Patent Application
20170283121
Not Applicable
Not Applicable
Not Applicable
This invention pertains generally to side gusseted bags or sacks that are especially useful for both retailing and shipping bulk amounts of a product. More particularly, the invention pertains to a shipping bag or sack having side gussets and a double fold easy open top end that is capable of withstanding internal forces against a sealed easy open top end during drop tests. The invention further pertains to a side gusseted bag that includes a stepped feature at the easy open end that may be incorporated into polywoven, thermoplastic and paper bags. The manufacture of these bags includes two fold and seal process steps.
Generally, traditional shipping bags have been assembled from a paper or poly woven sheet material that are formed into a tube and then sealed on the ends with an adhesive, thermal weld, or stitching. A seam adjoining the sides of the sheet material may be thermally welded or sealed with an adhesive. Pinch Bottom Open Mouth shipping sacks (sometimes referred to as “PBOM” bags) may be shipped from the bag manufacturer in a flattened condition with one end closed or sealed, and the other end open for filling the bag. A product packaging facility may incorporate these bags into their production line, using the open end to place or fill product into the bag. The open end of the sack is sometimes referred to by the bag manufacturer as the consumer end while the bottom closed end may be referred to by the bag manufacturer as the manufactured end. The open end of the bag may ultimately become either the top or the bottom of a bag that is filled with product and displayed for purchase by consumers. The product packaging facility may close or seal the open end with a desired fold or seal arrangement. At times, it may be desirable to provide one end of the bag with a means of easily opening the bag. The bag manufacturer may incorporate the easy open feature into the closed end of the bag that is sent from the bag manufacturer to the packaging facility. Alternatively, the packaging facility may seal the open end with an easy open feature once the bag is filled.
Also, when shipping or displaying bulk amounts of a product it may be desirable to include an amount of the bulk material contained within the bags that exceeds thirty pounds. The bags may be gusseted so that they lay flat in storage but expand to contain the larger quantities of bulk material. The heavier materials contained within the bag further requires a sealed or closed bag capable of withstanding heavier loads. Sealing the end that a consumer opens with a seal that withstand heavy loads may be in conflict with a desire to provide an end that opens easily. Prior bags have provided zippers or cover tape and stitching to allow easier access to the interior of the bag. In practice, users may simply cut open the bag to gain access to the interior, however, the cutting of the bag results in fragments contaminating the contents of the bag.
Embodiments according to aspects of the invention provides a uniquely stepped and folded top opening of a side gusseted easy open double fold bag or sack. The shipping bag or sack of the present invention is especially useful for both retailing and shipping bulk amounts of a product. When the easy open double fold of the bag is sealed, the bag is capable of withstanding internal forces at the easy open end from multiple drops during a drop test. The embodiments according to aspects of the invention further include a stepped feature that may be incorporated into polywoven, thermoplastic and paper bags.
These and other embodiments according to aspects of the invention include a bag or sack for holding heavy bulk product. The bag may be made from a polywoven, thermoplastic or paper sheet material, having opposing front and back panels, interconnecting opposing sides, and opposed ends. The interconnecting opposing sides of the bag interconnect the front and back panels. The opposing sides are formed from opposing gussets that extend longitudinally between the top and bottom opposed ends of the bag. The gussets include first and second gusset folds and an intermediate gusset fold. The first gusset fold extends inward from an outer longitudinal edge of the back panel, the second gusset fold extends inward from an outer longitudinal edge of the front panel, and the intermediate gusset fold extends longitudinally and transitions and interconnects the first gusset fold with the second gusset fold. The back panel, first gusset fold, second gusset fold and front panel each include a top edge, wherein the top edges of each are aligned together in a stepped fashion. Also, the top end of the intermediate gusset fold has a slope that interconnects the top ends of the first and second gusset folds.
Aspects of the invention may include a bag formed from a sheet material having a seam in the bag formed by overlapping side edges of the sheet material. An easy open end is formed in the bag wherein a portion of the back panel near the top end of the back panel includes a first lateral crease intersecting the slope of the intermediate gusset fold and extends laterally between the opposing sides of the bag. The front panel and a portion of the back panel may further include a second lateral crease that extends laterally between the opposing sides below the top end of the front panel. According to certain aspects of the invention, the back panel may fold along the first lateral crease such that the back panel folds onto itself and a first thermal weld adheres a portion the back panel to an adjacent portion of the back panel. Additionally, the folded portion of the back panel may be further folded along a second lateral crease such that the folded portion of the back panel overlaps the front panel and is thermal welded and engaged to an upper portion of the front panel.
Another embodiment according to aspects of the invention includes an easy open shipping sack having opposing front and back panels, interconnecting opposing sides, and opposed ends. The interconnecting opposing sides interconnect the front and back panels with opposing gussets, wherein the gussets extend longitudinally between the first and second opposed ends. Each gusset includes a first gusset, second gusset fold and an intermediate gusset fold. The first gusset fold extends inward from an outer longitudinal edge of the back panel, the second gusset fold extends inward from an outer longitudinal edge of the front panel, and an intermediate gusset fold transitions and interconnects the first gusset fold with the second gusset fold. The open top end is stepped so that a top end of the back panel, first gusset fold, second gusset fold and front panel all align with respect to each other in a stepped fashion. The top end of the intermediate gusset fold has a slope greater than zero and less than 1 extending between the top end of the first gusset fold and the top end of the second gusset fold. A portion of the back panel near the top end of the back panel includes a first lateral crease intersecting the slope of the intermediate gusset fold and extends laterally between the opposing sides of the bag. Also, the back panel folds along the first lateral crease such that the back panel folds onto itself and a first thermal weld adheres a portion the back panel to an adjacent portion of the back panel. Additionally, a portion of the front panel and a portion of the back panel may include a second lateral crease that extends laterally between the opposing sides below the top end of the front panel. The folded portion of the back panel may be folded along the second lateral crease such that the folded portion of the back panel overlaps the front panel and may be thermally welded and engaged to an upper portion of the front panel.
According to aspects of the invention an easy open double fold bag is formed by conveying a sheet material through a bag forming and separation units. Those skilled in the art will appreciate that each bag may be made from a pre-sized sheet of material, however, the manufacturing process may be enhanced with the use of rolled sheet material. Without limitation the bag forming and separation unit may utilize a cutting die or shaped knives having a defined step arrangement to cut or perforate a stepped pattern into the sheet material. An alternative suitable method of cutting utilizes a programmable laser to cut the stepped pattern into the sheet material. During formation of the bag, the side edges of the sheet material are overlapped to form a tube of an overlapped sheet material having opposing sides, a front panel, and a back panel. Gussets are formed on the opposing sides of the overlapped sheet material in a manner so that each gusset includes a first gusset fold extending inward from an outer longitudinal edge of the back panel, a second gusset fold extending inward from an outer longitudinal edge of the front panel, and an intermediate gusset fold extending longitudinally that transitions. The intermediate gusset fold interconnects the first gusset fold with the second gusset fold, wherein a top end of the intermediate gusset fold has a slope greater than zero and less than one extending between the top end of the first gusset fold and the top end of the second gusset fold. The top ends of the back panel, first gusset fold, second gusset fold and front panel are aligned with the cut steps aligned in a stepped fashion. The overlapping edges of the overlapped sheet material are sealed together with a hot melt, adhesive or weld.
The process of forming the bag may further include the step of folding a portion of the back panel near the top end of the back panel along a first lateral crease that intersects the slope of the intermediate gusset fold and extends laterally between the opposing sides of the bag. Additionally, the process of forming the bag may include the step of folding a portion of the front panel and a portion of the back panel along a second lateral crease that extends laterally between the opposing sides below the top end of the front panel. Further, when folding the back panel along the first lateral crease, the fold line or crease intersects the slope of the intermediate gusset. Once folded, the back panel is thermally welded onto itself.
Alternatively, the method of forming the bag may further include the steps of folding the back panel along a first lateral crease such that the back panel folds onto itself; thermally welding a portion the back panel to an adjacent portion of the back panel to form a folded portion of the back panel; folding the folded portion of the back panel along a second lateral crease such that the folded portion of the back panel overlaps the front panel; and thermally welding the folded portion of the back panel to an upper portion of the front panel.
The accompanying drawings, which are incorporated in and constitute a portion of this specification, illustrate embodiments of the invention and, together with the detailed description, serve to further explain the invention. The embodiments illustrated herein are presently preferred; however, it should be understood, that the invention is not limited to the precise arrangements and instrumentalities shown. For a fuller understanding of the nature and advantages of the invention, reference should be made to the detailed description in conjunction with the accompanying drawings.
In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components.
The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents.
The apparatus 10 of the present invention is particularly well suited for shipping or retailing heavy bulk product. The shipping bag 10 includes a front panel 12, back panel 16, and opposing sides 20. The bottom end 32 of the bag may be flush cut or left with the opposing mirroring step that is created during a step pattern cut manufacturing process that is described below in greater detail. Although a die cutting process and die cut pattern are described, those skilled in the art will appreciate that the stepped pattern that is cut into a top end 34 of the bag may be accomplished with a programmable laser cutting tool of known suitable construction. The bottom end 32 may be sealed with a double fold and then adhered to the bag with an adhesive, glue, heat seal, weld or other known sealing or closing. Further, the bottom may be sewn with or without bound over tape. The tape and thread of the sewn closure may be dipped in a sealing compound to reduce moisture entering through the sewn seam. Referring to the Figures, various embodiments according to aspects of the invention will be described in greater detail.
With reference to
Referring to
The preferred range of depths for the first fold, second fold, and intermediate fold have been described for large gusset bags, wherein the overall width of material used to form the gusset (measured between the longitudinal folds) is approximately 150 mm. Those skilled in the art will appreciate that other bag sizes may use different sized gussets, ranging for example between 60 mm to 200 mm for example, wherein the step dimensions are accordingly scaled. By way of example, a gusset having a width between the longitudinal folds measuring approximately 110 mm may have the depth of the first gusset fold step ranging between 10-12 mm, the depth of the second gusset fold step ranging between 17-19 mm, and the depth of the intermediate gusset fold rise ranging between 15-17 mm. The width of the corresponding first lateral fold ranges between 15-19 mm and the width of the lateral second fold ranges between 26-32 mm.
It should be appreciated that the sealing or closing of the ends of the bag may be accomplished by welding (ultrasonic, heat, laser, thermal welding, etc.), adhering, taping, stitching, or sealing dependent upon whether a polywoven, thermoplastic or paper material is used to form the bag. By way of example, and without limitation intended, the closing of the bag may be accomplished by conveying the bag through a folding and sealing device, wherein the folding device folds a top or bottom of the bag as the bag moves in a downstream direction. At the downstream end of the folding device, a welding device associated with the folding device welds the folder over end of the bag. Such a folding and welding device has been described by Miller Weldmaster Corporation of Navarre, Ohio. It will be appreciated that the sealing method that is utilized will primarily depend upon the material used to form the bag.
Those skilled in the art will appreciate that the easy open fold and seal of the present invention may be incorporated into the bag by the manufacture of the bag, with the easy open fold and seal forming the closed end and a pinch seal applied by the packaging facility after filling the bag. Alternatively, the bag manufacturer may apply a pinch and seal to form the closed bottom of the bag and the packaging facility may form the easy open fold and seal at the top of the bag after filling the bag. For discussion purposes, and without limitation intended, the bag of the present invention is described herein having a pinch bottom and easy open fold and seal top end. The bag may be filled through the open end by extending or pulling the top end 14 of the front panel 12 away from the back panel 16. The folded portion 72 is then folded along fold line 24 to form a second folded portion 74 and a second thermal weld 28 is applied approximately simultaneously with the folding of the folded portion. The second folded portion may have a width ranging between 28 to 35 mm. The second fold 74 forms an easy open flap that allows a user to grasp an edge portion and separate the second folded portion 74 from the front panel.
Although the bond between the second fold and the front panel allows for separation of the second fold and the front panel, the lateral fold intersecting the slope of the intermediate fold, together with the thermal weld that bonds the back panel to itself and the second fold 50, and the overlapping of the second fold onto the front panel, provides a sealed end that withstand the internal force of contents pressing against the inner walls of the bag during drop tests. By way of example, bags having a stepped construction similar to the bag shown in
Having described the constructional features of the invention the method of manufacture will now be described. In accordance with aspects of the invention, forming an easy open shipping sack of the present invention begins with conveying a sheet material through a cutter. The sheet material may be comprised of a polywoven, thermoplastic or paper material of known suitable construction. The cutting of the sheet material may utilize a die, for example, having a stepped die cut pattern. The sheet material is then conveyed through a former that overlaps the side edges of the sheet material to form an overlapped sheet material having opposing sides, a front panel, and a back panel. The former also forms opposing gussets on the opposing sides. Each gusset is formed to include a first gusset fold extending inward from an outer longitudinal edge of the back panel, a second gusset fold extending inward from an outer longitudinal edge of the front panel, and an intermediate gusset fold extending longitudinally that transitions and interconnects the first gusset fold with the second gusset fold. The top end of the intermediate gusset fold is cut having a slope greater than zero and less than one extending between the top end of the first gusset fold and the top end of the second gusset fold. When the gusset fold overlap the top end of the back panel, top end of the first gusset fold, top end of the second gusset fold and top end of the front panel align in a stepped fashion. The overlapping edges of the overlapped sheet material are adhered or sealing together.
In an embodiment of the invention, the stepped top is folded along a lateral fold line so that a portion of the back panel near the top end of the back panel folds along a first lateral crease that intersects the slope of the intermediate gusset fold and extends laterally between the opposing sides of the bag. A portion of the front panel and a portion of the back panel may be further folded along a second lateral crease that extends laterally between the opposing sides below the top end of the front panel. The folded portion is thermally welded or otherwise adhered so that the back panel attaches to itself. Alternatively, the process may include folding the back panel along a first lateral crease such that the back panel folds onto itself, thermally welding a portion the back panel to an adjacent portion of the back panel to form a folded portion of the back panel, folding the folded portion of the back panel along a second lateral crease such that the folded portion of the back panel overlaps the front panel; and thermally welding the folded portion of the back panel to an upper portion of the front panel.
These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.
