INNER LAMINATED PACKAGING BAG AND AUTOMATED METHODS OF MAKING AND USING THE SAME

FIELD OF THE DISCLOSURE

The present disclosure relates to bulk packaging for food and non-food products, including but not limited to rice and grain products, particularly in the market for consumer-facing goods, in contrast to the industrial market.

BACKGROUND OF THE DISCLOSURE

The prior art discloses several alternatives for packaging bulk products, particularly for small particle contents such as rice and grain or powder form contents such as sugar, flour or grain powder, for consumer-facing applications in the size range up to 50 or even 100 pounds. Those in the packaging industry understand this to be a different application from industrial “bulk packaging”, such as flexible intermediate bulk containers (“FIBC”s) or Rigid Intermediate Bulk Containers (“RIBC”s), both of such applications being intended for use with much heavier loads (e.g., up to ˜5,000 pounds).

As to consumer-facing applications, multiwall bags may comprise an outer, lacquer-coated paper layer or wall with flexographic printing on the surface for aesthetic purposes and to appeal to the consumer, and an inner layer or wall constructed with kraft paper. Although these prior art multiwall paper bags can be durable in structure, the printing quality is poor and thus not appealing to today's consumers. They are also associated with undesirable contamination of the bag contents with contaminants such as paper dust.

Alternatively, prior art multi layered consumer-facing plastic bags may comprise printed matter on top of a single layer, or a top layer with reverse printed matter laminated to a middle layer so the printed matter is situated in between the first and middle layers. Also a base layer can be laminated to come in direct contact with the inner contents of the bag. These prior art multi-layered plastic bags may further include printed matter, such as graphics, product information, logos, and the like wherein the printed matter is reverse printed to the laminated side of a first layer so that it is viewed through a second opposing laminate layer. While the printing quality of these prior art multi-layered plastic bags can be superior to other known multiwall bags, prior art multi-layered plastic bags are often less durable in structure.

To overcome some of the deficiencies with paper multiwall bags and plastic multi-layered bags, consumer-facing prior art bags for bulk products have also comprised polymer woven bags. These prior art woven bags may comprise a single polymer woven layer with printed matter on top or a top layer of film with reverse printed matter laminated to the polymer woven layer, or alternatively, a top layer of printed paper coated then laminated to the polymer woven layer.

Although the durability of the structure is enhanced in these prior art woven bags, thus making them more suitable for packaging consumer goods up to 50 or 100 pounds, many common problems are nevertheless associated with these prior art woven bags, particularly where a polymer woven layer is in direct contact with the bag contents. For example, substandard materials and construction can be associated with the fabrication of the polymer woven layer, which often leads to deterioration of the strength and integrity of the bag, and in some instances, mixing of broken-off pieces of the woven strips with the contents of the bag-a significant public health concern.

These prior art consumer-facing composite bags, while functional, nevertheless fail to meet expectations (particularly for packaging products of small particle contents such as rice and grain or powder form contents such as sugar, flour or grain powder), partly because these prior art bags can be aesthetically unattractive as a result of limited printing methods and poor printing quality. Moreover, while some prior art, multi-layered plastic bags have enhanced printing quality and aesthetic appearance, many of these bags are less durable and less appropriate for packaging consumer-facing bulk products. These prior art bags are also associated with undesirable contamination of the bag contents.

By way of example, prior art bags, such as that disclosed in US2007/0140600 to Nowak, are difficult to manufacture, fill, and close.

First, to manufacture this bag, a separate polymeric liner must be inserted into the bag manually as a part of the manufacturing process by first drawing the liner over a rectangular frame to open it, and then by sliding the bag over the liner manually. At that point the bag is considered to be complete, and it can be palletized and sent to a user to be filled. The bag must be manufactured in this way because the woven layer of the Nowak-type bag comprises a flattened woven tubular material that is laminated on both flattened faces with a polymeric outer layer. The inner surface of the Nowak-type bag, however, comprises the woven material, which can flake off and become mixed with the bag contents in the event that a separate inner liner is not used. While it is relatively easy to laminate the outer layers to the outer surface of the reinforcing tubular layer, to Applicant's knowledge, there is no effective way to laminate a polymeric tubular layer within the existing tubular reinforcing layer of the Nowak-type bag. As such, the Nowak-type bag presents an inherent technical limitation.

Second, once manufactured with the separate inner liner, the Nowak-style bag is nonetheless wholly unsuitable for filling on automated packaging lines because it must be filled manually. This is due to the presence of the separate polymeric liner that is simply resting within the outer bag. The inner liner must be held up by whoever is filling the bag to prevent the liner from becoming pushed down into the bag and covered with the contents.

Third, the Nowak-style bag suffers yet a further deficiency, namely that, once filled, the liner and outer bag must then be closed, such as by stitching, which also must be done at least partially manually by a user guiding the end of the liner and the bag through a machine to stitch the bag closed. As can be appreciated, the Nowak-style bag is unfit for large scale use in a country such as the United States because so much manual labor is required in order (i) to make it, (ii) to fill it, and (iii) to close it. Even though the Nowak-style bag is so inadequate, in the packaging industry, it is nonetheless still the state of the art, and has been so for many years. This clearly demonstrates the presence of a long-felt but heretofore unmet need for improved packaging designs for consumer-facing bulk packaging applications.

Additionally, the oxygen transmission rate and the moisture, humidity, or water vapor transmission rate of a bag must also be considered when the bag contents comprise dry powder form contents such as sugars, flours, and grain powders. When bag contents comprise dry powder form contents such as sugars, flours, and grain powders, the contents quickly gain or lose moisture until they are at equilibrium with the environmental relative humidity, and may consequently succumb to undesirable affects, such as becoming soggy or clumping together. Bags containing such contents should include a high barrier layer to block moisture and oxygen transmission in the bag.

Prior art consumer-facing composite bags for small particle contents, such as rice and grain products often include poor ventilation which can increase the moisture or relative humidity of the bag contents and the oxygen concentrations in the bag, thus leaving the contents more susceptible to mold formation and spoilage. Therefore, with respect to bags containing small particle contents such as rice and grains, there is a need for a composite bag that provides a plurality of holes that properly maintains the oxygen transmission rate and moisture or humidity transmission rates of the bag contents. Applicant perceives that there is also a need for improved methods of making such a composite bag to facilitate mass production and automated packaging.

SUMMARY OF THE DISCLOSURE

The present disclosure generally provides a composite bag that is ideal for consumer-facing bulk packaging and provides an overall improved appearance, quality, and utility over existing prior art composite bags, and that is attractive to the consumer both aesthetically and functionally. Embodiments of the present disclosure include composite bags that protect the contents of the woven composite bag from contaminants while simultaneously controlling the humidity, moisture level, and gas composition of the interior of the bag to provide safer and healthier food packaging solutions, such as, for example, the packaging of rice and grain, grain powder including flour or powder mix and sugar products.

The disclosure is directed to a consumer-facing bulk packaging bag that is easy to (i) make, (ii) easy to fill, and (iii) easy to close, on automated product filling lines. The disclosed embodiments satisfy these long-felt but heretofore unmet needs, and represent a new paradigm in the packaging industry, providing the potential for enormous cost savings, and as such, enable the use of such improved packaging in markets.

Bags of the disclosure include a woven structure that holds the bulk packaging with overall improved appearance and quality that is more appealing to consumer markets. Moreover, embodiments of the present disclosure are designed to protect contents from outer contamination by adding an inner barrier layer laminated to the woven structure to control the humidity and moisture level of the bag contents as well as the gas composition of the bag contents by the preferable incorporation of a plurality of air holes. The bags are easily and conveniently made and filled without requiring manual labor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an exploded perspective view of an exemplary embodiment of a multi-layer composite structure used to form a bag in accordance with the present disclosure.

FIG. 2 depicts a cross section of an embodiment of an illustrative multi-layer composite structure of the present disclosure.

FIG. 3A depicts a perspective view of an embodiment of the present disclosure with a plurality of optional breathing holes or air holes formed in the gusseted edges of the composite bag and a longitudinal back seam. The number of breathing holes or air holes can be added or reduced depending on the characteristics and needs of the inner contents.

FIG. 3B illustrates an embodiment of a gusseted bag at left including parallel rows of micro-perforations in the gusset regions, whereas the embodiment of a gusseted bag at right includes a row of perforations along each gusseted side region.

FIG. 4 illustrates a view of a back of an embodiment of an exemplary composite bag illustrating a back seam formed from a lap joint.

FIG. 5A illustrates an embodiment of a back seam configuration in accordance with the disclosure.

FIG. 5B illustrates another embodiment of a back seam configuration in accordance with the disclosure.

FIG. 6 illustrates an embodiment of a manufacture and processing of a woven material web layer in accordance with the disclosure.

FIG. 7 illustrates an embodiment of a roll of laminated composite material in accordance with the disclosure.

FIG. 8 illustrates an embodiment of a folding and sealing step of a moving composite material web in accordance with the disclosure.

FIG. 9 illustrates an embodiment of a folding, sealing, and gusseting process of a moving composite material web in accordance with the disclosure.

FIG. 10A illustrates an embodiment of a heat sealing operation performed on a moving web of composite material that has been longitudinally sealed as set forth in FIG. 9.

FIG. 10B illustrates an embodiment of a cutting operation performed on a moving web of composite material that has been longitudinally sealed as set forth in FIG. 9 and heat sealed as in FIG. 10A.

FIG. 11 illustrates an embodiment of a cutting operation performed on a moving web of composite material that has been longitudinally sealed as set forth in FIG. 9, wherein end closure follows in a subsequent step.

FIG. 12A illustrates an embodiment of a closure technique for an end of a bag formed in accordance with the disclosure.

FIG. 12B illustrates another embodiment of a closure technique for an end of a bag formed in accordance with the disclosure.

FIG. 12C illustrates yet another embodiment of a closure technique for an end of a bag formed in accordance with the disclosure.

FIG. 12D illustrates still another embodiment of a closure technique for an end of a bag formed in accordance with the disclosure.

FIG. 13 illustrates an embodiment of an automated filling operation of a composite bag made in accordance with the disclosure.

FIG. 14 illustrates a cross-section of an embodiment of a two-layer composite structure for an embodiment of a bag of the disclosure.

FIG. 15 illustrates a cross-section of an embodiment of a three-layer composite structure for another embodiment of a bag of the disclosure.

FIG. 16 illustrates a cross-section of another embodiment of a three-layer composite structure for another embodiment of a bag of the disclosure.

FIG. 17 illustrates a cross-section of an embodiment of a three-layer composite structure having an anti-skid coating for another embodiment of a bag of the disclosure.

FIG. 18 illustrates a cross-section of another embodiment of a four-layer composite structure including an anti-skid layer for another embodiment of a bag of the disclosure.

FIG. 19 illustrates a cross-section of an embodiment of a five-layer composite structure including an anti-skid layer for another embodiment of a bag of the disclosure.

DETAILED DESCRIPTION

Embodiments of the disclosure are directed to a consumer-facing bulk packaging bag that is easy to (i) make, (ii) easy to fill, and (iii) easy to close, on automated product filling lines. The disclosed embodiments satisfy these long-felt but heretofore unmet needs, and represent a new paradigm in the packaging industry, providing the potential for enormous cost savings, and as such, enable the use of such improved packaging in markets.

Embodiments of the present disclosure include a woven structure that holds the bulk packaging with overall improved appearance and quality that is more appealing to consumer markets. Moreover, embodiments of the present disclosure are designed to protect contents from outer contamination by adding an inner barrier layer laminated to the woven structure to control the humidity and moisture level of the bag contents as well as the gas composition of the bag contents by the preferable incorporation of a plurality of air holes. The protective inner barrier layer and the woven structure, together with any additional layers that may be present in various embodiments, form a composite web of material. The bags are easily and conveniently made and filled without requiring manual labor.

Other embodiments of the composite bag of the present disclosure may include a top outer layer that may further include an anti-skid coating or lamination on a first surface and reverse printed matter on a second surface, as well as a middle polymer woven layer, and a base inner-barrier layer that constitutes the interior layer of the bag of the present disclosure.

In embodiments of the disclosure, all layers of the present disclosure are preferably adhesively laminated to each other or laminated by other means, such as by heating sufficient to adhere layers to each other, along the entire surface area of the layers.

In embodiments of bags of the present disclosure, a multi-layer composite structure may be used to further increase the overall strength and durability of the bag. Embodiments of the present disclosure provide an aesthetically appealing composite bag with high print quality, while simultaneously providing a composite bag that is sufficiently durable for packaging bulk products, particularly for small particle contents such as rice and grain or powder form contents such as sugar, flour, or grain powder. Bags of the present disclosure also provide an interior, food-safe liner that comes into contact with the contents of the bag and creates an inner barrier layer between the contents of the bag and the remaining layers of the composite web of material to prevent ink or broken woven strips from mixing with the contents of the bag.

Preferably, a composite bag made in accordance with the present disclosure further defines a plurality of air holes, such as micro perforations, formed through the composite layers of the bag to help the contents of the bag retain a desired equilibrium relative humidity with the atmosphere thus helping to reduce the risk of mold formation, as well as prevent cracking, sticking, and spoilage of the bag contents. Moreover, the plurality of air holes can also help control the internal oxygen level of the bag which can be beneficial for prolonged storage and shelf life. More specifically, air holes or micro perforations can extend freshness of the product by controlling the amount of oxygen, carbon dioxide, and moisture inside the package and also by reducing bacteria growth. The number and size of the holes, together with the total area and layout of holes, can be designed based on the properties and characteristics of the contents in the bag.

Air holes or micro perforations can be formed by die cutting, punching, or laser perforating technique at any suitable stage of bag construction. In some embodiments, holes are formed in the composite web before a bag is formed, during bag making and particularly during the folding & gusseting stage, or at any suitable stage. The skilled practitioner will be able to select a suitable processing stage for forming microperforations or other holes.

Other alternative embodiments of the present disclosure may include easy-to-open seams, gusseted edges for improved dimensional stability and flatness, a back seam for improved strength and reliability, easily opened and re-sealed closures providing access to the contents of the bag, and an anti-skid coating or lamination on the surface layer.

In some embodiments, the disclosure provides a composite food packaging bag. The bag may have first and second generally rectangular planar opposing sides operably connected along three edges and open along a fourth edge to define an opening between the first and second generally rectangular planar opposing sides to an interior portion of the bag, wherein the opening is defined by unsealed edges of the bag. Each of the generally rectangular planar opposing sides includes (i) a base inner-barrier layer that includes a continuous polymeric film layer and (ii) a second layer that is laminated to the base inner-barrier layer that includes a polymer woven layer forming a woven structure.

In some embodiments, layers other than an inner barrier layer and a woven structure layer may be present in a composite web of material formed into a composite bag. Such embodiments of the disclosure also may include (iii) a top outer layer laminated to a side of the woven layer opposite the side laminated to the inner barrier layer polymer film. Each of the base inner-barrier layer, the woven layer, which serves as a middle layer in a three-component composite web, and the top outer layer are formed as a laminated sheet or composite web having two parallel longitudinal edges that are sealed to each other in a sealing region to form a longitudinal seal from a bottom of the bag to a top of the bag.

In various embodiments, the longitudinal seal typically is formed by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) stitching, and (iv) the application of adhesive. In some embodiments, the laminated sheet can be sealed to itself by way of a lap joint formed by overlapping the two parallel longitudinal edges. The longitudinal seal can bond the base inner barrier layer along one of the two parallel edges to the top layer along the other parallel edge. In other embodiments of the disclosure, a fin seal, in which the base inner barrier on one of the two parallel edges is sealed to the base inner barrier layer on the other of the two parallel edges, is formed.

Preferably, the base inner-barrier layer, the middle layer, and the top outer layer are laminated to each other over their entire extents. In other embodiments, the base inner-barrier layer, the middle layer, and the top outer layer can be laminated to each other over substantially their entire extents. As will be appreciated by those of skill in the art, the lamination technique that is selected is based typically on the material properties and characteristics of the layers of the composite bag. For example, extrusion coating or lamination, thermal or ultrasonic welding, wet lamination or dry lamination techniques can be used.

Throughout this disclosure, layers of adhesive typically are not separately identified and not separately depicted on the drawing figures. Such layers, also called “tie layers,” may be utilized anywhere adhesive is used. The skilled practitioner recognizes that adhesive is present between layers when adhesive or a tie layer is described, without regard to whether such adhesive layer is illustrated in a drawing figure.

In some embodiments, the composite food packaging bag can further include a fourth (and if desired, a fifth) layer of polymeric material, such as a polymeric adhesive layer (a “tie” layer) disposed between the polymeric woven layer and the inner layer and/or the outer layer. If desired, the composite food packaging bag can further include an additional layer of polymeric material disposed on an external surface of the outer layer, such as in the form of an anti-skid coating.

Embodiments of the disclosure are directed to methods of making composite food packaging bags. The method can include providing a base inner-barrier layer material web that includes a continuous polymeric film layer, forming a polymer woven layer material web by longitudinally slitting a tubular woven fabric material and laying the material flat into a sheet form, and laminating the base inner-barrier layer material web to a first face of the polymer woven layer material web. In some embodiments, an additional layer in the form of an outer layer material web may be laminated to a second face of the polymer woven layer material web to form a composite web of material having three layers. In embodiments of the disclosure, the composite web of material has a pair of longitudinal edges. The method can further include folding the composite web of material onto itself to bring the longitudinal edges together, and sealing the longitudinal edges of the composite web of material to each other to form a flat composite bag material that comprises a circumferential wall with a longitudinal seam suitable for forming bags. If desired, the method can further include cutting the flat composite bag material to a desired length to form a composite bag with an open first end and an open second end.

In some embodiments, the method can further include sealing one of the first end and the second end of the composite bag to form a sealed composite bag with a sealed closed end and an open end. The sealing of the end of the composite bag can be accomplished by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) taping and sewing, and (iv) the application of adhesive, (v) the application of zippering, as well as other suitable techniques. The base inner-barrier layer material web, polymer woven layer material web, and the outer layer material web can be joined in a single lamination operation or step, but are preferably joined in discrete lamination operations or steps. The method can further include forming gusseted sides along a length of the flat composite bag material.

In some embodiments, the method can further include laminating a fourth material web to one of the existing layers prior to joining the longitudinal edges of the web to form the circumferential wall with the longitudinal seam of the flat composite bag material. The fourth material web can include a layer, such as a polymeric tie layer, disposed between the polymer woven layer material web and the outer layer material web, and/or the inner layer. If desired, the method can further include laminating a further material web to one of the existing layers prior to joining the longitudinal edges of the web, such as by laminating an anti-skid or other layer on top of the outer layer. An anti-skid coating makes the bags less slippery, making them less prone to slip off a pile of other filled bags, thus reducing the chance of damage or injury from falling bags.

In some embodiments, the method can further include winding the composite web of material into a roll after laminating the outer layer material web to the second face of the polymer woven layer material web. If desired, the method can further include winding the flat composite bag material (including the circumferential wall with the longitudinal seam) into a roll after sealing the longitudinal edges of the composite web of material to each other. If desired, forming the polymer woven layer material web can include winding the slit tubular woven fabric material after it is laid flat into a sheet form. Preferably, the tubular woven fabric material is slit along both flattened edges to form two webs of woven material that are then wound into two separate rolls. In another embodiment, a flat weaving/looming technique can be used to form the woven sheet, rather than forming it by slitting a flattened roll of circularly woven material.

Generally speaking, during converting operations for manufacturing the composite bag structure, there are various discrete steps. During feeding, for example, material is fed through converting equipment for lamination, sealing, and cutting operations. Feeding can be a continuous operation, but is usually an intermittent operation. For example, operations like sealing and cutting typically are carried out when feeding has stopped.

During a folding operation, such as to form the bag material from a sheet, left and right edges of the moving composite web are folded over toward the middle of the web such that the two edges meet in or near the center of the web. Typically, a lap joint is formed continuously by laying down one edge on top of the other with a small amount of overlap, wherein the outer layer, which may be printed, ends up being outwardly facing.

As to forming the back seam, the overlapped edges mentioned above are welded or otherwise bonded together. The back seam can be centered, but it can also be off center. Other variations of back seam layout are possible such as left aligned, right aligned or side gusset aligned. While the back seam is being formed and sealed, gussets (if desired) can be formed into both side edges by applying rotating discs to the web material. The discs form creases in the material that in turn form the gussets. As a result of the aforementioned operations, the flat composite sheet is folded and sealed to form a tunnel like shape with or without gussets. The resulting material can then be wound into a roll. While gussets are typically formed into the longitudinal sides of the bag, gussets can also be formed into an end of the bag when the bag is formed. The disclosed back sealed seam enables much more flexibility in lamination in contrast to the Nowak-type bag mentioned above which is limited to a purely tubular geometry.

In one embodiment, the method can further include reverse printing on a surface of the outer layer material web that is laminated to the second face of the polymer woven layer material web prior to laminating the outer layer material web to the polymer woven layer material web. The reverse printing may be deposited directly on the outer layer of material, for example. If desired, the method can include depositing an anti-skid coating on an outer surface of the outer layer material. In other embodiments, printing may simply be accomplished by directly printing on the outer surface of the outer layer, which may then, if desired, be covered by an anti-skid or other protective coating. In alternative embodiments, the anti-skid layer may be provided with direct externally printed matter or reverse printed matter. Various printing techniques can be used, such as flexography, gravure, or digital printing techniques.

In some embodiments, the polymer woven layer material web typically includes polyolefin polymers and other additives that are used to form a sheet that is then slit into strips/tapes and woven together. While the material may be woven into a flat sheet and laminated to other polymeric layers to form the composite bag of the present disclosure, it is also possible to employ circular weaving techniques that form a tube of material that is then slit (e.g., with a heated knife) into one or more sheets of woven material. The polymer woven layer material web can include cross-woven polymeric strips having any desired width.

A variety of polymeric materials can be used as the layers of the composite bag, and/or as bonding materials. Suitable materials can include, for example, thermoplastic polymers such as polyolefins (polyethylene and polypropylene), polyesters (polyethylene terephthalate (PET or PETE), polycarbonate, and polyethylene naphthalate (PEN)), polyvinyl chloride (PVC), polyvinylidene chloride (PVdC), polystyrene, polyamide (e.g., NYLON®-type materials) and ethylene vinyl alcohol (EVOH). Polyolefins including polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), and polypropylene (PP), including biaxially oriented polypropylene (BOPP), are favorable to be used for threads of the woven fabric, lamination layers or as bonding materials/layers. Copolymers of the above polymers can also be used to optimize properties such as heat seal-ability, strength, and/or chemical resistance, particularly for the inner layer of the composite bag.

It should be appreciated that all layers of the composite bag need not be polymeric. For example, in some embodiments, paper material can be used as one of the layers of the composite structure, and be laminated to the top of woven fabric in order to enhance stiffness, durability, and/or aesthetic appeal for the consumer market. Kraft paper, sulfite paper or any other paper with suitable tensile strength can be used. In another embodiment, one or more paper layers can be sandwich laminated between the top printed polymer layer and the woven fabric layer.

In an embodiment, the method can further include reverse printing on a surface of the outer layer material web that is laminated to the second face of the polymer woven layer material web prior to laminating the outer layer material web to the polymer woven layer material web.

In other embodiments of this disclosure, a method of making a composite bag (and a composite bag resulting from the method) that can be formed continuously from a moving web of material such that the web of material can move at a constant speed during manufacture is provided. This can be accomplished by folding a web of moving material inwardly to move the longitudinal edges of the web to touch or overlap, and continuously sealing the longitudinal edges of the web together to form a circumferential structure defining a tunnel therethrough.

In further embodiments of the disclosure, one open edge of the bag, for example the top or the bottom, may be closed by forming the seal in the web of material as it is moving. It is a further objective of the disclosure, if desired, to continuously form gussets into the annular web, and thus the composite bag, while the web of material is moving. As can be understood, the entire bag-making process may be automated and continuous, in contrast with the Nowak-type bag. After the Nowak-type woven bags are cut to length, they must be taken to another manufacturing station to close the end of the bag, such as by stitching. In contradistinction, the inner layer of the composite web of material used to form a bag herein permits sealing of the bag, such as by way of heat sealing or ultrasonic sealing, for example, and cutting in the same operation, even when the composite web of material is moving constantly. Thus, embodiments of the disclosure may be made on a continuously moving bag manufacturing line to form bags constantly, permitting them to be stacked and palletized. As such, the disclosed composite bag and associated manufacturing process represents a significant departure from, and improvement over, the prior art.

In accordance with further embodiments of the disclosure, the bag has a plurality of air holes therethrough. Each of the plurality of air holes can be defined by a peripheral edge that is defined at least in part by the base inner barrier layer, the woven structure layer, and other layers that may be present. The air holes can have a diameter between about 0.01 inches and no more than 0.1 inches, for example. Thus, the holes may be microperforations in some embodiments of the disclosure.

In further embodiments, an automated method is provided of using and sealing a bag as described herein with a food product. The method can include (i) providing a composite food packaging bag as described herein, (ii) providing a first automated manipulator that grasps the composite food packaging bag on the first and second generally rectangular planar opposing sides near the opening of the composite food packaging bag to open the bag, (iii) directing the composite food packaging bag to a dispenser of a food product, (iv) dispensing food product into the composite food packaging bag, and (v) sealing the composite food packaging bag to close the opening and to contain the food product within the bag. The sealing can be accomplished by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) stitching, and (iv) the application of adhesive, (v) the application of taping, (vi) the application of zippering, or any other suitable technique. Closures may include easy-access or resealable closures.

The description and the drawings set forth in detail certain illustrative aspects of the disclosure. These aspects are indicative, however, of but a few of the various ways in which the principles of the disclosure may be employed and the present disclosure is intended to include all such aspects and their equivalents. Other advantages and novel features of the disclosure will become apparent from the following detailed description of the embodiments when considered in conjunction with the drawings.

As depicted in FIG. 1, a portion of one embodiment of a composite bag 100 of the present disclosure generally includes a base inner-barrier layer 101, preferably comprised of a polymer film; a middle layer 102, preferably comprised of a polymer woven layer; and a top outer layer 103, preferably comprised of a polymer film. As further depicted in FIG. 1, if desired, a plurality of air holes 104 is formed through the base inner-barrier layer 101, the middle layer 102, and the top outer layer 103 to help the contents of the bag retain a desired equilibrium relative humidity with the atmosphere as well as control the internal oxygen level of the bag.

As depicted in FIG. 2, the top outer layer 203 of the composite bag of the present disclosure preferably includes an anti-skid coating or lamination on its first outer surface 205, and reverse printed matter on its second inner surface 206. As used herein, the term “printed matter” may include graphics, product information, logos, and the like. The middle layer 202 is then laminated to the second inner surface 206 of the top outer layer 203 to provide a composite, wherein the printed matter is sandwiched between the top outer layer 203 and the middle layer 202. As further depicted by FIG. 2, the base inner-barrier layer 201 is laminated to the middle layer 202 so that the base inner-barrier layer 201 forms the interior layer of the composite bag and therefore comes into contact with and protects the contents of the bag.

In preferred embodiments of the present disclosure, the base inner-barrier layer 201, middle layer 202, and top outer layer 203 can be adhesively laminated to one another. In another embodiment of the present disclosure, the middle layer 202 is preferably a polymer woven layer comprised of suitable film-forming plastic resin strips interlaced or woven together to form a net-like structure.

In some embodiments, a “T-die” extrusion lamination technique can be used to bond the layers of the composite bag. In this extrusion lamination process, melted thermoplastic resin (polymer) is extruded through a horizontal slot-die (commonly referred to as a “T-die”) between two layers to be bonded, and acts as a bonding agent, resulting in the two layers becoming permanently bonded. By using this lamination technique, more than two layers can be laminated in successive operations. However, it will be appreciated that any suitable lamination technique can be used.

As depicted in FIG. 3A, once the middle layer 202 is laminated with the base inner-barrier layer 201 and top outer layer 203, the edges of the composite structure can be gusseted 302.

As further depicted in FIG. 3A, the composite bag of the present disclosure preferably comprises a plurality of air holes 301 punched through the plurality of composite layers as described above. The number of breathing holes or air holes can be added or reduced depending on the characteristics and needs of the inner contents. As further depicted in FIG. 3A and FIG. 3B, the gusseted edges 302 of the resulting composite bag are then punched with one or more breathing holes or air holes which are preferably between 0.01 inches to 0.1 inches in diameter. Embodiments of the disclosure may include rows of holes 302B, perforations 301B, or combinations thereof.

In some embodiments, the disclosure provides a composite food packaging bag including first and second generally rectangular planar opposing sides (illustrated as front and back sides in FIG. 3A and FIG. 3B) operably connected along three edges (presented as the side and top edges) and open along a fourth edge (illustrated as the bottom edge) to define an opening between the first and second generally rectangular planar open sides to an interior portion of the bag. As illustrated, the opening is defined by unsealed edges of the bag. As set forth above, each of the generally rectangular planar opposing sides typically includes at least (i) a base inner-barrier layer that includes a continuous polymeric film layer and (ii) a middle layer that is laminated to the base inner-barrier layer that includes a polymer woven layer forming a woven structure. Thus, a composite web of material including these two layers, with additional layers that may be present in other embodiments of the disclosure. The embodiments illustrated in FIG. 3A and FIG. 3B illustrate taped and sewn end 310.

While bag structures of the prior art, such as US2007/0140600, are formed by taking a flattened tube of woven material and laminating a polymer layer on the front and the back of the flattened tube, Applicant appreciated that it was not possible to laminate an inner lamination inside of the tube. However, Applicant appreciated that it would be desirable to do so because Applicant observed that the woven material has a propensity to flake off and mix with the contents of the bag, which is a particularly serious problem in the realm of food packaging. Accordingly, in order to address this problem, a flat sheet of woven material is laminated with an inner barrier layer and an outer polymeric layer to form a composite sheet. This composite sheet is then folded over longitudinally and sealed, thus providing the inner barrier layer across the entire inner periphery of the bag. This protects the contents of the bag from the woven layer and eliminates any chance that the material will flake off into the food contents.

In some embodiments, the method can further include laminating a further material web to one of the existing layers prior to joining the longitudinal edges of the web. The further material web can include a lamination disposed between the polymer woven layer material web and the outer layer material web (or the inner layer) such as a tie layer. If desired, the method can further include laminating a yet further material layer to one of the existing layers prior to joining the longitudinal edges of the web, such as an anti-skid layer.

Thus, a composite web of material comprises laminated sheets and two parallel longitudinal edges sealed to each other in a sealing region to form a longitudinal seal from a bottom of the bag to a top of the bag. The sealing region is delimited by lines 311, 312 in FIG. 3A and FIG. 3B, which represent the beginning and end of a lap joint formed by the overlap of the two longitudinal edges of the sheet material. Specifically, line 312 represents a first outwardly exposed longitudinal edge of the laminated sheet while line 311 represents a second, inwardly exposed longitudinal edge of the laminated sheet. Formation of such a longitudinal seal forms a tunnel structure that, if desired, can be wound on a roll, permitting bags of any desired length to be cut from the material when the roll is unwound.

In various embodiments, the longitudinal seal is typically formed by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) stitching, and (iv) the application of adhesive, (v) the application of taping, (vi) the application of zippering, as well as other suitable techniques. If desired, the laminated sheet can be sealed to itself by way of a lap joint formed by overlapping the two parallel longitudinal edges as presently illustrated in FIG. 3 and in FIG. 4. In this configuration, the longitudinal seal (303, 403) can bond the base inner barrier layer along one of the two parallel edges to the top layer along the other parallel edge. Preferably, the base inner-barrier layer, the middle layer, and the top outer layers are laminated to each other over their entire extents.

Embodiments of sealing techniques are illustrated in FIG. 5A and FIG. 5B. FIG. 5A illustrates in cross-section lap or overlap seal 520. The edge of sheet 521 overlaps the edge of sheet 522, and the edges are sealed together in the area of overlap for form an overlap seal or a lap seal. The inside surface 524 of sheet 522 is sealed to the outside surface 523 of sheet 521. The embodiment illustrated in FIG. 5B is fin seal 530. Fin seal 530 differs from overlap seal 520 in that the inside surface 533 of second sheet 531 is sealed to the inside surface 534 of second sheet 532.

In embodiments of the disclosure, the woven structure utilized in the composite structure is obtained from a tubular woven structure. Typically, the woven material is obtained from a tubular material that is made by a knitting process. In embodiments, this woven tubular material is flattened and further processed to slit it along one or both flattened edges to produce one (or two) web(s) of flattened, single layer, woven material in the form of a continuous web that can be wound and/or further processed. For example, FIG. 6 illustrates a tubular material 601 being slit along both peripheral edges, and then separated into upper and lower webs, and wound into separate rolls.

Tubular material 601 remains tubular, as illustrated at 610 and 615, as it moves or is moved in the direction of arrow 650. First slitter 620 and second slitter 622 slit material 601 into upper sheet 602 and lower sheet 604. The slit tubular material then may be rolled flat onto roll 632 for upper sheet 602 and roll 634 for lower sheet 604. Expanded view 630 illustrates detail for first slitter 620. The slitters may be the same or different, and skilled practitioners will be able to select suitable slitters.

The base inner-barrier layer material web can then be laminated to a first face of the polymer woven layer material web, and a third layer of material web can be laminated to a second face of the polymer woven layer material web to form a composite web of material with a pair of longitudinal edges. FIG. 7 presents a roll of composite material having three layers that have been laminated accordingly. FIG. 7 is a schematic illustration of such a lamination process. Inner barrier layer 701, woven structure 702, and a third sheet 703 are pressed together in the direction of arrows 710 to form composite web of material 705. Web 705 may be wound on roll 708. Third sheet 703 may be outer layer material, anti-slip material, printed or unprinted paper, or any suitable layer. It will be appreciated that third web 703 can be laminated to woven layer 702 prior to inner barrier layer 701 being laminated to the opposing face of woven layer 702, or vice-versa. In some embodiments, while it is possible to laminate all three layers in the same lamination step, it is more typical to laminate two layers at a time and wind the resulting product between lamination steps.

As mentioned above, the method further includes folding the composite web of material onto itself to bring the longitudinal edges together, and sealing the longitudinal edges of the composite web of material to each other to form a flat composite annular structure suitable for forming.

For purposes of illustration and not limitation, FIG. 8 illustrates folding the composite web of material inward continuously as it moves longitudinally to bring the longitudinal edges of the web together, permitting them to be bonded. As shown in FIG. 8, roll 808 may be a composite web of material 800 having any suitable number of layers having outer layer 804 and inner barrier layer 801. As material 800 moves in the direction of arrow 820, a first edge 811 is folded upward toward the second edge 812, as shown by arrow 830. Similarly, second edge 812 is folded upward and toward first edge 811, as shown by arrow 830. Edges 811 and 812 are overlapped and sealed at sealer 840 to form seal 845. Seal 845 may be a lap seal, a fin seal, or any suitable seal to for annular composite web 850. This bonded composite annular structure 850 can then be cut directly into lengths to form bags, or wound into a roll for storage and transport to be cut into bags later.

FIG. 9 illustrates an embodiment of a combined process for formation of gussets 913, 915 in annular composite web material 950. The process is illustrated using roll 908 of composite web 900 having any suitable number of layers including outer layer 904 and inner barrier 901. Edges 911 and 912 have been rolled or directed toward each other to form seal 945. In an alternative embodiment, material in which seal 945 already has been formed, such as the process illustrated in FIG. 8 and resulting in analogous seal 845, is supplied to this gusset-forming process.

Annular composite web material 950 is moved in the direction of arrow 960. Rollers 920 force side edge 926 inward to form gusset 915 as the web is moved and rollers 920 rotate in the direction of arrows 921. Rollers 920 may be motorized merely able to rotate by friction in contact with the web. Similarly, rollers 922 force side edge 927 inward to form gusset 913 as the web is moved and rollers 922 rotate in the direction of arrows 923. Rollers 922 may be motorized merely able to rotate by friction in contact with the web.

FIG. 10A presents a later step in bag manufacture, wherein seal bar 1010 is moved in the direction of arrow 1011 and seal bar 1020 is moved in the direction of arrow 1021. Any number of seal bars may be utilized. Seal bars 1010 and 1020 are pressed against moving web 1030 as it moves in the direction of arrow 1060. The bars may travel with the web to achieve spaced apart seals 1015 and 1025 along the web. The seal bars form seals extending from edge to edge across moving web 1030. The seals form bag precursors 1080 and 1081.

As illustrated, material 1050 is drawn from roll 1008. In alternative embodiments, annular web composite material 1050 is taken directly from the process illustrated in FIG. 9 as analogous annular web material 950 and fed directly to seal bars 1010 and 1020. In yet another embodiment, annular composite material 850 is fed to produce bags not having gussets.

Bag precursors 1080 and 1081 may be separated into bags 1090 and 1091 as shown in FIG. 10B. Often, the separation step is carried out consecutively with the sealing process of FIG. 10A. As shown in FIG. 10B, annular web material 1051 having seals 1015 and 1025 is fed to the process. Web 1051 is moved in the direction of arrow 1099. Cutting bar 1075 is arranged so that, when web 1051 is moved in the direction of arrow 1099, cutting bar 1075 is moved in the direction of arrow 1076 to cut web 1051 adjacent seal 1025 to form cut 1040 and form bag 1090 from bag precursor 1080. Similarly, cutting bar 1070 is arranged so that, when web 1051 is moved in the direction of arrow 1099, cutting bar 1070 is moved in the direction of arrow 1071 to cut web 1051 adjacent seal 1015 to form cut 1030 and form bag 1091 from bag precursor 1081. The cutting bars make cuts extending from edge to edge across moving web 1030.

Because the inner barrier layer of laminated composite web material 1050 is thermally bondable, the moving web of material 1050 allows formation of seals 1015 and 1025 while the web is moving. This sealing method is not possible with a Nowak-type bag.

In an alternative embodiment, bags may be cut to length leaving both ends of the bag open, as illustrated in FIG. 11. In such embodiments, a user retains the option to use any of a variety of techniques to close the bag.

As shown in FIG. 11, annular composite web material 1050 is fed from roll 1008. Alternatively, annular composite web material 1050 is fed directly from the process of FIG. 9 to form gusseted bags. In still another embodiment, annular composite web material 850 can be fed directly from the process of FIG. 8. Bags of this embodiment will not have gussets.

In FIG. 11, as annular composite web material 1050 is moved in the direction of arrow 1060, cutting bar 1175 is arranged so that, when web 1050 is moved in the direction of arrow 1160, cutting bar 1075 is moved in the direction of arrow 1176 to cut web 1050 to form cut 1140 and form bag 1190 from bag precursor 1080. Similarly, cutting bar 1170 is arranged so that, when web 1050 is moved in the direction of arrow 1160, cutting bar 1170 is moved in the direction of arrow 1171 to cut web 1051 to form cut 1130 and form bag 1191 from bag precursor 1081. Bags thus formed are open at both ends.

Bags open at both ends may be sealed on one end to form a bag for filling. Once the bags are cut to length, the method further includes sealing one of the first end and the second end of the composite bag to form a sealed composite bag with a sealed closed end and an open end that can then be filled with product, or palletized and transported to a location where it can be filled with product and sealed. The sealing of the end of the composite bag can be accomplished by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) taping and sewing, and (iv) the application of adhesive, (v) the application of taping, (vi) the application of zippering, as well as other suitable techniques.

Embodiments of sealing techniques are illustrated in FIG. 12A-FIG. 12D. Bag 1200 is sealed with stitched taping 1205 in FIG. 12A. Other embodiments include stitching without tape 1210 in FIG. 12B, heat sealing 1215 in FIG. 12C, and ultrasonic sealing 1220 in FIG. 12D. Other alternative sealing techniques include zippers, easily-resealable openings, and other seal types known to skilled practitioners.

Processes identified herein, such as slitting, seaming, sealing, and bag forming, may be identified as converting steps requiring converting equipment. Often, sealing is accompanied with cutting in such equipment. Both of these operations may occur stepwise, that is, when feeding has come to a stop. In heat sealing, one or more heating elements are brought close to or into contact with the external surfaces of the end of the bag. The sealing temperature, sealing time (“dwell”), and pressure are dependent on the type of material and lamination structure/construction. Importantly, the disclosed inner lamination of the composite bag allows heat sealing to occur with consistency. If desired, the heat sealing step (and cutting bags to length, as desired) can occur as the bag material is being formed, even while the web is still moving, as long as the converting equipment is suitably configured. Heat sealing of embodiments of the disclosure accordingly improves production capability and efficiency when compared, for example, with the Nowak-style bag. Alternatively, ultrasonic welding can be used similarly and provide the same benefits. It will nonetheless be appreciated that other closing methods can also be used, such as sewing or taping. Cutting can be performed after the sealing operation during the non-feeding time of the machine cycle. Without sealing, cutting can occur after folding and optional gusseting or zippering. The bag may then be closed via taping, sewing, and the like. After one of the ends of the bag is closed or sealed, it may be flattened, bundled, and packed for use in an automated filling machine.

In further embodiments, an automated method is provided of using and sealing a bag as described herein with a food product.

For purposes of illustration, and not limitation, the method can include (i) providing a composite food packaging bag as described herein, (ii) providing a first automated manipulator that grasps the composite food packaging bag on the first and second generally rectangular planar opposing sides near the opening of the composite food packaging bag to open the bag, (iii) directing the composite food packaging bag to a dispenser of a food product, (iv) dispensing food product into the composite food packaging bag, and sealing the composite food packaging bag to close the opening and to contain the food product within the bag.

As shown in FIG. 13, bag 1300 having a taped and stitched end 1310 is placed with end 1310 at the bottom. As shown schematically by arrow 1301, bag 1300 is arranged at bag manipulator 1320. The bag, the bag manipulator 1320, or both may be moved appropriately. First opposing side 1309 is grasped, such as by suction or releasable adhesion cups 1321, and urged in the direction of arrow 1322. Second opposing side 1308 is similarly grasped (not shown) and urged in the direction of arrow 1324. Thus, end 1329 opposite end 1310 is held open in anticipation of introducing the contents therethrough.

As further shown schematically by arrow 1302, bag 1300 is arranged at bag fill station 1330. The bag, the bag fill station 1330, or both may be moved appropriately. Funnel or similar aid 1340 for introducing bag contents into bag 1300 is moved in the direction of arrow 1341. Bag 1300 is filled through open end 1329 and aid 1340. Aid 1340 then is removed in the direction of arrow 1342.

As shown still further schematically by arrow 1303, bag 1300 is arranged at bag sealer 1350. The bag, the bag sealer 1350, or both may be moved appropriately. In embodiments of the disclosure, bag sealer 1350 seals the bag by heating to form a seal.

In particular, embodiments of the bag disclosed herein are amenable of sealing by application of heat. The inner barrier layer of the composite web of material is meltable to make a secure seal and ensures that the contents of the bar are not contaminated by the woven layer or other detritus. The inner barrier layer also is easily manipulated by manipulation of the outer layer of the composite web of material because the layers are laminated together, directly or indirectly (i.e., with intermediate layers). Thus, sealing can be accomplished by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) stitching, and (iv) the application of adhesive.

The present bag design facilitates the illustrated automated filling operation by virtue of its laminated inner layer. Heretofore, the solution in the art for avoiding the decomposition of a woven layer into a bag's contents is by manually placing a loose bag inside of a woven bag. As will be appreciated by those of skill in the art, such a bag must be filled manually, and cannot be filled automatically, because separation of the outer sides of the bag does not manipulate the inner liner, which is not attached to the interior of the bag, but is merely resting within it, in contrast with the disclosed composite bag that includes an integral inner layer, rather than an inner liner.

Generally, the disclosed composite bag with an inner lamination of the disclosure provides a multitude of advantages. The disclosed bags provide improved protection from contamination, incursion of woven fabric breakage, chemical migration (from ink), block unwanted moisture or water, chemicals, or bacteria. The bags are stronger and more durable, and they enable full automation in the bag manufacturing process. Automated filling and sealing are also enabled, and the disclosed bags may be used with existing heat sealing machinery. Automatic bag feeding is made possible by integration of the inner barrier layer, and this eliminates chances of direct human contact to the food content, thus preventing contamination and improving sanitation.

Some bag solutions on the market that have been attempted require the use of specialized and high cost equipment. However, the disclosed composite bags are designed for use in common heat sealing machines as with other flexible packaging materials. For example, hot bar sealers, continuous band-type heat sealers, hot melt adhesives and ultrasonic welding techniques can all be used. While stitching can be used, it is not preferred as sewing with/without tape commonly leaves behind untrimmed thread at both sides of the seal which can become loose and lead to leakage of package contents, as well as potential contamination of bag contents.

The net effect of the disclosed embodiments is higher productivity, efficiency, and cost savings in a filling/packaging process operation. Furthermore, by eliminating chances of human contact to food content directly, it can improve sanitation and preventing contamination as well in filling and packaging operations.

The disclosed configuration of a composite bag with a back seam is also advantageous as it permits a continuous image to be displayed across the seam on the back of the bag.

Embodiments of the disclosure include composite web of material that may have layers that provide particular properties to the bag. Various embodiments of the disclosure are illustrated in FIG. 14 through FIG. 19, which depict cross-sections of composite webs of material suitably used in embodiments of the disclosure.

Each embodiment of the disclosure illustrated in FIG. 14 through FIG. 19 includes inner barrier layer 1401 and woven structure 1402. For convenience herein, these two layers will be identified as foundation layers. Further, for other embodiments of the disclosure, additional layers are outside layers.

FIG. 14 illustrates composite web material 1400 comprising two layers, inner barrier layer 1401 and woven structure 1402, that is, only the foundation layers.

FIG. 15 illustrates composite web material 1500 comprising a layer of paper 1501 printed on the top or exposed side and laminated to the foundation layers.

Other embodiments of the disclosure may have a third layer exterior to the foundation layers wherein the layer is a reverse-printed translucent or transparent layer. Such an embodiment of the disclosure is illustrated in FIG. 16, wherein the third layer is a reverse-printed polymer layer illustrated as layer 1601 laminated to the foundation layer.

Some embodiments of the disclosure have four or more layers in the composite web of material. One such illustration is the three layer web 1700 in FIG. 17. As illustrated in FIG. 17, anti-skid coating 1701 is applied to the exterior or upper side of a reverse-printed polymer layer 1601. The reverse-printed side of layer 1601 is laminated to the woven structure of the foundation layers.

Another embodiment of a four-layer composite web of material is included in FIG. 18 as composite web of material 1800 including anti-skid layer 1701 on the exterior side of composite web of material 1500. Thus, anti-skid layer 1701 is laminated to the exterior or printed side of paper 1501.

Yet another embodiment of the disclosure is a five-layer composite web of material 1900, as illustrated in FIG. 19. Composite web of material 1900 comprises paper layer 1901 laminated to the exterior surface of web structure 1402. Reverse-printed polymer layer 1601 is laminated to the exterior surface of paper layer 1901, and anti-skid layer 1701 is laminated to the outer or exterior (i.e., unprinted) surface of layer 1601.

The foregoing description of possible embodiments consistent with the present disclosure does not represent a comprehensive list of all such embodiments or all variations of the embodiments described. The description of only some embodiment should not be construed as an intent to exclude other embodiments. For example, one of ordinary skill in the art will understand how to implement the disclosure in many other ways, using equivalents and alternatives that do not depart from the scope of the disclosure. Moreover, unless indicated to the contrary in the preceding description, none of the components described in the embodiments are essential to the disclosure.

	Number	Date	Country
	62383365	Sep 2016	US
	61523025	Aug 2011	US

	Number	Date	Country
Parent	13585569	Aug 2012	US
Child	15627705		US

	Number	Date	Country
Parent	15627705	Jun 2017	US
Child	15692539		US
Parent	13541927	Jul 2012	US
Child	13585569		US

INNER LAMINATED PACKAGING BAG AND AUTOMATED METHODS OF MAKING AND USING THE SAME

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