Resealable, Reusable, Recyclable Secondary Packaging Transport Bag

The present application claims priority of U.S. Provisional Patent Application Ser. No. 63/650,739, filed on May 22, 2024, the entire contents of which is incorporated herein by reference in its entirety.

The present invention relates generally to bags used for intermediary transfer of small packages within a distribution hub or center.

In a distribution hub or conveyance network, multiple packages of various sizes are processed for being shipped to customers. Relatively small packages in the distribution hub can be loaded into a secondary bag or container for transport through the hub. Such secondary bags or containers are not recyclable and lead to significant waste generation as the e-commerce market has grown.

There further remains a need for providing a durable, lightweight, flexible, and recyclable secondary transport bag or container which is amenable to mass-production at a reasonable cost.

In accordance with the present invention, a vented, ergonomic, resealable, reusable, and recyclable flexible bag made with post-consumer resin serves as intermediary packaging to functionally transport a collection of small packages within a distribution conveyor system. The small packages may be rigid and/or soft-sided. The reusable and resealable bag of the present invention provides a straightforward, right-sized functionality and a sustainably oriented end of life recycling solution.

In one broad form of the present invention, the secondary packaging transport bag includes a body formed from a multilayer polyethylene film containing post-consumer resin. The body defines a front panel, and a rear panel located opposite the front panel. The front and rear panels define an open top edge and are connected along opposite, left and right peripheral edges and are connected along a bottom edge to define an internal cavity configured to receive packages in a distribution hub. The body has a resealable closing means proximate to the open top edge.

According to one preferred form of the present invention, the resealable closing means is located at the open top edge. In an alternative embodiment, the closing means is recessed below the open top edge.

According to one preferred form of the present invention, the multilayer polyethylene film has thickness of about 4 mil.

In yet another preferred form of the present invention, the multilayer polyethylene film contains at least 20% post-consumer resin by weight.

In yet another preferred form of the present invention, the body includes at least two vent holes that extend fully through both of the front and the rear panels at a location below the resealable closing means. Preferably, the vent holes are configured to withstand at least 25 reuses at less than 50% deformation of area.

According to one preferred form of the present invention, the bottom edge includes a gusset to permit axial expansion of the internal cavity.

In yet another preferred form of the present invention, the resealable closing means is a polyolefin slider constrained to polyethylene zipper tracks on the front panel and the rear panel.

According to another form of the present invention, portions of the front and the rear panels are corona treated to have a surface energy of about 50 dyne.

In yet another preferred form of the present invention, the bag includes an external pouch that is adhered to, or integral with, one of the front or the rear panels for retaining scannable tracking documentation.

In yet another preferred form of the present invention, the front and the rear panels have a depth of about 30 inches (vertical direction) and a width of about 36 inches (horizontal direction), when the bag is upright. Preferably, a gusset is provided and configured to provide about 10 inches of depth at a midpoint of the body.

According to one preferred form of the present invention, the polyethylene film has an impact strength of about 670 g.

According to another preferred form of the present invention, the polyethylene film has a machine direction flexural modulus of about 30-40 kpsi and a transverse direction flexural modulus of about 40-50 kpsi.

According to another form of the present invention, the body is configured to be recycled, after no fewer than 25 uses.

In still another form of the present invention, the resealable closing means lies along a central horizontal axis and is configured to remain closed when the top edge of the body is subjected to a pulling force (i.e., suspended by the top edge) of up to 25 lbf in a vertical direction that is perpendicular to the central horizontal axis. Preferably, the resealable closing means is configured to remain closed when the front and the rear panels of the body are subjected to a separating (i.e., pulling apart from one another) force of up to 12 lbf in a horizontal direction that is perpendicular to the central horizontal axis.

In another broad form of the present invention, the secondary packaging transport bag includes a body formed from a multilayer polyethylene film containing at least 20% post-consumer resin by weight. The body defines a front panel, and a rear panel located opposite the front panel. The front and rear panels define an open top edge and are connected along opposite, left and right peripheral edges and are connected along a bottom edge to define an internal cavity configured to receive packages in a distribution hub. The body has a polyolefin slider closing means located at the top or recessed location relative to the open top edge. The bottom edge has a gusset to permit axial expansion of the internal cavity. The body has at least two vent holes extending fully through both of the front and rear panels at a location below the polyethylene zipper closing means. The body is further configured to be recycled.

In another broad form of the present invention, a method of using a secondary packaging transport bag includes the step of obtaining a secondary packaging transport bag having a body formed from a multilayer polyethylene film containing post-consumer resin, the body defining a front panel and a rear panel located opposite the front panel, the front and rear panels defining an open top edge and being connected along opposite, left and right peripheral edges and being connected along a bottom edge to define an internal cavity configured to receive packages in a distribution hub. The body has a resealable closing means proximate to the open top edge. The method includes the further steps of using the secondary packaging transport bag a plurality of times for intermediary transfer of packages within a distribution hub and depositing all of the secondary packaging transport bag in a recycling stream.

Other features and advantages will become readily apparent from the accompanying drawings and the appended claims.

While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described the presently preferred embodiment, with the understanding that the present disclosure should be considered as an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated.

In accordance with the illustrated preferred embodiments of the invention, and components thereof, as illustrated in the attached, the invention has the form of an article of manufacture in the form of a secondary transport bag.

With reference to, the secondary transport bagincludes a bodyformed from a multilayer polyethylene (PE) film. The PE film contains a post-consumer resin (PCR), preferably at least 20% by weight, and more preferably at least 25% PCR by weight. Preferably, the PE film is 4 mils thick to provide the right balance of structural rigidity and flexural modulus. The stiff film and strong seams support the shape of the bodyto deter collapsing during filling or becoming wedged or caught in machinery pinch points during conveyance. The bodyof the secondary transport bagincludes a front paneland a rear panel, located opposite the front panel. The panels,are connected or sealed along opposite, left and right peripheral edges,and are connected along a bottom edge. The bodyincludes a gusset(visible in) to permit further axial expansion or depth of the bag. The panels,have an open top edgeto define an internal cavityconfigured to receive packages in a distribution hub for internal conveyance of smaller packages.

Still referring to, the bodyis further provided with a resealable closing meansin the form of a slider on zipper tracks at the top edge(as shown in) or at a location that is recessed location below the top edge(as shown in). The zipper and tracks are preferably formed from a polyolefin, more preferably a PP, resin. In other forms, the zipper and zipper tracks may be formed from the same resin of the bodysuch that the bag, and its components, such that the bagmay be fully recycled in a single resin identification code recycling stream. The slider preferably has a color (e.g., red) that differs from a color (e.g., white) of the bodyfor easy identification by workers within the distribution hub.

Again referring to, the bodyincludes a pair of spaced apart vent holesthat extend fully through both the front and rear panels,. The vent holesare located below the resealable closing meansto support the bodyon arms of a standduring filling or removing packages from within the cavity. The vent holesfunction to prevent or at least minimize the over pressurization of the transport bag. The vent holesare preferably configured to withstand at least 25 uses of the transport bag, experiencing typical use at the transport hub, at less than 50% deformation (e.g., stretching or change of shape).

Referring now to, the transport bagmay further be provided with an optional external pocket or pouchthat may be adhered to, or formed integrally with, the body. The external pouchis configured to retain scannable tracking documentation that may accompany the transport bag.

Still referring to, areas or portionsof the bodymay optionally be corona treated to have a surface energy of about 50 dyne for improved adhesion of the external pouchto the body.

In one presently preferred embodiment of the transport bag, the front and rear panels,have a depth “D” of about 30 inches (+/−3 in.) and a width “W” of about 36 inches (+/−3 in.). The gussetpreferably provides about 10 inches (+/−1 in.) of additional depth of the cavityat the midpoint or center of the bag.

In the preferred embodiment of the invention, the PE film of the bodyhas an impact strength of about 670 g, a machine direction flexural modulus of about 30-40 kpsi, and a transverse direction flexural modulus of about 40-50 kpsi. The bagis preferably configured to be fully recyclable after no fewer than 25 uses within the distribution hub. It will be understood that the bagmay be recycled before this threshold, such as in the case where the bagbecomes degraded or damaged prior to this threshold service life.

The resealable closing means, which extends along a central horizontal axis when the bagis upright, is configured to remain closed (i.e., sealed) when the top edge of the bodyis subjected to a pulling force of up to 25 lbf, as measured in a vertical direction (e.g., upwards in the illustrations) that is perpendicular to the central horizontal axis. Furthermore, the resealable closing meansis configured to remain closed (i.e., sealed) when the front and rear panels,of the bodyare subjected to a separating force of up to 12 lbf, in opposite directions in a horizontal direction that is perpendicular to the central horizontal axis.

show various embodiments of the secondary packaging transport bagaccording to the present invention, wherein like numerals illustrate common features throughout.

From the foregoing, it will be observed that numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiment illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.