Method of making a hanging file folder and the folder made thereby

A method for manufacturing a hanging file folder, comprising the steps of:

• forming a web of thermoplastic sheet material;
• cutting the thermoplastic web to form a file folder body having first and second upper edges and a width;
• providing first and second thermoplastic support bar profile having first and second support bars, each of which has two terminal ends, a thicker upper support portion, and a thinner lower web-contacting portion defined on one side, by a tapered surface on an inner face of said lower portion and, on the other side, by a strip having a thickness which is about the same as that of the web of thermoplastic material extending downwardly from an outer face of the upper portion with a slot formed between the tapered surface and strip;
• positioning the file folder body such that its first upper edge engages the slot and overlaps the lower portion of the first support bar so as to form a first region of contact between the first edge of the open file folder body and the strip of the first support bar;
• positioning the file folder body such that its second upper edge engages the slot and overlaps the lower portion of the second support bar so as to form a second region of contact between the second edge of the open file folder body and the strip of the second support bar;
• heat bonding the first and second support bars to the first and second upper edges of the file folder body at, respectively, the first and second regions of contact, wherein said lower portion and said thermoplastic web are heated at approximately the same rate to form a smooth, flat bond, thereby minimizing puckering;
• and
• scoring at least one fold line that extends across the width of the file folder body and folding the file folder body along said fold line, so that the hanging file folder has two sides and two walls having upper edges that are attached to the support bars.