Patent Application
20080085065
These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiments of the invention which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
The description of preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “joined,” “connected,” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
Referring to
Package 10 includes a front panel 12 and a rear panel 14 each with a bottom edge 19, side edges 20, and a top edge 21. In some embodiments, the respective opposite edges 20 of front panel 12 and rear panel 14 are joined directly. In other embodiments, the respective opposite side edges 20 of front panel 12 and rear panel 14 are joined via a side gusset 22 (a fold/crease that gives the bag a three-dimensional shape). Side gusset 22 initially projects inwardly between front panel 12 and rear panel 14 and allows package 10 to expand in volume. Side gussets 22 are typically formed integrally with the front and rear panels. Front panel 12 and rear panel 14 may be manufactured integrally as a continuous substrate suitably folded and joined to itself with a longitudinal seam in a tube-like configuration. Alternatively, front panel 12 and rear panel 14 may be manufactured separately as independent films or sheets of substrate to be joined at their respective opposite edges. Bottom edge 19 of front panel 12 is joined to bottom edge 19 of rear panel 14. When the front and rear panels are joined at their respective opposite side edges 20 and bottom edges 19, the panels form a bag or pouch defining an interior space. The top portions 21 of the front and rear panels define a mouth or opening 23. See
Front panel 12 and rear panel 14 can be made from any variety of substrates suitable for packaging, wrapping, covering, casing, or encasing materials. Conventionally, packages have been composed of multiple layers of paper and solid plastic films with an outer ply typically including a polymer-coated paper with a smooth printing surface, wherein the paper may be laminated to a layer of film and another paper layer. Some embodiments provide a package comprising a middle layer of woven mesh tubing to which an outer layer of solid plastic film is adhered using polypropylene or other polylaminates. The outside layer of film (comprising the outside of the package) may be printed or reverse-printed with graphics and product labeling. Solid films are utilized, which provide excellent printability and strength and meet or exceed performance standards dictated by the marketplace. Some embodiments also use films that are treated or coated to prevent slippage of packages during manufacturing, filling, transport, and storage. The materials to be used may partially or wholly comprise compostable, degradable, or recyclable materials. In some embodiments, a package is provided in the form of a multi-layered composite bag used to store bulk-type products such as pet food, seeds, fertilizer, cereals, grains and other bulk products intended for human and non-human consumption.
In some embodiments wherein front panel 12 and rear panel 14 are manufactured integrally, a woven mesh material is formed into a tube to which a sheet of plastic film is adhered using a lamination process. The mesh material is comprised of suitable film-forming plastic resin that is split and/or stretched and then woven to form a mesh or net-like material. The woven mesh material is formed into a tubular shape to easily adapt to high-speed bag-forming equipment. The tube, which is flattened and gusseted, is then fed into a laminator with two extruders, and laminated on both sides of the flattened tube to a solid plastic film using polypropylene or other polylaminate.
Among the alternative films that can be employed in making the mesh tubes are, without limitation, thermoplastic synthetic polymers, including polyolefins such as low density polyethylene, linear low density polyethylene, polypropylene coated with a layer of polyethylene, high density polyethylene, metallocene, electron-beam cured solid films, copolymers of ethylene and propylene and combinations of these polymers, polyesters, polyamides, polyvinyl polymers, and copolymers, and polylactic acid (PLA) resins. Preferred resins are polyethylene, low density, high density, or linear low density, and combinations thereof, as well as polypropylene coated or laminated with a layer of polyethylene, and polyesters. The solid plastic film to which the mesh tubes are adhered are comprised of various thermoplastic resins or polymers or combinations thereof, including but not limited to, low density polyethylene, high density polyethylene, linear low density polyethylene, metallocene, and/or polypropylene coated with a layer of polyethylene, films coated with electron-beam surfaces that may or may not be pre-printed, and PLA resins.
An outer solid plastic film layer provides a surface for printing or reverse-printing graphics and/or product labeling. The outer solid plastic film is then adhered to the mesh tubes using adhesives, laminating using nip rollers, poly extrusion laminating, or some other known means of attaching the two layers. The mesh tube comprises the inside layer of the package, giving the package strength and integrity. Alternatively, a layer of transparent or colored film may serve as an inside liner of the package and may or may not be printed. In such an embodiment, the package has three layers: (a) an outer polymeric solid film layer; (b) a middle polymeric mesh woven layer, and (c) an inner polymeric solid film layer. The outside film layer is also treated or otherwise coated on one side with any material that alters the level of slipperiness or tackiness of the outer surface, including the static coefficient of friction measure, making the package less likely to slip during manufacturing, transporting and/or storing.
In an embodiment wherein front panel 12 and rear panel 14 are manufactured as separate films to be joined, the respective opposing side and bottom edges of front panel 12 and rear panel 14 may be joined by any number of various methods of sealing and shutting packages, including, but not limited to, using adhesives or heat seals.
In some embodiments, the folded handle 16 is formed by folding a plurality of marginal portions at the top of the front and rear panels from rear panel 14 toward the direction of front panel 12. The penultimate folded-over marginal portion is joined to the front panel 12 substantially along seam 50 but not along at least one non-joined portion 52. In the vicinity of each non-joined portion 52, a pocket or handle 54 defined by first marginal portion 46, second crease 44, and front panel 12 is formed. The pocket 54 can receive the digits of a user's hand so that the user can grip package 10.
From the foregoing description, assembly and use of an exemplary package will be readily apparent. Referring to
The first marginal portion 46 and front panel 12 may be joined along seam 50 by any suitable means, including, for example, use of welding, bonding, stitching or sewing, or any of a variety of adhesives, binders, heat seals, cold seals, or any other joining means. In some embodiments, an adhesive such as a glue is used to join the first marginal portion and the front panel. Preferably, after first crease 40 is formed and while second crease 44 is being formed, glue is applied either to front panel 12 or to first marginal portion 46 by a programmable glue nozzle machine such as, for example, a BOSCH® DOBOY® GS-1000 bag gluer-sealer. In some embodiments, a programmable glue nozzle machine applies a single, straight, continuous bead of glue substantially along seam 50 from one side edge 20 of front panel 12 approximately one third (⅓) of the way transversely across front panel 12, the glue nozzle applies no glue along non-joined portion 52, which is near or around an approximate middle one third (⅓) of the transverse length of front panel 12, and the glue nozzle machine applies a single, straight, continuous bead of glue substantially along seam 50 near or around a final one third (⅓) of the transverse length of front panel 12 from the end of non-joined portion 52 to an opposite side edge 20. In some embodiments, the programmable glue nozzle may be adjusted to apply different types, amounts, or patterns of glue. For example, in some embodiments, different types of glue may be used (e.g., a cold melt resin glue or a hot melt glue). A thicker or thinner bead of glue may be applied (e.g., a bead one eighth (⅛) inches in thickness or a bead one quarter (¼) inches in thickness). The glue may be applied across more than or less than a combined two thirds (⅔) of the front panel (e.g., across two (2) one quarter (¼) lengths near the opposite side edges 20, with non-joined portion 52 extending over a middle half (½) length across the package). More than one single, straight, continuous bead of glue may be applied (e.g., two parallel, straight, continuous beads of glue). And, one or more non-straight beads of glue (e.g., a wavy line or a series of overlapping circles) or non-continuous beads of glue (e.g., a dashed or dotted line or other non-continuous pattern) may be applied. In these different embodiments, the type, pattern, and amount of glue applied may be variable based on, for example, the material used for the substrate of the package and/or the weight of the intended contents of the package. The glue may be applied by a programmable glue nozzle machine either by moving the package with respect to the glue nozzle or by moving the glue nozzle with respect to the package.
When joining means of suitable strength are used to join first marginal portion 46 and front panel 12, the strength of folded handle 16 is at least as great as the tensile strength of the substrate material. Because there are no cuts or cut-outs used to form folded handle 16, the strength of the handle is not dependent on the shear strength of the substrate material. The strength of the handle will depend largely on the strength of the joining means used to join first marginal portion 46 and front panel 12, particularly in the vicinity of the areas immediately surrounding either end of non-joined portion 52. When the package is loaded with contents and gripped by the folded handle, the concentration of tensile forces caused by the weight of the contents will be in the areas immediately surrounding the ends of non-joined portion 52. For this reason, the suitability of joining means used to join first marginal portion 46 and front panel 12 will be affected by the weight of the intended contents of package 10.
In some embodiments, multiple folds and creases (e.g., more than two) may be implemented to close package 10. For example, in some embodiments, two folds forming two creases may be implemented before a third fold brings a penultimate marginal portion in contact with front panel 12.
First marginal portion 46 and second marginal portion 42 may be of any width or widths suitable for folding and sealing package 10. Preferably the marginal portions are each about ½ (0.5) inches to about 2 inches, and most preferably the marginal portions are each about 1¼ (1.25) inches. First marginal portion 46 may or may not have a width equal to the width of second marginal portion 42.
In some embodiments, there is a single non-joined portion 52. The single non-joined portion 52 may be of any length suitable for allowing pocket 54 to receive a hand. Preferably, non-joined portion 52 is about 3 inches to about 6 inches in length, and most preferably non-joined portion 52 is about 4 inches in length.
In some embodiments, seam 50 has a width that is substantially less than the width of said first marginal portion 46. For example, in some embodiments, first marginal portion 46 has a width of about 1¼ (1.25) inches and seam 50 has a width of about ⅛ (0.125) inches to ¼ (0.25) inches. In some embodiments, seam 50 is provided substantially adjacent to first crease 40. In other words, seam 50 is provided closer to first crease 40 than to second crease 46.
In some embodiments not pictured in
In some embodiments, package 10 is loaded with contents via the end of the package opposite the end containing folded handle 16. In this way, package 10 can be manufactured with folded handle 16 at one end of the package and the opposite end of the package can be left open and/or unsealed. The package can thus be conveniently and economically manufactured, stored, sold, and shipped substantially flat. Subsequently, the package can be filled with contents at the open end and the open end can thereafter be closed and/or sealed in accordance with the present invention or by other means. In other embodiments, package 10 is closed or sealed at one end, filled with contents at the opposite, open end, and that opposite end is then closed or sealed in accordance with the present invention to fabricate folded handle 16.
It is to be understood that the present invention is by no means limited only to the particular constructions herein disclosed and shown in the drawings. The appended claims should be construed broadly to cover any variations or modifications within the scope or range of equivalents of the claims.
