Easy Access Woven Plastic Bags

Abstract

A woven laminated plastic bag having a weakened portion is provided. The weakened portion is generally defined by a plurality of perforations in the bag. In various aspects the bag can be fabricated from woven polypropylene and/or polyethylene layer which can be laminated with a film layer, can form a pinch bottom bag, and can have one or both sides include graphics and/or printing. The bag can also provide a top end and/or a bottom end either or both of which provide a discrete area which may contain discrete graphics and/or printing.

Claims

1. A bag comprising: a front wall, a back wall, a first side wall, and a second side wall, a top end, and a bottom end; wherein each of the front wall, the back wall, the first side wall, and the second side wall respectively further comprise: an interior surface, an exterior surface, a top end, and a bottom end; wherein each of the front wall, the back wall, the first side wall, and the second side wall comprise a first layer and a second layer, with the first layer and the second layer laminated together; wherein the first layer comprises woven strips comprising polypropylene, and the second layer comprises a polymer film comprising polypropylene; wherein the bag further comprises a plurality of perforations proximal the top end of the bag that define a line; wherein each of the plurality of perforations penetrates through at least a portion of the first layer or a portion of the second layer; wherein the top end of the back wall extends further than a first portion of the first side wall and a first portion of the second side wall at respective top ends of the first portion and the second portion; wherein the first portion of the first side wall and the first portion of the second side wall extend further than a second portion of the first side wall and a second portion of the second side wall at respective top ends of the second portion of the first side wall and the second portion of the second side wall, the second portions of the first side wall and the second side wall each being proximal to the front wall; wherein the second portion of the first side wall and the second portion of the second side wall extend further than the top end of the front wall; wherein the first portion of the first side wall and the second portion of the first side wall are separated by a first angled cut, and the first portion of the second side wall and the second portion of the second side wall are separated by a second angled cut; and wherein the bag further comprises an adhesive on the exterior surface of the first side wall.

2. The bag according to claim 1, wherein the first angled cut extends at an angle of 45 degrees with respect to the top end of the bag.

3. The bag according to claim 1, wherein the adhesive on the exterior surface of the first side wall extends from a first location at which the first side wall and the back wall join to a second location at which the first side wall and the front wall join.

4. The bag according to claim 3, wherein the adhesive closes a portion of the first side wall.

5. The bag according to claim 1, wherein the adhesive on the exterior surface of the first side wall is located proximal the top end of the bag.

6. The bag according to claim 1, wherein the first layer and the second layer are laminated together using adhesive lamination.

7. The bag according to claim 1, wherein the first layer and the second layer are laminated together using extrusion lamination.

8. The bag according to claim 1, wherein each of the front wall, the back wall, the first side wall, and the second side wall comprise a third layer between the first layer and the second layer, the third layer laminating the first layer and the second layer together.

9. The bag according to claim 8, wherein the third layer comprises a film comprising polypropylene.

10. The bag according to claim 1 wherein the plurality of perforations enables opening the bag by tearing the plurality of perforations using less force than tearing other portions of the bag.

11. A bag comprising: a front wall, a back wall, a first side wall, and a second side wall, a top end, and a bottom end; wherein each of the front wall, the back wall, the first side wall, and the second side wall respectively further comprise: an interior surface, an exterior surface, a top end, and a bottom end; wherein each of the front wall, the back wall, the first side wall, and the second side wall comprise a first layer and a second layer, with the first layer and the second layer laminated together; wherein the first layer comprises woven strips comprising polyethylene, and the second layer comprises a polymer film comprising polyethylene; wherein the bag further comprises a plurality of perforations proximal the top end of the bag that define a line; wherein each of the plurality of perforations penetrates through at least a portion of the first layer or a portion of the second layer; wherein the top end of the back wall extends further than a first portion of the first side wall and a first portion of the second side wall at respective top ends of the first portion and the second portion; wherein the first portion of the first side wall and the first portion of the second side wall extend further than a second portion of the first side wall and a second portion of the second side wall at respective top ends of the second portion of the first side wall and the second portion of the second side wall, the second portions of the first side wall and the second side wall each being proximal to the front wall; wherein the second portion of the first side wall and the second portion of the second side wall extend further than the top end of the front wall; wherein the first portion of the first side wall and the second portion of the first side wall are separated by a first angled cut, and the first portion of the second side wall and the second portion of the second side wall are separated by a second angled cut; and wherein the bag further comprises an adhesive on the exterior surface of the first side wall.

12. The bag according to claim 11, wherein the first angled cut extends at an angle of 45 degrees with respect to the top end of the bag.

13. The bag according to claim 11, wherein the adhesive on the exterior surface of the first side wall extends from a first location at which the first side wall and the back wall join to a second location at which the first side wall and the front wall join.

14. The bag according to claim 13, wherein the adhesive closes a portion of the first side wall.

15. The bag according to claim 11, wherein the adhesive on the exterior surface of the first side wall is located proximal the top end of the bag.

16. The bag according to claim 11, wherein the first layer and the second layer are laminated together using adhesive lamination.

17. The bag according to claim 11, wherein the first layer and the second layer are laminated together using extrusion lamination.

18. The bag according to claim 11, wherein each of the front wall, the back wall, the first side wall, and the second side wall comprise a third layer between the first layer and the second layer, the third layer laminating the first layer and the second layer together.

19. The bag according to claim 18, wherein the third layer comprises a film comprising polyethylene.

20. The bag according to claim 11 wherein the plurality of perforations enables opening the bag by tearing the plurality of perforations using less force than tearing other portions of the bag.

21. A bag comprising: a front wall, a back wall, a first side wall, and a second side wall, a top end, and a bottom end; wherein each of the front wall, the back wall, the first side wall, and the second side wall respectively further comprise: an interior surface, an exterior surface, a top end, and a bottom end; wherein each of the front wall, the back wall, the first side wall, and the second side wall comprise a first layer and a second layer, with the first layer and the second layer laminated together; wherein the first layer comprises woven polymer strips and the second layer comprises an oriented polymer film; wherein the top end of the back wall extends further than a first portion of the first side wall and a first portion of the second side wall at respective top ends of the first portion and the second portion; wherein the first portion of the first side wall and the first portion of the second side wall extend further than a second portion of the first side wall and a second portion of the second side wall at respective top ends of the second portion of the first side wall and the second portion of the second side wall, the second portions of the first side wall and the second side wall each being proximal to the front wall; wherein the second portion of the first side wall and the second portion of the second side wall extend further than the top end of the front wall; and wherein the bag further comprises an adhesive on the exterior surface of the first side wall.

22. The bag according to claim 21, wherein the adhesive on the exterior surface of the first side wall extends from a first location at which the first side wall and the back wall join to a second location at which the first side wall and the front wall join.

23. The bag according to claim 22, wherein the adhesive closes a portion of the first side wall.

24. The bag according to claim 21, wherein the adhesive on the exterior surface of the first side wall is located proximal the top end of the bag.

25. The bag according to claim 21, wherein the first layer and the second layer are laminated together using adhesive lamination.

26. The bag according to claim 21, wherein the first layer and the second layer are laminated together using extrusion lamination.

27. The bag according to claim 21, wherein each of the front wall, the back wall, the first side wall, and the second side wall comprise a third layer between the first layer and the second layer, the third layer laminating the first layer and the second layer together.

28. The bag according to claim 27, wherein the third layer comprises a polymer film.

29. The bag according to claim 21, wherein the first side wall further comprises a gusset.

30. The bag according to claim 29, wherein the adhesive closes first and second sides of the gusset of the first side wall proximal the top end of the bag.

31. The bag according to claim 21, further comprising an adhesive located on an exterior surface of the second side wall.

32. The bag according to claim 29, wherein the second side wall comprises a gusset, and wherein the adhesive closes the gussets of the first side wall proximal the top end of the bag and the second side wall proximal the top end of the bag.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The following drawings are included to further demonstrate certain aspects and embodiments of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

[0026] FIG. 1 shows an outline of a step cut bag with a weakened area near the top end of the bag comprising a line of perforations extending from the front panel of the bag across the first side panel of the bag to the back panel of the bag according to one embodiment of the present disclosure.

[0027] FIG. 2 shows the top portion of the bag of FIG. 1 after closing the top end of the bag.

[0028] FIG. 3 shows the first step in opening the closed bag from FIG. 2.

[0029] FIG. 4 shows the second step in opening the closed bag from FIG. 2.

[0030] FIG. 5 shows the third step in opening the closed bag from FIG. 2.

[0031] FIG. 6 shows the fourth step in opening the closed bag from FIG. 2.

[0032] FIG. 7 shows the top portion of the bag of FIG. 1 after closing the top end of the bag and a location for optional application of adhesive to keep the top portion of the gusseted portion of the first side panel closed.

[0033] FIG. 8 shows an outline of a step cut bag with a weakened area near the top end of the bag comprising a line of perforations extending from the front panel of the bag across the first side panel of the bag to the back panel of the bag, and angled corners at the top and bottom of the portions of the first and second side panels on either side of the gusset fold, according to one embodiment of the present disclosure.

[0034] FIG. 9 shows an outline of a bag with a step cut top end and a flush cut bottom end, and a weakened area near the top end of the bag comprising a line of perforations extending from the front panel of the bag across the first side panel of the bag to the back panel of the bag according to one embodiment of the present disclosure.

[0035] FIG. 10 shows an outline of a bag with a flush cut top end and a flush cut bottom end, and a weakened area near the top end of the bag comprising a line of perforations extending from the front panel of the bag across the first side panel of the bag to the back panel of the bag according to one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0036] Referring to FIG. 1, a planar view of an embodiment of a substantially flat sheet of material from which a step cut bag 1 is to be formed is shown. Shown on the sheet are front wall 2, rear wall 3, seam 4, first side wall 5 having gusset portion 6, and second side wall 7 having gusset portion 8. As shown in FIG. 1, the bag 1 has a first or top end 9 and a second or bottom end 10, and thus each of the front wall 2, rear wall 3, first side wall 5 and second side wall 7 has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends 9 and 10 are unimportant and the top and bottom references are useful but may change depending upon the orientation from which one views the bag. Bag 1 is considered a step cut bag because the front wall 2, the first side wall 5 and the second side wall 7, and the rear wall 3 are cut so that the front wall 2, the first side wall 5 and the second side wall 7, and the rear wall 3 have different lengths on one end (or both ends) of the bag. As shown in FIG. 1, the first side wall 5 and the second side wall 7 are cut to different lengths on either side of the gusset portion 6 and 8, respectively. As shown in FIG. 1 the first end 9 of bag 1 has portions 3a and 3b of the rear wall 3 of the bag that extend further from the body of the bag 1 than do portions 5a and 7a of the first side wall 5 and second side wall 7, respectively, which in turn extend further from the body of the bag 1 than do portions 5b and 7b of the first side wall 5 and second side wall 7, respectively, which in turn extend further from the body of the bag 1 than does the top end of the front wall 2 of the bag 1. In addition, the bottom end of the front wall 2 at the second end 10 of bag 1 extends further from the body of the bag 1 than do portions 5c and 7c of the first side wall 5 and second side wall 7, respectively, which in turn extend further from the body of the bag 1 than do portions 5d and 7d of the first side wall 5 and second side wall 7, respectively, which in turn extend further from the body of the bag 1 than do portions 3c and 3d the bottom end of the rear wall 3 of the bag 1. Therefore, in the embodiment shown in FIG. 1 both of the ends of the bag 1 have a step cut. Also shown is weakened portion 20, which in this embodiment is near the first end 9 of the bag 1 and comprises a plurality of perforations 21 extending from a first end 21a on the front wall 2 of the bag 1 across the first side wall 5 of the bag 1 to a second end 21b on the rear wall 3 of the bag 1. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end 9 of the bag 1. This weakened portion can be opened with less force than required to open or tear other portions of the bag 1.

[0037] Referring to FIG. 2, the upper portion of the bag 1 from FIG. 1 is shown after sealing the first end 9 of the bag 1. Visible in FIG. 2 is front wall 2, back wall 3 having portions 3a and 3b, seam 4, first side wall 5 having gusset portion 6, and weakened portion 20 comprising a plurality of perforations 21 terminating at second end 21b.

[0038] Bag 1 can be opened as shown in FIG. 3 through FIG. 6. FIG. 3 once again shows the upper portion of the bag 1 from FIG. 2, and visible is front wall 2, back wall 3 having portions 3a and 3b, seam 4, first side wall 5 having gusset portion 6, and weakened portion 20 comprising a plurality of perforations 21 terminating at second end 21b. Bag 1 is opened by initially pulling on the portions 3 and 3 of the rear wall 3 on both sides of the plurality of perforations 21, which creates a tear in the weakened portion 20 of the bag 1 and begins separating the portions of the first side wall 5 that are separated by the gusset portion 6. In FIG. 4 the portions 3 and 3 of the rear wall 3 on both sides of the plurality of perforations 21 are further pulled apart, resulting in the expansion of the tear in the weakened portion 20 toward the second end 21b of the plurality of perforations 21. Additionally visible in FIG. 4 are front wall 2, back wall 3 having portions 3a and 3b, seam 4, and first side wall 5 having gusset portion 6. In FIG. 5 the portions 3 and 3 of the rear wall 3 on both sides of the plurality of perforations 21 are pulled completely apart, resulting in the expansion of the tear in the weakened portion 20 further toward the second end 21b of the plurality of perforations 21 and to the first end 21a of the plurality of perforations (not visible in FIG. 5). This results in uncovering the top end 6a of the gusset portion 6 of the first side wall 5, which can then be pulled open. Additionally visible in FIG. 5 are front wall 2, back wall 3 having portions 3a and 3b, and seam 4. In FIG. 6 the plurality of perforations 21 are pulled completely apart, resulting in the expansion of the tear in the weakened portion 20 to the second end 21b of the plurality of perforations 21. This results in a large opening in bag 1 that can be used to pour out the contents of the bag 1. Additionally visible in FIG. 6 are front wall 2, back wall 3 having portions 3a, 3b, 3 and 3, seam 4, first side wall 5 and gusset portion 6 having a top end 6a.

[0039] Referring to FIG. 7, the upper portion of the bag 1 from FIG. 1 is shown after sealing the first end 9 of the bag 1, with optional adhesive 30 located near the top end of the first side wall 5, which serves to keep the top end of the first side wall 5 closed (see arrows). Although not visible in FIG. 7, the optional adhesive can also be applied near the top end of the second side wall. Although shown as a spot in FIG. 7, the adhesive can be applied in any manner that results in the closure of the top end of the first side wall 5, for example as a strip that runs from the edge of the intersection of the first side wall 5 and the back wall 3 to the edge of the intersection of the first side wall 5 and the front wall 2. Also visible in FIG. 7 is front wall 2, back wall 3 having portions 3a and 3b, seam 4, first side wall 5 having gusset portion 6, and weakened portion 20 comprising a plurality of perforations 21 terminating at second end 21b.

[0040] Once the bag 1 is sealed at one end, it can be filled with the desired materials. For example, it has been found that a bag 1 with 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 1, and in certain embodiments the contents can weigh up to 100 pounds or so without undue risk of tearing or damage to bag 1. Once the bag 1 is filled, the second end typically needs to be sealed. The second end of the bag 1 can be sealed in a similar manner as that described above. Alternatively, the bag 1 can 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 bag 1 can be sealed using any conventional technique once bag 1 has been filled with the selected amount of the desired material.

[0041] Referring to FIG. 8, a planar view of an embodiment of a substantially flat sheet of material from which a step cut bag 101 is to be formed is shown. Shown on the sheet are front wall 102, rear wall 103, seam 104, first side wall 105 having gusset portion 106, and second side wall 107 having gusset portion 108. As shown in FIG. 8, the bag 101 has a first or top end 109 and a second or bottom end 110, and thus each of the front wall 102, rear wall 103, first side wall 105 and second side wall 107 has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends 109 and 110 are unimportant and the top and bottom references are useful but may change depending upon the orientation from which one views the bag. Bag 101 is considered a step cut bag because the front wall 102, the first side wall 105 and the second side wall 107, and the rear wall 103 are cut so that the front wall 102, the first side wall 105 and the second side wall 107, and the rear wall 103 have different lengths on one end (or both ends) of the bag. As shown in FIG. 8, the first side wall 105 and the second side wall 107 are cut to different lengths on either side of the gusset portion 106 and 108, respectively. As shown in FIG. 8 the first end 109 of bag 101 has portions 103a and 103b of the rear wall 103 of the bag that extend further from the body of the bag 101 than do portions 105a and 107a of the first side wall 105 and second side wall 107, respectively, which in turn extend further from the body of the bag 101 than do portions 105b and 107b of the first side wall 105 and second side wall 107, respectively, which in turn extend further from the body of the bag 101 than does the top end of the front wall 102 of the bag 101. In addition, the bottom end of the front wall 102 at the second end 110 of bag 101 extends further from the body of the bag 101 than do portions 105c and 107c of the first side wall 105 and second side wall 107, respectively, which in turn extend further from the body of the bag 101 than do portions 105d and 107d of the first side wall 105 and second side wall 107, respectively, which in turn extend further from the body of the bag 101 than do portions 103c and 103d the bottom end of the rear wall 103 of the bag 101. Therefore, in the embodiment shown in FIG. 8 both of the ends of the bag 101 have a step cut. In addition, the portions 105a and 105b, 107a and 107b, 105c and 105d, and 107c and 107d are not separated by a straight line, but rather an angled cut (see circles). Although in FIG. 8 this 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 120, which in this embodiment is near the first end 109 of the bag 101 and comprises a plurality of perforations 121 extending from a first end 121a on the front wall 102 of the bag 101 across the first side wall 105 of the bag 101 to a second end 121b on the rear wall 103 of the bag 101. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end 109 of the bag 101. This weakened portion can be opened with less force than required to open or tear other portions of the bag 101.

[0042] Referring to FIG. 9, a planar view of an embodiment of a substantially flat sheet of material from which a bag 201 is to be formed is shown. Shown on the sheet are front wall 202, rear wall 203, seam 204, first side wall 205 having gusset portion 206, and second side wall 207 having gusset portion 208. As shown in FIG. 9, the bag 201 has a first or top end 209 and a second or bottom end 210, and thus each of the front wall 202, rear wall 203, first side wall 205 and second side wall 207 has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends 209 and 210 are unimportant and the top and bottom references are useful but may change depending upon the orientation from which one views the bag. The top end 209 of bag 201 is has a step cut because the front wall 202, the first side wall 205 and the second side wall 207, and the rear wall 203 are cut so that the front wall 202, the first side wall 205 and the second side wall 207, and the rear wall 203 have different lengths. As shown in FIG. 9, the first side wall 205 and the second side wall 207 are cut to different lengths on either side of the gusset portion 206 and 208, respectively. As shown in FIG. 9 the first end 209 of bag 201 has portions 203a and 203b of the rear wall 203 of the bag 201 that extend further from the body of the bag 201 than do portions 205a and 207a of the first side wall 205 and second side wall 207, respectively, which in turn extend further from the body of the bag 201 than do portions 205b and 207b of the first side wall 205 and second side wall 207, respectively, which in turn extend further from the body of the bag 201 than does the top end of the front wall 202 of the bag 201. In the embodiment shown in FIG. 9, the bottom end of the front wall 202, the first side wall 205, the second side wall 207, and the rear wall 203 at the second end 210 of bag 201 each extend the same distance from the body of the bag 201. Therefore, in the embodiment shown in FIG. 9 the bottom end 210 of the bag 201 has 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 220, which in this embodiment is near the first end 209 of the bag 201 and comprises a plurality of perforations 221 extending from a first end 221a on the front wall 202 of the bag 201 across the first side wall 205 of the bag 201 to a second end 221b on the rear wall 203 of the bag 201. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end 209 of the bag 201. This weakened portion can be opened with less force than required to open or tear other portions of the bag 201.

[0043] Referring to FIG. 10, a planar view of an embodiment of a substantially flat sheet of material from which a flush cut bag 301 is to be formed is shown. Shown on the sheet are front wall 302, rear wall 303, seam 304, first side wall 305 having gusset portion 306, and second side wall 307 having gusset portion 308. As shown in FIG. 10, the bag 301 has a first or top end 309 and a second or bottom end 310, and thus each of the front wall 302, rear wall 303, first side wall 305 and second side wall 307 has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends 309 and 310 are unimportant and the top and bottom references are useful but may change depending upon the orientation from which one views the bag. The top end 309 of bag 301 has a flush cut because the front wall 302, the first side wall 305 and the second side wall 307, and the rear wall 303 are cut to the same length. In the embodiment shown in FIG. 10, the bottom end of the front wall 302, the first side wall 305, the second side wall 307, and the rear wall 303 at the second end 310 of bag 301 each extend the same distance from the body of the bag 301. Therefore, in the embodiment shown in FIG. 10 the bottom end 310 of the bag 301 also has a flush cut. Also shown is weakened portion 320, which in this embodiment is near the first end 309 of the bag 301 and comprises a plurality of perforations 321 extending from a first end 321a on the front wall 302 of the bag 301 across the first side wall 305 of the bag 301 to a second end 321b on the rear wall 303 of the bag 301. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end 309 of the bag 301. This weakened portion can be opened with less force than required to open or tear other portions of the bag 301.

[0044] Those skilled in the art will understand and appreciate that the bag according to the invention may vary in size, dimensions, and shape without departing from the scope of the invention, and that the foregoing description of the preferred embodiments is not intended to limit the scope of the invention as defined by the claims. For example, those skilled in the art will understand and appreciate that the foregoing bag 1 can have sealed and sewn ends in a tubular bag with side gussets as shown, or a block bottom and top, or a combination thereof, although not shown. Those skilled in the art will also appreciate that a weakened portion or area can be provided in a number of ways that may vary from those expressly described and shown, such as by stressing portions of the bag wall with or without deforming or perforating same, as well as varying the size, number, depth, and/or pattern of perforations and/or deformations in a bag wall. Similarly, those skilled in the art will understand that the bag 1 may be provided with a re-usable opening (not shown). Such features are conventional with prior art bags. Similarly, those skilled in the art will appreciate that terms such as front and rear, and top and bottom, are useful in describing a bag, but essentially depend on a bag's orientation when such terms are used, and are therefore not limiting as to a bag's orientation.