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Patent 2951405 Summary

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(12) Patent Application: (11) CA 2951405
(54) English Title: RECLOSABLE BAG AND METHOD TO MAKE SAME
(54) French Title: SAC REFERMABLE ET METHODE DE FABRICATION ASSOCIEE
Status: Examination Requested
Bibliographic Data
(51) International Patent Classification (IPC):
  • B65D 33/16 (2006.01)
  • B31B 70/86 (2017.01)
  • A45C 3/04 (2006.01)
  • A45C 13/26 (2006.01)
(72) Inventors :
  • ROSS, MICHAEL A. (United States of America)
(73) Owners :
  • POLY-AMERICA, L.P. (United States of America)
(71) Applicants :
  • POLY-AMERICA, L.P. (United States of America)
(74) Agent: MBM INTELLECTUAL PROPERTY AGENCY
(74) Associate agent:
(45) Issued:
(22) Filed Date: 2016-12-14
(41) Open to Public Inspection: 2017-06-15
Examination requested: 2021-12-13
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
14/969,259 United States of America 2015-12-15

Abstracts

English Abstract


The present invention relates to improvements for shopping and merchandise
bags with
integral handles. Disclosed is a bag with integral handles and closure
elements located below the
integral handles. Further disclosed is a process for manufacturing a
reclosable bag with integral
handles. The handles and bag may be formed from a wave-cut polymeric tube. In
addition, the
handles of the bag may be formed from a wave-cut polymeric tube while the body
of the bag is
formed from a side-gusseted polymeric tube. The disclosed bags and methods to
make such bags
provide cost effective solutions for providing reclosable bags with integral
handles.


Claims

Note: Claims are shown in the official language in which they were submitted.


CLAIMS
I claim:
1. A bag formed from polymeric blown film, the bag comprising:
a front panel and a rear panel, each panel having a first side, a second side,
an upper edge,
and a bottom edge, the front and rear panel joined at a bottom edge,
a front handle and a rear handle, each handle having a first side, a second
side, a bottom edge
and an upper edge, the upper edges defining an opening of the bag,
the front handle sealed to the front panel by a front handle seal,
the rear handle sealed to the rear panel by a rear handle seal,
opposing side gusset panels joined to and between the front panel and rear
panel,
a first closure element disposed on an interior of the bag, and
a second closure element disposed on an interior of the bag opposite from the
first closure
element.
2. The bag of claim 1 further comprising:
the front handle seal extending from the first side to the second side of the
front handle, and
the rear handle seal extending from the first side to the second side of the
rear handle.
3. The bag of claim 2 further comprising:
the front handle seal adjacent to the front panel upper edge and front handle
bottom edge, and
the rear handle seal adjacent to the rear panel upper edge and rear handle
bottom edge.
4. The bag of claim 1 further comprising:
the first closure element affixed to an interior of the front handle and
extending generally
from the first side to the second side of the front handle, and
the second closure element affixed to an interior of the rear handle and
extending generally
from the first side to the second side of the rear handle.
5. The bag of claim 4 further comprising:
19


the first closure element located between the front handle upper edge and the
front handle
seal, and
the second closure element located between the rear handle upper edge and the
rear handle
seal.
6. The bag of claim 1 further comprising:
each of the front and rear handle upper edges having a wave-shaped profile,
the wave-shaped
profile defining a lobe in each of the front and rear handles,
a circular opening defined centrally within each lobe of the front and rear
handles,
a peak of the wave-shaped profile of both the front and rear handles located
generally
equidistant from the first side and the second side, and
the wave-shaped profile comprising a sinusoid.
7. The bag of claim 1 further comprising:
the first and second closure elements comprising male and female press to
close closure
elements.
8. The bag of claim 7 further comprising:
the first and second closure elements affixed to the front and rear panels by
one or more heat
seals.
9. The bag of claim 7 further comprising:
the first and second closure elements affixed to the front and rear handles by
a pressure
sensitive adhesive.

10. A method of forming a bag from polymeric blown film, the method
comprising:
forming a side-gusseted tube having a first machine direction,
the side-gusseted tube collapsed to define a front side and a rear side, both
the front side
and rear side having leading distal edges,
forming a partial wave-cut tube haying a second machine direction,
the partial wave-cut tube collapsed to define a front side and a rear side,
the front side and the rear side of the partial wave-cut tube each having a
first side edge
with a wave-cut profile and an opposing second side edge,
the side-gusseted tube intersecting with the partial wave-cut tube,
placing the leading distal edges of the side-gusseted tube adjacent to the
second side edges of
the partial wave-cut tube,
sealing the front side leading distal edge to the front side second side edge
and the rear side
leading distal edge to the rear side second side edge,
forming a bottom seal in the side-gusseted tube and opposing side seals in the
partial wave-
cut tube to define a bottom and side edges of the bag,
severing the bag from the side-gusseted tube and the partial wave-cut tube.
11. The method of claim 10 further comprising:
the second side edges of the partial wave-cut tube extending generally
linearly in the second
machine direction.
12. The method of claim 11 further comprising:
the first machine direction arranged generally perpendicular to the second
machine direction.
13. The method of claim 12 further comprising:
the bottom seal formed generally perpendicular to the machine direction of the
side-gusseted
tube and generally parallel to the partial wave-cut tube.
14. The method of claim 10 further comprising:
the side-gusseted tube having a pair of inwardly folded opposing side gussets
between the
21

front side and rear side.
15. The method of claim 10 further comprising:
a plurality of hand openings defined within the partial wave-cut tube,
a pair of the plurality of hand openings defined between opposing bases of the
wave-cut
profile and,
a pair of side seals placed at the opposing bases of the wave-cut profile.
16. The method of claim 10 further comprising:
affixing a first closure element to an interior of the front side of the
partial wave-cut tube, and
affixing a second closure element to an interior of the rear side of the
partial wave-cut tube.
17. The method of claim 16 further comprising:
the first and second closure elements affixed to the partial wave-cut tube by
heat seals.
18. The method of claim 16 further comprising:
the first and second closure elements comprising interlocking male and female
closure
elements.
19. The method of claim 16 further comprising:
the first and second closure elements affixed to the partial wave-cut tube by
an adhesive.
20. The method of claim 16 further comprising:
affixing the first closure element in proximity to the second side edge of the
front side of the
partial wave-cut tube, the first closure element extending generally in the
second machine
direction, and
affixing the second closure element in proximity to the second side edge of
the rear side of
the partial wave-cut tube, the second closure element extending generally in
the second
machine direction.
22

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02951405 2016-12-14
RECLOSABE BAG AND METHOD TO MAKE SAME
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to an improved merchandise or shopping
bag with an
integral handle and reclosable feature. Particularly, the present invention
relates to a bag with
integral handles which includes a closure mechanism with male and female
closure elements that
is adapted for high speed and cost effective manufacturing.
2. Description of the Related Art
[0002] Thermoplastic films are used in a variety of applications. For example,
thermoplastic
films are used in sheet form for applications such as drop cloths, vapor
barriers, and protective
covers. Thermoplastic films can also be converted into plastic bags, which may
be used in a
myriad of applications. The present invention is particularly useful for bags
constructed from
thermoplastic film.
[0003] Polymeric bags are ubiquitous in modern society and are available in
countless
combinations of varying capacities, thicknesses, dimensions, and colors. The
bags are available
for numerous applications including typical consumer applications such as long-
term storage,
food storage, shopping, and trash collection. Like many other consumer
products, increased
demand and new technology have driven innovations in polymeric bags improving
the utility and
performance of such bags. The present invention is an innovation of particular
relevance to food
storage bags.
[0004] Polymeric bags are manufactured from polymeric film produced using one
of several
manufacturing techniques well-known in the art. The two most common methods
for
manufacture of polymeric films are blown-film extrusion and cast-film
extrusion. In blown-film
extrusion, the resulting film is tubular while cast-film extrusion produces a
generally planar film.
The present invention is generally applicable to bags manufactured from a
blown-film extrusion
process resulting in tubular film stock.
[0005] In blown film extrusion, polymeric resin is fed into an extruder where
an extrusion
1

CA 02951405 2016-12-14
screw pushes the resin through the extruder. The extrusion screw compresses
the resin, heating
the resin into a molten state under high pressure. The molten, pressurized
resin is fed through a
blown film extrusion die having an annular opening. As the molten material is
pushed into and
through the extrusion die, a polymeric film tube emerges from the outlet of
the extrusion die.
[0006] The polymeric film tube is blown or expanded to a larger diameter by
providing a
volume of air within the interior of the polymeric film tube. The combination
of the volume of
air and the polymeric film tube is commonly referred to as a bubble between
the extrusion die
and a set of nip rollers. As the polymeric film tube cools travelling upward
toward the nip
rollers, the polymeric film tube solidifies from a molten state to a solid
state after it expands to
its final diameter and thickness. Once the polymeric film tube is completely
solidified, it passes
through the set of nip rollers and is collapsed into a collapsed polymeric
tube, also referred to as
a collapsed bubble.
[0007] One common method of manufacturing polymeric bags involves segregating
the
collapsed polymeric tube into individual trash bags by forming seals which
extend transversely
across the entire width of the tube with each seal forming the bottom of a
bag. Typically, a line
of perforations is formed immediately adjacent and parallel to each seal to
facilitate separation of
the trash bags one from another. The opening of the perforations then forms
the top of a bag and
opposing edges of the collapsed polymeric tube then form the opposing sides of
a bag.
[0008] It is known to provide wave-cut bags by a continuous multi-bag
manufacturing process
from a collapsed bubble or tube. The collapsed bubble may be slit through both
a front and back
of the bubble with a repeating waveform pattern. Repeating evenly spaced pairs
of transverse
heat seals may be placed on both halves of the slit bubble to define left and
right side edges of
each bag. In between each pair of heat seals a perforation or cut line may be
placed so that the
formed bags may be separated. The slit middle of the collapsed bubble forms
the top of the bag
and one of the two opposing edges of the collapsed bubble forms the bottom of
the bag.
[0009] The lobe-shaped features, or lobes, of wave-cut bags can have holes
punched out or
otherwise provided in the middle of the lobe to provide a convenient handle
for the user to carry
the bag. Unfortunately, if only a single lobe is provided on each side of the
bag it is difficult to
close the bag and if the lobes are used to tie the bag then the lobes no
longer function as handles
2

CA 02951405 2016-12-14
since their length is taken up in a knot. Hence, it would be useful to provide
a cost-effective
means to close the bag while still maintaining use of the bag's handles.
Providing a means to
reclose the bag also allows the bag to be repurposed as a storage bag after
being used as a
merchandise or shopping bag.
[0010] United States Patent No. 4,125,220 (the '220 patent), filed December 2,
1977 and
hereby incorporated by reference, discloses a wave-cut shopping bag with a
sinusoid waveform
defining a top handle of the shopping bag. A width of the bag is disclosed as
equal to a single
wavelength with a hole or handle opening centered vertically on the base line
of the wavelength
and centered horizontally at the peak of the waveform. The '220 patent,
however, fails to
disclose any convenient means to close the bag.
[0011] Reclosable plastic bags are well-known in the art and are available in
a variety of
different sizes and configurations. Most commonly, reclosable plastic bags
have one or more
pairs of opposing, interlocking closures near the top opening of the
reclosable bag. The closure
may generally be opened and closed many times and are typically designed to
ensure that the
contents of the reclosable plastic bag are securely contained within the bag
when the opposing
closures are mutually engaged.
[0012] The closures of reclosable bags can be opened and closed in a number of
different
ways. For example, a slider or zipper device can be incorporated into the bag
design to facilitate
engagement and disengagement of the opposing closures. However, many
reclosable bags have
closures that are designed to be opened by physically pulling the closures
apart and closed by
pressing the closures together along the length of the closure. These bags may
commonly be
referred to as press to close reclosable bags.
[0013] United States Patent No. 3,402,749 (the '749 patent), filed on March
10, 1967 and
hereby incorporated by reference, discloses a plastic film shopping bag with a
reclosable zipper
device and hand holes formed in integral flanges above the reclosable zipper
device. However,
the '749 patent relies upon straight cut upper flanges for handles which
provides a difficult to
grasp handle and fails to efficiently utilize material for forming the bag and
its corresponding
handles.
3

CA 02951405 2016-12-14
[0014] United States Pat. No. 4,165,832 (the '832 patent), filed on July 10,
1978 and hereby
incorporated by reference, discloses a side-gusseted shopping bag formed from
a side-gusseted
collapsed polymeric tube. Such bags are commonly referred to as "t-shirt"
bags. The '832
patent discloses bags with integral handles but fails to disclose any means of
closing the bag
without the use of the bag's handles.
[0015] In consideration of the shortcomings of the above discussed prior art,
it would be
desirable to provide a merchandise or shopping bag having an integral handle
and a reclosable
opening. It would further be desirable to provide such a bag that takes
advantage of high speed
manufacturing processes and efficiently utilizes material. The present
invention represents a
novel solution to address these needs.
SUMMARY OF THE INVENTION
[0016] According to one embodiment of the present invention, a bag is formed
from a
collapsed tube of polymeric film. The bag may comprise a first panel and a
second panel. The
first panel and the second panel may be joined at a first side edge by a first
side seal, at a second
side edge by a second side seal, and at a bottom edge. The bottom edge may be
defined by a first
edge of the collapsed tube. The first panel may have a first top edge opposite
the bottom edge
and the second panel may likewise have a second top edge opposite the bottom
edge. The first
top edge and second top edge may define an opening of the bag. The first top
edge and the
second top edge may have a wave-shaped profile and the wave-shaped profile may
define a lobe
in the first panel and a lobe in the second panel. A first closure element may
be disposed on an
interior of the first panel and extend generally from the first side edge to
the second side edge.
The first closure element may be located below the wave-shaped profile of the
first top edge. A
second closure element may be disposed on an interior of the second panel
opposite from the
first closure element and extend generally from the first side edge to the
second side edge. The
second closure element may be located below the wave-shaped profile of the
second top edge.
[0017] In certain embodiments of the present invention, a peak of the wave-
shaped profile of
both the first top edge and second top edge may be located generally
equidistant from the first
side edge and the second side edge. A circular opening may be defined
centrally within each
lobe of the first and second panels. The circular opening may be located
equidistant from the
4

CA 02951405 2016-12-14
first side edge and the second side edge. A gusset may also be defined within
the bottom edge of
the bag. The first and second closure elements may comprise male and female
closure elements
and the first and second closure elements may be affixed to the first and
second panels by one or
more heat seals. In an alternative embodiment, the first and second closure
elements may be
affixed to the first and second panels by a pressure sensitive adhesive.
[0018] In a further embodiment of the present invention, a polymeric bag may
be formed from
a continuous polymeric film tube. The polymeric film tube may be collapsed to
form a collapsed
tube. Prior to collapsing the polymeric film tube, a gusset may be formed
within a first side and
an opposing second side of the polymeric film tube. The collapsed tube may
have front and rear
sections, opposing first and second folded edges, and a machine direction. The
collapsed tube
may be slit in a repeating waveform through the front and rear sections of the
collapsed tube in
the machine direction. The slitting of the collapsed tube may result in a
plurality of lobes with
the waveform centered between the first and second folded edges. A central
opening may be
formed within each of the plurality of lobes. The slitting may further result
in first and second
tube sections with the first and second tube sections having front and rear
sections. A distal end
of the front section of the first tube section may be separated from a distal
end of the rear section
of the first tube section. A first closure element may be affixed to an
interior of the front section
of the first tube section with the first closure element extending generally
in the machine
direction. A second closure element may be affixed to an interior of the rear
section of the first
tube section with the second closure element also extending generally in the
machine direction.
The first tube section may then be formed into a plurality of bags.
[0019] The plurality of bags may be formed by sets of closely spaced, parallel
seals that extend
transversely across a width of the first tube section. Perforations may also
be formed that extend
transversely across the width of the first tube section with a perforation
between and parallel
with each set of parallel seals. Each waveform may have a plurality of peaks
and bases with
each set of parallel seals centered at each base so that each peak of the
waveform is centered in
the machine direction between sets of parallel seals. In an alternate
preferred embodiment, a
plurality of side seals may be formed with each side seal extending
transversely across a width of
the first tube section at each base of the wave-shape profile. Simultaneously
with the formation
of each side seal, the first tube section may be cut through about or within
each side seal.

CA 02951405 2016-12-14
[0020] In at least one embodiment, the first closure element may be affixed to
the front section
of the first tube section with one or more heat seals and the second closure
element may be
affixed to the rear section of the first tube section with one or more heat
seals. In an alternative
embodiment, the first closure element may be affixed to the front section of
the first tube section
with a pressure sensitive adhesive and the second closure element may likewise
be affixed to the
rear section of the first tube section with a pressure sensitive adhesive. The
first and second
closure elements may be comprised of male and female closure elements. The
first and second
closure elements may also be comprised of interlocking press to close closure
elements.
Additionally, the first closure element may be interlocked with the second
closure element.
[0021] According to a further embodiment of the present invention, a bag can
be formed from
polymeric blown film. The bag may comprise a front panel and a rear panel with
each panel
having a first side, a second side, an upper edge, and a bottom edge. The bag
may also comprise
a front handle and a rear handle with each handle having first side, a second
side, a bottom edge
and an upper edge. The front and rear handle upper edges may define an opening
of the bag and
the front and rear panel may be joined at the bottom edge. The front handle
may be sealed to the
front panel by a front handle seal and the front handle seal may extend from
the first side to the
second side of the front handle. The front panel seal may also be adjacent to
the front panel
upper edge and front handle bottom edge. The rear handle may be sealed to the
rear panel by a
rear handle seal. The rear handle seal may extend from the first side to the
second side of the
rear handle. The rear panel seal may be adjacent to the rear panel upper edge
and rear handle
bottom edge.
[0022] In the same embodiment, a pair of opposing side gusset panels may be
joined to and
between the front panel and rear panel. Furthermore, each of the front and
rear handle upper
edges may have a wave-shaped profile and the wave-shaped profile may define a
lobe in each of
the front and rear handles. A first closure element may be disposed on an
interior of the front
handle and extend generally from the first side to the second side of the
front handle. The first
closure element may be located between the wave-shaped profile and the front
handle seal. A
second closure element may be disposed on an interior of the rear handle
opposite from the first
closure element and extend generally from the first side to the second side of
the rear handle.
The second closure element may be located between the wave-shaped profile and
the rear handle
6

CA 02951405 2016-12-14
seal.
[0023] In an additional embodiment of the present invention, a bag may be
formed from
polymeric blown film. A side-gusseted tube may be formed with a first machine
direction. The
side-gusseted tube may be collapsed to define a front side and a rear side
with both the front and
rear sides having leading distal edges. A partial wave-cut tube with a second
machine direction
may be formed and collapsed to define a front side and a rear side. The front
and rear sides of
the partial wave-cut tube may each have a first side edge with a wave-cut
profile and an
opposing second side edge. Each second side edge of the partial wave-cut tube
be may extend
generally linearly in the second machine direction. The side-gusseted tube may
intersect with the
partial wave-cut tube and the first machine direction may be arranged
generally perpendicular to
the second machine direction. The leading distal edges of the side-gusseted
tube may be placed
adjacent to the second side edges of the partial wave-cut tube. The front side
leading distal edge
may be sealed to the front side second side edge and the rear side leading
distal edge may be
sealed to the rear side second side edge. A bottom seal may be formed in the
side-gusseted tube
and opposing side seals in the partial wave-cut tube to define a bottom and
side edges of the bag.
The bag may be severed from the side-gusseted tube and the partial wave-cut
tube.
[0024] In certain embodiments, the bottom seal may be formed generally
perpendicular to the
machine direction of the side-gusseted tube and generally parallel to the
partial wave-cut tube.
The side-gusseted tube may have a pair of inwardly folded opposing side
gussets between the
front side and rear side. A first closure element may be affixed to an
interior of the front side of
the partial wave-cut tube and a second closure element may be affixed to an
interior of the rear
side of the partial wave-cut tube.
[0025] It is contemplated that the present invention may be utilized in ways
that are not fully
described or set forth herein. The present invention is intended to encompass
these additional
uses to the extent such uses are not contradicted by the appended claims.
Therefore, the present
invention should be given the broadest reasonable interpretation in view of
the present
disclosure, the accompanying figures, and the appended claims.
7

CA 02951405 2016-12-14
[0026] BRIEF DESCRIPTION OF THE RELATED DRAWINGS
[0027] A full and complete understanding of the present invention may be
obtained by
reference to the detailed description of the present invention and the
preferred embodiments
when viewed with reference to the accompanying drawings. The drawings can be
briefly
described as follows.
[0028] Fig. 1 provides a perspective view of a reclosable bag as contemplated
by one
embodiment of the present invention.
[0029] Fig. 2 provides a front view of the reclosable bag of the embodiment of
Fig. 1.
[0030] Fig. 3 provides a top view of a collapsed polymeric tube utilized in a
method to form
the bag of Figs. 1 and 2.
[0031] Fig. 4 provides a cross-sectional view of the collapsed polymeric tube
of Fig. 3 taken
along line A-A with the material thickness exaggerated for purposes of
clarity.
[0032] Fig. 5 provides a side view of a manufacturing apparatus according to
the method to
form the bag of Figs. 1 and 2 with a first tube section of the collapsed
polymeric tube of Fig. 3
shown in cross-section.
[0033] Fig. 6a provides a top view of the first tube section of the collapsed
polymeric tube of
Fig. 3.
[0034] Fig. 6b provides another top view of an alternative embodiment of the
first tube section
of Fig. 3.
[0035] Fig. 7 provides a front perspective view of an additional embodiment of
a reclosable
bag contemplated by the invention.
[0036] Fig. 8 provides a front plan view of the reclosable bag of the
embodiment of Fig. 7.
[0037] Fig. 9 provides a front perspective view of a bag body of the
reclosable bag of the
embodiment of Figs. 7 and 8.
8

CA 02951405 2016-12-14
[0038] Fig. 10 provides a top perspective view of a handle of the reclosable
bag of the
embodiment of Figs. 7 and 8.
[0039] Fig. 11 provides a top plan view illustrating a method to form the bag
of the
embodiment of Figs. 7 and 8.
[0040] Fig. 12 provides a cross-sectional view taken along A-A of Fig. 11
showing a step of
the method illustrated in Fig. 11.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The present disclosure illustrates one or more preferred embodiments of
the present
invention. It is not intended to provide an illustration or encompass all
embodiments
contemplated by the present invention. In view of the disclosure of the
present invention
contained herein, a person having ordinary skill in the art will recognize
that innumerable
modifications and insubstantial changes may be incorporated or otherwise
included within the
present invention without diverging from the spirit of the invention.
Therefore, it is understood
that the present invention is not limited to those embodiments disclosed
herein. The appended
claims are intended to more fully and accurately encompass the invention to
the fullest extent
possible, but it is fully appreciated that certain limitations on the use of
particular terms is not
intended to conclusively limit the scope of protection.
[0042] The bag 100 is shown having a first panel 102 and a second panel 104.
The two panels
102 and 104 are joined together at a first side 106 by first seal 107, at a
second side 108 by a
second seal 109, and at a bottom edge 110. The first panel 102 and second
panel 104 may be
formed from a single piece of polymeric film which is folded to define the
bottom edge 110. A
first top edge 112 and second top edge 114 are shown defined at an upper
distal end of the first
panel 102 and the second panel 104 respectively. Each top edge 112 and 114 may
be in the form
of a wave-shaped profile to form lobe 116 and 118 in each bag panel 102 and
104. Lobe 116 and
118 each comprise one period of the wave-shaped profile such that a width of
bag 100 from the
first side 106 to the second side 108 is one wavelength of the wave-shaped
profile. The wave-
shaped profile may comprise a sinusoidal wave shape but other wave-shaped
profiles are also
contemplated by the invention.
9

CA 02951405 2016-12-14
[0043] As further shown in Figs. 1 and 2, below top edges 112 and 114 are
handle openings
124 and 126. The handle openings 124 and 126 are shown positioned vertically
between a peak
and base (i.e. lowest point) of the wave-shaped profile within each lobe 116
and 118. The handle
openings 124 and 126 are further shown positioned horizontally midway between
opposing bases
of the wave-shaped profile. Due to the symmetry of bag 100, handle openings
124 and 126 are
also shown equidistant from first and second sides 106 and 108. Also shown in
Figs. 1 and 2 is
each opening 124 and 126 having a generally circular shape.
[0044] Looking again at Figs. 1 and 2, a first closure element 120 is shown
disposed on an
interior surface of the first panel 102 and a second closure element 122 is
shown disposed on an
interior surface of the second panel 104. Both the first and second closure
elements 120 and 122
are shown extending from the first side 106 to the second side 108 of bag 100.
The first and
second closure elements 120 and 122 may be configured to engage with each
other for closing
bag 100 below the closure elements 120 and 122. In a preferred embodiment,
closure elements
120 and 122 may be affixed to bag 100 by one or more heat seals with each heat
seal extending
in a lengthwise direction of closure elements 120 and 122. In an alternative
embodiment, closure
elements 120 and 122 may be affixed to bag 100 by a pressure sensitive
adhesive. Further
shown in Figs. 1 and 2 is a gusset 128 formed in a bottom portion of bag 100.
[0045] The dimensions of polymeric bag 100 may vary but in one particular
embodiment a
width of bag 100, from the first side edge 106 to the second side edge 108 may
be about 10-14
inches. A height of bag 100 from bottom edge 100 to closure elements 120 and
122 may be
about 8-14 inches. A height of each bag 100 handle from a base to a peak of
the wave-shaped
profile may be about 4-8 inches. A total of height of bag 100 from the bottom
edge 110 to a peak
of the wave-shaped profile may be about 12-20 inches. A thickness of the
polymeric film of bag
100 may also vary but in particular embodiments may range from about 0.4 mils
to 4 mils. The
diameter of each handle opening 124 and 126 may also vary but in certain
embodiments of bag
100 it may be about 2.5-5 inches.
[0046] Shown in Figs. 3 and 4 is a collapsed polymeric tube 300 utilized in a
process for
forming bag 100. Collapsed polymeric tube 300 may be formed from a polymeric
film tube by a
blown film extrusion process. As shown in Fig. 4, the collapsed polymeric tube
comprises a

CA 02951405 2016-12-14
front side 318 and a rear side 320. The collapsed polymeric tube 300 has a
machine direction
extending in the direction of extrusion which may also be referred to as a
lengthwise direction of
the polymeric film tube. The direction perpendicular to the machine direction
of the polymeric
film tube is commonly referred to as the cross-direction. Prior to the
collapsing of the polymeric
film tube, continuous gusset lines 308 and 310 may be formed in the polymeric
film tube as
shown in Figs. 3 and 4, as is known in the art.
[0047] The polymeric resin used in the blown film extrusion process may vary.
However, for
forming polymeric bags, a polyethylene resin is commonly used. In the current
state of the art
for polymeric bags, a blend of various polyethylene polymers may be used. A
polymer blend can
have linear low-density polyethylene (LLDPE) or high-density polyethylene
(HDPE) as the
primary component. Other polymers may be utilized such as low-density
polyethylene (LDPE).
The polymer blend may include additives including, but not limited to,
coloring additives, anti-
blocking agents, and/or odor control additives. The film utilized to form
polymeric bags may
also comprise multiple layers of blown film resin. The resultant multi-layer
film may be formed
by co-extrusion, a lamination process, or other methods of forming a multi-
layer film known in
the art. In each layer, one or more of the above-discussed polymers may be
used.
[0048] As further shown in Figs. 3 and 4, once the polymeric film tube is
collapsed, the
collapsed tube 300 is longitudinally severed in the shape of a repeating
waveform pattern 306 by
a slitting operation. In at least one embodiment, as shown by Figs. 3 and 4,
the waveform 306 is
sinusoidal. The slitting operation severs both the front side 318 and rear
side 320 of the
collapsed tube 300. The waveform 306 is shown centered between a first side
edge 302 and a
second side edge 304 of the collapsed tube 300 so that once severed, the
collapsed tube is
divided into two equal sections, a first tube section 314 and a second tube
section 316 such that
both sections have a repeating waveform pattern at an open top edge of each
tube section 314
and 316.
[0049] Once the collapsed tube 300 is severed with waveform 306, circular
openings 322 may
be punched or otherwise formed in collapsed tube 300. In an alternative
embodiment, circular
openings 322 maybe formed in collapsed tube 300 prior to the slitting
operation. Each circular
opening 322 is shown located about a centerline of collapsed tube 300 and also
aligned in a
11

CA 02951405 2016-12-14
machine direction of the collapsed tube at each peak of waveform 306. Once
circular openings
322 are placed in the collapsed tube 300, first and second tube sections 314
and 316 may be
separated from each other for further conversion into polymeric bags.
[0050] Shown in Fig. 5 is a cross-section of first tube section 314 which
comprises front
section 340 and rear section 342. Second tube section 316 may be manufactured
in a likewise
manner as first tube section 314 and hence is not discussed further. As shown
by Fig. 5, first
tube section 314 may be partially open by a bag converting process so that
distal edges of front
section 340 and rear section 342 are separated from each other. Once the
distal edges of front
and rear sections 340 and 342 are separated, first and second continuous
closure elements 344
and 346 may be placed on interior surfaces of front and rear sections 340 and
342 of first tube
section 314. Closure application guides 348a and 348b may be used to place
continuous closure
elements 344 and 346 onto front and rear sections 340 and 342 of first tube
section 314.
[0051] As further shown in Fig. 5, once continuous closure elements 344 and
346 are placed
on front and rear sections 340 and 342 of the first tube section 314, sealing
mechanisms 350a
and 350b may seal the continuous closure elements onto the front and rear
sections 340 and 342.
In at least one preferred embodiment, continuous closure elements 344 and 346
may be sealed
onto the front and rear sections 340 and 342 by heat sealing. In another
alternative embodiment,
continuous closure elements 344 and 346 may be affixed to front and rear
sections 340 and 342
with a pressure sensitive adhesive. Once continuous closure elements 344 and
346 are affixed to
the first tube section 314, the distal edges of front and rear sections 340
and 342 may be brought
back towards each other and closure elements 344 and 346 may be mutually
engaged so that bag
first tube section 314 is fully closed.
[0052] Continuous closure elements 344 and 346 may be press and close type
closure elements
with one of the closure elements a female closure element and the other of the
closure elements a
male closure element as is known in the art. One particular example of female
and male closure
elements is disclosed in United States Pat. Appl. Publ. No. US2011/0311167A1
(the '167
publication) which is hereby incorporated by reference. Fig. 2 of the '167
publication discloses
a first male closure element 200 and a first female closure element 220.
Another example of
male and female closure elements also shown in Fig. 2 of the '167 publication
are second male
12

CA 02951405 2016-12-14
closure element 240 and second female closure element 260. In one particular
embodiment of
the present invention, it may be desirable for continuous closure elements 344
and 346 to be
similar to the second male and female closure elements 240 and 260 of the '167
publication since
the asymmetric shape of the male closure element 240 provides for a higher
interior opening
force in comparison to an exterior opening force, as explained in the '167
publication.
[0053] In one particular embodiment of the present invention, continuous
closure elements 344
and 346 may be manufactured separately from the collapsed tube 300 and
provided as roll stock,
or in other various bulk forms, for application to each tube section 314 and
316. In an alternative
embodiment, continuous closure elements 344 and 346 may be manufactured in-
line with the
contemplated manufacturing process of the present invention and formed in-line
prior to
application to each tube section 314 and 316.
[0054] Shown in Fig. 6a is first tube section 314 with continuous closure
elements 344 and
346 applied to front and rear sections 340 and 342 of the first tube section
314. Front and rear
sections 340 and 342 are shown adjacent to each other and generally in the
same plane. A
plurality of closely spaced generally parallel sets of seals 366 are shown
formed on the first tube
section 314 by a bag converting process to form side seals for individual bags
100. Each set of
seals 366 is shown placed at the base, i.e. the lowest points, of waveform 306
and extending in
the cross-direction from the first side edge 302 to the upper edge waveform
306 of the first tube
section 314.
[0055] As further shown in Fig. 6a, once the sets of seals 366 are formed,
perforations 368a
may be made in the first tube section 314 in between and parallel to each set
of seals 366 to form
individual bags 100. However, in at least one preferred embodiment, the first
tube section 314
may be partially cut through with through-cut 368b. Through-cut 368b extends
from waveform
upper edge 306 to below continuous closure elements 344 and 346. Utilization
of through-cut
368b in proximity to continuous closure elements 344 and 346 prevents
continuous closure
elements 344 and 346 from interfering with later separation of the
perforation. The perforated
tube section 314 may then be rolled for packaging or the perforated tube
section 314 may further
be separated into individual bags 100.
[0056] Fig. 6b illustrates an alternative embodiment from Fig. 6a of the
process of forming
13

CA 02951405 2016-12-14
first tube section 314 into individual bags 100. Rather than parallel seals
and perforations, burn-
through seal 370 is shown forming individual bags 100 from first tube section
314. Burn-
through seal 370 is shown traversing first tube section 314 in the cross-
direction at each base of
wave-form profile 306 in place of the perforation 368 of the previous
embodiment. Burn-
through seals, or hot-knife edge seals, as known in the art, simultaneously
seal adjoining layers
of film together and cut through the layers ¨ i.e. burn through. Thus, once
burn-through seal 370
is applied to first tube section 314, first tube section 314 is separated into
individual bags 100.
Since burn-through seal 170 simultaneously seals and cuts, no closely spaced
sets of seals 366
are necessary as described for the previous embodiment. The burn-through seal
370 forms
opposing side seals such that first seal 107 is formed at first side 106 and
second seal 109 is
formed at second side 108 of bag 100 as shown in Fig. 6b. Once individual bags
100 are
separated by burn-through seal 170, the bags may be stacked or otherwise
arranged for
packaging.
[0057] Figs. 7 and 8 depict a further embodiment of the invention comprising a
side-gusseted
reclosable shopping or merchandise bag 400. The bag 400 shown comprises a
handle 402 and
bag body 404. In at least one embodiment, the handle section 402 may be formed
from a first
collapsed polymeric film tube and the bag body may be formed from a second
collapsed
polymeric film tube.
[0058] As more clearly shown in Fig. 9, the bag body 404, shown with its upper
opening
expanded, includes a front panel 406 and an opposing rear panel 408. Prior to
collapsing of the
second polymeric film tube that may form bag body 404; the tube may be
inwardly gusseted on
both opposing sides. Thus, the bag body 404 may include opposing inwardly
folded side gussets
410 and 412 on a first side 414 and a corresponding opposing second side 416
of the bag body
404. The bag body 404 is further shown having a top edge 422 of front panel
406 and a top edge
424 of rear panel 408. Shown between the front panel 406 and the rear panel
408 of bag body
404 is a first side gusset panel along the first side 414 and an opposing
second side gusset panel
along the second side 416. Shown opposite top edges 422 and 424 is bag bottom
420 which
forms a closed end of bag body 404. In at least one preferred embodiment, bag
bottom 420 may
be formed by heat sealing.
14

CA 02951405 2016-12-14
[0059] As shown in Fig. 10, handle 402 of bag 400 includes a front handle
portion 440 and a
rear handle portion 442. Also shown are front and rear upper edges 444 and 446
of handle
portions 440 and 442, which may have a wave-shaped profile. The wave-shaped
profile of the
front and rear upper edges 444 and 446 may be a sinusoid or other various
repeating waveforms.
[0060] As best shown in Fig. 10, handle 402 includes a bottom edge 448
opposite from top
edge 444 of front handle portion 440 and a bottom edge 450 opposite from top
edge 446 of rear
handle portion 442. The wave-shaped profile of upper edges 444 and 446 of
handle portions 440
and 442 may define a lobe in each handle portion. Each lobe comprises one
period of the wave-
shaped profile such that a width of handle 402 is one wavelength of the wave-
shaped profile.
[0061] As further shown in Fig. 10, defined within each lobe of handle
portions 440 and 442
are a front handle opening 452 in front handle portion 440 and a rear handle
opening 454 in rear
handle portion 442. The handle openings 452 and 454 are shown positioned
vertically between a
peak and base (i.e. lowest point) of the wave-shaped profile within each lobe.
The handle
openings 452 and 454 are further shown positioned horizontally midway between
opposing bases
of the wave-shaped profile. Also shown in Figs. 7 and 10 are side edges 464
and 466 on
opposing sides of handle 400 with handle portions 440 and 442 sealed or
otherwise joined to
each other along side edges 464 and 466.
[0062] Handle 402, as shown in Fig. 10, further includes a front closure
element 458 disposed
on an interior surface of front handle portion 440 and a rear closure element
460 disposed on an
interior surface of the rear handle portion 442. Both the front and rear
closure elements 458 and
460 are shown extending from the first side 454 to the second side 456 of
handle 402. The front
and rear closure elements 458 and 460 may be configured to engage with each
other for closing
bag 400 below the closure elements 458 and 460 with handle 402 attached to bag
body 400. In a
preferred embodiment, closure elements 458 and 460 may be affixed to handle
402 by one or
more heat seals with each heat seal extending in a lengthwise direction of
closure elements 458
and 460. In an alternative embodiment, closure elements 458 and 460 may be
affixed to handle
402 by a pressure sensitive adhesive.
[0063] Now returning to Figs. 7 and 8, handle 402 is affixed to bag 400 with a
front handle
seal 461 and rear handle seal 462. Front handle seal 461 is shown sealing
together the front

CA 02951405 2016-12-14
handle portion 440 to the front panel 406, the front handle seal 461 extending
from the first side
414 to the second side 416 of bag 400. In a likewise fashion, rear handle seal
462 is shown
sealing together the rear handle portion 442 to the rear panel 408, the rear
handle seal 462
extending from the first side 414 to the second side 416 of bag 400. In at
least one preferred
embodiment, front handle seal 461 and rear handle seal 462 are formed by heat
sealing.
However, in at least one alternative embodiment, a pressure sensitive adhesive
may be used
rather than heat to form seals 461 and 462.
[0064] As further shown in Figs. 7 and 8, front handle seal 461 may close off
or seal together
side gussets 410 and 412. Seal 461 is shown sealing off side gussets 410 and
412 in a straight
line fashion with side gussets 410 and 412 extending linearly from bag bottom
420 and forming
generally a perpendicular intersection with seal 461. In an alternative
embodiment, side gussets
410 and 412 may taper at an angle towards seal 461 so that bag body 404 is
provided with a
greater amount of usable internal volume.
[0065] The dimensions of polymeric bag 400 may vary but in one particular
embodiment a
width of bag 400, from the first side 414 to the second side 416, may be about
6-14 inches. A
height of bag 400 from bottom 420 to closure elements 458 and 460 may be about
8-14 inches.
A height of each bag handle 402 from a base to a peak of the wave-shaped
profile may be about
4-8 inches. A total of height of bag 400 from the bottom 420 to a peak of the
wave-shaped
profile may be about 12-20 inches. A thickness of the polymeric film of bag
400 may also vary
but in particular embodiments may range from about 0.4 mils to 4 mils. The
diameter of each
handle opening 452 and 454 may also vary but in certain embodiments of bag 400
it may be
about 2.5-5 inches.
[0066] Shown in Figs. 11 and 12 is a depiction of a method of forming bag 400
from a side-
gusseted collapsed blown film tube 502 and a partial wave-cut collapsed blown
film tube 504.
Partial wave-cut tube 504 may be formed in a similar process as described
above for the
formation of first and second tube sections 314 and 316 as shown in Figs. 3
and 4, with partial
wave-cut tube 504 comprising one of the tube sections 314 and 316. However,
the width of
collapsed tube 300 may be adjusted accordingly to form the appropriate height
and width for
handle 402 formed from partial wave-cut tube 504. Furthermore, the adjoining
side edge of
16

CA 02951405 2016-12-14
partial wave-cut tube, first or second side edges 302 and 304 of collapsed
tube 300, may be slit
so that front side 528 and rear side 530 of partial wave-cut tube 504 are
detached from each other
as shown in Fig. 12. The partial wave-cut tube 504 is shown with a first
machine direction.
[0067] As further shown in Figs. 11 and 12, continuous closure elements 524
and 526 may be
affixed to interior surfaces of the front side 528 and the rear side 530 of
partial wave-cut tube
504. The application of continuous closure elements 524 and 526 may be
performed in a
likewise manner as the application of continuous closure elements 344 and 346
previously
described and illustrated in Fig. 5. Continuous closure elements 524 and 526
may also be of the
same or similar structure as the previously described continuous closure
elements 344 and 346.
[0068] Further shown in Figs. 11 and 12 is a side-gusseted blown film tube 502
which may be
formed utilizing various methods commonly known in the art. Side-gusseted tube
502 may be
formed in a one-up process with a single side-gusseted tube formed from a
single collapsed tube
of blown film or multiple side-gusseted tubes may also be formed from a single
blown film
collapsed tube with the use of slit seals. Side-gusseted tube 502 is further
shown having a front
side 532 and rear side 534 in Fig. 12.
[0069] Side-gusseted tube 502 is shown in Fig. 11 having a second machine
direction
perpendicular to the first machine direction of partial wave-cut tube 504. The
side-gusseted tube
502 intersects with the partial wave-cut tube 504 such that the leading distal
edges of side-
gusseted tube 502, upper edges 506 and 508, are in proximity with outer side
edges 510 and 512
of partial wave-cut tube 504. The waveform, or wave-shaped profile 540, of the
partial wave-cut
tube 504 is formed so that each base of the waveform is aligned with a side
edge 518 of side-
gusseted tube 502 and a peak of the waveform is centered between a pair of
opposing side edges
518. Additionally, aligned with each peak of the waveform 540 is a circular
opening 536 defined
between each pair of bases of the waveform of partial wave-cut tube 504.
[0070] Fig. 12 shows a cross-sectional view of side-gusseted tube 502 and
partial wave-cut
tube 504. Further shown in Fig. 12 is a front side upper edge 506 of gusseted-
tube 502 and a
front side outer edge 510 of a front section of partial wave-cut tube 504
folded upwards. Also
shown are a rear side upper edge 508 of gusseted tube 502 and a rear side
outer edge 512 of
wave-cut tube 504 folded downwards. Prior to folding, the opposing side edges
518 of side-
17

CA 02951405 2016-12-14
gusseted tube 502 may be slit a limited distance below upper edges 506 and 508
so that the upper
edges may be folded away from each other as described.
[0071] Once edges 506 and 510 are folded upwards, the two films of the side-
gusseted tube
502 and partial waVe-cut tube 504 may be sealed to each other with sealing
mechanism 514. In a
likewise fashion, edges 508 and 512 may be sealed to each other with sealing
mechanism 516.
Simultaneously with the sealing of the upper and outer edges, the slit
portions of side edges 518
may be resealed. Also, preferably simultaneously with the sealing of the upper
and outer edges
506, 508, 510, and 512, hot-knife seals can be placed transversely across side-
gusseted tube 502
to form bottom edge 420 of bag 400 and also at opposing sides 522 of handle
portion 520 of
partial wave-cut tube 504 to form fully sealed side edges 464 and 466 of bag
400. The hot knife
seals can seal the adjoining films together and simultaneously sever the film.
[0072] Along with the sealing of the edges and sides, closure elements 524 and
526 may be
crushed together, or ultrasonically welded, adjacent to sides 522 to ensure
proper sealing and
operation of closure elements 524 and 526. Once bag 400 is completely formed,
it can be
severed from tubes 502 and 504, preferably by the previously described hot-
knife seals. Once
separated from tubes 502 and 504, bag 400 may be packaged or otherwise
processed further.
[0073] As previously noted, the specific embodiments depicted herein are not
intended to limit
the scope of the present invention. Indeed, it is contemplated that any number
of different
embodiments may be utilized without diverging from the spirit of the
invention. Therefore, the
appended claims are intended to more fully encompass the full scope of the
present invention.
18

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Title Date
Forecasted Issue Date Unavailable
(22) Filed 2016-12-14
(41) Open to Public Inspection 2017-06-15
Examination Requested 2021-12-13

Abandonment History

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Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $400.00 2016-12-14
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Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
POLY-AMERICA, L.P.
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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