Woven Pouch Bag and Methods of Making the Same

This application is a continuation of and claims benefit of priority to U.S. patent application Ser. No. 18/210,592, filed Jun. 15, 2023, entitled “WOVEN POUCH BAG AND METHODS OF MAKING THE SAME”, the disclosure which is hereby incorporated by reference in its entirety.

The present disclosure generally relates to woven bags, and more particularly to woven pouch bags and methods of making the same

Conventional plastic bags of a wide variety of size and shape are used in various situations. Bulk materials, such as flour, sugar, rice, seed, animal feed, chemicals, powdered materials or the like, for example, typically have been packaged in woven plastic bags in the past. Pet food, bird seed and other products sold in retail stores typically have not been packaged in conventional woven plastic bags. Among other reasons for this, woven plastic bags were considered too rudimentary to be printed with high end graphics suitable for consumer type of packaging. In addition, the high speed requirements in the filling and packaging operations limited the use of the woven bags in these applications.

Laminated woven sacks (LWS) were developed using a woven polypropylene structure laminated to a bi-oriented polypropylene film (BOPP) that can be reverse printed with high end graphics suitable for consumer type of packaging. The LWS provides a stronger, more attractive bag than the more conventional multiwall bags used for that purpose over the last 20 years. Due to their tough strong structure, conventional LWS bags are typically sewn shut on both ends. These LWS recently met with success and have been successfully substituted for the conventional multiwall paper bags used in the pet food industry for many years.

One major drawback of the sewn LWS has been the closing of the bags at high speed filling lines, such as those for filling such bags with pet food. Experience has shown that sewing production lines are typically slower than the filling of the multiwall pinch bottom bags. Additionally, the sewn bags do not provide an aesthetically pleasing and useful clean display on the ends of the bags, thus making it difficult for consumers to identify or find a desired brand quickly when the bags are displayed on the shelves at the point of sale, such as when they are stacked on top of one another. In addition, the sewn ends required puncturing the plastic bags and thus result in a bag that is not sealed, leading to somewhat reduced shelf-life and possible infestation of the contents of the bag.

Woven plastic bags have been used and are conventional for certain applications. An example of a conventional woven plastic bag is provided in U.S. Pat. No. 4,373,979 (“the '979 patent”), issued on Feb. 15, 1983. The '979 patent describes the use of woven strips of highly longitudinally-oriented, high-density polyethylene or polypropylene in a bag construction in which the bag is formed from a seamed tube made of the woven plastic material. The seamed tube has gussets on either side and, when a portion is cut from the rest of the tube, a bag having two open, unsealed ends is provided. The '979 patent describes the use of ultrasonic spot welds to seal portions of a bag made of such woven plastic strips, as opposed to sewing the seams of a bag or using a hot melt adhesive to seal the gusset forming pleat. The '979 patent is hereby incorporated by reference herein. The '979 patent purports to be an improvement for sealing a plastic bag. As noted in the '979 patent, sewing one end tends to take longer, thus adding time to the manufacturing process. In addition, the sewn ends in a conventional bag tend to be a weak portion of the bag, and a likely location for rips, tearing, and subsequent loss of contents during storing, shipping and handling. In addition, such bags may not provide sufficient protection from infestation from vermin and/or insects.

Another example of plastic bags is disclosed in U.S. Patent Application Publication Number US 2010/0029455 A1 (“the '455 publication”), published on Feb. 4, 2010, which describes production of web sections from a flexible web material that is provided with tear-off lines produced by laser beam processing at the distance of the length of the web sections to be formed. The tear-off lines weaken the flexible web material, but do not result in complete separation of the web sections from the web material, which occurs upon tearing the flexible web material. The '455 publication is incorporated by reference herein.

More recently, some types of plastic bags have provided improvements in sealing the ends of the bags. For example, in U.S. Pat. No. 6,800,051 B2 (“the '051 patent”), issued on Oct. 5, 2004, a process for sealing side fold sacks made of plastic film is described. According to the '051 patent, a web of plastic tubular film is cut to provide a staggered detachment along a perforation so that one wall (e.g., the front wall) projects beyond the opposing wall (e.g., the back wall). The projecting portion of the first wall is then folded over and sealed to the opposing wall by means of a plastic adhesive such as a polyurethane adhesive or hot melt. The '051 patent is hereby incorporated by reference herein. However, such bags involve plastic films, not woven plastic materials, and therefore are unable to handle the weight loads of conventional bulk bags made of paper and other materials. Such bags are useful for only certain lightweight contents, such as bread.

There are a variety of conventional ways of providing for reusable openings in bags. For example, U.S. Pat. No. 6,478,465 B1 (“the '465 patent”), issued Nov. 12, 2002, describes a peelable opening in a multiwall, pinched bottom open mouth bag construction. The '465 patent also describes the use of an adhesive layer that can be used so that the bag opening is reclosable. The '465 patent is hereby incorporated by reference herein.

In other types of conventional plastic bags, such as those used in retail and grocery stores, the use of weakened portion provided by one or more perforations in the plastic bag wall is known. A number of approaches have been taken in connection with such bags, including those shown in U.S. Pat. No. 5,188,235 (the '235 patent), issued Feb. 23, 1993, as well as in U.S. Published Patent Application No. 2005/0087542 A1 (the '542 application), published Apr. 28, 2005, U.S. Pat. No. 5,979,655 (the '655 patent), issued Nov. 9, 1999, and U.S. Published Patent Application No. 2006/0072856 (the '856 application), issued Apr. 6, 2006. However, none of these bags are woven bags, let alone bags with multiple layers. The '235 patent, the '655 patent, the '542 application, and the '856 application are hereby incorporated by reference.

Newly developed pinch laminated woven sacks overcome these drawbacks in the filling and closing operations while allowing an attractive graphic display of the bags' ends at the retail outlet and also providing a strong, durable bag which remains sealed. However, such bags still remain susceptible to leakage, breakage and infestation at both ends of the seam and in the area along the top and bottom of the gussets. There is a need for such a pinch bottom laminated woven sack that includes one or more feature(s) that prevent leakage, breakage and/or infestation at both ends of the seam and in the area along the top and bottom of the gussets. Moreover, the bag needs to be strong enough to avoid leakage, breakage or infestation, which can begin with a small opening or crack that then gets larger over time, such as with additional forces or movement of the bag. At the same time, however, it is desirable to avoid “solutions' that require additional plastic material, additional adhesive material, such as for extra strength, or that slow the speed of manufacture. Such “solutions” increase the cost of the bag.

Typically, woven and non-woven bags are sealed with a single or double fold at each end with tape over the single or double fold, stitching at both ends, or a zipper at one end and a single or double fold at the other end. However, opening woven and certain non-woven bags has proven difficult due to the strength of the bag. Therefore, what is needed are woven and non-woven bags that are easier to open, that do not add much to the cost or time to manufacture, and are not susceptible to inadvertent tearing, punctures, breaking, or the like.

Woven and non-woven bags also often need additional, secondary packaging, such as a cardboard box, when moving through the commerce stream after being filled with material. Sometimes such boxes or packaging are provided for protection of the bag and its contents. Sometimes such boxes or packaging are provided for ease of shipment, such as by making it easier to create a single load of bags by placing them on a pallet or otherwise forming an easily moved grouping. However, this secondary packaging produces additional, unnecessary waste. Therefore, what is needed are woven and non-woven bags that have a structure, size, and/or shape that can be used in and withstand moving through the commerce stream without a need for secondary packaging.

The present disclosure provides woven plastic bags comprising one or more features that prevent leakage and/or infestation at both ends of the seam and in the area along the top and bottom of the gussets as well as recyclable woven plastic bags comprising at least one of a quad-seal or a K-seal.

The present disclosure provides bags that have certain sections that are separated by an angled portion or edge, a curved portion or edge, or a combination thereof, and/or bags that comprise a cut-out and corresponding tab at opposing ends of the bag proximal to the portions of the back wall that form the seam. In one embodiment, the bag comprising a front wall, a back wall having a first portion and a second portion, a first side wall having a first portion proximal to the first portion of the back wall and a second portion proximal to the front wall, a second side wall having a first portion proximal to the second portion of the back wall and a second portion proximal to the front wall, an interior surface, an exterior surface, a top end, a bottom end, a first layer and a second layer, each of the front wall, back wall, first side wall and second side wall having an interior surface, an exterior surface, a top end and a bottom end, wherein the first layer comprises a woven polymer and the second layer comprises a polymer or paper attached to the first layer, wherein the back wall projects further than the top end of the first portion of the first side wall and the top end of the first portion of the second side wall, the top end of the first portion of the first side wall and the top end of the first portion of the second side wall projects further than the top end of the second portion of the first side wall and the top end of the second portion of the second side wall, and the top end of the second portion of the first side wall and the top end of the second portion of the second side wall projects further than the top end of the front wall, wherein at least a portion of the bottom end of the front wall projects further than the bottom end of the second portion of the first side wall and the bottom end of the second portion of the second side wall, the bottom end of the second portion of the first side wall and the bottom end of the second portion of the second side wall project further than the bottom end of the first portion of the first side wall and the bottom end of the first portion of the second side wall, and the bottom end of the first portion of the first side wall and the bottom end of the first portion of the second side wall project further than the bottom end of the back wall, and wherein the top end of the first portion of the back wall and the top end of the first portion of the first side wall, the top end of the first portion of the first side wall and the top end of the second portion of the first side wall, the top end of the second portion of the first side wall and the top end of the front wall, the top end of the front wall and the top end of the second portion of the second side wall, the top end of the second portion of the second side wall and the top end of the first portion of the second side wall, the top portion of the first portion of the second side wall and the top portion of the second portion of the back wall, the bottom end of the first portion of the back wall and the bottom end of the first section of the first side wall, the bottom end of the first portion of the first side wall and the bottom end of the second portion of the first side wall, the bottom end of the second portion of the first side wall and the bottom end of the front wall, the bottom end of the front wall and the bottom end of the second portion of the second side wall, the bottom end of the second portion of the second side wall and the bottom end of the first portion of the second side wall, and the bottom end of the first portion of the second side wall and the bottom end of the second portion of the back wall are separated by an angled edge or portion, a curved edge or portion, or a combination thereof, and wherein the top end of the second portion of the back wall comprises a cut-out and the bottom end of the second portion of the back wall comprises a corresponding tab.

In certain embodiments the angled edge or portion is between about 15° and about 75°, or between about 30° and about 60°, with respect to the top end of the front wall. In other embodiments the angled edge or portion is about 10°, 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, or 80° with respect to the top end of the front wall. In further embodiments the curved edge or portion is a radial edge or portion, an elliptical edge or portion, a parabolic edge or portion, or a hyperbolic edge or portion. In additional embodiments the bag comprises an easy open or easy access feature, which in certain embodiments can comprise a weakened area.

The present disclosure additionally provides a bag comprising a front wall, a back wall, a first side wall, a second side wall, an interior surface, an exterior surface, a top end, a bottom end, a first layer and a second layer, each of the front wall, back wall, first side wall and second side wall having an interior surface, an exterior surface, a top end and a bottom end, wherein the first layer comprises a woven polymer and the second layer comprises a polymer or paper attached to the first layer, and wherein the bag comprises a weakened area located on the front wall of the bag, the first side wall of the bag and the back wall of the bag proximal the top end of the bag. In some embodiments the first layer comprises polypropylene, high density polyethylene, low density polyethylene, polyester, or any combination thereof. In other embodiments the second layer comprises a film. In still other embodiments the second layer comprises polypropylene, polyethylene, polyethylene terephthalate, polyamide, or any combination thereof or paper. In yet other embodiments the second layer comprises oriented polypropylene, biaxially-oriented polypropylene, oriented polyethylene, biaxially-oriented polyethylene, oriented polyethylene terephthalate, biaxially-oriented polyethylene terephthalate, oriented polyamide, biaxially-oriented polyamide, coated paper or any combination thereof. In further embodiments at least a portion of the second layer comprises a printed area thereon. In still further embodiments the first layer and second layer are laminated together. In yet further embodiments the first layer and second layer are laminated together using adhesive lamination or extrusion lamination.

In additional embodiments the weakened area comprises a plurality of perforations that penetrate through at least a portion of the front wall of the bag, the first side wall of the bag and the back wall of the bag. In some embodiments the plurality of perforations forms a line. In various embodiments the plurality of perforations forms a line that extends from any position on the front wall of the bag, for example about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 97%, about 98% or about 99% of a distance across the front wall of the bag, across the first side wall of the bag, to any position on the back wall of the bag, for example about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 97%, about 98% or about 99% of a distance across the back wall of the bag. In other embodiments the plurality of perforations forms a wave pattern. In further embodiments the plurality of perforations forms a zigzag pattern. In still further embodiments the weakened area comprises a deformation in least a portion of the front wall of the bag, the first side wall of the bag and the back wall of the bag. In yet further embodiments the weakened area further comprises a scoring mark. In certain embodiments each of the first layer and the second layer of the bag comprise a weakened portion. In still other embodiments the back wall of the bag comprises a seam.

In certain embodiments the top end of the back wall projects further than the top end of a portion of the first side wall proximal to the back wall and the top end of a portion of the second side wall proximal to the back wall, the top end of a portion of the first side wall proximal to the back wall and the top end of a portion of the second side wall proximal to the back wall projects further than the top end of a portion of the first side wall proximal to the front wall and the top end of a portion of the second side wall proximal to the front wall, and the top end of a portion of the first side wall proximal to the front wall and the top end of a portion of the second side wall proximal to the front wall projects further than the top end of the front wall. In other embodiments at least a portion of the bottom end of the front wall projects further than the bottom end of a portion of the first side wall proximal to the front wall and the bottom end of a portion of the second side wall proximal to the front wall, the bottom end of a portion of the first side wall proximal to the front wall and the bottom end of a portion of the second side wall proximal to the front wall project further than the bottom end of a portion of the first side wall proximal to the back wall and the bottom end of a portion of the second side wall proximal to the back wall, and the bottom end of a portion of the first side wall proximal to the back wall and the bottom end of a portion of the second side wall proximal to the back wall project further than the bottom end of the rear wall. In further embodiments the top end of a portion of the first side wall proximal to the back wall and the top end of a portion of the first side wall proximal to the front wall are separated by an angled cut, and the bottom end of a portion of the first side wall proximal to the back wall and the bottom end of a portion of the first side wall proximal to the front wall are separated by an angled cut.

In additional embodiments the portion of the bottom end of the front wall that projects further than the bottom end of the first side wall and the bottom end of the second side wall, and the portion of the bottom end of the first side wall and the bottom end of the second side wall that project further than the bottom end of the rear wall are sealed to the outer surface of the bottom end of the rear wall. In certain embodiments the bottom end of the bag is sealed using an adhesive sealing, heat sealing, adhesive lamination, extrusion lamination, stitching, ultrasonic energy, pressure, tape, or any combination thereof. In some embodiments the bottom end of the bag is sealed using adhesive-to-adhesive sealing or adhesive-to-bag sealing. In further embodiments the bottom end of the front wall, the bottom end of the first side wall, the bottom end of the rear wall and the bottom end of the second side wall each project the same distance. In still further embodiments at least a portion of a single fold of the bottom end of the bag is sealed to the outer surface of the front wall or the outer surface of the rear wall of the bag. In yet further embodiments at least a portion of a double fold of the bottom end of the bag is sealed to the outer surface of the front wall or the outer surface of the rear wall of the bag.

In other embodiments the top end of the front wall, the top end of the first side wall, the top end of the rear wall and the top end of the second side wall each project the same distance. In certain embodiments at least a portion of the bottom end of the front wall projects further than the bottom end of a portion of the first side wall proximal to the front wall and the bottom end of a portion of the second side wall proximal to the front wall, the bottom end of a portion of the first side wall proximal to the front wall and the bottom end of a portion of the second side wall proximal to the front wall project further than the bottom end of a portion of the first side wall proximal to the back wall and the bottom end of a portion of the second side wall proximal to the back wall, and the bottom end of a portion of the first side wall proximal to the back wall and the bottom end of a portion of the second side wall proximal to the back wall project further than the bottom end of the rear wall. In still other embodiments the portion of the bottom end of the front wall that projects further than the bottom end of the first side wall and the bottom end of the second side wall, and the portion of the bottom end of the first side wall and the bottom end of the second side wall that project further than the bottom end of the rear wall are sealed to the outer surface of the bottom end of the rear wall. In additional embodiments the bottom end of the front wall, the bottom end of the first side wall, the bottom end of the rear wall and the bottom end of the second side wall each project the same distance. In certain embodiments the top end and the bottom end of the bag are sealed, and wherein the bag comprises at least ten pounds by weight of a filling material.

In some embodiments the bag further comprises a third layer comprising a polymer between the first layer and the second layer. In certain embodiments the third layer comprises a woven polymer. In other embodiments the third layer comprises polypropylene, high density polyethylene, low density polyethylene, polyester, or any combination thereof. In further embodiments the third layer comprises a polymeric film. In additional embodiments the third layer comprises polypropylene, polyethylene, polyethylene terephthalate, polyamide, or any combination thereof. In still other embodiments each of the first layer, the second layer and the third layer of the bag comprise a weakened portion.

In still further embodiments, the first layer, second layer, and third layer (if present) may each consist essentially of polypropylene, polyethylene, or a combination of polypropylene and polyethylene. Such embodiments are advantageous because they can be more easily recycled. In such embodiments, other compounds may exist in small amounts in one or more of the layers without affecting the ability to recycle the bag or portions thereof, such as by reheating the same and using it as feedstock for a new bag.

In further embodiments the bag comprises printing on the front wall, the first side wall, the back wall, the second side wall, the first end, the second end, or any combination thereof. In still further embodiments at least portions of the exterior surfaces of each of the front wall and the back wall comprise a plurality of discrete areas further comprising printing thereon. In yet further embodiments a portion of the front wall and a portion of the back wall combine to form a discrete portion of the bag located at or near either the top end or the bottom end, wherein the discrete portion of the bag comprises printing thereon.

According to certain embodiments of the present invention, a bag comprises a front wall, a back wall, a first side wall, a second side wall, a top end, and a bottom end. In some embodiments, the first side wall and the second side wall are disposed on opposite sides of the front wall and the back wall and connect the front wall to the back wall. In further embodiments, the first side wall is heat sealed to a first edge of the front wall and a first edge of the back wall, and the second side wall is heat sealed to a second edge of the front wall and a second edge of the back wall to form a quad seal. In still further embodiments, each of the front wall, back wall, first side wall and second side wall consist essentially of (i) a first layer consisting essentially of a woven polyethylene and (ii) a second layer laminated to the first layer, said second layer consisting essentially of a polyethylene film.

In additional embodiments, the second layer is laminated to the first layer by a film layer consisting essentially of polyethylene. In some embodiments, the second layer forms an exterior surface of the bag. In further embodiments, the front wall, the back wall, the first side wall, and the second side wall further consist essentially of a third layer consisting essentially of a polyethylene laminate resin. In still further embodiments, the third layer forms an interior surface of the bag. In certain embodiments, the first layer forms an interior surface of the bag. In some embodiments, the woven polyethylene of the first layer further consists essentially of a high-density polyethylene fabric. In additional embodiments, the polyethylene film of the second layer further consists essentially of low-density polyethylene.

In certain embodiments, at least one of the top end or the bottom end is heat sealed to close the bag.

In some embodiments, a portion of the top end of the front wall is folded over the top end of the bag and an interior surface portion of the front wall is sealed to a portion of an exterior surface portion of the back wall proximal the top end of the back wall, to form a sealed closure of the top end of the bag. In some embodiments, the sealed closure comprises a first portion having a first peel strength and a second portion having a second peel strength that is lower than the first peel strength. In further embodiments, at least a portion of a surface of the front wall is adapted to be separable from a portion of the back wall by applying the second peel strength. In still further embodiments, a difference between the first peel strength and the second peel strength is associated with a plurality of surface treatments applied to at least the interior surface portion of the front wall or the exterior surface portion of the back wall.

In additional embodiments, the second peel strength is lower when the front wall or the back wall is pulled in a first direction than when the front wall or the back wall is pulled in a second direction different from the first direction. In some embodiments, the top end and the bottom end are sealed, and wherein the bag comprises between 10 and 60 pounds by weight of a filling material. In further embodiments, the quad seal exhibits less than a 3% failure rate when the bag is subjected to a drop test in accordance with ASTM D5276 including hanging a filled bag at 145° F. for 72 hours followed by a 6 point drop test from a height of at least 4 feet, followed by storage at −27° F. for 24 hours followed by another 6 point drop test from a height of at least 4 feet. In still further embodiments, the quad seal exhibits less than a 3% failure rate when the bag is subjected to a drop test in accordance with ASTM D5276 including hanging a filled bag at 145° F. for 144 hours followed by a 10 point drop test from a height of at least 4 feet followed by storage at −27° F. for 72 hours followed by another 10 point drop test from at height of at least 4 feet.

According to certain embodiments of the present invention, a bag comprises a front wall, a back wall, a first side wall, a second side wall, a top end, and a bottom end. In some embodiments, the first side wall and the second side wall are disposed on opposite sides of the front wall and the back wall and connect the front wall to the back wall. In further embodiments, the front wall, the back wall, the first side wall, and the second side wall comprise a plurality of additional seals arranged at the bottom end and extending between approximately 30° and approximately 45° from an edge of each of the front wall, the back wall, the first side wall, and the second side wall to form a K-seal at the bottom end. In still further embodiments, each of the front wall, back wall, first side wall and second side wall consist essentially of (i) a first layer consisting essentially of a woven polyethylene and (ii) a second layer laminated to the first layer, said second layer consisting essentially of a polyethylene film.

In additional embodiments, a second layer is laminated to the first layer by a film layer consisting essentially of polyethylene. In some embodiments, the second layer forms an exterior surface of the bag. In further embodiments, the front wall, the back wall, the first side wall, and the second side wall further consist essentially of a third layer consisting essentially of a polyethylene laminate resin. In still further embodiments, the third layer forms an interior surface of the bag. In certain embodiments, the first layer forms an interior surface of the bag. In some embodiments, the woven polyethylene of the first layer further consists essentially of a high-density polyethylene fabric. In additional embodiments, the polyethylene film of the second layer further consists essentially of low-density polyethylene.

In further embodiments, at least one of the top end or the bottom end is folded so that the front wall is at least partially covered by a portion of the back wall and an adhesive is arranged between the front wall and the portion of the back wall to form a pinch seal. In still further embodiments, one of the top end or the bottom end forms the pinch seal and the other of the top end or the bottom end is heat sealed to close the bag. In some embodiments, the top end and the bottom end of the bag are sealed, and wherein the bag comprises between 10 and 60 pounds by weight of a filling material. In further embodiments, the K-seal exhibits less than a 3% failure rate when the bag is subjected to a drop test in accordance with ASTM D5276 including hanging a filled bag at 145° F. for 72 hours followed by a 6 point drop test from a height of at least 4 feet, followed by storage at −27° F. for 24 hours followed by another 6 point drop test from a height of at least 4 feet. In still further embodiments, the K-seal exhibits less than a 3% failure rate when the bag is subjected to a drop test in accordance with ASTM D5276 including hanging a filled bag at 145° F. for 144 hours followed by a 10 point drop test from a height of at least 4 feet followed by storage at −27° F. for 72 hours followed by another 10 point drop test from at height of at least 4 feet. In certain embodiments, the first side wall is heat sealed to a first edge of the front wall and a first edge of the back wall, and the second side wall is heat sealed to a second edge of the front wall and a second edge of the back wall to form a quad seal.

According to certain embodiments of the present invention, a bag comprises a front wall, back wall, first side wall, second side wall, top end, and bottom end; wherein the first side wall and the second side wall are disposed on opposite sides of the front wall and the back wall and connect the front wall to the back wall; wherein at least one of a first edge of the first side wall and a first edge of the front wall and a first edge of the back wall and a first edge of the second side wall are sealed to form a sealed corner, wherein the sealed corner is heat sealed; wherein the bag is adapted to form a cube shape when filled with a filling material and both the top and bottom end of the bag are sealed; and wherein each of the front wall, back wall, first side wall and second side wall comprise (i) a first woven layer comprising polyethylene, polypropylene, or a combination thereof; and (ii) a second film layer laminated to the first layer, said second layer comprising polyethylene, polypropylene, or a combination thereof.

These and other objects of the invention will be apparent to those skilled in the art from the following detailed description.

The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “upper,” “lower,” “down,” “top,” “left,” “right,” “bottom,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. These references are for the convenience of the reader and are not limiting with respect to the scope of the disclosure or the claims. For the purposes of this disclosure, “recyclable” means that an item, e.g., a bag, is formed from substantially a single material, e.g., polyethylene, and contains no more than approximately 20%, or approximately 10%, or approximately 5% of other materials that would prevent the recycling of the item, such as by melting the bags or portions thereof back into feed stock pellets. Additionally, for the purposes of this disclosure, the use of “consisting essentially of” means that the described object is limited to substantially only the listed material(s) and contains no substantial amount of any other material that would prevent recycling.

Referring to, a planar view of an embodiment of a substantially flat sheet of material from which a “step cut” bagis to be formed is shown. Shown on the sheet are front wall, rear wall, seam, first side wallhaving gusset portion, and second side wallhaving gusset portion. As shown in, the baghas a first or top endand a second or bottom end, and thus each of the front wall, rear wall, first side walland second side wallhas a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag endsandare unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. Bagis considered a “step cut” bag because the front wall, the first side walland the second side wall, and the rear wallare cut so that the front wall, the first side walland the second side wall, and the rear wallhave different lengths on one end (or both ends) of the bag. As shown in, the first side walland the second side wallare cut to different lengths on either side of the gusset portionand, respectively. As shown inthe first endof baghas portionsandof the rear wallof the bag that extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan does the top end of the front wallof the bag. In addition, the bottom end of the front wallat the second endof bagextends further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandthe bottom end of the rear wallof the bag. Therefore, in the embodiment shown inboth of the ends of the baghave a “step cut.” Also shown is weakened portion, which in this embodiment is near the first endof the bagand comprises a plurality of perforationsextending from a first endon the front wallof the bagacross the first side wallof the bagto a second endon the rear wallof the bag. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first endof the bag. This weakened portion can be opened with less force than required to open or tear other portions of the bag.

Referring to, the upper portion of the bagfromis shown after sealing the first endof the bag. Visible inis front wall, back wallhaving portionsand, seam, first side wallhaving gusset portion, and weakened portioncomprising a plurality of perforationsterminating at second end

Bagcan be opened as shown inthrough.once again shows the upper portion of the bagfrom, and visible is front wall, back wallhaving portionsand, seam, first side wallhaving gusset portion, and weakened portioncomprising a plurality of perforationsterminating at second end. Bagis opened by initially pulling on the portions′ and″ of the rear wallon both sides of the plurality of perforations, which creates a tear in the weakened portionof the bagand begins separating the portions of the first side wallthat are separated by the gusset portion. Inthe portions′ and″ of the rear wallon both sides of the plurality of perforationsare further pulled apart, resulting in the expansion of the tear in the weakened portiontoward the second endof the plurality of perforations. Additionally visible inare front wall, back wallhaving portionsand, seam, and first side wallhaving gusset portion. Inthe portions′ and″ of the rear wallon both sides of the plurality of perforationsare pulled completely apart, resulting in the expansion of the tear in the weakened portionfurther toward the second endof the plurality of perforationsand to the first endof the plurality of perforations (not visible in). This results in uncovering the top endof the gusset portionof the first side wall, which can then be pulled open. Additionally visible inare front wall, back wallhaving portionsand, and seam. Inthe plurality of perforationsare pulled completely apart, resulting in the expansion of the tear in the weakened portionto the second endof the plurality of perforations. This results in a large opening in bagthat can be used to pour out the contents of the bag. Additionally visible inare front wall, back wallhaving portions,,′ and″, seam, first side walland gusset portionhaving a top end

Referring to, the upper portion of the bagfromis shown after sealing the first endof the bag, with optional adhesivelocated near the top end of the first side wall, which serves to keep the top end of the first side wallclosed (see arrows). Although not visible in, the optional adhesive can also be applied near the top end of the second side wall. Although shown as a spot in, the adhesive can be applied in any manner that results in the closure of the top end of the first side wall, for example as a strip that runs from the edge of the intersection of the first side walland the back wallto the edge of the intersection of the first side walland the front wall. Also visible inis front wall, back wallhaving portionsand, seam, first side wallhaving gusset portion, and weakened portioncomprising a plurality of perforationsterminating at second end

Once the bagis sealed at one end, it can be filled with the desired materials. For example, it has been found that a bagwith dimensions of 16.5 inches by 6.5 inches by 39.5 inches can durably hold up to about fifty five (55) pounds of material without showing undue stress, undue tearing, undue breakage, undue deformation, or leakage or the like. It is believed that any bulk material can be contained by bag, and in certain embodiments the contents can weigh up to 100 pounds or so without undue risk of tearing or damage to bag. Once the bagis filled, the second end typically needs to be sealed. The second end of the bagcan be sealed in a similar manner as that described above. Alternatively, the bagcan have its second end sealed by conventional means such as sewing. Still another approach is to stitch the second end, and then seal the second end in a manner like that described above (not shown). Although not shown, those skilled in the art will understand and appreciate that a second end of bagcan be sealed using any conventional technique once baghas been filled with the selected amount of the desired material.

Referring to, a planar view of an embodiment of a substantially flat sheet of material from which a “step cut” bagis to be formed is shown. Shown on the sheet are front wall, rear wall, seam, first side wallhaving gusset portion, and second side wallhaving gusset portion. As shown in, the baghas a first or top endand a second or bottom end, and thus each of the front wall, rear wall, first side walland second side wallhas a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag endsandare unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. Bagis considered a “step cut” bag because the front wall, the first side walland the second side wall, and the rear wallare cut so that the front wall, the first side walland the second side wall, and the rear wallhave different lengths on one end (or both ends) of the bag. As shown in, the first side walland the second side wallare cut to different lengths on either side of the gusset portionand, respectively. As shown inthe first endof baghas portionsandof the rear wallof the bag that extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan does the top end of the front wallof the bag. In addition, the bottom end of the front wallat the second endof bagextends further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandthe bottom end of the rear wallof the bag. Therefore, in the embodiment shown inboth of the ends of the baghave a “step cut.” In addition, the portionsand,and,and, andandare not separated by a straight line, but rather an angled cut (see circles). Although inthis cut is shown as about 45°, the angle can vary in different embodiments (not shown). This angled cut serves to further prevent leakage of contents out of the bag, or infestation of organisms into the contents of the bag. Also shown is weakened portion, which in this embodiment is near the first endof the bagand comprises a plurality of perforationsextending from a first endon the front wallof the bagacross the first side wallof the bagto a second endon the rear wallof the bag. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first endof the bag. This weakened portion can be opened with less force than required to open or tear other portions of the bag.

Referring to, a planar view of an embodiment of a substantially flat sheet of material from which a bagis to be formed is shown. Shown on the sheet are front wall, rear wall, seam, first side wallhaving gusset portion, and second side wallhaving gusset portion. As shown in, the baghas a first or top endand a second or bottom end, and thus each of the front wall, rear wall, first side walland second side wallhas a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag endsandare unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. The top endof bagis has a “step cut” because the front wall, the first side walland the second side wall, and the rear wallare cut so that the front wall, the first side walland the second side wall, and the rear wallhave different lengths. As shown in, the first side walland the second side wallare cut to different lengths on either side of the gusset portionand, respectively. As shown inthe first endof baghas portionsandof the rear wallof the bagthat extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan does the top end of the front wallof the bag. In the embodiment shown in, the bottom end of the front wall, the first side wall, the second side wall, and the rear wallat the second endof bageach extend the same distance from the body of the bag. Therefore, in the embodiment shown inthe bottom endof the baghas a “flush cut.” Although not shown, in certain embodiments the top end of the bag can be flush cut, and the bottom end of the bag can be step cut. Also shown is weakened portion, which in this embodiment is near the first endof the bagand comprises a plurality of perforationsextending from a first endon the front wallof the bagacross the first side wallof the bagto a second endon the rear wallof the bag. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first endof the bag. This weakened portion can be opened with less force than required to open or tear other portions of the bag.

Referring to, a planar view of an embodiment of a substantially flat sheet of material from which a flush cut bagis to be formed is shown. Shown on the sheet are front wall, rear wall, seam, first side wallhaving gusset portion, and second side wallhaving gusset portion. As shown in, the baghas a first or top endand a second or bottom end, and thus each of the front wall, rear wall, first side walland second side wallhas a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag endsandare unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. The top endof baghas a “flush cut” because the front wall, the first side walland the second side wall, and the rear wallare cut to the same length. In the embodiment shown in, the bottom end of the front wall, the first side wall, the second side wall, and the rear wallat the second endof bageach extend the same distance from the body of the bag. Therefore, in the embodiment shown inthe bottom endof the bagalso has a “flush cut.” Also shown is weakened portion, which in this embodiment is near the first endof the bagand comprises a plurality of perforationsextending from a first endon the front wallof the bagacross the first side wallof the bagto a second endon the rear wallof the bag. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first endof the bag. This weakened portion can be opened with less force than required to open or tear other portions of the bag.

Referring to, a planar view of an embodiment of a substantially flat sheet of material from which a “step cut” bagis to be formed is shown. Shown on the sheet are front wall, rear wall, seam, first side wallhaving first gusset portion, and second side wallhaving second gusset portion. As shown in, the baghas a first or top endand a second or bottom end, and thus each of the front wall, rear wall, first side walland second side wallhas a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag endsandare unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. Bagis considered a “step cut” bag because the front wall, the first side walland the second side wall, and the rear wallare cut so that the front wall, the first side walland the second side wall, and the rear wallhave different lengths on both ends of the bag. As shown in, the first side walland the second side wallare cut to different lengths on either side of the gusset portionand, respectively. As shown inthe first endof baghas portionsandof the rear wallof the bag that extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan does the top end of the front wallof the bag. In addition, the bottom end of the front wallat the second endof bagextends further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandthe bottom end of the rear wallof the bag. Therefore, in the embodiment shown inboth of the ends of the baghave a “step cut.” However, the skilled artisan will readily appreciate that in other embodiments (not shown), one or both ends of the bag can be a different type of step cut, or another type of cut altogether, for example a flush cut end as described herein. As shown in, the portionsand,and,and,and,and,and,and, andand, respectively, are separated from one another not by straight lines and right angles but by curved portions or edges, which inare shown as radial (circular) elements. Although one particular size and shape of radial portion is shown in, for the features between the foregoing portions, those skilled in the art will appreciate that in other embodiments (not shown), these radial portions can be as small or as large as desired. In addition, the portionsand,and,and, andand, respectively, are not defined or separated by a radial portion or edge, but rather an angled portion or edge (see circles). Although inthis angled portion is shown as about 45° with respect to the top end of the front wall, the angle can vary in different embodiments (not shown). These radial and angled portions serve to further prevent breakage, leakage of contents out of the bag, or infestation of organisms into the contents of the bag, by providing extra material at one end of the bag that improves sealing. Further shown inis cut-outand corresponding tabat opposing ends of the seam. Since the bagis formed from a continuous sheet of material, the formation of the cut-out(removal of material) at one end of the bagresults in a tab(extra material) at the other end of the bag. The cut outand tabextend into the seam, and also serve to further prevent breakage, leakage of contents out of the bag, or infestation of organisms into the contents of the bag. This is because since extra material can be present between the seamof the bag and the edge of the rear panelof the bag that is not sealed, a hole can be present that can serve as an access point into or out of the sealed bag. But the presence of the cut-outand the tabensures that the ends of any such hole will be sealed, preventing access into or out of the sealed bag. The cut-outand tabcan be any depth/height desired and can extend further into the seam as desired (not shown). Although inthe cut-outand tabare shown as extending from within the seamto the edge of the rear panelof the bag, in other embodiments (not shown) the cut-out and tab can extend from within the seamonly a portion of the distance to the edge of the rear panelof the bag. Furthermore, as shown, the tab and cut-out are illustrated as primarily rectangular in shape. It is understood that the shape is not limited to rectangles but can also be configured as an angular or rounded cut-out and matching tab as long as the configuration fits together to form a seal effective to prevent leakage or infestation. Additionally, in other embodiments (not shown), the bag can comprise an easy open or easy access feature, such as the weakened portion near the top of the bag as shown herein above (for example in), or the easy open features detailed in United States Patent Application Publication Number US 2013/0206631 and United States Patent Application Publication Number US 2013/0209002, each of which is incorporated by reference herein in its entirety.

Referring to, a planar view of the top portion of an embodiment of a substantially flat sheet of material from which a bagis to be formed is shown. Shown on the sheet are front wall, rear wall, seam, first side wallhaving first gusset portion, and second side wallhaving second gusset portion. As shown in, the baghas a first or top endand a second or bottom end(not visible in), and thus each of the front wall, rear wall, first side walland second side wallhas a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag endsandare unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. The top endof baghas a “step cut” because the front wall, the first side walland the second side wall, and the rear wallare cut so that the front wall, the first side walland the second side wall, and the rear wallhave different lengths. As shown in, the first side walland the second side wallare cut to different lengths on either side of the gusset portionand, respectively. As shown inthe first endof baghas portionsandof the rear wallof the bagthat extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan do portionsandof the first side walland second side wall, respectively, which in turn extend further from the body of the bagthan does the top end of the front wallof the bag. As shown in, the portionsand,and,and,and,and, andand, respectively, are separated not by straight lines and right angles but by curved portions or edges, such as radial (circular) portions as shown. Although one particular size and shape of the curved portions is shown in, those skilled in the art will understand that in other embodiments (not shown) these curved edges can be of different shapes (e.g., elliptical, or different segments of a curve, etc.), and can be as small or as large as desired. These curved portions serve to further prevent breakage or leakage of contents out of the bag, or infestation of organisms into the contents of the bag. Further shown inis cut-outat one end of the seam(corresponding tabat the other end of the seamis not shown in). Since the bagis formed from a continuous sheet of material, formation of the cut-out(removal of material) at one end of the bagresults in a tab (extra material; not shown in) at the other end of the bag. The cut outand tab (not shown in) extend into the seam, and also serve to further prevent breakage, leakage of contents out of the bag, or infestation of organisms into the contents of the bag. The cut-outand tab (not shown) can be any depth/height desired, and can extend further into the seam as desired (not shown). Although inthe cut-out(and corresponding tab, not shown) is shown as extending from within the seamto the edge of the rear panelof the bag, in other embodiments (not shown) the cut-out (and tab) can extend from within the seamonly a portion of the distance to the edge of the rear panelof the bag. Additionally, in other embodiments (not shown), the bag can comprise an easy open or easy access feature, such as the weakened portion near the top of the bag as shown herein above (for example in), or the easy open features detailed in United States Patent Application Publication Number US 2013/0206631 and United States Patent Application Publication Number US 2013/0209002, each of which is incorporated by reference herein in its entirety.

Referring to, shown is an outline of a portion of one end of a bagwith a step cut end, generally corresponding to a mirror image of the region marked as “A” in, detailing an alternate embodiment with angled portions between the front panelof the bag and the first section of the side wall′, between the first section of the side wall′ and the second section of the side wall″, and between the second section of the side wall″ and the back panelof the bag, respectively, and a featureat one end of the bag that extends into the seam. Since the bagis formed from a continuous sheet of material, the featureforms a cut-out(removal of material; see) at one end of the bag and a tab(extra material; see) at the other end of the bag.shows an image of one end of the bag depicted inupon sealing the seam, showing cut-out.shows an image of the other end of the bag depicted inupon sealing the seam, showing the tab.

Referring to, shown is an outline of a portion of one end of a bagwith a step cut end, generally corresponding to a mirror image of the region marked as “A” in, detailing an alternate embodiment with a combination of radial and angled cuts between the front panelof the bag and the first section of the side wall′, between the first section of the side wall′ and the second section of the side wall″, and between the second section of the side wall″ and the back panelof the bag, respectively, and a featureat one end of the bagthat extends into the seam. Since the bagis formed from a continuous sheet of material, the featureforms a cut-out(removal of material; see) at one end of the bagand a tab(extra material; see) at the other end of the bag.shows an image of one end of the bag depicted inupon sealing the seam, showing cut-out.shows an image of the other end of the bag depicted inupon sealing the seam, showing the tab.

Referring to, shown is an outline of a portion of one end of a bagwith a step cut end, generally corresponding to a mirror image of the region marked as “A” in, detailing an alternate embodiment with a combination of radial and angled cuts between the front panelof the bag and the first section of the side wall, between the first section of the side walland the second section of the side wall, and between the second section of the side walland the back panelof the bag, respectively, and a featureat one end of the bagthat extends into the seam. Since the bagis formed from a continuous sheet of material, the featureforms a cut-out(removal of material; see) at one end of the bagand a tab(extra material; see) at the other end of the bag.shows an image of one end of the bag depicted inupon sealing the seam, showing cut-out.shows an image of the other end of the bag depicted inupon sealing the seam, showing the tab.

The step cut profile shown inincludes angled step cuts of a variety of shapes and angles. A first step cutadjacent the front panel, includes an angled cut without a separate vertical portion, as shown inabove. The first step cutis at a particular angle, variable over a large range of angles, for example between ten degrees and eighty degrees with respect to the top edge of front panel. A second step cutincludes a curved cutas well as an angled cut. The curved cutmay be a cut having a constant radius, may be elliptical, parabolic, or otherwise curved. The angled cutis positioned below the curved cutand separated by a vertical portion of the second step cut. A third step cut, adjacent the back panelis shown with a single angled cut, similar to the first step cut. In some examples, the first step cutand the second step cutmay include angled cuts at different angles or may be at or about the same angle. Additionally, the length or distance traversed over the step cuts may vary, in addition to a spacing or distance between adjacent step cuts, such as by varying a width of the first section of the side walland a width of the second section of the side wall. In some examples additional step cuts may be introduced between the first step cutand the third step cut. For example, a total of four or more step cuts may be included in the step cut profile. Additional step cuts may be included for purposes of including second, third, or fourth gussets to the side wall, thereby dividing the side wall into an additional third section, fourth section, and other sections as determined by the number and placement of additional gussets. Furthermore, the step cut profile shown inmay be used for one side of the top of the bag. In some examples, the left and right sides of the bagmay include different step cut profiles, for example to accommodate different styles of bags and different opening panels, such as the easy open panels described herein.

Referring to, shown is an outline of a portion of one end of a bagwith a step cut end, generally corresponding to a mirror image of the region marked as “A” in, detailing an alternate embodiment with a combination of radial and angled cuts between the front panelof the bag and the first section of the side wall, between the first section of the side walland the second section of the side wall, and between the second section of the side walland the back panelof the bag, respectively, and a featureat one end of the bagthat extends into the seam. Since the bagis formed from a continuous sheet of material, the featureforms a cut-out(removal of material; see) at one end of the bagand a tab(extra material; see) at the other end of the bag.shows an image of one end of the bag depicted inupon sealing the seam, showing cut-out.shows an image of the other end of the bag depicted inupon sealing the seam, showing the tab.