Note: Descriptions are shown in the official language in which they were submitted.
Docket No. 377-003CA
LOW COST INSULATED CARRYING BAG
FIELD OF THE INVENTION
[0001] The present invention relates to the field of insulated carrying bags.
In particular, the
present invention relates to low-cost multilayer insulated carrying bags with
enhanced structural
features for aid in transport.
BACKGROUND
[0002] With the rise of online and app-based food ordering, home deliveries of
temperature
sensitive, cold or warm, or hot foods and other goods requiring protection
from high or low
ambient temperatures, have grown substantially. Traditional methods to protect
such goods during
transport from source to destination have included reusable insulated totes or
single-use solutions
including a combination of paper or plastic carrying bags with an insulated
liner. The latter two
solutions are used in combination since existing insulated liners are
typically designed and built
for use inside rigid devices such as corrugated containers, and therefore,
lack the rigidity and
carrying convenience needed to be used as a carrying device. Single-use, low
cost insulating bags
with carrying capability have also been produced, but they lack the carrying
ability necessary for
heavier goods since the materials they are made of are prone to tearing. The
combined methods
such as paper bag and insulated liner, while effective, present cost and
convenience disadvantages
in that two different items must be purchased, stored and handled in order to
achieve the solution
for effective temperature-controlled delivery of lightweight or heavy goods
that can be easily
carried. The need exists for a singular protective carrying device that
provides easy carrying
capability and protection from ambient temperatures and has a low total cost.
SUMMARY OF THE INVENTION
[0003] The subject matter of the present disclosure relates to improved
insulated carrying bags
and methods for its manufacture.
[0004] In one embodiment, the present disclosure provides an insulated
carrying bag comprising
a multilayer first panel comprising a top free edge, a bottom edge, a first
side edge a second side
edge, a strengthened section comprising strengthening material, and a holding
aperture positioned
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,
in the strengthened section; a multilayer second panel comprising a top free
edge, a bottom edge,
a first side edge and a second side edge, a strengthened section comprising
strengthening material,
and a holding aperture positioned in the strengthened section; and a
multilayer bottom panel
comprising a front edge and a back edge. The first panel first side edge is
connected to the second
panel first side edge along the two edges of the panels. The first panel
second side edge is
connected to the second panel second side edge along the two edges of the
panels. The first panel
bottom edge is connected to the front edge of the bottom panel along the
edges, and the second
panel bottom edge is connected to the back edge along the two edges of the
panels. The connected
first panel, second panel and bottom panel form a compartment accessible
through the top free
edges of the first and second panels, and the layers of the first panel,
second panel and bottom
panel comprise an insulating thermoplastic layer and a vapor barrier layer,
and the first and second
panels additionally comprise a layer of the strengthening material. Although
vapor barriers in
general will provide improved protection, metalized films provide improved
isolative properties
due to their radiant barrier properties. For the purposes of this invention,
radiant barrier and
reflective films can be used interchangeably with vapor barrier materials.
[0005] In another embodiment, the present disclosure provides a process for
producing an
insulated carrying bag comprising a multilayer first panel comprising a top
free edge, a bottom
edge, a first side edge a second side edge, a strengthened section comprising
strengthening
material, and a holding aperture positioned in the strengthened section; a
multilayer second panel
comprising a top free edge, a bottom edge, a first side edge and a second side
edge, a strengthened
section comprising strengthening material, and a holding aperture positioned
in the strengthened
section; and a multilayer bottom panel comprising a front edge and a back
edge. The first panel
first side edge is connected to the second panel first side edge along the two
edges. The first panel
second side edge is connected to the second panel second side edge along the
two edges. The first
panel bottom edge is connected to the front edge of the bottom panel along the
edges, and the
second panel bottom edge is connected to the back edge along the edges. The
connected first
panel, second panel and bottom panel form a compartment accessible through the
top free edges
of the first and second panels, and the layers of the first panel, second
panel and bottom panel
comprise an insulating thermoplastic layer and a vapor barrier layer, and the
first and second panels
additionally comprise a layer of the strengthening material. The process
comprises feeding the
multilayer first panel, multilayer second panel and multilayer bottom panel to
an assembly device;
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folding the multilayer bottom panel material; and inserting the folded
multilayer bottom panel
material between the multilayer first panel material and the multilayer second
panel material; and
then sealing and cutting the resultant material to form the insulated carrying
bag.
[0006] In still another embodiment the present disclosure provides an
insulated carrying bag
comprising a multilayer first panel comprising a top free edge, a bottom edge,
a first side edge a
second side edge, a strengthened section comprising strengthening material,
and a holding aperture
positioned in the strengthened section; a multilayer second panel comprising a
top free edge, a
bottom edge, a first side edge and a second side edge, a strengthened section
comprising
strengthening material, and a holding aperture positioned in the strengthened
section; a multilayer
bottom panel comprising a front edge and a back edge, and a tamper-evident
sealing device. The
first panel first side edge is connected to the second panel first side edge
along the two edges of
the panels. The first panel second side edge is connected to the second panel
second side edge
along the two edges of the panels. The first panel bottom edge is connected to
the front edge of
the bottom panel along the edges, and the second panel bottom edge is
connected to the back edge
along the two edges of the panels. The connected first panel, second panel and
bottom panel form
a compartment accessible through the top free edges of the first and second
panels, and the layers
of the first panel, second panel and bottom panel comprise an insulating
thermoplastic layer and a
vapor barrier layer, and the first and second panels additionally comprise a
layer of the
strengthening material.
[0007] In another embodiment the present disclosure provides an insulated
carrying bag
comprising a multilayer first panel comprising a top free edge, a bottom edge,
a first side edge a
second side edge, a strengthened section comprising strengthening material,
and a holding aperture
positioned in the strengthened section; a multilayer second panel comprising a
top free edge, a
bottom edge, a first side edge and a second side edge, a strengthened section
comprising
strengthening material, and a holding aperture positioned in the strengthened
section; a multilayer
bottom panel comprising a front edge and a back edge, and a venting device
connected to the first
or second panel. The first panel first side edge is connected to the second
panel first side edge
along the two edges of the panels. The first panel second side edge is
connected to the second
panel second side edge along the two edges of the panels. The first panel
bottom edge is connected
to the front edge of the bottom panel along the edges, and the second panel
bottom edge is
connected to the back edge along the two edges of the panels. The connected
first panel, second
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panel and bottom panel form a compartment accessible through the top free
edges of the first and
second panels, and the layers of the first panel, second panel and bottom
panel comprise an
insulating thermoplastic layer and a vapor barrier layer, and the first and
second panels additionally
comprise a layer of the strengthening material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The subject matter of the present disclosure will be more fully
understood from the
following detailed description, taken in connection with the accompanying
drawings, in which:
[0009] Figure 1 shows a front perspective view of the insulated carrying bag.
[0010] Figure 2 shows a side perspective view of the insulated carrying bag.
[0011] Figure 3 shows a top perspective view of the insulated carrying bag.
[0012] Figure 4 shows a roller assembly for producing panels of the insulated
carrying bag, along
with a strengthening material unwind roller.
[0013] Figure 5 is a sectional perspective view of the insulated carrying bag.
[0014] Figure 6 is an exploded view of the multilayer panel of the insulated
carrying bag in the
region of the holding apertures.
[0015] Figure 7 is an alternate exploded view of the multilayer panel of the
insulated carrying bag
in the region of the holding apertures.
[0016] Figure 8 is a top view of a sequential manufacturing process for an
insulating carrying
bag.
[0017] Figure 9 is a front view of the folded, flat insulated carrying bag
with gussets.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The subject matter of the present disclosure relates to a low-cost
solution for both transport
and protection of goods using a novel insulated carrying bag, and method for
manufacturing the
same. The invention achieves this by utilizing an innovative method of
selective strengthening of
the materials by employing a supported carrying handle with a soft sided
insulated bag in a unique
method of manufacturing of the bags. This method allows for the high speed,
automated
production of single-use, low cost insulated carrying bags that require no
combined additional
carrying devices. The selective strengthening prevents sagging of the bag when
loaded about the
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handles compared to non-strengthened bags, as well as conferring a lighter,
more flexible feel to
the bag. This is a desirable enhancement over conventional bags that do not
selectively strengthen
the bag, i.e., the majority of the bag is strengthened, because the selective
strengthening
communicates to the user that the bag is a single-use and/or environmentally
friendly material, and
not a heavy duty/wasteful article. The lighter feel to the bag also conveys
the sense to the user that
shipping costs will be minimized, compared to conventionally strengthened
bags. Finally, there
are efficiencies in the thermal performance of lighter gauge structures. The
placement of the
strengthening material and its interaction with the holding apertures on the
first and second panels
provides enhanced performance by acting to improve the distribution of the
load carried.
[0019] Conventional insulating bags incorporate low cost, single-use
thermoplastic materials with
integrated handles; but the corresponding manufacturing processes lack the
step of providing the
selective strengthening of the materials. The aforementioned strengthening
presents great
advantages when compared to conventional bags providing improved tear
resistance and load
distribution, where the strengthening material has the transforming effect of
providing tear
resistance to a material that typically tears easily. This tear resistance
when placed in the hand-
hole region, allows for the production of a carrying bag with improved weight
capability.
[0020] The placement of the strengthening material in the hand-hole region has
additional
advantages that include the distribution of weight for the load placed into
the bag. A typical plastic
bag when loaded with weight and lifted in a relatively small hand-hole region
will present sagging
in the regions adjacent the hand-hole. This sagging can result in reduced
comfort in handling by
the user and other disadvantages. The strengthening material incorporated in
the bags of the
current subject matter has the added advantage of the distribution of the
weight of the goods placed
inside the bag, thereby reducing the sagging near the said hand-hole. By way
of example, the
strengthening material can be made of materials such as plastic films, elastic
polymers including
low density polyethylene, polypropylene, in single or multi-layer form.
Additionally, such films
can be manufactured with high melt materials, such as nylon or polyethylene
materials containing
comonomers of hexene or octene to increase their heat resistance and melt
points. Other examples
include strengthening plastic materials that resist tearing. The strengthening
material can comprise
multiple layers of materials that are different, as thickness and differing
properties of the layers
could enhance a resistance to tearing.
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[0021] The insulated carrying bag of the present subject matter generally has
a box-like shape
when open, with holding apertures; i.e., hand holes for ease of
transportation, and is open for access
through its top. The holding apertures are configured to accommodate a
person's hand in carrying
the bag, and generally have a rectangular or oval shape. The holding apertures
have a width
corresponding to the vertical distance from the top to the bottom of the
aperture at their maximum
separation.
[0022] The bags include a first front panel, a second back panel and a bottom
panel that are
interconnected, such that when the bag is open, the panels form a compartment
accessible through
its open top. The front and back panels and bottom panel of the bag are
multilayer, and each
contain a thermoplastic insulating layer and a vapor barrier layer to maintain
the environmental
conditions within the bag to protect its contents from damage or spoilage. The
bag is specially-
designed to contain a section in the area of the hand holds that is reinforced
with a strengthening
material, where the holding apertures are positioned within the strengthened
section. The
strengthened section is present as a separate layer than the insulating
thermoplastic layer and the
vapor barrier layer in the multilayer structure and is positioned between the
thermoplastic
insulating layer and the vapor barrier layer. Typically, the strengthened
section extends across
both the front and back panels running parallel to the top free edges, and is
positioned
symmetrically about the vertical access on the first front and second back
panels. The strengthened
section is typically positioned from the horizontal midline of the front/back
panels to the top free
edge of the front/back panels. Preferably, the strengthened section extends
from above the
horizontal midline to the top free edge. More preferably, the strengthened
section extends from a
position four holding aperture widths below the top free edge to the top free
edge. Most preferably,
the strengthened section extends from the bottom of the holding aperture to
the top of the holding
aperture.
[0023] The bag may optionally contain a sealing device below the hand holds to
provide a hermetic
closure. Preferably, the sealing device is selected from an adhesive strip,
press-seal closure, or
slide lock closure. The sealing device may also be tamper evident. For the
purposes of this
specification the term "tamper evident" means that the sealing device shows
visible evidence to
the consumer that tampering has occurred. For example, in one embodiment the
tamper evident
seal will self-destruct to indicate the seal has been broken. In another
embodiment, the insulated
carrying bag may contain a venting device that is attached to the front or
back panel, for venting
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the bag. Preferably, the venting device is connected to the sealing device,
which in turn is
connected to the front or back panel.
[0024] The front and back panels are generally of square or rectangular shape.
Because the bag is
designed to be capable of being folded or opened up, the bottom panel layer is
equipped with
gussets that confer a generally oval or hexagonal shape to the bottom panel.
When the bag is
folded flat, the gusset extends downward as shown in Figure 9. The gussets
allow the bag to
expand and forms the interior of the bag. The front and back panels of the bag
oppose each other,
as do the bottom panel of the bag and the bag opening when the bag is
unfolded. Each of the front
and back panels are oriented vertically, and have a top free edge
corresponding to the open top of
the bag, a bottom edge that is proximate to the bottom panel, and two side
edges. The bottom
panel layer is oriented horizontally when the bag is in an open position ready
to be loaded with
goods and has a front edge and a back edge. Because of the gusset running
along the long axis of
the bottom layer, the bottom panel front edge and back edge on each side are
angled or curved
toward each other from opposite sides when the bag is opened, and meet at the
intersection with
the long axis. The front and back panels are attached to each other along
their two corresponding
side edges. The front panel is attached to the bottom panel along its front
edge. The back panel
is also attached to bottom panel along its back edge.
[0025] The front panel, also referred to in this specification as the first
panel; and the back panel,
also referred to in this specification, as the second panel, are multilayer
materials containing an
insulating thermoplastic layer and a vapor barrier layer. The insulating
thermoplastic layer is
selected from a low density polyethylene bubble material, thermoplastic
cushioning material, a
polyethylene foam cushioning material or combinations thereof The vapor
barrier material is
selected from a metalized polyester attached to a biaxially oriented
polypropylene (BOPP) film,
multi-layer polyethylene film, a metalized polyethylene film, a barrier film,
or a nylon-containing
polyethylene film.
[0026] Insulating Thermoplastic Layer
[0027] The insulating thermoplastic layer is selected from low density
polyethylene bubble
material, thermoplastic cushioning material, a polyethylene foam cushioning
material or
combinations thereof
[0028] A. Low Density Polyethylene Bubble Material
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[0029] When the insulating thermoplastic layer is polyethylene bubble
material, a first
polyethylene film is first fed to a heated roll system comprising a first
vacuum roller comprising
dimples and a second roller, wherein the first vacuum roller contacts the
first heated polyethylene
film, thereby forming a bubble layer having a top side and an unsealed bottom
side. A second
polyethylene film is also fed to the heated roll system, wherein one side of
the second heated
polyethylene film contacts the unsealed bottom side of the bubble layer while
under pressure,
thereby sealing the bubble layer with a bubble base layer. Preferably, both
the first and second
polyethylene films are low density polyethylene material as described above.
Optionally, a third
polyethylene layer can be attached to the bubble layer forming a bubble cover
layer. Preferably,
each of the first, second and third polyethylene films are low density
polyethylene material. For
the purposes of this application, a low-density polyethylene (LDPE) is a
polyethylene having a
density of 0.910 g/cc to 0.925 g/cc, where the polyethylene can be a
homopolymer of ethylene or
a copolymer of ethylene with an alpha-olefin CH2=CHR, wherein R is an alkyl
radical containing
from 1 to 18 atoms of carbon. When a metalized vapor barrier is used,
preferably the bubble layer
and bubble base layer are clear. This configuration is effective in reflecting
heat back into the bag,
which is desirable for protecting hot or warm goods.
[0030] B. Thermoplastic Cushioning Material
[0031] When the insulating thermoplastic layer is thermoplastic cushioning
material it is selected
from polyethylene or polypropylene materials having a cellular or fibrous
form.
[0032] C. Polyethylene Foam Cushioning Material
[0033] When the insulating thermoplastic layer is a polyethylene foam
cushioning material, the
layer is produced from a polyethylene resin heated in a process where a
bubbling or foaming effect
is induced. It is then made into a film put through a die 1/36" to 1/2" thick,
so that when cooled
the stable and firm film maintains the bubbling that results in insulating
properties.
[0034] Vapor Barrier Layer
[0035] The vapor barrier material is selected from a metalized polyester
attached to a biaxially
oriented polypropylene film, multi-layer polyethylene film, aluminum oxide
containing film
structure, silicon oxide containing film structure, an ethylene vinyl alcohol
film structure, linear
low density polyethylene film, polypropylene containing film structure, an
high density
polyethylene containing film structure, a metalized polyethylene film, or a
nylon-containing
polyethylene film.
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[0036] D. Metallized Polyester Attached to Polyethylene Film
[0037] The preferred vapor barrier layer is a metalized polyester film
attached to a biaxially
oriented polypropylene film, the total layer having a thickness of 0.25 to 1.5
mil. Preferably, the
total layer has a thickness of 1.0 to 1.5 mil. For the purposes of this
specification, the term "mil"
means 0.001 inch. The metalized polyester film is attached to the polyethylene
film by extrusion
coating or lamination using an adhesive material. The metal used in the
metallization is preferably
aluminum. The metallization can be conducted in any manner well known to those
skilled in the
art. Preferably, the method is by vacuum deposition. The thickness layer of
the metal on the film
after metallization is preferably 2 to 100 micron, More preferably, the
thickness of the layer is 5
to 75 micron. Most preferably, the thickness is 10 to 50 micron.
[0038] E. Multilayer Polyethylene Film
[0039] When the vapor barrier layer is a multilayer polyethylene film it is
preferably two or more
co-extruded layers
[0040] F. Metalized Polyethylene Film
[0041] When the vapor barrier layer is a metalized polyethylene film, the
metalized polyethylene
film has a total thickness of 0.30 to 3.0 mil, and contains a metal layer and
a barrier base layer.
Preferably, the metalized polyethylene film thickness is 0.50 to 1.0 mil. The
metalization process
is as described above. The metalized polyethylene film is produced by vacuum
metalization of a
corona treated polyethylene film. Preferably, the film is tinted white.
[0042] G. Nylon-containing Polyethylene Film
[0043] When the vapor barrier layer is a nylon-containing polyethylene film,
the film has a
thickness of 0.5 to 2.5 mil. Preferably, the thickness of the nylon-containing
low density
polyethylene film has a thickness of 0.75 to 1.5 mil. The nylon-containing low
density
polyethylene film is produced by formation of a multi-layer structure of film,
where the extruded
layers include at least one layer of nylon containing film that is bonded to
other layers of film that
do not contain nylon.
[0044] H. Other Vapor Barrier and Radiant Barrier Materials
[0045] The vapor barrier and radiant barrier material can also be selected
from an metalized BOPP
(biaxially-oriented polypropylene), metalized BON (biaxially oriented nylon),
metalized Biaxially
Oriented Polyethylene Terephthalate (BOPET), metalized Polyvinylidene chloride
or PVdC,
aluminum oxide containing film structure, a silicon oxide containing film
structure, an ethylene
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vinyl alcohol film structure, linear low density polyethylene film,
polypropylene containing film
structure, or a high density polyethylene containing film structure. Film
thicknesses are preferably
in the range of 0.5 to 2.5 mil.
[0046] Strengthening Section
[0047] The film corresponding to the strengthening material is selected from a
low density
polyethylene film, polypropylene film, elastic polymers, and a nylon-
containing low density
polyethylene film, or thermoplastic woven material such as netting or textiles
manufactured from
thermoplastic yarn, thread or other material that can be woven. Non-woven
material such as
polyester or polyethylene fiber bonded together creating a fabric like
consistency, preferably, using
a spun bonding process in a single or multi-layer form can also be used. The
strengthening material
can be one or more layers, with the layers being the same or different.
Preferably, the layers are
different.
[0048] I. Low Density PE Film Strengthening Material
[0049] When the strengthening material is a low density polyethylene film, the
film layer has a
thickness of 1.0 to 6.0 mil. More preferably, the thickness is 1.5 to 3.0 mil.
Even more preferably,
the thickness is 2.0 to 3.0 mil. The low density polyethylene film is produced
by an extrusion
process where the low density polyethylene film is heated and put through a
die that determines
the end thickness of the film, then the film is cooled and wound, or put
directly into a secondary
manufacturing process.
[0050] J. Nylon-containing Low Density PE Film
[0051] When the strengthening material is a nylon-containing low density
polyethylene film, the
film layer has a thickness 1.0 to 6.0 mil. More preferably, the thickness is
1.5 to 3.0 mil. The
nylon-containing low density polyethylene film is produced by formation of a
multi-layer structure
of film, where the extruded layers include at least one layer of nylon
containing film that is bonded
to other layers of film that do not contain nylon.
[0052] K. Polypropylene or Elastic Polymer Film
[0053] When the strengthening material is a polypropylene film or elastic
polymers, the polymer
is selected from propylene homopolymers or copolymers of propylene with C2-C8
comonomers.
[0054] L. Thermoplastic Woven or Non-woven material
[0055] When the strengthening material is a thermoplastic woven or nonwoven
material it is
produced by or thermoplastic woven material such as netting or textiles
manufactured from
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thermoplastic yarn, thread or other material that can be woven. Non-woven
material such as
polyester or polyethylene fiber is bonded together creating a fabric like
consistency, preferably,
using a spun bonding process in a single or multi-material form.
[0056] Except as described below, the various components of the insulating
carrying bag: front
panel, back panel and bottom panel are typically attached to each other by hot
press rolling (heat
and pressure), or alternately with adhesives, sonic welding or mechanical
pressure, with folding as
necessary to produce the bag gussets, the details of which are described
below.
[0057] Preparation of Insulated Carrying Bag
[0058] The insulated carrying bag is comprised of a first panel, second panel
and bottom panel of
insulation material that are connected together. The material for the panels
is manufactured using
multiple individual film webs that are each unwound from the appropriate size
roll stock.
Alternatively, as few as a single panel of strengthened insulation material
can be used, wherein a
web can be folded or shaped and further converted to produce the square bottom
carrying device.
Also, the materials can be processed while originating in a bubble or other
bulky cushioning
material manufacturing and combining process as an alternative to roll storage
and utilization.
[0059] Preferably, the thermoplastic insulating layer comprises a bubble film
layer. The bubble
film manufacturing process is typically performed by applying heat and suction
to a thermoplastic
film that starts out as a film on a roll, or alternatively as a resin that is
extruded into a film. Such
film is heated immediately before or while simultaneously being run over a
suction roller with a
pattern of impressions that match the pattern of bubbles of the bubble film
being manufactured.
After the suction is applied to the heated film, the 'dimples' formed by the
suction are encapsulated
by applying another film to the 'bottom' of the structure to seal off the
dimples that were created.
This film that seals the bottom of the structure is the bubble base layer.
This combined structure
is typically cooled to create a firm, stable plastic bubble film, but complete
cooling can be delayed
or reheating can be performed so as to add an additional laminate structure
using heat and pressure
on top of the bubble material that is formed; such as a vapor barrier or
metalized layer. Alternative
methods of bonding of the laminate structures include adhesives, sonic
welding, or mechanical
pressure. A vapor barrier material or other desired material may be added to
the top and/or bottom
of the plastic bubble film. In addition, strengthening material is added
during the process in a
strategic location to maximize performance and efficiency, and is placed in
between the bubble
material and the vapor barrier material, such as metalized polyester. The
final step in such a
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manufacturing process is the winding of the finished bubble film into a roll.
Then the roll of bubble
film is ready for a subsequent manufacturing step for converting into bubble
bags or other articles.
[0060] For the purposes of the invention, an alternative to creating a roll of
bubble film and
transferring that roll into a subsequent process for fabrication of bubble
bags is to feed the bubble
film directly into a converting process while it is manufactured. This method
is advantageous
since cushioning materials are typically bulky, and the linear yield of rolls
of the same are
relatively low when compared to flat films. If bubble film rolls are used in a
bubble bag converting
process, frequent stoppage of bag converting and changeover of rolls will be
required. The
advantage of the alternate manufacturing method is that the inline production
method of producing
bubble film with the necessary laminate and strengthening structure, allows
feeding directly into
the bag converting process, skipping the roll storage altogether. Using the
direct conversion
process, each production run will be significantly longer and changeovers less
frequent, since
instead of bulky rolls of bubble film, the 'raw material' of such a bag
converting process will be
the flat film or strengthening material being fed into the bubble
manufacturing process. Both such
raw materials are available in roll forms that are significantly higher yield.
When resin is used to
create the bubble material or other components, there is a theoretically
infinite yield since such
resins can typically be replenished without stopping the production process
using existing
hardware and technology; when considering the extruded materials and their
replenishment only.
Similar advantages exist for other cushioning/insulating materials such as
expanded polyethylene
or other similar materials. An alternative method of adding strengthening
material to the insulation
materials can be attachment of the same to the exterior portions of the
combined cushioning and
vapor barrier material, using an adhesive or other fastening method.
[0061] The web-based manufacturing method involves multiple webs of
cushioning/insulating
material that are subjected to a converting process to produce the insulated
bag. If in roll form,
the various rolls are placed in strategic positions so that when they are
unwound, they are easily
processed to allow for the correct sealing and cutting steps to produce the
correct sized bag. For
example, in one embodiment, the first and second panels and a bottom panel of
the insulated
carrying bag are represented by three rolls of cushioning/insulating material
being unwound into
three webs; wherein the bottom gusset web is folded and inserted in between
the top and bottom
web. The structure is then sealed together connecting the bottom gusset to the
top and bottom
webs, then cut and sealed to length to create a single square bottom bag. In
another embodiment,
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a single roll of material is unwound and folded into a two-ply web, after
which the folding device
places a bottom gusset at the fold area, and such an adjusted web is segmented
to create a square
bottom pouch. In yet another embodiment, a single roll of material is formed
into a flat pouch that
is then sealed and cut to size, creating a flat pouch suitable for holding
products yet with relatively
lower expansion ability and aesthetic appearance when loaded with goods.
[0062] The insulation materials, such as polyethylene bubble film laminated to
metalized
polyester, are typically produced with a heat sealable thermoplastic on one
side only; allowing for
easy heat seal capability. Adhesives can be used as an alternative to heat
sealable materials.
[0063] In one method, the materials may be connected in a sequence of steps
that creates a bag
with a bottom gusset or pocket allowing the bag to open in three dimensions,
allowing for
additional volume of goods to be packaged. The insulated carrying bag can have
an integrated
carrying handle formed from the holding apertures in the first and second
panels that allows for
easy holding and portability of goods inside. Such goods when carried can be
of little to substantial
weight. The steps in the converting process can include heat sealing the
thermoplastic portions of
the cushioning/insulating material (such as bubble film) that comprise the
bottom, sides and
gussets, cutting to finalize gussets and to segment the web into individual
bags of the proper size
and die cutting or other method of creating an integrated hand hole; all are
performed in a sequence
or at once; while the creating of the hand hole can be performed at any time.
The gusseting is an
option that provides more volume to the bag. During this converting process,
the integrated hand
hole can be created in the bag by mechanical punching, thermal burning, or
melting methods.
[0064] Another aspect of the current subject matter involves the manufacture
of the insulation
material, wherein a strengthening method is performed during this process to
improve the tear
resistance of the panels. An improved hand-hole is formed by the holding
apertures into the
insulated carrying bag to create a handle portion that will not tear when a
load is applied to the
bag. The insulation material, made of a combined thermoplastic and vapor
barrier, is produced
and stored in possibly roll form. During production, a unique step is taken
where only a certain
portion of the roll is strengthened; this selective strengthening presents
cost and other advantages
as further described below.
[0065] In the preferred embodiment, the result of the manufacturing process is
a two-ply bag
having an outer layer made of a vapor barrier and an inner layer made of
thermoplastic. In between
the outer layer and the inner layer may be one or more strips of a
strengthening material. The
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insulated carrying bag is defined by the bottom panel, first and second panels
and an opening
opposite the bottom defined by the panel top free edges of the first and
second panels. Near the
opening, on the first and second panels is the strengthening material running
parallel with the top
free edges. Hand-hole apertures can be punched through the sidewalls and
through the
strengthening material. The creation of hand-holes results in the formation of
the handles.
Because the hand-holes are created through the strengthening material, the
handles are much
stronger than they would have been without the strengthening material.
100661 The addition of the strengthening material creates a significant
improvement in the weight
capacity of the bag in that it provides significant tear resistance to the
integrated hand hole.
Additionally, since vapor barriers like metalized polyester are typically more
rigid than other
polymers like polyethylene; when such components are exposed to die cutting
and other methods
of applying the hand hole, fractures or micro-fractures can be created that
will 'run' or contribute
to tearing when a load is applied to them. Since the strengthening materials
are typically elastic
polymers that resist tearing such as low density polyethylene film, their
addition to such low
elasticity structures enhances the tear resistance of the combined structure.
In testing, bags with
strengthened integrated hand holes demonstrate significantly larger weight
capacity compared to
bags with non-strengthened hand holes, and tearing of the integrated hand hole
is negligible to
null. In fact, such strengthened hand holes demonstrate such a tear resistance
that other portions
of the bag tend to tear first when load is gradually increased in a failure
test. The strengthened bags
have demonstrated up to five times or greater the weight capacity of un-
strengthened bags. The
selective strengthening is performed by providing a roll of strengthening
material that may be
combined with the other components during the manufacture combining process. A
typical
method is lamination, where the strengthening material may be provided in a
size of web sufficient
for the improved functioning of the finished bag, but narrower than the entire
web of material or
materials involved in the portion of the bag with a hand-hole. This reduced
width provides a cost
advantage because it is unnecessary for the full width of material to be
strengthened. An additional
cost savings results from the strengthened integrated hand hole allowing the
use of thin and lower
cost materials for the cushioning and vapor barrier materials used to create
the bag. Since only the
hand hole area is reinforced, the majority of the material used to create the
bag will be of lower
cost, thinner material, thus lowering the manufacturing cost of the bag.
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,
[0067] The unique process of insertion of the strengthening material involves
placement in
between the vapor barrier layer and thermoplastic insulating layer so that the
finished product
presents integrated strengthening. Thus, one side of the layer comprising the
strengthening
material contacts the vapor barrier layer and the other side contacts the
thermoplastic insulating
layer, where the vapor barrier faces the environment and the thermoplastic
layer faces the interior
of the bag. Otherwise, if the strengthening material was attached to the
outside of the thermoplastic
or vapor barrier material, the strengthening effect may be less pronounced and
there is higher risk
of its detachment under a load. Heat and/or adhesives can be used during the
combining and
lamination process, and if the strengthening material is of like materials
with one of the
constituents, such as the thermoplastic portion, a heating process can be used
to create a combining
effect. A benefit of the combining effect is the facilitation of the placement
of the integrated handle
wherein, a thicker stiffer plastic or combination of materials allows easier
mechanical cutting;
especially when considering the mechanical cutting of soft or cushioning
materials.
[0068] A method of adding the strengthening material is highlighted in Figure
4 where a roll of
strengthening material is positioned and the web of strengthening material is
guided using rollers
to be fed in between the thermoplastic and vapor barrier material during the
joining process.
Additionally, the narrower tear resistant material can be added to the vapor
barrier and/or
cushioning materials prior to the process where the two are adjoined.
[0069] The effect of adding a strengthening material is pronounced given that
typical vapor
barriers like metalized polyester film are prone to tearing if weakened. The
combination of a
strengthening material and tear-prone materials has advantages; however,
additional strengthening
materials provide an added benefit of a multi-layer strengthening. Similar to
multi-thread rope or
other materials where multiple layers provide added breakage resistance, this
enhancement is an
added benefit in tear resistance of an integrated hand hole as well as
increased strength of the
combined material. Further, if a strengthening material with a higher melt
temperature due to
chemical make up or gauge is used in a heat facilitated combining step, the
strengthening effect
may be improved because of the multi-layer enhancement since the multiple
melting temperatures
will resist full combining of the materials. Additionally, a higher melt temp
of the strengthening
material further assists in the combining process when heat is used in that
the insertion process is
facilitated. The insertion process involving thermoplastics into a heat
lamination process requires
careful placement of the 'webs' of material being combined and since both heat
and tension are
CA 3013611 2018-08-07
applied, a narrow web of material such as the strengthening material, has a
risk of breaking when
dispensed during production. Therefore, a higher melting temperature of the
narrower
strengthening material will assist in maintaining an unbroken web where heat
and tension are
applied during the combining process where heat and tension are present since
the higher melt
temperature allows the material to stay firm while encountering the same heat
necessary to
melt/combine other materials used in the process. Further, in the traditional
combining process
for manufacturing insulation material, where the thermoplastic cushioning
material is combined
with the vapor barrier material, both webs of materials are presented in
similar widths. The subject
matter of the current subject matter describes a method where the
strengthening material inserted
during the process described above, is performed in the select region of the
webs so that when such
webs are later placed in the aforementioned bag converting process, the
strengthening material
will lie in the aforementioned integrated hand-hole or handle region. For
efficiency in
manufacturing, multiple webs can be reinforced during the combining process to
be later used in
the manufacture of multiple bags at a time.
[0070] To aid in the performance and closure of the bag, a sealing device
selected from an adhesive
or closure material can be applied to the area below the holding apertures, as
shown in Figure 5.
Once the contents have been added to the bag, the backing covering the
adhesive can be removed
and the panels of the bag can be pressed together to seal the bag closed, or
the closure material can
be engaged. The sealing device can be an adhesive strip, a press-seal closure
or a slide lock closure.
In one embodiment, the sealing device can be tamper evident.
[0071] Referring now to Figure 1, shown is a frontal perspective view of
insulating bag 100 with
opening 120 and having first panel 102 and second panel 104. The first panel
102 has a
strengthened section 18, a top free edge 10, a first side edge 14, a second
side edge 16, bottom
edge 12, and a holding aperture 20 having a width 21b. The second panel 104,
has a strengthened
section 32, a top free edge 22, a first side edge 26, a second side edge 28,
and a holding aperture
30. The first panel first side edge 14 is connected to the second panel first
side edge 26 along the
portions of the two side edges. The first panel second side edge 16 is
connected to the second
panel second side edge 28 along the portions of the two side edges. The first
panel bottom edge
12 is connected to the bottom panel front edge 34 along the portions of the
two edges. When the
bag 100 would be carried, holding apertures 20 and 30 would form a carrying
handle.
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[0072] Referring now to Figure 2, shown is a side perspective of insulating
bag 100 with opening
120 and having first panel 102, second panel 104, and bottom panel 106. The
first panel 102 has
a strengthened section 18, a first side edge 14, a second side edge 16, and
bottom edge 12. The
second panel 104 has a strengthened section 32, first side edge 26, and second
side edge 28. The
first panel first side edge 14 is connected to the second panel first side
edge 26 along the portions
of the two side edges. The first panel second side edge 16 is connected to the
second panel second
side edge 28 along the portions of the two side edges. The first panel bottom
edge 12 is connected
to the bottom panel front edge 34 along the portions of the two edges. The
second panel bottom
edge 24 is connected to the bottom panel back edge 36 along the portions of
the two edges.
[0073] Referring now to Figure 3, shown is a top perspective view of
insulating bag 100 with
opening 120 and having first panel 102, second panel 104, bottom panel 106
having a longitudinal
axis 40, and a gusset 38. The first panel 102 has a strengthened section 18, a
top free edge 10, a
first side edge 14, a second side edge 16 and bottom edge 12, and a holding
aperture 20. The
second panel 104, has a strengthened section 32, a top free edge 22, a first
side edge 26, a second
side edge 28, a bottom edge 24, and a holding aperture 30. The bottom panel
106 has front edge
34 and back edge 36. The first panel first side edge 14 is connected to the
second panel first side
edge 26 along the portions of the two side edges. The first panel second side
edge 16 is connected
to the second panel second side edge 28 along the portions of the two side
edges. The first panel
bottom edge 12 is connected to the bottom panel front edge 34 along the
portions of the two edges.
The second panel bottom edge 24 is connected to the bottom panel back edge 36
along the portions
of the two edges. When the bag 100 would be carried, holding apertures 20 and
30 would form a
carrying handle.
[0074] Referring now to Figure 4, shown is a perspective view of roller
assembly 208 containing
first roller 210, second roller 212, second roller dimples 214, and
strengthening material unwind
roller 230, where the strengthening material 202 is being deposited on a film
layer.
[0075] Referring now to Figure 5, shown is a sectional perspective view of the
insulating bag 100
with first panel 102, second panel 104, bottom panel 106, sealing device 206,
and midline 228.
The first panel 102 has a strengthened section 18, a top free edge 10, a
second side edge 16, bottom
edge 12, and a holding aperture 20. The second panel 104, has a strengthened
section 32, a top
free edge 22, a second side edge 28, a bottom edge 24, and a holding aperture
30. The bottom
panel 106 has front edge 34 and back edge 36. The first panel second side edge
16 is connected
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to the second panel second side edge 28 along the portions of the two side
edges. The first panel
bottom edge 12 is connected to the bottom panel front edge 34 along the
portions of the two edges.
The second panel bottom edge 24 is connected to the bottom panel back edge 36
along the portions
of the two edges.
[0076] Referring now to Figure 6, shown is an exploded sectional view of first
panel 102 in the
area of the strengthening section as shown in Figure 5. The first panel 102 in
the area of the
strengthening section contains vapor barrier layer 204, strengthening layer
202, and thermoplastic
insulating layer 200. Where one side of the vapor barrier layer 204 faces the
environment outside
the bag, one side of the thermoplastic layer 200 faces the interior of the
bag, and one side of both
204 and 200 contact strengthening layer 202.
[0077] Referring now to Figure 7, shown is an alternate exploded sectional
view of first panel 102
in the area of the strengthening section. Barrier layer contains metal layer
224, a barrier layer
substrate 222, strengthening layer 202, bubble base layer 218, and bubble
layer 226, where the
metal layer faces the environment outside the bag, the bubble layer faces the
interior of the bag,
and one side of the strengthening material layer 202 contacts the barrier
layer substrate 222, and
the other contacts the bubble cap layer 218.
[0078] Referring now to Figure 8, shown is a top view of a manufacturing
process for producing
an insulating carrying bag that demonstrates a more efficient process where
roll forms of combined
insulation material are not used during the bag converting process.
Thermoplastic film unwinding
step 300 is followed by processing in roller assembly 208 followed by a vapor
barrier unwinding
step 302. Following the vapor barrier unwinding step 302 the thermoplastic
insulating layer is
combined with the vapor barrier film from step 302 yielding multiple layers of
insulation material
306. Then, the bottom sealing step 304 is applied to top and bottom layers of
the combined
material. An aperture hole punch step 308 follows and then a gusset forming
unit 310 applies the
gusset to a folded layer of the combined material 306. Finally, the side seal
and top seal cuts are
made in step 312. Finished bag 314 results from the process. The steps
described in this process
can be applied with any orientation of the finished bag product, with one or
more bags being
manufactured at a time and with the described steps being performed in any
order.
[0079] Referring now to Figure 9, shown is a front view of an insulating
carrying bag 100 that is
folded flat, so that gussets 38 extend down. Bag 100 contains first panel 102,
first panel top free
edge 10, first panel first side edge 14 and first panel second side edge 16
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[0080] The foregoing description of the preferred embodiment of the invention
has been presented
for the purposes of illustration and description. It is not intended to be
exhaustive or to limit the
invention to the precise form disclosed. Many modifications and variations are
possible in light
of the above teaching. It is intended that the scope of the invention not be
limited by this detailed
description, but by the claims and the equivalents to the claims appended
hereto.
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