profile areas of the roll crush at least three sets of alternating rails and ribs. In the illustrated embodiment, the high-profile areas crush three sets of alternating rails and ribs on the ends of the first and second fastener members 152, 154. The low-profile leave the alternating rails and ribs in a portion of the first and second fastener members unchanged, for example, in the center of the first and second fastener members as illustrated. In some embodiments, the flange zones have a width that is at least the width of three, four, or five alternating sets of ribs and rails.

FIG. 10 is a schematic cross-section view of the pouch 120 of FIG. 5 to 7, where the upper seal region 140 has been broken upon the first opening of the pouch and the self-mating fastener 150 is in the open configuration. As shown in FIG. 10, the user may now access the interior volume 122 of the pouch 120 through the opening 124 and through the self-mating fastener 150. The user may then manipulate the self-mating closure 150 from the open configuration to the closed configuration such that the user can no longer access the interior volume 122 of the pouch 120.

FIG. 11 is a schematic cross-section view of an embodiment of the opening 124 of pouch 120 of FIG. 5 to 7, where the self-mating fastener 150 is in the closed configuration. The self mating fastener 150 includes a first fastener member 152 and a second fastener member 154. In the illustrated embodiment, the first fastener member 152 and the second fastener member 154 are part of the same strip of material, folded over onto itself. The self-mating fastener 150 is folded, for example, along an axis parallel to the width (W) of the fastener, referring to FIG. 1A, so that a rib 106 is visible in the cross-section view. In the embodiment illustrated in FIG. 11, the first fastener member 152 is disposed on an inner surface 131 of the front panel 130 and the second fastener member 154 is disposed on an inner surface 133 of the back panel 132 of the pouch. The first fastener member 152 is attached to inner surface 131 of the front panel 130 and the second fastener member 154 is attached to inner surface 133 of the back panel 132 using tie layer 103. Advantageously, the thickness of the self-mating fastener 150 in this folded configuration can be up to 750, 700, 600, 500, 450, or 400 micrometers.

Any suitable technique or techniques may be utilized by the user to manipulate the self mating fastener 150 to the closed configuration. For example, the user may press the self-mating closure 150 together by placing one hand on the front panel 130 and another hand on the back panel 132 and pressing the first fastener member 152 against the second fastener member 154. Further, for example, the user may place the package 100 on a flat surface such that either the first or second panels 130, 132 are in contact with the surface, and then press the first and second fastener members 152, 154 together.

When in the closed configuration as shown in FIG. 8, the self-mating fastener 150 may prevent consumer goods disposed within the interior volume 122 of the pouch 120 from falling or spilling out of the pouch through the opening 124. Further, in some embodiments, the self-mating fastener 150 may seal the pouch 120 in the closed configuration such that the consumer goods disposed within the interior volume 122 remain fresh.

Any suitable technique or techniques can be utilized to determine whether the self-mating fastener 150 is in the closed configuration. For example, in some embodiments, the self-mating faster 150 is considered to be in the closed configuration when a force to open the self-mating fastener is at least about 0.1 Newtons and no greater than 10.0 Newtons as determined from the mean maximum load from the T-Peel Test Method described in the Examples. In some embodiments, the force to open the self-mating fastener is in a range 0.2 N to 5.0 N or 1.0 N to 5.0 N as determined from the mean maximum load from the T-Peel Test Method described in the Examples. As shown in the Examples, below, the force to open the self-mating fattener is reduced in comparison to some commercially available fasteners. This can be advantageous for consumers to open the self-mating fastener without damaging the package.

Further, in some embodiments, the force required to achieve a closed configuration from an open configuration, as previously defined, is no more than 4.0 Newtons (N) but at least 0.3 N as determined utilizing the Force to Close Test Method described in the Examples. In some embodiments, the force required to achieve a closed configuration from an open configuration is in a range from 0.45 N to 3.0 N or 0.6 N to 2.4 N as determined utilizing the Force to Close Test Method. In some embodiments, transition from an open configuration to a closed configuration is readily achieved with finger pressure.

The self-mating fastener 150 and the material utilized for the pouch 120 can be selected to provide any desirable stiffness in resistance to bending about a pouch axis 102 that is perpendicular to a length 104 of the self-mating fastener as shown in FIG. 5. Any suitable technique or techniques can be utilized to determine the stiffness in resistance to bending of the pouch 120 and the self-mating fastener 150. The self-mating fastener 150 can have a flexural rigidity of at least about 100 mN/mm and up to about 1500 mN/mm as determined utilizing the Flexural Stiffness Test described in the ASTM D790 (2003). In this method, the test specimens are closed, flattened, and placed in the 3 -point bend fixture. The gap between the bottom 2 points is set to 12 mm and the force to displace the sample a set distance is measured. The upper compression point diameter is 4 mm, and the support diameters are 5 mm. The upper compression point is advanced at a linear rate of 12 in/minute (30.5 cm/minute). Flexural stiffness is derived from the first primary slope of the force versus displacement curve before the fastening elements slip and begin to slide past one another resulting in a second primary slope. In some embodiments, the bending stiffness of the fastener is in a range from 100 mN/mm to 1500 mN/mm, 200 mN/mm to 1200 mN/mm, or 300 mN/mm to 1000 mN/mm as measured by the Flexural Stiffness Test Method. The self-mating fastener can also have a Gurley Stiffness of up to one milligram of force (mgf), or up to 1.5 mgf, up to 2 mgf, or up to 2.5 mgf in the cross direction as measured using the method described in the Examples, below. The self-mating fastener can also have a Gurley Stiffness of up to 10 mgf, up to 9 mgf, up to 8.5 mgf, or up to 8 mgf in the machine direction.

With a bending stiffness in these ranges, typically and advantageously, the fastener does not unintentionally open when the fastener is bent. Furthermore, the design of the fastener can be adjusted to adjust the stiffness and bending behavior as desired for manufacturing and use.

The various embodiments of a reclosable package described herein can include any suitable configuration of pouch. For example, FIGS. 12 and 13 are various views of another embodiment of a reclosable package 200. All of the design considerations and possibilities regarding the package 100 of FIGS. 5 to 11 apply equally to the package 200 of FIGS. 12 and 13. The reclosable package 200 includes a pouch 220 that defines an interior volume 222 and an opening 224 that provides access to the interior volume. In the embodiment illustrated in FIGS. 12 and 13, the opening is disposed adjacent atop edge 226 of the pouch 220. The pouch 220 also includes an upper seal region 240 disposed adjacent the opening 224 that is adapted to be broken to allow a first opening of the pouch.

The pouch 220 further includes a front panel 230 and a back panel 232. The pouch 220 can be formed utilizing a single film that can be sealed along a first side seal region 234 and a second side seal region 236. In some embodiments, the pouch 220 also includes the upper seal region 240. Further, an opening 241 can be disposed adjacent the upper seal region 240 such that the pouch 220 can be hung on a display rack.

The package 200 also includes a self-mating fastener 250 according to the present disclosure connected to the pouch 220. The self-mating fastener 250 can be connected to the pouch 220 in any suitable location. In some embodiments, the self-mating fastener 250 is disposed adjacent the opening 224 of the pouch 220.

The pouch 220 can also include a bottom gusset 270 disposed adjacent a bottom edge 228 of the pouch. The bottom gusset 270 can be folded inwardly from the bottom edge 228 of the pouch. The bottom gusset 270 can be formed utilizing any suitable technique or techniques.

Further, FIGS. 14 and 15 are various views of another embodiment of a reclosable package 300. All of the design considerations and possibilities regarding the reclosable package 100 of FIGS. 5 to 11 apply equally to the package 300 of FIGS. 14 and 15. The reclosable package 300 includes a pouch 320 having a front panel 330 and a rear panel 332 that can be joined together at a first side seal region 334 and a second side seal region 336. The front and back panels 330,

332 can also be joined together at an upper seal region 340 adjacent a top edge 326 of the pouch. An opening 341 can be disposed adjacent the top edge 326 such that the package 300 can be hung on a display rack. The reclosable package 300 also includes a self-mating fastener 350 of the present disclosure.

The front panel 330 includes a perforated opening 324 that is adapted to allow a user to separate the perforation and access consumer goods disposed within an inner volume 322 of the pouch 320. In some embodiments, the pouch 320 can also include a tear strip (not shown) disposed over the self-mating fastener 350 that is adapted to allow the user to remove the strip and access the interior volume 322 of the pouch.

The self-mating fastener 350 can be disposed adjacent opening 324 on an outer surface 331 of the front panel 330. In some embodiments, portions of the self-mating fastener 350 can extend over the opening. For example, a first fastener member 352 of the self-mating fastener 350 can cover the opening 324 while a second fastener member 354 of the fastener includes a first portion disposed on a portion of the outer surface 331 of the front panel 330 above the opening when the pouch 320 is positioned in a vertical orientation (i.e., a pouch axis that extends parallel to the first and second side seal regions 334, 336 is substantially parallel to a normal to the Earth’s surface), and a second portion of the second fastener member is disposed below the opening. A recess 302 can be formed in the self-mating fastener 350 to allow a user to grasp the first fastener member 352 and pull the first fastener member in a direction away from the second fastener member 354 to manipulate the self-mating fastener from a closed configuration to an open configuration.

The various embodiments of reclosable packages described herein can be manufactured using any suitable technique or techniques. For example, FIG. 16 is a schematic perspective view of one embodiment of an apparatus 400 and method for forming the reclosable package 100 of FIGS. 5 to 15. Although described in reference to reclosable package 100 of FIGS. 5 to 15, the apparatus 400 can be utilized to form any suitable reclosable package. A film 402 is provided either in roll or sheet form and conveyed to station 410, where closure material 408 is connected to the film using any suitable technique or techniques. The film can include a top edge 404 and a bottom edge 406. The closure material 408 can be disposed in any suitable location on the film 402, e.g., adjacent the top edge 404.

The closure material 408 can include any suitable closure material. In some embodiments, the closure material 408 includes the first fastener member 152 mated with the second fastener member 154. In some embodiments, the closure material 408 can include either the first fastener member 152 or the second fastener member 154. In some embodiments, the same closure material can be utilized to form both the first fastener member 152 and the second fastener member 154. In such embodiments, the first fastener member 152 can be disposed on a first region of the film 402, and the second fastener member 154 can be disposed on a second region of the film such the first and second fastener members 152, 154 are aligned when the pouch 120 is formed from the film.

At station 411, the film 402 can be slit or cut to form several individual sheets that are utilized to form individual pouches 120. Further, the lower seal region 142 can be formed at the bottom edge 128 of the pouch 120 at station 411 prior to disposal of consumer goods 416 within the interior volume 122 of the pouch at station 412. After the pouch 120 is filled, the upper seal region 140 can be formed at the top edge 126 of the pouch at station 418 such that the consumer goods 416 are sealed within the package 100. Any suitable technique or techniques can be utilized to form the upper and lower seal regions 140, 142.

FIG. 17 illustrates an embodiment of film useful in an embodiment of the process for making the reclosable package 100 of the present disclosure. Film 500 includes a first longitudinal edge 538 separated from a second longitudinal edge 539 by a width 564. Additionally, film 500 has a first side 531 and a second side 535, which eventually form the interior surface and exterior surface of the reclosable package 100, respectively. Attached to the first side 531 of the packaging film 500 are self-mating fasteners 550 of the present disclosure.

In some embodiments, self-mating fastener 550 has an elongate form oriented perpendicular to the first longitudinal edge 538 and the second longitudinal edge 539 and is located in a central portion 546 of the film 500 not including the first or second longitudinal edges 538, 539. In general, the central portion 546 of the film 500 includes the geometric center between the first longitudinal edge 538 and the second longitudinal edge 539. The self-mating fastener 550 has a length 565 that is defined as the distance between the first end portion 556 and a second end portion 558. The first end portion 556 of the self-mated fastener is closer to the first longitudinal edge 538 than the second longitudinal edge 539 of the film 500, and the second end portion 558 of the self-mated fastening strip is closer to the second longitudinal edge 539 than the first longitudinal edge 538 of the film 500. In some embodiments, the length 565 of the self-mating fastener 550 is the same as the distance 564 between the first and second opposing longitudinal edges 538, 539. In some embodiments, there is at least one of a gap 567 between the first end portion 556 and the first longitudinal edge 538 or a gap 569 between the second end portion 558 and the and the second longitudinal edge 539. In some embodiments, gap 567 and gap 569 are the same distance. In other embodiments, gap 567 and gap 569 are different. In other embodiments, there may a gap 567 and no gap 569 such that the second end portion 558 and the second longitudinal edge 539 are coincident. In some embodiments, the length 565 of the self-mating fastener 550 is not more than 95, 90, 85, 80, or 75 percent of the distance 564 between the first and second opposing longitudinal edges 538, 539.

Film 500 can include a row of self-mating fasteners 550, in which each self-mating fastener 550 is parallel with one another and separated by a generally uniform distance 563. Although film 500 depicts only two self-mating fasteners 550, a typical film 500 useful in the process of making a reclosable package of the present disclosure may include substantially more self-mating fasteners 550 each separated from one another by distance 563.

The self-mating fasteners 550 can be connected to the film 500 using any suitable technique or techniques. In some embodiments, the self-mating fasteners 550 are adhered to the film 500 using any suitable adhesive or combination of adhesives, including any of the hot melt adhesives described herein. The self-mating fasteners 550 each include first and second fastener members 152, 154 as shown in FIGS. 8 to 11, which are part of the same strip of material in which the first fastener member can be folded over to contact the second fastener member. In some embodiments, the first and second fastener members are adhered to the film 500 with a pressure sensitive adhesive. Further, in some embodiments, the first and second fastener members are ultrasonically bonded to the film 500. In some embodiments, the first and second fastener members can be mechanically attached to the film 500 using any suitable technique or techniques. In some embodiments, a tie layer as described herein in any of its embodiments may be disposed between the first fastener member and the second fastener member and the film 500.

To form a resealable package 100 using film 500, the first longitudinal edge 538 and second longitudinal edge 539 are brought together to form tube-like shape. In the embodiments illustrated in FIGS. 17 and 18, the first longitudinal edge 538 and the second longitudinal edge 539 are permitted to maintain uninterrupted contact since neither longitudinal edge includes the self mating fastener 550, and heat and pressure may be applied uniformly throughout the length of the vertical seal 138 to form a hermetic seal.

In some embodiments, gap 567 is overlapped at least partially with gap 569 to form a lap seal. The widths of the gaps 567, 569 may vary depending upon package dimensions but will coincide approximately with the width of the vertical seal 138 of the resultant package formed from film 500. In some embodiments, the gap distance 567 is between 1.27 and 2.54 centimeters. In addition to a lap seal, the vertical seal 138 can be made as a fin seal, pinch seal, or a combination of a lap seal and fin seal. In some of these embodiments, portions of the gaps 567, 569 on both edges of the film would be reserved for forming a seal.

In some embodiments of the process for making a reclosable package of the present disclosure, the process further comprises forming a lower seal perpendicular to the vertical seal 138 to form a bottom edge 142 of the reclosable package 100, which typically forms an open- ended package. The process can include dispensing consumer goods into the reclosable package 100, which can be any of the consumer goods described herein. In some embodiments, the process further comprises forming an upper seal 140 in the reclosable package 100 perpendicular to the vertical seal 138. Typically, one of the self-mating fasteners 550 is between the upper seal 140 and bottom seal 142 and closer to the upper seal 140. In some embodiments, an inert gas can be added to the package before an upper seal 140 is created. The completed reclosable package 100 may then be separated from film 500.

Reclosable packages of the present disclosure and/or made by some embodiments of the process of the present disclosure can be made by a vertical form, fill, and seal machine. An embodiment of a vertical form, fill, and seal machine useful in the process for making the reclosable package of the present disclosure is shown in FIG. 18. Vertical form, fill, and seal machine 600 is generally capable of high-speed production of reclosable packages 100 such as those illustrated in FIGS. 5 to 7, from a roll of film, such as film 500 shown in FIG. 17.

The depiction of vertical form, fill, and seal machine 600 in FIG. 18 is simplified and excludes the cabinet and support structures that typically enclose the machine, and some components may not be drawn to scale. The terms "upstream" and "downstream" may be used to describe the relative placement of certain components of vertical form, fill, and seal machine 600, using the direction of product flow as reference. Thus, a component located towards the top of FIG. 18 is located upstream from a component located towards the bottom of FIG. 18.

Vertical form, fill, and seal machine 600 generally includes a forming collar 670 at least partially encompassing former 672. Attached to the outer surface of the former 672, downstream from the forming collar 670, is a vertical sealer 674. Further downstream is a transverse sealer 676. Vertical form, fill, and seal machine 600 may also include one more pull belts 678 aligned with former 672 to advance film 500 downstream along the body of former 672. The packaging film 500 is maintained on a roll 680 and fed through a series of tensioners 682 before receipt by the forming collar 670.

In the embodiment illustrated in FIG. 18, film 500 is unwound from roll 680 and passed through a set of tensioners 682 that maintain tension along a length of unwound film 500. Film 500 is directed over forming collar 670, which transitions the shape of the film 500 from a substantially planar shape to a shape generally resembling a cross-section of former 672. The first side 531 of the film 500 is generally in contact with the former 672 during the bag forming process, and the second side 535 of the film 500 is outwardly exposed. In the embodiment illustrated in FIG. 18, former 672 has a circular cross-section; however former 672 may have an oval -like shape. The advancement of film 500 along vertical form, fill, and seal machine 600 is controlled, at least in part, by one or more pull belts 678 during the bag-making process.

Film 500 attains a generally tubular shape as it is wrapped around former 672. Referring again to FIG. 17, the tubular shape can be achieved by overlapping the longitudinal edges 538 and 539 of film 500, which are then sealed together by vertical sealer 674 to form a typically hermetic vertical seal 138. Vertical sealer 674 is a sealing apparatus that provides heat and pressure necessary to form vertical seal 138 in the back panel of reclosable package 100. Vertical sealer 674 can create a vertical seal 138 by pressing two layers of film 500 together against the exterior surface of a former 672 in the presence of heat.

Referring again to FIG. 18, the transverse sealer (e.g., sealing jaws 676) can be used to form a lower seal 142 perpendicular to the vertical seal 138 to form a bottom edge of the reclosable package. The transverse sealer may take any alternate form, such as a continuous motion sealer. Once a lower seal 142 has been formed, consumer goods (not shown) may be introduced into the reclosable package 100 before the upper seal 140 is added using sealing jawas 676. Thereafter, a completed downstream reclosable package 100 can be separated from a partially completed upstream reclosable package. In some embodiments of the reclosable package of the present disclosure and the process for making the reclosable package, the self-mating fastener has a thickness of up to 750 (in some embodiments, up to 700, 600, 500, 450, or 400) micrometers. In some embodiments, the self mating fastener has a thickness of at least 200 (in some embodiments, at least 250, 300, or 350) micrometers. With a thickness of up to 750 micrometers, the self-mating fastener is also thin enough that equipment including the forming collar and former that are configured to convert packaging film into a bag can be used without requiring adjustment because of presence of the fastener.

It has been reported in U.S. Pat. App. Pub. No. 2017/0233143 (Huebner), for example, that attempts to install a zipper like fastener using an apparatus such as that shown in FIG. 18 have been unsuccessful because either the continuity of the zipper fastener is interrupted when the vertical seal is made or the presence of the zipper fastener interferes with the formation of the vertical seal. An interrupted zipper fastener prevents the package from being reclosed along the entire width. Interference by the zipper fastener with the formation of the vertical seal may prevent the formation of a hermetic vertical seal or adversely affect the durability of the vertical seal. Since the self-mating fastener has a thickness of up to 700 (in some embodiments, up to 700, 600, 500, 450, or 400) micrometers, some embodiments of the process of making the self-mating fastener according to the present disclosure include bringing together the first and second longitudinal edges and sealing the first and second longitudinal edges together with the first and second end portions of one of the self-mating fastener to form a vertical seal. The self-mating fastener typically does not prevent the formation of the vertical seal, and the continuity of the self mating fastener is typically not interrupted when the vertical seal is made.

While reclosable packages with fasteners have been reported, the fasteners can be stiff and bulky, making these packages difficult to manufacture and fill with consumer goods. Furthermore, fasteners than utilize hooks and loops can collect particles from the stored consumer goods or the environment outside of the package that contaminate the fastener. Such contamination can prevent the fastener from being completely closed, thereby allowing portions of the consumer goods to spill out of the package or prevent the package from preserving the freshness of the consumer goods.

In addition to the advantages of the fastener of the present discourse described above, various embodiments of the fastener of the present disclosure can provide one or more advantages over other fasteners currently available for reclosable packages. For example, some embodiments of the fastener can have a reduced thickness compared to currently available fasteners such that the fastener can be connected to a packaging film used to form the package without compromising roll stability while also minimizing roll loss. As described above, in some embodiments, the thickness of the fastener of the present disclosure is up to 750, 700, 600, 500, 450, or 400 micrometers.

Also, as described above, in some embodiments, the fastener includes a tie layer or hot melt adhesive that can be thermally activated at relatively low temperature (e.g., 90 to 125 °C). In some embodiments, at least one of the thickness of the fastening system or the low-temperature activation of the tie layer can provide aesthetic advantages when the fastener is attached to a package. For example, any graphics on the package may have little or no distortion in the location of the fastener. Further, the fastener of the present disclosure can be more flexible than currently available fasteners such that the fastener does not unintentionally open if the fastener is bent, thereby preventing consumer goods disposed within the pouch from spilling out of the pouch. Further, some embodiments of the fastener of the present disclosure can be more contamination- resistant by preventing food debris such as small particles and salt from contaminating the fastener.

Some Embodiments of the Disclosure

In a first embodiment, the present disclosure provides a fastener comprising: a backing having opposing first and second major surfaces, a length, a width, and a thickness; rails and ribs protruding perpendicularly from the first major surface of the backing, wherein the rails and ribs alternate, wherein each of the rails has a continuous base portion attached to the backing and a continuous cap portion distal from the backing, wherein the continuous cap portion has a cap width that is greater than a width of the continuous base portion, wherein the continuous cap portion overhangs the continuous base portion on opposing sides, wherein each of the ribs has a continuous proximal portion attached to the backing, a height that is no greater than a height of rails, and a continuous distal portion distal from the backing, and wherein the continuous distal portion has a width that is no greater than the width of the continuous proximal portion.

In a second embodiment, the present disclosure provides the fastener of the first embodiment, wherein the continuous distal portion is not provided with a series of notches.

In a third embodiment, the present disclosure provides the fastener of the first or second embodiment, wherein the thickness of the backing combined with the height of the rails is up to 750 micrometers.

In a fourth embodiment, the present disclosure provides the fastener of any one of the first to third embodiments, wherein the fastener has at least three of the rails alternating with at least three of the ribs. In a fifth embodiment, the present disclosure provides the fastener of any one of the first to fourth embodiments, wherein the fastener has a zone in which at least three of the rails alternating with at least three of ribs are crushed to provide a flange zone.

In a sixth embodiment, the present disclosure provides the fastener of any one of the first to fifth embodiments, wherein a shortest distance between one of the ribs and one of the continuous base portions of an adjacent rail is within 20 percent of the cap width.

In a seventh embodiment, the present disclosure provides the fastener of any one of the first to sixth embodiments, wherein a shortest distance between one of the ribs and one of the continuous base portions of an adjacent rail is substantially the same as the cap width.

In an eighth embodiment, the present disclosure provides the fastener of any one of the first to seventh embodiments, wherein the height of the ribs is up to 95 percent of the height of the rails.

In a ninth embodiment, the present disclosure provides the fastener of any one of the first to eighth embodiments, wherein the continuous base portion of the rails has a first rail width adjacent the backing and a second rail width adjacent the continuous cap portion, wherein the first rail width is greater than the second rail width.

In a tenth embodiment, the present disclosure provides the fastener of any one of the first to ninth embodiments, wherein the continuous base portion of the rails has a first rail width adjacent the backing and a second rail width adjacent the continuous cap portion, wherein the first rail width is the same as the second rail width.

In an eleventh embodiment, the present disclosure provides the fastener of any one of the first to tenth embodiments, wherein the continuous cap portion overhangs the continuous base portion at amount of at least 25 micrometers on the opposing sides.

In a twelfth embodiment, the present disclosure provides the fastener of any one of the first to eleventh embodiments, wherein the backing is formed without through-holes.

In a thirteenth embodiment, the present disclosure provides the fastener of any one of the first to twelfth embodiments, wherein the backing does not have stretch-induced molecular orientation.

In a fourteenth embodiment, the present disclosure provides the fastener of any one of the first to thirteenth embodiments, wherein the fastener comprises polyethylene.

In a fifteenth embodiment, the present disclosure provides the fastener of any one of the first to fourteenth embodiments, wherein the fastener comprises a polyethylene elastomer.

In a sixteenth embodiment, the present disclosure provides the fastener of any one of the first to fifteenth embodiments, further comprising adhesive on at least a portion of the first major surface of the backing. In a seventeenth embodiment, the present disclosure provides the fastener of the sixteenth embodiment, wherein the adhesive is a pressure sensitive adhesive.

In an eighteenth embodiment, the present disclosure provides the fastener of any one of the first to seventeenth embodiments, further comprising a tie layer on the second major surface of the backing.

In a nineteenth embodiment, the present disclosure provides the fastener of the eighteenth embodiment, wherein the tie layer comprises a polyolefin elastomer.

In a twentieth embodiment, the present disclosure provides the fastener of any one of the first to seventeenth embodiments, further comprising an adhesive on the second major surface of the backing.

In a twenty-first embodiment, the present disclosure provides the fastener of the twentieth embodiment, wherein the adhesive is a hot melt adhesive.

In a twenty-second embodiment, the present disclosure provides the fastener of any one of the first to twenty-first embodiments, attached to a portion of a package.

In a twenty-third embodiment, the present disclosure provides a fastening system comprising first and second fastener members, wherein at least one of the first or second fastener members comprises the fastener of any one of the first to twenty-second embodiments.

In a twenty-fourth embodiment, the present disclosure provides the fastening system of the twenty-third embodiment, wherein each of the first and second fastener members comprises the fastener of any one of the first to thirty-first embodiments.

In a twenty-fifth embodiment, the present disclosure provides the fastening system of the twenty-third embodiment, wherein the first fastener member comprises the fastener of any one of the first to twenty-third embodiments, and wherein the second fastener members comprises a backing having opposing first and second major surfaces, a length, a width, and a thickness and rails protruding perpendicularly from the first major surface of the backing, wherein each of the rails has a continuous base portion attached to the backing and a continuous cap portion distal from the backing, wherein the continuous cap portion has a cap width that is greater than a width of the continuous base portion, wherein the continuous cap portion overhangs the continuous base portion on opposing sides.

In a twenty-sixth embodiment, the present disclosure provides the fastening system of any one of the twenty-third to twenty-fifth embodiments, wherein when the first and second fastener members are fastened, they can slide relative to each other in a direction parallel to the length of the backing.

In a twenty-seventh embodiment, the present disclosure provides the fastening system of any one of the twenty-third to twenty-sixth embodiments, having an improved air seal over a comparative fastening system, wherein the comparative fastening system is the same as the fastening system except that the continuous rails are replaced with rail segments separated by gaps and that the continuous ribs are replaced by rows of posts.

In a twenty-eighth embodiment, the present disclosure provides the fastening system of any one of the twenty-third to twenty-seventh embodiments, wherein when the first and second fastening members are fastened, the fastening system has a thickness of up to 800 micrometers.

In a twenty-ninth embodiment, the present disclosure provides a reclosable package comprising: a package defining an interior volume and an opening providing access to the interior volume, wherein the package comprises a flexible material and a seal region disposed adjacent the opening that is adapted to be broken to allow a first opening of the package; and the fastening system of any one of the twenty-third to twenty-eighth embodiments connected to the package, wherein the fastening system further comprises an open configuration and a closed configuration, wherein when in the open configuration the fastening system is adapted to allow access to the interior volume of the package through the opening after the seal region has been broken, and wherein when in the closed configuration the fastening system is adapted to prevent access to the interior volume of the package through the opening.

In a thirtieth embodiment, the present disclosure provides the reclosable package of the twenty-ninth embodiment, wherein the fastening system is disposed adjacent the opening of the package.

In a thirty-first embodiment, the present disclosure provides the reclosable package of the twenty-ninth embodiment or thirtieth emboidment, wherein the package further comprises first and second side edges, wherein the fastening system is connected to the package adjacent atop edge of the package and extends between the first and second side edges of the package.

In a thirty-second embodiment, the present disclosure provides the reclosable package of any one of the twenty-ninth to thirty-first embodiments, wherein the first fastener member is disposed on an inner surface of a front panel of the package and the second fastener member is disposed on an inner surface of a back panel of the package.

In a thirty-third embodiment, the present disclosure provides the reclosable package of any one of the twenty-ninth to thirty-second embodiments, wherein the fastening system is adhered to the package.

In a thirty-fourth embodiment, the present disclosure provides the reclosable package of any one of the twenty-ninth to thirty-third embodiments, wherein the fastening system is ultrasonically bonded to the package. In a thirty-fifth embodiment, the present disclosure provides the reclosable package of any one of the twenty-ninth to thirty-fourth embodiments, wherein the opening of the package is defined by a top edge of the package.

In a thirty-sixth embodiment, the present disclosure provides process for making the reclosable package of any one of the twenty-ninth to thirty fifth embodiments, the process comprising: wrapping a film around a former to provide a tube of film, wherein the film comprises first and second opposing longitudinal edges, a distance between the first and second opposing longitudinal edges, and a plurality of fastening strips extending perpendicularly to the first and second longitudinal edges, wherein each of the fastening strips comprises: the fastener of any one of the first to twenty-second embodiments, with the rails and ribs exposed to an interior of the tube of film and the second major surface attached to the film, and a first end portion closer to the first longitudinal edge and a second end portion closer to the second longitudinal edge; bringing together the first and second longitudinal edges; and sealing the first and second longitudinal edges together to form a vertical seal.

In a thirty-seventh embodiment, the present disclosure provides the process of the thirty- sixth embodiment, wherein bringing together the first and second longitudinal edges includes overlapping the first and second longitudinal edges, and wherein sealing includes sealing the first and second longitudinal edges while they are overlapped.

In a thirty-eighth embodiment, the present disclosure provides the process of the thirty- sixth or thirty-seventh embodiment, further comprising forming a lower seal perpendicular to the vertical seal to form a bottom edge of the reclosable package.

In a thirty-ninth embodiment, the present disclosure provides the process of any one of the thirty-sixth to thirty-eighth embodiments, further comprising dispensing consumer goods into the reclosable package.

In a fortieth embodiment, the present disclosure provides the process of any one of the thirty-sixth to thirty-ninth embodiments, further comprising forming an upper seal in the reclosable package perpendicular to the vertical seal such that one of the self-mated fastening strips is between the upper seal and bottom seal and closer to the upper seal.

In order that this disclosure can be more fully understood, the following Examples are set forth. It should be understood that these Examples are for illustrative purposes only and are not to be construed as limiting this disclosure in any manner. EXAMPLES

Example 1

A tooling roll was prepared by diamond turning a pattern of grooves into a roll coated with hard copper at a thickness of 125 micrometers (microns). The molding roll had repeating features of a groove machined into the surface with a base of 130 microns at a 3 degree taper, a depth of 480 micron every 960 micron repeat, and a second shorter groove using the same tooling used to machine the first groove machined every other taller groove at a depth of 317 micron spaced on center at 482 microns so the shorter groove was centered between the two taller grooves. The alternating groove heights were machined across the face of a laboratory roll that had a 9-inch (22.9-cm) diameter by 14-inch (35.6-cm) face with the pattern at a width of 6 inches (15.2 cm). A twin-screw 40-mm extruder was used to extrude a food grade high density polyethylene (HDPE) obtained from Dow Chemical USA, Inc., Midland, Mich., under the trade designation “DMDA- 8904”, and a food grade performance polymer obtained from ExxonMobil Chemical, Houston, Tex., under the trade designation “VISTAMAXX 3980”, at a 90/10 ratio, respectively. Molten polymer was extruded at 280 ^° C from the flat sheet die as a sheet into a rolling cast extrusion takeaway nip with a rubber roll and a tooling roll. The rubber roll forced the molten polymer into the tooling roll having a nominal surface temperature of 75 ^° C. The molten polymer solidified on the roll, and the structured film was removed from the molding roll after a 180-degree wrap from the rubber roll nip point as described by U.S. Pat. No. 6,106,922 (Cejka). The resultant film had a combination of high and low continuous ribs. The taller continuous ribs were then capped using the method described in U.S. Pat. No. 5,868,987 (Kampfer) to produce caps having peaks and grooves, with further manipulation of the caps using U.S. Patent No. 6,132,660 (Kampfer) to deform the heads downward towards the backing as illustrated in FIGS. 1, 2, and 3. The web was slit into strips having widths of 6 mm, 9.5 mm, and 13 mm. When tested by hand by folding a strip sample onto itself, the fastener was easy to close and had sufficient resistance to peel open for each of the widths. The fastener was self-mating and when closed had a thickness < 0.020 inch (<0.5 mm). Referring to FIG. 2, the dimensions of the fastener were measured using a Keyence Digital Microscope, Model VHX-600 and are reported in Table 1, below. Each reported dimension is an average of 5 measurements. Table 1.

Example 2

A 1.5-inch (3.8-cm) single screw extruder was used to extrude a 100% by weight of “VISTAMAXX 3980FL” Performance Polymer from ExxonMobil Chemical which was combined with a separate stream of polymer from the 40-mm twin screw extruder as described in Example 1 having a 90/10 ratio of “DMDA-8904” HDPE from Dow Chemical Company and “VISTAMAXX 3980FL” Performance Polymer from ExxonMobil Chemical in a coextruder setup to make an A/B fdm. Both feed streams were introduced to the flat sheet die to make a structured A/B film as illustrated in FIG. 1 with the non-structured side of the mold having a skin layer of the 100%

“VISTAMAXX 3980FL” Performance Polymer (not shown). The molten polymer solidified on the molding roll as described in Example 1, and the structured film was removed from the molding roll after a 180-degree wrap from the rubber roll nip point as described by U.S. Pat. No. 6, 106,922 (Cejka). The tool roll had a combination of high and low continuous ribs. The taller continuous ribs were then capped using the method described in U.S. Pat. No. 5,868,987 (Kampfer) to produce caps having peaks and grooves, with further manipulation of the caps using U.S. Patent No. 6,132,660 (Kampfer) to deform the heads downward towards the backing as illustrated in FIGS. 1, 2 and 3. The web was slit into strips having widths of 6 mm, 9.5 mm, and 13 mm. Samples were then bonded to an oriented polypropylene (OPP) film, and the “VISTAMAXX 3980FL” Performance Polymer tie layer exhibited excellent adhesion at low bond temperature to the polypropylene film. When tested by hand by folding a strip onto itself, the fastener was easy to close and had sufficient resistance to peel open for each of the widths. The fastener is self-mating and when closed has a thickness < 0.020 inch (<0.5 mm). Example 3

A polyisobutylene -based pressure sensitive adhesive at a 75-micron thickness was transfer coated onto the fastener made according to Example 1 on the smooth fdm side (that is, second major surface). This construction was used for the Air Seal evaluation below.

The PSA-backed closure was then adhered to a biaxially oriented polypropylene (BOPP) fdm obtained from Bryce Company, Memphis, Tennessee, and no wrinkling of the fdm was observed. The BOPP fdm had a thickness of 1.2 mil (30.5 microns). The pressure sensitive adhesive delivered a high bond strength to the fdm since cohesive failure in the layers of the BOPP fdm was observed when removal of the fastener was carried out by hand.

Example 4

Using a fastener made according to Example 1, a flange was introduced by zone crushing elements so they will not engage. A 7-inch (17.8-cm) diameter lab roll with the ability to be heated by oil was machined that had one group of nine 4.8-mm wide recesses and one group of nine 5.8-mm wide recesses, each spaced every 12.5 mm over a width of 14 inches (35.6 cm) on the roll face, the recesses were machined 0.035 inch (0.89 mm) in depth. The roll was heated to an internal setpoint of 154 °C, whereas surface temperature of the recessed roll was recorded at 146 °C. The recessed roll was installed into a nip with pressure capable of up to 100 pli and run at this force. The roll with recesses was engaged against a flat smooth roll which was also driven so the surfaces of both rolls were the same direction (one clockwise and the other counterclockwise) to facilitate the fastener being introduced into the ingoing nip at a line speed of 8 meters/minute.

After exiting the nip, there were 4.8-mm wide zones untouched by the roll which would engage as a self-mating fastener and 7.4-mm wide zones which had no functional elements. The total height in the crushed zone was 190 microns.

Example 5 and 6

Examples 5 and 6, which were subjected to Gurley Stiffness Measurement as described below, were made according to Example 1 with the modification that the backing of Example 5 was 80 micrometers thick, and the backing of Example 6 was 100 micrometers thick.

Comparative Example A

Comparative Example A was a zipper closure on a 11 -ounce Pepperidge Farm Goldfish Baked Snack Crackers re-sealable bag, purchased from Target. Comparative Example B

Comparative Example B was a zipper closure on a 11.2-ounce Snack Factory Pretzel Crisps re-sealable bag, purchased from Target.

Comparative Example C (C.E. C)

Comparative Example C was a commercially available reclosure from Presto Products Company, Lake Forest, Illinois, sold under the trade designation “FRESH-LOCK 106 DSSS”. This is a product that is very similar in both form, function, and performance to Comparative Examples A and B.

For the Air Seal evaluation below, the polyisobutylene-based pressure sensitive adhesive at a 75 -micron thickness used in Example 3 was transfer coated onto the fastener of Comparative Example C on the smooth fdm side (that is, second major surface).

Comparative Example D (C.E. D)

Comparative Example D was prepared as described in Example 4 of U.S. Pat. Appl. Pub. No. 2020/0352287 (Gorman et ah), with the modification that no tie layer was coextruded on the flat side of the structured film.

For the Air Seal evaluation below, the polyisobutylene-based pressure sensitive adhesive at a 75 -micron thickness used in Example 3 was transfer coated onto the fastener of Comparative Example D on the smooth film side (that is, second major surface).

Evaluations

Force to Open (T-Pccl) Test Method

The force to open values for a self-mating fastener were determined utilizing ASTM D1876 (designation D1876-08(2015)el). For Example 1, T-Peel was measured using strips that were 14 inches (35.6 cm) long in the machine direction and having the widths of 6 mm and 9.5 mm. Each strip was folded in half and self-mated to provide a specimen about 7 inches (17.5 cm) long. For Comparative Examples A and B, the tops of the bags were cut off and subjected to the test. A calibrated 11.5-pound (5.22 kg) stainless steel roller was used to roll down the specimen. The roller was applied for a full round trip back and forth on each side of the specimen. The ends of the specimen were peeled open so that one inch (2.54 cm) was separated on each end. The separated portions were bent perpendicular to the specimen plane for clamping in the grips of the Instron machine. A cross-head speed of 12-inches per minute (30.5 cm/minute) was used to peel open the specimen over a distance of 4.5 inches (11.4 cm). Five replicates were used per specimen. The max force averaged over the length of the sample is reported in Table 2, below. Force to Close Test Method

The force required to close a fastener was measured by pulling an open strip of closure device through a set gap, at a rate of 12 in/minute (30.5 cm/minute). Either side of the gap was composed of a radial piece of PTFE to minimize friction while maintaining said gap. A multi directional load cell is utilized to measure the force normal and tangential to the closure device. The average kinetic peel force is obtained by averaging the force 1 inch (2.54 cm) after closure begins and 1 inch (2.54 cm) before closure ends. This measurement was repeated for a total of 5 measurements, which were then averaged. The results are reported in Table 2, below.

Table 2: Force to Close and Force to Open (T-Peel) Measurements

Air Seal Measurement

Pouches with reclosures were tested in the following manner to quantify the level of air pressure the reclosure itself could withstand before failing. This correlates the effectiveness and strength of the closure to control air and water transfer between the package contents and the environment. Pouches were constructed from thin gage (0.002 inch to 0.003 inch) (0.05 mm to 0.076 mm) films designed for flexible food packaging. For the hermetic seal and Comparative Examples C and D, the films were ABA multilayer film structures consisting of polyethylene core layers with printable and heat sealable low density polyethene skin layers. For the Example 3 sample, the film had a polyethylene core with OPP skins. The pouches created for these tests were folded in half onto themselves, had reclosure applied between the two film halves using the polyisobutylene pressure sensitive adhesive described in Example 3, and then had the 2 open sides sealed together via heat and pressure. These pouches were then partially inflated with air, sealed with the reclosure and placed into a sealed water bath apparatus for testing. The specific apparatus used for these tests was a model FP181210-EVP Leak Detector from FlexPak Leak Detectors Inc. When the pouch is submerged and the chamber is sealed, a vacuum pump removes air from the chamber allowing the air contained in the pouch to expand. As the vacuum pressure increases, the pouch expands generating increasing pressure on the reclosure. Any leaks that occur in the pouch are clearly visible as air bubbles in the water bath. The recorded pressures in Table 3, below, are the vacuum pressures required to cause a failure and corresponding leak in the reclosure of the pouch. The higher the vacuum pressure the package can withstand, the better it is able to resist air movement through the closure. The heat sealed (or hermetic) sample was a pouch made as described above but with all 3 open sides sealed shut via heat and pressure.

Table 3. Air Seal. Pressures measured in inHg. ^a Pouch leaked from being submerged at ambient pressure.

Guriev Stiffness Measurement Samples of reclosure were tested under the following methods to quantify their bending stiffness in multiple directions. The test performed in the samples below was a variation on ASTM-6125. The samples were prepared by cutting a 2”x 1” (5.1 cm x 2.54 cm) sample from a parent roll. The orientation of these samples as they were cut from the parent roll was adjusted by 90 degrees to be able to test the bending strength of the material in the cross direction and the machine direction of the parent roll. Samples were securely loaded into the upper arm of a Gurley Stiffness tester from Gurley Precision Instruments.

A 50-g weight was secured into the bottom most position of the lower arm. A motorized arm moves the sample in the upper arm past the lower arm with the fixed weight. As the upper arm moves and makes contact with the sample it, pushes the lower arm up a scale and a sensor detects how far up the scale the lower arm moves until the sample can no longer resist bending. The tester outputs stiffness values in terms of Gurley units which is equivalent to a milligram of force (mgf).

Table 4. Gurley Stiffness Measurement (mgf) ^a Curling of the sample affected the measurement. Various modifications and alterations of this disclosure may be made by those skilled the art without departing from the scope and spirit of the disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth herein. All patents and patent applications cited above are hereby incorporated by reference into this document in their entirety.