Note: Descriptions are shown in the official language in which they were submitted.
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Recloseable Bag
FIELD OF THE INVENTION
The present invention relates generally to the art of bag making.
BACKGROUND OF THE INVENTION
There are many type of bags and equipment to make them. Bags are
designed with various manufacturing concerns in mind,. including ease of
manufacturing,
handles, type of material, type of closure, as well as features related to the
bag when
filled with product such as ability to stand on its own, the ability to stack
easily, the
ability to display the product name when stacked, etc. Often designing a bag
to enhance
one or more features results in a trade off of other features.
For example, relatively easy to manufacture bags with a zipper are made
by sealing one machine direction edge of a bag to form the bottom, and
affixing a zipper
on the other machine direction edge. However, while easy to manufacture, the
bag
cannot stand on its own. Affixing, as used herein, includes attaching so that
it is not
easily removed, such as sealing, melting, together, gluing, etc. Machine
direction edge,
as used herein, includes an edge that is parallel to the machine direction.
Machine
direction, as used herein, includes the direction a film travels through a
machine.
Different uses for bags make certain features more or less important. For
example, bags used for pet food would preferably have a two-dimensional
bottom. so that
the bag can stand on its own when filled. Another desirable feature for pet
food bags is
that they form a cuboid when filled, to make shipping and stacking in stores
easier.
(Cuboid, as used herein, includes a six sided,shape with generally right
angles between
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the sides.) Moreover, they would preferably present a side of the bag (as
opposed to the
top or bottom) when stacked so customers can easily read the label. Handles
(one or
more straps, loops,'etc that may be used to pick up a bag) make a bag that is
heavy when
filled easier to carry. Also, a bag formed of multiple walls helps avoid
dimpling of the
outer walls of the bag by the pet food (thus preserving the appearance of the
bag).
Customers might also prefer a pet food bag with a resealable closure (a
closure that may
be resealed by the consumer, such as a zipper, hook and loop, friction fit,
etc.), and/or has
a tamper-proof seal (a seal that can be visually inspected to determine if it
has been
opened previously). Of course, ease of manufacture is desirable to reduce
costs.
Most bags produced thus far cannot provide all or even most of these
features. For example, typical pet food bags have non-resealable tops. Also,
they cannot
stand on their own, and their shape is not conducive to stacking. If they are
stacked, it is
usually.on.their side, and the stack is often unstable, with only a thin
profile of the top of
each bag visible to the customer.
One prior art bag that did provide some of these features is shown in US
Patent D444,948, to Buchanan et al. That bag has a rectangular bottom and a
cuboid
shape (when filled). Even when filled the top can lay flat on the top of the
cuboid, for
ease of stacking. The side of the bag is presented to the customer when
stacked. A
handle is attached, and a hook and loop top seal allows for resealing. While
this bag has
advantages over the prior art it would be costly to' manufacture, and the top
seal does not
extend across the entire top -- thus the entire top isn't resealable.
Accordingly, a bag that enjoys one or more of the features mentioned
above, yet is not expensive or difficult to manufacture, is desirable.
SUMMARY OF THE PRESENT INVENTION
According .to a first aspect of the invention a bag comprises a lower
portion and an upper portion. The lower portion has a generally rectangular
bottom with
first, second, third and fourth bottom edges. It also has a generally
rectangular front,
back left and right walls, each having a lower edge joined with the a bottom
edge. The
upper portion is joined to the lower portion, and has a zipper closure. at a
top thereof.
According to a second aspect of the invention a bag includes the upper
portion is joined to the lower portion, and has a top peak with a resealable
closure that
extends the length thereof.
According to a third aspect of the invention a bag includes a lower portion
and. ab upper portion joined to the lower portion. The lower portion has a
generally
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rectangular bottom with first and second pairs of generally parallel sides.
Pairs generally
vertical walls are attached at lower edges thereof to =the pairs of generally
parallel sides.
Four generally vertical corner seals, each joining one of the first pair of
generally vertical
walls to one of the second pair of generally vertical walls; extend part of
the way up the
generally vertical walls.
According to a fourth aspect of the invention a plurality of bags are
formed from two webs moving in a machine direction. Each bag is formed with
transverse seals extending the width of the webs. Each bag has a resealable
closure
mounted on a first machine direction edge of the bag, and a gusseted insert
and a bottom
seal.-on the second machine direction edge of the bag. A plurality of corner
seals art
disposed between the transverse seals, and extend a portion of the way from
the from the
bottom seal toward the resealable closure.
According to a fifth aspect of the invention a machine for making bags
from two films includes an input section, and a sealing section. Each section
has at least
one driven roller that contacts the film as it follows a film path and. moves
in a machine
direction. The sealing section is downstream of the input section, and has two
transverse
sealers, spaced in the machine direction, such that each bag is formed with
spaced
transverse seals extending the width of the webs. It also has a resealable
closure fixture,
mounted on a first machine direction edge of the bag, and a gusseted insert
fixture, on a
second machine direction edge of the bag, and a plurality of corner sealers,
disposed
between the transverse sealers, and extending .,a portion of the way from the
from the
gusseted insert fixture toward the resealable closure fixture.
According to a sixth aspect of the invention a method-of making a bag
includes forming a lower portion with a bottom and forming an upper portion,
joined to
the lower portion, and having a top, and affixing a zipper closure to the top.
According to an eighth aspect of the invention a method'of making a bag
includes forming a lower portion having a bottom and two pair of generally
parallel sides
walls,, each side wall being adjacent to two of the other side walls and each
attached on
lower edges thereof to the bottom. Also, four generally vertical corner seals
are formed.
0 and.each joins one of the first pair of generally vertical walls to one of
the second pair of
generally vertical walls. The corner seals do not extend the entire height .of
the generally
vertical walls. An upper portion is formed and joined to the lower portion.
According to a ninth aspect of the invention a method of forming a
plurality of bags from first and second webs moving in a machine direction,
comprises
forming spaced transverse seals extending the width of the webs, affixing a
resealable
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closure mounted on a first machine direction edge of the bag, affixing a
gusseted insert to
a second machine direction edge of the bag, and forming corner seals between
the
transverse seals, that extend only a portion of the way from the from the
bottom seal
toward the resealable closure.
According to a tenth aspect of the invention a method of making a bag
includes forming a lower portion to have a bottom with four side walls
attached on lower
edges thereof to the bottom, and forming an upper portion, joined to the lower
portion,
and having a top peak with a resealable closure affixed. along the entire
length of the top
peak.
The upper portion includes a top peak with a zipper closure and/or a
tamper proof seal that extends the length thereof, in various embodiments.
Four generally vertical corner seals join the front wall and the left side
wall, and the corner seals do not extend the entire height of the walls, in
another
embodiment.
The side walls each have a generally vertical side seal extending from the
top of the bag towards the bottom, below an upper end of the corner seals or
to the
bottom in various embodiments.
The bag is one of a plurality of bags formed from a film, and the side seals
separate adjacent bags in another embodiment.
The bottom is a gusseted insert sealed to the front and back walls in
another embodiment.
The lower portion is comprised of a laminated material, and/or the upper
portion is comprised of a poly material, in various embodiments
A handle is sealed between layers of the laminate, near the top of the
lower portion in another embodiment.
The bag, when filled with product to a fill level, the shape of the filled
portion is generally a cuboid, and/or the upper portion lays flat to form a
top of the
cuboid, in various embodiments.
The peak is formed at least partially from a top edge on each of the front
30. and back walls, in another embodiment.
One pair of generally vertical walls are formed from two webs of material
with a gusset insert. to form the bottom, in another embodiment.
Angle seals extend from each transverse seal to the bottom seal, and each'
angle seal. meets the transverse seals and the bottom seals at a distance from
a point
where the transverse seals meet the bottom seal, in another embodiment.
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Other principal features and advantages of the invention will become apparent
to
those skilled in the art upon review of the following drawings, the detailed
description
and the appended claims, and the appended claims.
Applicant seeks to provide a bag comprising a generally rectangular bottom
having
first and second pairs of generally parallel sides, a first pair of generally
vertical walls
having a first height and attached at lower edges thereof to the first pair of
generally
parallel sides, a second pair of generally vertical walls having a second
height and
attached at lower edges thereof to the second pair of generally parallel
sides, a plurality
of corner means for joining along less than the first and second heights each
of the first
pair of generally vertical walls to one of the second pair of generally
vertical walls,
wherein means for releasably closing the bag is disposed along entire top of
the bag
wherein length of said top of said bag is equal to a length of one of said
first pair of
vertical walls plus length of one of said second pair of vertical walls.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is.photograph from a front view of a bag in accordance with the
invention;
Figure 2 is photograph from a perspective view of a bag in accordance with the
invention;
Figure 3 is schematic of a perspective of a bag in accordance with the
invention;
Figure 4 is schematic of a perspective of a bag in accordance with the
invention;
Figure 5 is schematic of a bag formed in accordance with the invention;
Figure 6 is schematic of bags being formed in accordance with the invention;
and
Figure 7 is schematic of bag machine in accordance with the invention.
Before explaining at least one embodiment of the invention in detail it is to
be
understood that the invention is not limited in its application to the details
of construction
and the arrangement of the components set forth in the following description-
or
illustrated in the drawings. The invention is capable of other embodiments or
of being
practiced or carried out in various ways. Also, it is to be understood that
the phraseology
and terminology employed herein is for the purpose of description and should
not be
regarded as limiting. Like reference numerals are used to indicate like
components.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the present invention will be illustrated with reference. to it should
be
understood at the outset that the invention is described with respect to a
preferred bag
with preferred seals and manufactured in a preferred manner, the invention can
also be
implemented with other bags, having other shapes, made with other seals, and
manufactured in other ways.
Generally, the preferred embodiment is a bag made to stand on its own when
filled, and to a bag with seals disposed in a desirable fashion such that the
bag is
inexpensive to manufacture, and can have a full length resealable closure.
More
specifically, the bag has a lower portion that when filled with product has a
generally
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cuboid shape, and an upper portion that lays flat on the top of the cuboid.
Generally a
cuboid, as used herein, includes shapes that are similar to cuboids, but do
not need to
have generally 90 degree angles between sides, for example the sides may angle
outward.
The bottom is generally rectangular, and the lower portion has four
generally vertical walls. with lower edges attached to bottom edges (i.e., the
edges of the
rectangular bottom)., Alternatives provide for non-vertical walls and non-
rectangular
bottoms. The walls extend upward at generally 90 degree right angles, and the
front and
back are generally parallel, as are the side when filled. Generally
rectangular, as used
herein, includes a four sided shape that has generally 90 degree angles.
Generally 90
degree angles, as used herein, includes angles that appear close to 90
degrees, and serve
the purpose of a 90 degree angle. Wall, as used herein, includes the sides of
the bag.,
Vertical,-as used herein, includes generally perpendicular to the bottom of
the bag.
Four corner seals join the front and back walls to side walls. The four
corner seals extend to the top of the lower portion, or to the fill level, in
the preferred
-embodiments. The seals can extend higher or lower in alternative embodiments.
The
corner seals and rectangular bottom help the bag stand on its own when filled,
and to
have a cuboid shape. .
Each side wall has a side seal (i.e., a seal on a side, preferably midway
front to back), disposed generally vertically, and midway front to back. The
side seal
extends from the top of the bag towards the bottom, preferable to the lower
portion, and
more preferably to the bottom. Thus, the only seals extending to the top are
the side
seals, and the top of the bag is a peak formed from the top edges of the
front, back and
side walls, and extending from' side seal to side seal. The upper portion of
the bag does
not have corner seals, and the peak is that which would be made if the mid-
sides of a
rectangle (at the top.of the side seals) are pulled outward, drawing the front
and back
toward each other, until they meet and'form a peak having a length equal to
length of a
side wall plus the length of the front or back wall. The lower part of the
upper portion
retains its rectangular shape, because it is attached to the lower portion,
which has the
four corner seals, and is filled with product. The upper edge of the lower
portion may.
' also include an insert to help retain the rectangular shape where the upper
and lower
portions meet.
Figures 1 and 2 are front and perspective views, respectively, of a bag 100
such as that described above. The lower portion of bag 100 is preferably
comprised of a
laminate or laminated material (such as some pet food bags. are currently made
of, e.g.),
'including a poly layer. The multi-walled construction helps provide support
to the bag
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prevent the bag from dimpling. The poly layer of the laminate extends to, and
forms, the
upper portion. The flexible poly upper portion is easily folded upon itself to
form the top
of the cuboid, thus the bag is easily stacked, and the side is displayed.
Handles are sealed between the laminate layers, near the top of the lower
portion, on the front and back walls. Sealing the handles to bag 100 give.
good strength
to the bag, and allows the user to easily carry the bag. A zipper closure, or
other
resealable closure, is preferably mounted to extend the entire length of the
top peak.
Referring now to Figures 3 and 4, schematics showing two perspective
views of bag 100 show its various features. Three of the four corner seals 201
can be
seen to join or seal adjacent walls, such as side wall 203 and front wall 205.
(Seals are
indicated as thick lines). It may be seen that corner seals- 201 do not extend
the entire
height of the generally vertical walls. In the preferred embodiment they
extend only to
the top of the laminated lower portion. Join, or joined with, as used herein,
includes
attaching such that the attached items are not easily removed, for example, by
sealing,
melting, together, gluing, etc. Corner seal, as used herein, includes seals
that will form- a
corner of the bag after it is filled.
Two bottom seals 207 are shown, as wells as angle seals 211, which are
on the side walls. They will be explained in greater detail below. Angle
seals, as used
herein, includes seals at an angle (other than 90 degrees) to the machine
direction.
Bottom seal, as used herein, includes the seals that will be at the bottom of
a bag after it
is filled.
Side seal 213 is shown, and extends from the top of bag 100 to the bottom
in the preferred embodiment. It may be seen-that the corner seals on the lower
portion
and the rectangular bottom helps form the cuboid bag shape, while the lack of
corner
25. seals *on the upper portion allow the top of the bag to form a peak 214
with a zipper 215
extending the entire length thereof. A tamper proof seal 217 (such as that
known in the
prior art) is also shown.. Other resealable closures may be used, including
friction fit,
hook and loop, etc. Handles are also shown.
Referring now to Figure 5 a schematic of bag 100, as produced is shown. _
Also, Figure 6 shows multiple bags 100 in production. Bag 100 may be produced
in a
"lay flat" fashion, and is relatively inexpensive -to make. Bag 100 is
preferably formed
from 2 continuous films 601 and 602 (Figure.6). The films are generally
parallel and
follow a parallel film path through the machine. Film 601 forms the front and
half of
each side, and film 602 forms the back and the other half of each side.
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Each film includes a laminate portion 603 that extends part way across the
film, with one layer being a poly material that extends the entire width of
the film. The
poly portion can be part of or sealed to the laminate portion. The laminate
will form the
lower part 501 of bag 100, and the poly portion will form the upper portion
503 of the.
bag. Transverse seals 201 (generally perpendicular to the machine direction)
are formed
across the laminate portion only to form the comer seals. Transverse seals 213
are
formed across the poly and laminate portions to form the side seals. Angle
seals 211 are
formed at an angle between side seals 213 and corner seals 201. The angle
seals help
provide support for the side and bottom.
A gusseted insert 610 is sealed to the two laminate portions, on the
machine direction edge to form the bottom of the bag. Gusseted insert, as used
herein,
includes an insert that is affixed to one or more films, and the insert
includes at least one
gusset.
Side seals 213 also indicate the end of one bag and the start of the next.
The seal can include a perforated center portion to help separate adjacent
bags from one
another, as is known in the art (separate includes physically disjoining or
denoting the
end of a leading bag and the start of a succeeding bag). Adjacent bags, as
used herein,
includes bags next to one another as they are formed from continuous film or
films.
A zipper with a tamper proof seals is affixed to the machine direction edge
opposite the gusseted inse tr The zipper is continuous because the peak
extends the
length of the side plus the front -- thus there is no portion which cannot
have the
recloseable seal (which is different from the prior art). Other resealable
closures are used
in alternative embodiments.
Handles are sealed between layers of the laminate (preferably to the poly
layer) near the top of the lower portion, which allows the user to easily
carry heavy bags.
Referring now to Figure 7, a machine for making the bag 100 described
above is a pouch machine 700, and includes seven modules: an input-section 1,
a
resealable closure or zipper sealer station 2, =a long sealer module 3, a
cross sealer module
or 4, a cross seal extension module 5, a slider module 6, and a cut-off module
7. Some of
the modules, such as 4, 6 and 7, include drawrolls or driven rollers (10, 11
and 12). Input
section, as used herein, includes a processing station that receives a film
and feeds it to
subsequent processing stations, it may include machinery for folding the film.
Resealable closure fixture, as used herein, includes a fixture that affixes a
resealable
closure to a film.
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Zipper sealer station 2 includes a zipper or resealable closure fixture for
apply a zipper or other resealable closure to one machine direction edge of
the films. The
slider portion of the zipper may be applied at the zipper station or at a
distinct slider
station. Slider station, as used herein, includes a processing station applies
a "slider"
onto a pouch, usually in the machine direction. Cut-off station, as used
herein, includes a
processing station that cuts the film, such as that used to separate adjacent
pouches (such
as at the side seals). Zipper sealer station, as used herein, includes a
processing station
that welds or forms a zipper onto a pouch, usually in the machine direction.
Resealable
closure fixture, as used herein, includes a fixture that affixes a resealable
closure to a
film, and it may encompass distinct zipper and slider stations.
A gusseted insert fixture for sealing a gusseted insert is provided in the
preferred. embodiment, and may be in long sealer sation 1, or another section
of the
machine. Long sealer section or station, as used herein, includes a processing
station that
forms a machine direction seal. Gusseted insert fixture, as used herein,
includes a fixture
that applies a gusseted insert to one or more films. Sealing section, as used
herein,
includes one or more sections of a bag machine that includes one or more seal
bars or
other devices to form a seal on a film.
Cross sealer station or module 4 includes corner sealers, for forming the
corner seals that extend across only part of the film, and transverse sealers
for forming
the side seals that also separate adjacent-bags. It may also include angle
sealers for
forming the angle seals, or they may be included in a separate station or
module. It may
further include a fixture for sealing a handle to the film (or the handle
sealing fixture may
be in another section). Cross sealer station, as used herein, includes a
processing station
that forms a cross-seal, such as the seals separating successive pouches.
Cross seal
extension station, as used herein, includes a processing station that forms
cross seals over
an extended length. Angle sealers, as used herein, includes seal bars (or
other seal-
creating devices) disposed to-create a seal angled (other than 90 degrees)
relative to the
machine direction. Corner sealers, as used herein, includes seal bars (or
other seal-
creating devices) disposed to create a seal that will form a corner of the bag
after it is
filled: Transverse sealers, as used herein, includes seal bars (or other seal-
creating
devices) that apply a transverse seal.
A machine capable of having the appropriate sealing and other stations to
implement the present invention is. one such as that described in detail in
United States
Patent Application 20020155936, Wied et al. (and.has as a co-inventor the
inventor of the
present invention), filed April 23, 2001, and entitled Modular Pouch Machine.
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Alternatives provide for the invention to implemented with other systems, that
might or
might not be modular.
Numerous modifications may be made to the present invention which still
fall within the intended scope hereof. Thus, it should be apparent that there
has been
provided in accordance with the present invention a method and apparatus for a
bag and
machine to make it that fully satisfies the objectives and advantages set
forth above.
Although the invention has been described in conjunction with specific
embodiments
thereof, it is evident that many alternatives, modifications and variations
will be apparent-
to those skilled in the art. Accordingly, it is intended to embrace all such
alternatives,
modifications and variations that fall within the spirit and broad scope of
the appended
claims.
