US20050178493A1 - Method and apparatus for making flexible articles having elastic-like behavior with visually distinct regions - Google Patents
Method and apparatus for making flexible articles having elastic-like behavior with visually distinct regions Download PDFInfo
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- US20050178493A1 US20050178493A1 US10/780,846 US78084604A US2005178493A1 US 20050178493 A1 US20050178493 A1 US 20050178493A1 US 78084604 A US78084604 A US 78084604A US 2005178493 A1 US2005178493 A1 US 2005178493A1
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- United States
- Prior art keywords
- sheet material
- making
- continuous web
- article according
- opening bar
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B70/00—Making flexible containers, e.g. envelopes or bags
- B31B70/003—Opening or distending bags
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B70/00—Making flexible containers, e.g. envelopes or bags
- B31B70/74—Auxiliary operations
- B31B70/88—Printing; Embossing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B70/00—Making flexible containers, e.g. envelopes or bags
- B31B70/74—Auxiliary operations
- B31B70/92—Delivering
- B31B70/94—Delivering singly or in succession
- B31B70/942—Delivering singly or in succession by winding up
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B70/00—Making flexible containers, e.g. envelopes or bags
- B31B70/74—Auxiliary operations
- B31B70/92—Delivering
- B31B70/98—Delivering in stacks or bundles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B2160/00—Shape of flexible containers
- B31B2160/10—Shape of flexible containers rectangular and flat, i.e. without structural provision for thickness of contents
- B31B2160/106—Shape of flexible containers rectangular and flat, i.e. without structural provision for thickness of contents obtained from sheets cut from larger sheets or webs before finishing the bag forming operations
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1003—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by separating laminae between spaced secured areas [e.g., honeycomb expanding]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1007—Running or continuous length work
- Y10T156/1016—Transverse corrugating
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1056—Perforating lamina
- Y10T156/1057—Subsequent to assembly of laminae
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
Landscapes
- Making Paper Articles (AREA)
- Purses, Travelling Bags, Baskets, Or Suitcases (AREA)
- Nonwoven Fabrics (AREA)
- Air Bags (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
A method of forming flexible bags from a continuous web is disclosed. The method includes introducing a continuous web of sheet material and passing it through a process whereby the flexible bag is formed having elastic-like behavior. The continuous web is processed into a continuous web having at least two regions that are visually distinct. A sheet material is introduced having one portion of the sheet material overlapping another portion of the sheet material. The sheet material is formed into a strainable network. The strainable network includes a plurality of first regions and a plurality of second regions. The first regions are substantially un-deformed and the second regions are formed into disengageable pleat elements. As the overlapped portions of the sheet material are formed they engage each other at the pleat elements. The pleat elements of each overlapped portion become engaged within each other and resist disengagement because of the frictional forces of the sheet material. The overlapped portions of the sheet material are separated using a disengaging means so that the overlapped portions become disengaged and are separated from each other while riding on the disengaging means. The disengaging means is in the form of either air knife, static opening bar, dynamic opening bar, or suction means, and any combinations thereof.
Description
- The present invention relates to a method and apparatus for the production of flexible articles from a continuous web; and more particularly, a method and apparatus for the making of flexible bags having elastic-like behavior is disclosed.
- Flexible articles, particularly flexible bags made of comparatively inexpensive plastic materials, have been widely employed for the containment and/or disposal of various items. As utilized herein, the term “flexible” refers to materials that are capable of being flexed, stretched, or bent, especially repeatedly, such that they are pliant and yieldable in response to externally applied forces. Accordingly, “flexible” is substantially opposite in meaning to the terms inflexible, brittle, or unyielding. Materials and structures that are flexible, therefore, may be altered in shape and structure to accommodate external forces and to conform to the shape of objects brought into contact with them without losing their integrity. Flexible bags of the type commonly available are typically formed from materials having consistent physical properties throughout the structure of the flexible bag including such properties as stretch, tensile, and/or elongation properties. Typically, such flexible bags are utilized as trash bags, body bags, Christmas tree disposal bags, colostomy bags, dry cleaner bags, laundry bags, stock pick bags, and shopping bags. Methods for making such bags are well known in the art. Typical of such prior art is that disclosed in U.S. Pat. No. 4,867,735 issued to Wogelius on Sep. 19, 1989 that discloses a method and apparatus for continuous fabrication of bags from a multilayer thermoplastic film web.
- Some flexible bags have also been made from thin films that have deformations formed in them. A known method of forming such films is by passing a continuous web between a pair of matched forming rollers to form an intentional pattern of deformations on the film. One problem that arises when making flexible bags from a film formed in this manner is that, if the film has at least one overlapped layer or is made in a tubular manner, when having deformations formed therein, one layer becomes engaged within the other and is difficult to separate for subsequent processing. A similar problem arises when films such as thermoplastic elastomeric films exhibit excessive blocking characteristics. Blocking is the tendency of a film to adhere to itself. One approach to resolving this problem for continuous webs made in a tubular manner is to inflate the tube of film with air to separate the two formed layers. For example, U.S. Pat. No. 3,857,144 issued to Bustin on Dec. 31, 1974 discloses making a flexible bag in which a polyethylene film is passed between a pair of matched forming rollers and the continuous formed web is then inflated or an air bubble is trapped within the web to separate the two formed layers. Also, illustrative of the state of the art with regard to flexible bags and continuous webs with intentional patterns of deformations formed in them are, for example, U.S. Pat. No. 5,554,093 issued to Porchia et al. on Sep. 10, 1996, U.S. Pat. No. 5,575,747 issued to Dais et al. on Nov. 19, 1996, U.S. Pat. No. 5,723,087 issued to Chappell et al. on Mar. 3, 1998, and U.S. Pat. No. 6,394,652 issued to Meyer et al. on May 28, 2002.
- It is frequently difficult to separate the overlaying or overlapping layers of film in which deformations have been formed which can cause problems during subsequent processing. This problem is even more acute when the continuous web from which the flexible bags are made is not in a tubular configuration that can be easily inflated using air. In particular, many flexible bags are made by simply laying at least one thin plastic sheet over another or by folding a sheet or a continuous web over onto itself in an overlapped or “C” fold configuration. In these instances, inflating the continuous web using air is not a practical method to separate the overlapping layers since the air has a tendency to escape through the open edge opposite the fold. Even when a tubular configuration of continuous web is used, an air bubble can have a tendency to leak air out through the deformations or creases formed in the continuous web. Consequently, it is desirable to identify a process for easily separating overlapped layers of a continuous web after patterns of deformations have been formed in the continuous web. Additionally, it is desirable to provide such a process and apparatus capable of producing flexible bags from a continuous web at high speeds in a consistent manner.
- The present invention provides a method and apparatus for making flexible articles such as flexible bags and the like from a continuous web of sheet material.
- In one embodiment of the present invention, a continuous process for making flexible articles having elastic-like behavior is provided. The process comprises several steps. A sheet material is introduced having one portion of the sheet material overlapped onto another portion of the sheet material. The sheet material is formed into a strainable network. The strainable network includes a plurality of first regions and a plurality of second regions. The first regions are substantially un-deformed and the second regions are formed into disengageable pleat elements. As the overlapped portions of the sheet material are formed they engage each other in the pleat elements. The pleat elements of each overlapped portion become trapped within each other and resist disengagement because of the frictional forces and attractive forces of the sheet material. The overlapped portions of the sheet material are separated using a disengaging means so that the overlapped portions become disengaged and separated from each other upon riding on the disengaging means. Preferably, the disengaging means is in the form of a static opening bar, a dynamic opening bar, or a suction means. More preferably, the flexible article is a flexible bag that is formed from the sheet material.
- While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying drawing figures, in which like reference numerals identify like elements, and wherein:
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FIG. 1 is a perspective view of a flexible bag made in accordance with the present invention; -
FIG. 2 is a schematic illustration of a process to manufacture flexible bags in accordance with the present invention; -
FIG. 3 is a simplified perspective illustration of a forming apparatus in accordance with the present invention; -
FIG. 4 is a simplified side view of an alternative forming apparatus with the continuous web in accordance with the present invention; -
FIG. 5 is a partial plan view illustration of the continuous web of sheet material resulting from the present invention in a partially tensioned condition; -
FIG. 6 is a perspective illustration of a static opening bar in accordance with the present invention; -
FIG. 7 is an illustration of a static opening bar and continuous web taken at section line 7-7 ofFIG. 6 ; -
FIG. 8 is a perspective illustration of one embodiment of a dynamic opening bar in accordance with the present invention; -
FIG. 9 is a perspective illustration of another embodiment of a dynamic opening bar in accordance with the present invention; -
FIG. 10 is a side view illustration of a dynamic opening bar with the continuous web of the present invention; -
FIG. 11 is a perspective illustration of one embodiment of an end cap in accordance with the present invention; -
FIG. 12 is a perspective illustration of a preferred embodiment of a dynamic opening bar in accordance with the present invention; -
FIG. 13 is a side view illustration of a preferred dynamic opening bar with the continuous web of the present invention; -
FIG. 14 is a perspective illustration of yet another embodiment of a dynamic opening bar in accordance with the present invention; -
FIG. 15 is a perspective illustration of the dynamic opening bar ofFIG. 13 captured within a cage in accordance of the present invention; -
FIG. 16 is a side view illustration of an alternative embodiment of a dynamic opening bar and a cage; -
FIG. 17 is a perspective illustration of an alternative embodiment of a disengaging means in accordance with the present invention with vacuum manifold disconnected for clarity; -
FIG. 18 is a side view illustration of yet another alternative embodiment of a disengaging means in accordance with the present invention; and -
FIG. 19 is a perspective view of a roll of flexible bags made in accordance with the present invention. - In this detailed description of the present invention, any patent or non-patent literature referenced herein and the disclosure contained therein is intended to be and is hereby incorporated by reference.
- Referring now to
FIG. 1 in which is illustrated a preferred embodiment of aflexible bag 10 made according to the present invention.Flexible bag 10 includesbag body 20, an opening alongtop edge 28, a sealedfirst seam 21, a sealedsecond seam 23, and a closed bottom formed atbottom fold 22. Preferably,flexible bag 10 includesfirst regions 64 andsecond regions 66 forming a strainable network acrossbag body 20. In one embodiment offlexible bag 10,first regions 64 are in a substantially crisscrossing pattern acrossbag body 20. In this embodiment,flexible bag 10 is tubular in shape and has an interior 12.Flexible bag 10 is illustrated with optional closure means 30 located at or adjacent totop edge 28. Optional closure means 30 can be used to closeflexible bag 10 forming a fully enclosed container to assure the contents contained in its interior 12 do not escape through the opening attop edge 28. - Preferably,
flexible bag 10 is constructed from asheet material 52 that is suitable for containing and protecting a wide variety of items and/or objects contained withininterior 12 offlexible bag 10. The term “sheet material” as used herein is the composition or substance from which the articles described herein are made. Various materials known in the art are suitable for constructingsheet material 52 used inflexible bags 10 made in accordance with the present invention. For example, sometypical sheet materials 52 for making suchflexible bags 10 can be substantially impermeable materials including any polymeric material. Exemplary, but non limiting, polymeric materials can include polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), and any polyolefin such as linear low density polyethylene (PE), low density PE, high density PE or polypropylene (PP). Other types of materials may include aluminum foil, thin sheet metal, coated (waxed, etc.) and uncoated paper, coated nonwovens, or can even be substantially permeable materials including any scrims, meshes, wovens, nonwovens, or perforated or porous films, whether predominantly two-dimensional in nature or formed into three-dimensional structures.Such sheet materials 52 may comprise a single composition or layer or may alternatively be a composite or laminate structure of disparate materials or multiple layers, or any combinations thereof. - In yet another embodiment of the present invention,
sheet material 52 can be formulated to include a slip agent. Slip agents can bloom to the surface ofsheet material 52. In addition to having slip agents incorporated in the composition ofsheet material 52, additional slip agents can be applied to the surface of at least a portion ofsheet material 52. A slip agent is a compound or composition that can help to reduce the coefficient of friction on the surface ofsheet material 52 thereby making thesheet material 52 easier to disengage and separate from any overlapping portion. Slip agents may even prevent portions ofsheet material 52 from adhering to each other. Some exemplary slip agents can include, for example, talc (hydrated magnesium silicate), diatomaceous earth, ceramic microspheres, N-Ethylenebisstearammide, erucamide, acrawax C, graphite, or the like. Ceramic microspheres useful herein are commercially available from 3M Corporation under the name Zeeospheres™ ceramic microspheres. - Various articles other than
flexible bags 10 can be produced using the present invention including, for example, cartons, cans, containers, bottles, boxes, jars, packages, pouches, plates, wraps, webs, films, sheets, and the like. Some of the numerous product applications forflexible bags 10 made as disclosed herein include, for example, sandwich bags, food storage bags, trash bags, body bags for containment of human or animal remains, Christmas tree disposal bags, colostomy bags, dry cleaning and/or laundry bags, bags for collecting items picked from warehouse inventory (stock pick bags), shopping bags, and the like. - In one embodiment of the present invention,
flexible bags 10 can be made from raw materials in that the process begins with the manufacture of acontinuous web 53 ofsheet material 52 from which a multiplicity offlexible bags 10 is produced. The term “continuous web” as used herein is an integral length ofsheet material 52 sufficient to fabricate a multiplicity offlexible bags 10 connected in an edge-to-edge configuration. In another embodiment of the present invention,flexible bags 10 can be made from a previously produced roll or discrete piece ofsheet material 52 which is then introduced into the process defined herein. - Referring now to
FIG. 2 , one method for makingflexible bag 10 is by creatingsheet material 52 and converting it into multipleflexible bags 10 through a continuous or discontinuous process. A raw plastic material can be formed by blowing or casting acontinuous web 53 ofsheet material 52 as is well known in the art. For example, acontinuous web 53 can be blown from a raw stock of plastic material introduced in pellet form into anextruder 120, from which a tubular structure such as atube 51 of thin plastic material is extruded throughtubular die 121.Tube 51 is inflated by blowing or capturing an air bubble withintube 51. Typically, thistube 51 is cooled as it rises.Tube 51 can be pressed together through a set of pinchingrollers 122. Pinchingrollers 122 collapse the air bubble and compress the walls oftube 51 together into a flattenedcontinuous web 53 ofsheet material 52 having at least one overlapped portion. Overlap or overlay as used herein includes, without limitation, any ply, layer, web, film or sheet laid on any portion of another. For example, overlapped can include multiple layers, multiple-ply, laminates, tubes, folded sections, gussets, or any two sheets laying on any part of another sheet or even on any part of the same sheet. Consequently,sheet material 52 can be overlapped in a manner that the overlapped portions are placed into contact with each other. It is when the overlapped portions ofsheet material 52 are in contact that they can thereafter be disengaged and separated such that they are no longer in contact with each other. One method for making acontinuous web 53 ofsheet material 52 is disclosed in U.S. Pat. No. 3,857,144 issued to Bustin on Dec. 31, 1974. Another way to make acontinuous web 53 ofsheet material 52 is by casting thecontinuous web 53 and one such casting method is disclosed in U.S. Pat. No. 4,428,788 issued to Kamp on Jan. 31, 1984. - In a preferred embodiment of the present invention,
continuous web 53 can pass through or over cuttingstation 154 after passing through pinchingrollers 122.Cutting station 154 can simply be a blade or a set of blades that can cut or slitcontinuous web 53 longitudinally as it passes over cuttingstation 154. In one embodiment of the present invention, a singlecontinuous web 53 can be cut into two or morecontinuous webs 53 which can then be wound intorolls 11 and stored for future use or, alternatively, one or more of suchcontinuous webs 53 are introduced into additional converting station as described herein. For example,continuous web 53 can be cut by cuttingstation 154 so as to separatecontinuous web 53 into four separatecontinuous webs 53 such that two of the resultingcontinuous webs 53 are substantially curved having a substantially “C” shaped transverse cross-section and the other twocontinuous webs 53 are substantially flat. The two flatcontinuous webs 53 can then be passed throughseparate folding stations 133 to foldsheet material 52 in order to overlap at least one portion over another and then thesecontinuous webs 53 can be wound onto rolls 11. Alternatively, the two flatcontinuous webs 53 can be wound intorolls 11 without folding. Likewise the two substantially curvedcontinuous webs 53 can be passed throughseparate folding stations 133 to overlap at least one portion ofsheet material 53 onto another. The substantially “C” shaped cross-section is formed by overlapping or overlaying at least a portion of the sidewalls ofsheet material 52 over each other. Thereafter the sidewalls are referred to as being connected through a folded region, which in the present embodiment isbottom fold 22. Alternatively, two flatcontinuous webs 53 or other discrete pieces ofsheet material 53 can be laid into contact with each other and sealed together along a longitudinal edge forming the region referred to asbottom fold 22. Eachcontinuous web 53 ofsheet material 52 can then be independently wound intorolls 11 for future use or can be immediately processed according to the present invention. - Once
sheet material 52 is produced, it can be introduced into a continuous or discontinuous process for making articles such asflexible bags 10 throughtransport rollers 123. In this same manner,sheet material 52 can be introduced into multiple converting stations for immediate processing. At various points along the process described herein,continuous web 53 ofsheet material 52 can be wound into aroll 11 and stored for future use in this or another process as is known by those of ordinary skill in the art. “Continuous process” as used herein means repetitive, ongoing or continuing steps that are not intended to stop or cease until multipleflexible bags 10 are produced. As used herein, “introduce” can mean pass, feed, insert, engage, flow or pushsheet material 52 into the next converting station. At windingstation 111,sheet material 52 is wound intorolls 11 ofsheet material 52 as is known by those of ordinary skill in the art.Sheet material 52 can be introduced into any one of the numerous converting station by unwinding a previously woundroll 11 ofsheet material 52 and introducing it throughtransport rollers 123. - The processing of
continuous web 53 ofsheet material 52 continues assheet material 52 passes through the next converting station which can be an alternative or optional step. This optional step can beclosure station 160 which incorporates or forms closure means 30 ontosheet material 52. Closure means 30 is formed atedge 28 and is used to seal or close off interior 12 afterflexible bag 10 is filled with contents. Under some circumstances a closure means 30 formed by a lesser degree of encirclement (such as, for example, a closure means disposed along only one side of edge 28) may provide adequate closure integrity. Closure means 30 can be made from a strip of flexible plastic material in accordance with U.S. Pat. No. 4,624,654 issued to Boyd et al. on Nov. 25, 1986. - Other types of closure means 30 may alternatively be utilized including, for example, drawstring-type closures, tieable handle tabs or flaps, twist tie or interlocking strip closures, adhesive-based closures, interlocking mechanical seals with or without slider-type zipper closure mechanisms, removable ties or strips made of plastic or other materials, heat seals, or any other suitable closure means 30 can be used. Such closure means 30 are well known in the art as are methods of manufacturing and making them. Alternatively, closure means 30 of any design and configuration suitable for its intended purpose may be utilized in constructing
flexible bags 10 according to the present invention. In yet another alternative embodiment, closure means 30 can be omitted fromflexible bag 10. After closure means 30 is incorporated intocontinuous web 53 ofsheet material 52,continuous web 53 ofsheet material 52 can be introduced to the next converting station throughtransport rollers 123. - Now referring to
FIG. 3 , formingapparatus 500 includes a pair ofrollers First roller 502 includes a plurality oftoothed regions 506 and a plurality ofgrooved regions 508 that extend acrosscylindrical roller 502.Toothed regions 506 include a plurality ofteeth 507.Second roller 504 includes a plurality ofteeth 510 which mesh withteeth 507 onroller 502. An alternative embodiment of intermeshingfirst roller 502 andsecond roller 504 is illustrated in FIG. 4 along with acontinuous web 53 ofsheet material 52.Continuous web 53 ofsheet material 52 can be introduced into formingapparatus 500 to form a strainable network having at least two visuallydistinct regions continuous sheet material 52 is passed betweenintermeshing rollers grooved regions 508 will leave portions ofcontinuous web 53 ofsheet material 52 unformed producingfirst regions 64. The portions ofcontinuous web 53 ofsheet material 52 passing betweentoothed regions 506 andteeth 510 will be formed byteeth disengageable pleat elements 74 insecond regions 66. - As
sheet material 52 passes between first formingroller 502 and second formingroller 504,disengageable pleat elements 74 are formed into the overlapped portions ofsheet material 52. The overlapped portions ofsheet material 52 are pressed into contact with each other atfirst regions 64 and are pressed into engaging contact with one another insecond regions 66 where the raisedpleat elements 74 are formed.Regions 66 can comprise rows of deeply formed deformations insheet material 52 ofcontinuous web 53, whileregions 64 can comprise intervening un-deformed portions ofcontinuous web 53. - Forming
apparatus 500 can form discrete areas having an increased frequency ofpleat elements 74 or discrete areas having a decreased frequency ofpleat elements 74 insheet material 52 by increasing or decreasing the concentration ofteeth 507 along the circumference of formingroller 502 and along the width of formingroller 502. Likewise, the height ofteeth 507 on formingroller 502 can vary within a particulartoothed region 506 and along the circumference of formingroller 502 in order to vary the height of correspondingpleat elements 74. Such a configuration of formingapparatus 500 allowspleat elements 74 to be formed insheet material 52 having predetermined elongation characteristics. As used herein, the term “formed” refers to the creation of a desired three-dimensional structure or geometry uponsheet material 52 that will substantially retain its shape when it is not subjected to any externally applied elongation or other forces. The term “pleat” refers to a formation having a major axis and a minor axis wherein the major axis is equal to or preferably greater than the minor axis. - In accordance with the present invention as illustrated in
FIG. 5 , thesefirst regions 64 andsecond regions 66impart bag body 20 offlexible bag 10 with an elastic-like behavior. As used herein, the term “elastic-like” describes the behavior of flexible materials which when subjected to an applied elongation force, the flexible materials extend in the direction of the applied elongation and when the applied elongation is released the flexible materials return, to a substantial degree, to their untensioned condition. In particular,sheet material 52 includes a “strainable network” ofdistinct regions first regions 64 andsecond regions 66 which enable the elastic-like behavior. This strainable network can be extended to some useful degree in a predetermined direction, such as along axis “T”, in response to the applied and subsequently released elongation force. In particular,pleat elements 74 are able to unbend, unfold or geometrically deform in a direction substantially perpendicular to theirfirst axis 76 to allow extension ofsheet material 52 in response to such an applied axial elongation.Sheet material 52 made in accordance with the present invention is configured such that the un-deformedfirst regions 64 are visually distinct from the substantially deformedsecond regions 66. As used herein, the term “visually distinct” refers to features ofsheet material 52 which are readily discernible to the normal naked eye whensheet material 52 or articles incorporatingsheet material 52, such asflexible bags 10, are observed. - Additionally, while it is presently preferred to construct substantially the
entire bag body 20 from asheet material 52 having the structure and characteristics made in accordance with the present invention, it may be desirable under certain circumstances to provide such elastic-like behavior in only one or more portions or zones ofbag body 20 rather than its entirety. For example,bag body 20 offlexible bag 10 can have discrete areas wherefirst regions 64 andsecond regions 66 exist and the strainable network is evident while also having discrete areas ofbag body 20 without any such strainable network. These discrete areas can be produced when formingrollers pleat elements 74 are intermittently retracted or removed from being in contact withsheet material 52 ascontinuous web 53 passes through formingapparatus 500. This intermittent removal or opening of formingrollers un-deformed sheet material 52 to be created. Such intermittent removal can be synchronized to create a repeating pattern of discrete areas that are un-deformed while also providing discrete areas that are formed offirst regions 64 andsecond regions 66 in a strainable network. Sealingland 26,first seam 21,bottom fold 22, and second seam 23 (shown inFIG. 1 ) are each an example of areas that can be wholly void of any such strainable network. Sealingland 26,first seam 21, andsecond seam 23 can be un-deformed areas that help assure proper sealing. -
Sheet materials 52 such as those illustrated and described herein as suitable for use in accordance with the present invention are described in greater detail in commonly assigned U.S. Pat. No. 5,518,801 issued to Chappell et al. on May 21, 1996; U.S. Pat. No. 5,691,035 issued to Chappell et al. on Nov. 25, 1997; and U.S. Pat. No. 5,650,214 issued to Anderson et al. on Jul. 22, 1997; and U.S. Pat. No. 5,723,087 issued to Chappell et al. on Mar. 3, 1998. Aflexible bag 10 made fromsheet material 52 including the strainable network for use with the present invention is illustrated and described in greater detail in commonly assigned U.S. Pat. No. 6,394,652 issued to Meyer et al. on May 28, 2002. Whilecontinuous web 53 has been described in this process along with formingrollers sheet material 52 can be substituted for suchcontinuous web 53 and reciprocating forming plates or any other device can alternatively be used to form the strainable network havingfirst regions 64 andsecond regions 66. The term “discrete piece” as used herein is an integral length ofsheet material 52 sufficient to fabricate only a portion of or only a fewflexible bags 10 connected in an edge-to-edge configuration. - Another method of forming
sheet material 52 suitable for use in the present invention is vacuum forming. An example of a vacuum forming method is disclosed in commonly assigned U.S. Pat. No. 4,342,314 issued to Radel et al. on Aug. 3, 1982. Alternatively, thesheet material 52 may be hydraulically formed in accordance with the teachings of commonly assigned U.S. Pat. No. 4,609,518 issued to Curro et al. on Sep. 2, 1986. After the strainable network is incorporated intosheet material 52, it can be introduced to the next converting station throughtransport rollers 123. - After forming
continuous web 53 in the manner described, it is frequently difficult to separate overlaying or overlapping layers ofsheet material 52 in which pleatelements 74 have been formed. This problem is even more acute whencontinuous web 53 is not in a tubular configuration that can be easily inflated using air. A similar problem with overlapped layers adhering to each other occurs withcontinuous webs 53 that are highly blocked. Consequently, in one embodiment of the present invention a means for disengagingpleat elements 74 and/or separating overlapped portions ofsheet material 52 is provided. Preferably,continuous web 53 is introduced into pre-opening or disengaging means 130 prior tosheet material 52 being introduced into bag-makingmachine 32. - Referring now to
FIG. 6 , disengaging means 130 in the form of anopening bar 200 is illustrated as astatic opening bar 201 having a staticleading edge 203. The term “static” as used herein means without movement or fixed in once place. In this embodiment, staticleading edge 203 is static relative to the other components of disengaging means 130. Preferably, staticleading edge 203 has a substantially rounded configuration. One example of astatic opening bar 201 can include asupport arm 205 that extends from and is supported at only one end by amount 209 in a cantilevered manner. Extending outwardly fromsupport arm 205 in a manner that can be substantially horizontal isforward extension 207. Preferably,forward extension 207 has a substantially cylindrical or roundedleading edge 203. - As illustrated in
FIG. 7 , the cantilevered configuration ofstatic opening bar 201 allows insertion ofstatic opening bar 201 between the overlapped portions ofcontinuous web 53 ofsheet material 52. Preferably,static opening bar 201 can extend at least partially across the width ofsheet material 52. More preferably,static opening bar 201 is smooth and, in one embodiment, cylindrical allowingsheet material 52 to flow over an outer surface thereof without encountering any sharp corners that would disrupt the movement ofsheet material 52. The forwardly extending portion ofstatic opening bar 201 is oriented substantially planar with the path ofsheet material 52 immediately upstream of staticleading edge 203. Staticleading edge 203 encounters the overlapped portions ofsheet material 52 causing the overlapped portions to separate from each other asstatic opening bar 201 is forced between the overlapped portions. In this manner,static opening bar 201 is used to disengage pleat elements 74 (not shown) and separate the overlapped portions ofsheet material 52 assheet material 52 rides overstatic opening bar 201. “Ride” as used herein means to come into physical contact with or to be carried on something or supported on or by the thing contacted. To “Ride” or “Riding” indicates that an item has come into contact with or against the thing over which it is being conveyed. As staticleading edge 203 encounters the overlapped portions ofsheet material 52, the frictional forces engagingpleat elements 74 ofsheet material 52 are overcome. Assheet material 52 rides onstatic opening bar 201, the amount of force encountered aspleat elements 74 are disengaged increases as the rate at whichsheet material 52 rides overstatic opening bar 201 increases. - In another embodiment of the present invention illustrated in
FIG. 8 , separating the overlapped portions ofsheet material 52 includes the use of a disengaging means 130 in the form of anopening bar 200 that is adynamic opening bar 202 having a dynamicleading edge 204. Dynamic, as used herein, means that leadingedge 204 is not static relative to the other components of disengaging means 130. Dynamic leadingedge 204 includes a pair of adjacentidler rollers base 210. Adjacent, as used herein, means that the pair ofidler rollers idler rollers sheet material 52 without slippage and to assist in pullingcontinuous web 53 overidler rollers idler rollers idler rollers idler rollers sheet material 52. Alternatively,idler rollers Idler rollers base 210. In this embodiment,idler rollers leading edge 204 in thatidler rollers sheet material 52. - In a preferred embodiment of
dynamic opening bar 202, illustrated inFIG. 9 ,idler rollers base 210 at one end and inend cap 230 at the other end. In this preferred embodiment,end cap 230 is mounted onsupport arm 211 but alternatively,end cap 230 can be made integral withsupport arm 211. Optionally,end cap 230 andsupport arm 211 can be omitted as previously described.Support arm 211 is mounted onbase 210 and spans betweenbase 210 andend cap 230 just behindidler rollers stream trailing edge 238 ofsupport arm 211 is positioned so as not to interfere with the flow ofsheet material 52.Dynamic opening bar 202 extends at least partially across the width ofsheet material 52 in a cantilevered manner. In this configuration,end cap 230 is positioned to allow the C folded region ofcontinuous web 53 to ride uponouter surface 235. - As illustrated,
idler rollers idler roller idler roller 206 includes firstintermediate roller 251 connected end to end with a secondintermediate roller 253. Similarly,idler roller 208 is of the same configuration having a firstintermediate roller 252 connected end to end with a secondintermediate roller 254.Bracket 250 is mounted between firstintermediate rollers intermediate rollers intermediate rollers intermediate rollers Bracket 250 is shaped somewhat like a “figure 8” and is recessed from the outer diameter of eachcorresponding roller continuous web 53 ofsheet material 52 can ride overidler rollers bracket 250. This configuration enables a widerdynamic opening bar 202 for handling widercontinuous webs 53. - An
end cap 230 is configured with rounded edges to allow the overlapped portion ofsheet material 52 to pass overouter surface 235 without encountering any sharp edges. In one embodiment,end cap 230 is substantially hemispherical at a forward portion and tapers towardrear end 239 in a somewhat “tear drop” shape.End cap 230 is attached to supportarm 211 using fasteners that pass throughfastener recesses 237 inouter surface 235. Preferably,end cap 230 is aligned with oppositeouter segments idler rollers idler rollers end cap 230. Any such misalignment can result in tearing, ripping or disfiguring ofsheet material 52 ascontinuous web 53 rides overdynamic opening bar 202. Consequently, in a most preferred embodiment,end cap 230 is slightly recessed below oppositeouter segments idler rollers edge 238 ofsupport arm 211 does not extend beyondrear end 239 ofend cap 230. - As illustrated in
FIG. 10 ,inner segments idler rollers idler rollers outer segments idler rollers sheet material 52 just upstream ofdynamic opening bar 202 andidler rollers sheet material 52 just upstream ofdynamic opening bar 202. The overlapped portions ofsheet material 52 ride over oppositeouter segments idler rollers pleat elements 74 to disengage and overlapped portions ofsheet material 52 to separate from each other. Location “U” is the point at which overlapped portions ofsheet material 52 naturally begin disengaging and separating from each other. The distance from dynamicleading edge 204 to location U varies depending on the rate at whichcontinuous web 53 is traveling, and the tension ofcontinuous web 53 and adherence between the overlapped portions ofsheet material 52. Location U may oscillate in the machine direction or in a cross direction. This oscillation can be toward and away from dynamicleading edge 204 even whencontinuous web 53 is moving at a constant rate of speed. - Referring now to
FIG. 11 , in an alternative embodiment,end cap 230 can havedimples 236 inouter surface 235 in order to enablecontinuous web 53 ofsheet material 52 to ride overend cap 230 with less friction than whenouter surface 235 is smooth. Preferably, dimples 236 inouter surface 235 are substantially hemispherical. Fastener recesses 237 are also illustrated inouter surface 235 ofend cap 230. To assure thatsheet material 52 and the overlapped portions thereof smoothly flow as they ride overend cap 230,end cap 230 preferably has a highly polishedouter surface 235. Preferablyouter surface 235 has a low coefficient of friction such as with a plasma coating. One exemplary plasma coating is PC-14015-02 plasma coating commercially available from Plasma Coatings of TN, Inc. - In one preferred embodiment of the present invention as illustrated in
FIG. 12 ,dynamic opening bar 202 includes two sets of adjacentidler rollers idler rollers end cap 230 are substantially the same as described in reference toFIGS. 8 through 10 . In this embodiment, first set of adjacentidler rollers idler rollers continuous web 53. First set of adjacentidler rollers frame 221 having high-speed bearings mounted on both ends ofidler rollers Frame 221 can be constructed of multiple components or as one unitary component. Second set ofidler rollers base 210 in a cantilevered manner and havingend cap 230 affixed on the ends oppositebase 210. Additionally,support arm 211 is mounted onbase 210 and spans betweenbase 210 to endcap 230 just behindidler rollers idler rollers support arm 211 can be mounted on a portion offrame 221 that is positioned so second set ofidler rollers idler rollers - Now referring to
FIG. 13 , when disengaging means 130 is in the form of two sets of adjacentidler rollers sheet material 52 are disengageable as they pass between first set ofidler rollers sheet material 52 are disengaged and separated from each other as each overlapped portion encounters and moves toward oppositeouter segments idler rollers Sheet material 52 rides between first set ofidler rollers sheet material 52 are pulled away from each other in a manner that disengagespleat elements 74 and separates the overlapped portions ofsheet material 52 assheet material 52 moves toward and rides on second set ofidler rollers Sheet material 52 rides oninner segments idler rollers outer segments idler rollers idler rollers idler rollers idler rollers sheet material 52. In a preferred configuration, spacing Z between first set ofidler rollers idler rollers rollers - In still another embodiment of the present invention as illustrated in
FIG. 14 ,dynamic opening bar 202 is shown including anend cap 230 at either end. Oftencontinuous webs 53 ofsheet material 52 are extruded and blown and further processed without cutting ofcontinuous web 53 and without folding to overlap any portions ofcontinuous web 53. In these instances,continuous web 53 remains in a substantially tubular configuration without any open edges. During processing, overlapped portions are formed simply by collapse of the tubular walls. Consequently, there are no open edges to insert and maintain the support of disengaging means 130 in even a cantilevered manner. In order to separate suchcontinuous webs 53 an alternative embodiment of disengaging means 130 is utilized.Dynamic opening bar 202 includes a pair ofidler rollers leading edge 204. The axis of bothidler rollers idler rollers Idler rollers end caps 230. Opposingend caps 230 are used to supportidler rollers idler rollers Support arm 211 spans between both opposingend caps 230 and is positioned just behindidler rollers end cap 230 is attached to supportarm 211 at opposite ends ofsupport arm 211 using fasteners that pass throughfastener recesses 237 inouter surface 235 in the same manner as previously discussed. During use, this configuration ofdynamic opening bar 202 can be wholly surrounded by overlapped portions ofsheet material 52. - Now referring to
FIG. 15 ,dynamic opening bar 202 is capable of movement betweenupper support rollers lower support rollers cage 290 arounddynamic opening bar 202 so thatdynamic opening bar 202 is captured withincage 290. In this embodiment,dynamic opening bar 202 is illustrated as being horizontally disposed withincage 290.Upper support rollers lower support rollers dynamic opening bar 202. At a forward end ofcage 290 are positioned a set ofadjacent support rollers Support roller 280 is aligned in an upper position whilesupport roller 281 is aligned in a lower position.Forward support rollers continuous web 53 to pass between them while preventing the forward migration ofdynamic opening bar 202. At this forward location dynamic leadingedge 204,idler rollers support rollers FIG. 12 . Positioned just behind and outboard ofidler rollers dynamic opening bar 202 aremiddle support rollers Middle support rollers dynamic opening bar 202 in order to maintaindynamic opening bar 202 in its horizontal position parallel to the flow ofcontinuous web 53. In a preferred configuration two sets ofmiddle support rollers dynamic opening bar 202 in its horizontal position.Middle support rollers dynamic opening bar 202 whilemiddle support rollers dynamic opening bar 202.Rear support rollers dynamic opening bar 202 does not migrate rearward from its desired position. In this mannerdynamic opening bar 202 is captured withincage 290. - In order to insert and extract
dynamic opening bar 202 from withincage 290,middle support rollers dynamic opening bar 202 can be lifted out ofcage 290. Alternatively,middle support rollers middle support rollers dynamic opening bar 202 for maintenance or other purposes. For example, during start up ofcontinuous web 53dynamic opening bar 202 can be inserted within the tubular walls whenmiddle support rollers Middle support rollers dynamic opening bar 202 captive. - In this configuration,
continuous web 53 ofsheet material 52 can wholly enclosedynamic opening bar 202 which floats within the tubular walls ofcontinuous web 53. The overlapped portions ofsheet material 52 ride betweenforward support rollers cage 290 and over oppositeouter segments idler rollers dynamic opening bar 202 thus causingpleat elements 74 to disengage and overlapped portions ofsheet material 52 to separate from each other. In this manner,continuous web 53 is threaded betweendynamic opening bar 202 andcage 290. The overlapped portions ofcontinuous web 53 ofsheet material 52 can ride over opposite sides ofdynamic opening bar 202. - Referring now to
FIG. 16 in which is illustrated, an alternativedynamic opening bar 202 withincage 290 withcontinuous web 53 threaded betweendynamic opening bar 202 andcage 290. In this alternative configuration ofdynamic opening bar 202, an additional pair of upperidler rollers dynamic opening bar 202 down stream ofidler roller 206 and an additional pair of loweridler rollers dynamic opening bar 202 down stream ofidler roller 208. Upperidler rollers lower idler rollers end caps 230. Upperidler rollers lower idler rollers continuous web 53 ofsheet material 52 ascontinuous web 53 is threaded betweenmiddle support rollers dynamic opening bar 202 andmiddle support rollers dynamic opening bar 202. Upperidler rollers lower idler rollers middle support rollers middle support rollers continuous web 53 as continuous web rides overdynamic opening bar 202 while also maintainingdynamic opening bar 202 in a horizontal position. Optionally, upperidler rollers lower idler rollers - In another alternative embodiment of the present invention as illustrated in
FIG. 17 , the step of separating the overlapped portions of sheet material 52 (not shown) includes the use of a disengaging means 130 in the form of a suction means 550. Suction means 550 is used to disengage and separate the overlapped portions ofsheet material 52 assheet material 52 rides on suction means 550. In this embodiment, suction means 550 can be an integral part of formingroller apertures 575 in at least one of formingrollers small apertures 575 on eachtooth 507 are connected with avacuum manifold 570 through passageways internal to formingrollers Openings 576 are depicted on a faceplate at one end ofrollers Vacuum manifold 570 is attached toopenings 576 in a manner that allows rotation ofrollers sheet material 52 passes between formingrollers pleat elements 74 are formed, suction is also applied to the overlapped portions ofsheet material 52 throughapertures 575. A vacuum, indicated generally by arrow “V”, is created and suction applied throughvacuum manifold 570 extending throughopenings 576 into passageways andapertures 575 inteeth 507. This vacuum allows a suction force to be applied to the overlapped portions ofsheet material 52 thereby disengagingpleat elements 74 immediately after they are formed by formingrollers apertures 575 pulls the overlapped portions ofsheet material 52 apart. In that manner,pleat elements 74 are disengaged and the overlapped portions ofsheet material 52 are separated. - In yet another alternative embodiment, as illustrated in
FIG. 18 , suction means 550 can be in the form of opposingplenums 579 that are situated in close proximity tosheet material 52 just aftercontinuous web 53 passes through formingapparatus 500. A vacuum, as indicated generally by arrows “V”, can be applied through eachplenum 579 sufficient to pull the overlapped portions ofcontinuous web 53 ofsheet material 52 apart in order forpleat elements 74 to become disengaged from each other. The vacuum also provides sufficient suction to separate the overlapped portions ofsheet material 52 from each other. Afterpleat elements 74 are disengaged and overlapped portions ofsheet material 52 are separated from each other,continuous web 53 can be introduced to the next converting station throughtransport rollers 123. - In an alternative embodiment of the present invention, disengaging means 130 can be in the form of an air knife used to disengage and separate overlapped portions of
sheet material 52. Air knives are well known by those of ordinary skill in the art in that air can be blown between the overlapped portions ofsheet material 52 to disengagepleat elements 74. In still another alternative embodiment, disengaging means 130 can include an air bearing. For example, an air bearing can be a surface disposed between the overlapped portions ofsheet material 52 and wherein a layer of air is introduced onto the surface such thatsheet material 52 rides on the layer of air. Air bearings of this type are well known in the art. Alternatively, such surfaces can utilize any gas, liquid, gel or flowable solid to form the layer on whichsheet material 52 traverses including, for example, nitrogen, oil, glycerol, graphite, grease, water, and any combinations thereof. - Referring back to
FIG. 2 , optionally, a pair of opposing gussets 54 can be formed incontinuous web 53 at an optional converting station using methods well known in the art. Such anoptional gusseting station 150 is illustrated as being just before bag-makingmachine 32 but alternatively gussets can be inserted intocontinuous web 53 in various other sequences as is known by those of ordinary skill in the art. - The processing of
continuous web 53 can continue by introducingcontinuous web 53 into a bag-makingmachine 32.Continuous web 53 passes through bag-makingmachine 32 to formflexible bag 10 including a strainable network having at least two visually distinct regions. For example,flexible bags 10 can be formed fromcontinuous web 53 such that saidcontinuous web 53 has a perforated or tear section adjacent to a sealed section which extends transversely across a width of saidcontinuous web 53. A perforated section adjacent to sealed section can be spaced apart longitudinally from a next pair of similarly configured perforated section and sealed section. One such method of forming such aflexible bag 10 is disclosed in U.S. Pat. No. 4,867,735 issued to Wogelius on Sep. 19, 1989. Afterflexible bags 10 are incorporated intocontinuous web 53,continuous web 53 can be introduced to the next converting station throughtransport rollers 123. - Alternatively, converting station, just ahead of bag-making
machine 32 can be acalender station 150 used to processcontinuous web 53 by flattening or pressing together at least a portion ofcontinuous web 53 to improve bonding or sealing capabilities ofsheet material 52. In particular, discrete areas ofcontinuous web 53 should stay in close contact with each other to insure effective sealing, bonding and forming ofsheet material 52. Consequently,continuous web 53 can be pretreated by uniformly flatteningpleat elements 74 via the application of pressure and heat uponsheet material 52. To form these discrete portions ontocontinuous web 53 at the required locations, a set of rolls can be used.Continuous web 53 passes between smooth rollers as they are pressed into contact with each other to flattensheet material 52. In a preferred embodiment, smooth rollers are heated using steam or some other method of heating smooth rollers. Assheet material 52 passes between smooth rollers,pleat elements 74 ofsecond region 66 become substantially planar with the un-deformedfirst region 64. Smooth rollers flatten or collapsepleat elements 74 while not changing the functional structure of the strainable network. Aftercontinuous web 53 passes through this converting station,continuous web 53 can be introduced to the next converting station throughtransport rollers 123. - The processing of
continuous web 53 continues ascontinuous web 53 is introduced to afolding station 133.Continuous web 53 passes throughfolding station 133 that is preferably positioned after bag-makingmachine 32. Folding ofcontinuous web 53 is in a manner that reduces the transverse width ofcontinuous web 53 by overlapping portions ofcontinuous web 53 upon each other. Folding bars 33 comprisefolding station 133 and are used in a manner known by those of ordinary skill in the art. After the folding is completed,continuous web 53 can be introduced to the next converting station throughtransport rollers 123. - The processing of
continuous web 53 continues ascontinuous web 53 is introduced into rewindingstation 111 that is preferably positioned after all of the processing ofcontinuous web 53 is completed. Rewinding station windscontinuous web 53 intorolls 11 offlexible bags 10. Theseflexible bags 10 are wound in a manner such that upon unwinding a section ofcontinuous web 53 allowsflexible bags 10 to be severed from each other for individual use. Rewinding can includecontinuous web 53 being wound around a cylindrical core to form rolls 11 offlexible bags 10. Cylindrical cores can be utilized or omitted using winding methods that are known in the art. - Alternatively, once the desired
sheet materials 52 are manufactured, comprising all or part of the components to be utilized forbag body 20,flexible bag 10 may be constructed in any known and suitable fashion such as those known in the art for making suchflexible bags 10 in a commercially available form. Heat, mechanical, ultrasonic, or adhesive-sealing technologies may be utilized to join various components or elements offlexible bag 10 to themselves or to each other. In addition,bag body 20 may be folded or bonded to constructflexible bag 10 from a singlecontinuous web 53 or a singular discrete piece ofsheet material 52 or any combinations thereof. - A further alternative embodiment of the present invention can include taking a
roll 11 of previously formed disposable bags or aroll 11 ofsheet material 52 and unwindingroll 11 and introducingcontinuous web 53 fromsuch roll 11 into a process as previously described above. Optionally many additional processing steps can be added either before or after the forming or separating offlexible bags 10 as described herein. Other processing steps can be completed such an alternative converting station illustrated asprocessing station 127 which can include, for example, printing labels, additional folding, cutting, forming or sealing or any combination of these or other converting processes. - While the process for making
flexible bags 10 from asheet material 52 has been described in a particular order, it is known that these steps can be performed in various orders. For example, a preferred sequencing of the process for making suchflexible bags 10 can be to introduce the raw material into an extruder and then blow or cast formcontinuous web 53. Thereafter,continuous web 53 can be processed through a number of converting station or, alternatively,continuous web 53 ofsheet material 52 can be wound onto aroll 11 at any stage during the process. Such aroll 11 ofsheet material 52 can then be set aside or introduced into any step of the process desirable. A particularly preferred process involves taking apre-existing roll 11 of overlappedsheet material 52 and introducing thissheet material 52 intoclosure station 160.Next sheet material 52 can be introduced into formingapparatus 500 in order to formpleat elements 74 insheet material 52. Then,sheet material 52 is introduced into separatingstation 130 in order to disengagepleat elements 74 and to separate the overlapped portions ofsheet material 52. Thereafter,sheet material 52 is introduced into bag-makingmachine 32 to makeflexible bags 10. - While particular examples and exemplary methods to introduce
continuous web 53 andsheet material 52 have been described, numerous variations of such examples are well know in the art. For example,continuous web 53 or an individual or discrete sheet ofprecut sheet material 52 having a single-ply can be introduced into formingapparatus 500 and then folded in afolding station 133 and introduced into bag-makingmachine 32. Alternatively, multiplecontinuous webs 53 or multiple discrete sheets ofsheet material 52 in a flat configuration can be introduced into formingapparatus 500 and then folded in afolding station 133 and introduced into bag-makingmachine 32. Alternatively, the overlapped portions can be multiplecontinuous webs 53 or multiple discrete sheets ofsheet material 52 sealed at one longitudinal edge to formbottom fold 22. Another alternative can be the introduction of at least one or morecontinuous webs 53 or discrete sheets ofsheet material 52 that are overlapped upon themselves and havingpleat elements 74 formed therein that are introduced into disengaging means. Yet another alternative method of introducingcontinuous webs 53 can be one ormore tubes 51 that havepleat elements 74 formed therein can be introduced into disengaging means 130. Still another alternative can be to introduce one ormore tubes 51 havingpleat elements 74 formed therein that can then be cut, disengaged, separated, folded and then introduced to bag-makingmachine 32. As illustrated herein it should be apparent to those of ordinary skill in the art that the converting stations and steps described herein can be sequenced in various orders other than those described herein without any undue experimentation. -
FIG. 19 illustrates the results of one embodiment of the present invention, aroll 11 offlexible bags 10. In this embodiment, multipleflexible bags 10 are joined in end-to-end fashion formingcontinuous web 53 from which a multiplicity of individualflexible bags 10 can be separated. In the embodiment illustrated,sheet material 52 has a perforation orfrangible zone 25 between sealededge 21 and sealededge 23. Closure means 30 is shown in the form of a draw tape 31 which can be attached by inserting a strip of draw tape 31 into thecontinuous web 53 ofsheet material 52 through a hem orchannel 34 formed alongtop edge 28. A scallopedarea 17 can also be cut out oftop edge 28 to provide access to a portion of draw tape 31. Sinceflexible bags 10 in their pre-use condition may be externally smaller than typical bags of lesser stretch capability, the dimensions ofroll 11 may be likewise smaller sinceflexible bags 10 can expand in use to the desired size. Such a reducedsize roll 11 may be particularly useful for dry cleaning bags. - In yet still another converting station,
continuous web 53 ofsheet material 52 can be divided, separated, severed or torn apart into individualflexible bags 10 at finishingstation 161. Dividingcontinuous web 53 ofsheet material 52 into individualflexible bags 10 can be accomplished by tearing eachflexible bag 10 away fromcontinuous web 53 alongfrangible zone 25. Alternatively, eachflexible bag 10 can be separated fromcontinuous web 53 by cutting across the width ofcontinuous web 53 during a severing and sealing step at the location offrangible zone 25. In particular, afterflexible bags 10 have been formed, a sever-sealing device can be provided that creates sealededge 21 and sealededge 23 using heat or some other means while simultaneously severing or cuttingcontinuous web 53 between sealededge 21 and sealededge 23 alongfrangible zone 25. Cuttingcontinuous web 53 in this manner separates individualflexible bags 10 from the remainder ofcontinuous web 53.Flexible bags 10 can then be stacked together or folded in an interleaved manner. This allowsstack 129 of interleavedflexible bags 10 to be placed into a package from which a consumer may extract each individualflexible bag 10 one by one without having to tear oneflexible bag 10 from another. - While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various additional changes and modifications can be made without departing from the spirit and scope of the present invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Claims (20)
1. A method of making an article having elastic-like behavior comprising the steps of:
Introducing a sheet material having at least one overlapped portion;
Forming said overlapped portion of sheet material into a strainable network including a plurality of first regions and a plurality of second regions, said first regions being substantially un-deformed and said second regions being formed into disengagable pleat elements; and
Disengaging said pleat elements using a disengaging means:
2. The method of making an article according to claim 1 , wherein said disengaging means is selected from the group consisting of air knife, static opening bar, dynamic opening bar, and suction means, and any combinations thereof.
3. The method of making an article according to claim 1 , further comprising the step of overlapping one portion of sheet material over another portion of sheet material.
4. The method of making an article according to claim 2 , further comprising the step of separating said overlapped portions of said sheet material using said disengaging means.
5. The method of making an article according to claim 2 , wherein said dynamic opening bar comprises at least one first set of rollers and said pleat elements are disengaged from each other while at least one portion of said sheet material rides over an opposite outer segment of at least one roller.
6. The method of making an article according to claim 5 , wherein said dynamic opening bar includes an end cap.
7. The method of making an article according to claim 5 , wherein said dynamic opening bar is wholly surrounded by said overlapped portions of said sheet material.
8. The method of making an article according to claim 5 , wherein said dynamic opening bar comprises a second set of rollers and said pleat elements remain engaged as said sheet material passes between a first set of rollers and thereafter said pleat elements are disengaged while at least a portion of said sheet material is riding over at least one opposite outer segment of a second set of rollers.
9. The method of making an article according to claim 1 , wherein said disengaging step further comprising riding said sheet material on said disengaging means.
10. The method of making an article according to claim 2 , wherein the step of forming further comprises forming said pleat elements as said sheet material passes between a pair of forming rollers, at least one forming roller having toothed regions and grooved regions.
11. The method of making an article according to claim 2 , wherein said disengaging step further comprises the step of applying a vacuum to at least one overlapped portion of said sheet material.
12. The method of making an article according to claim 1 , further comprising the step of winding said sheet material onto a roll.
13. The method of making an article according to claim 1 , further comprising the step of incorporating a closure means into said sheet material.
14. The method of making an article according to claim 1 , further comprising the step of unwinding a continuous web of sheet material from a roll.
15. The method of making an article according to claim 1 , further comprising the steps of extruding a raw plastic material and converting the extruded plastic material into a continuous web of sheet material.
16. The method of making an article according to claim 1 , further comprising the step of forming flexible bags from said sheet material.
17. The method of making an article according to claim 16 , further comprising the step of sealing at least one edge of said flexible bag, and severing said sheet material across a width thereof at said sealed edge to separate said sheet material into individual flexible bags.
18. The method of making an article according to claim 16 , further comprising the step of sealing at least one edge of said flexible bag, and perforating said sheet material across a width thereof at said sealed edge.
19. The method of making an article according to claim 18 , further comprising the step of interleaving said individual flexible bags.
20. A method of making an article having elastic-like behavior comprising the steps of:
Introducing at least one sheet material having at least one overlapped portion;
Forming said overlapped portion of sheet material into at least one region of disengagable pleat elements; and disengaging said pleat elements using a disengaging means selected from the group consisting of air knife, static opening bar, dynamic opening bar, and suction means, and any combinations thereof.
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/780,846 US20050178493A1 (en) | 2004-02-18 | 2004-02-18 | Method and apparatus for making flexible articles having elastic-like behavior with visually distinct regions |
JP2006553358A JP2007521930A (en) | 2004-02-18 | 2005-02-16 | Method for producing a flexible bag having an elastic-like behavior comprising a region molded into a pleated element |
PCT/US2005/004912 WO2005080071A2 (en) | 2004-02-18 | 2005-02-16 | Method for making flexible bags having elastic-like behaviour comprising regions formed into pleat elements |
KR1020067016533A KR100754545B1 (en) | 2004-02-18 | 2005-02-16 | Method and apparatus for making flexible articles having elastic-like behavior with visually distinct regions |
CNA2005800047562A CN1918000A (en) | 2004-02-18 | 2005-02-16 | Method for making flexible bags having elastic-like behaviour comprising regions formed into pleat elements |
EP05723152A EP1758731A2 (en) | 2004-02-18 | 2005-02-16 | Method for making flexible bags having elastic-like behaviour comprising regions formed into pleat elements |
CA2556534A CA2556534C (en) | 2004-02-18 | 2005-02-16 | Method for making flexible bags having elastic-like behaviour comprising regions formed into pleat elements |
NZ548717A NZ548717A (en) | 2004-02-18 | 2005-02-16 | Method and apparatus for making flexible articles having elastic-like behaviour with visually distinct regions |
AU2005215773A AU2005215773B2 (en) | 2004-02-18 | 2005-02-16 | Method for making flexible bags having elastic-like behaviour comprising regions formed into pleat elements |
ZA200606425A ZA200606425B (en) | 2004-02-18 | 2006-08-02 | Method for making flexible bags having elastic-like behaviour comprising regions formed into pleat elements |
JP2010232431A JP2011068131A (en) | 2004-02-18 | 2010-10-15 | Method of manufacturing flexible bag having resilience behavior including region formed into pleat element |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/780,846 US20050178493A1 (en) | 2004-02-18 | 2004-02-18 | Method and apparatus for making flexible articles having elastic-like behavior with visually distinct regions |
Publications (1)
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US20050178493A1 true US20050178493A1 (en) | 2005-08-18 |
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Family Applications (1)
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US10/780,846 Abandoned US20050178493A1 (en) | 2004-02-18 | 2004-02-18 | Method and apparatus for making flexible articles having elastic-like behavior with visually distinct regions |
Country Status (10)
Country | Link |
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US (1) | US20050178493A1 (en) |
EP (1) | EP1758731A2 (en) |
JP (2) | JP2007521930A (en) |
KR (1) | KR100754545B1 (en) |
CN (1) | CN1918000A (en) |
AU (1) | AU2005215773B2 (en) |
CA (1) | CA2556534C (en) |
NZ (1) | NZ548717A (en) |
WO (1) | WO2005080071A2 (en) |
ZA (1) | ZA200606425B (en) |
Cited By (15)
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US20060228051A1 (en) * | 2005-04-07 | 2006-10-12 | Lg Electronics Inc. | Collapsible bag |
US20080260996A1 (en) * | 2002-12-20 | 2008-10-23 | The Procter & Gamble Company | Apparatus and process for producing a web substrate having indicia disposed thereon and elastic-like behavior imparted thereto |
US20090094943A1 (en) * | 2007-10-10 | 2009-04-16 | The Procter & Gamble Company | Absorbent article package with enhanced grip |
US20100086242A1 (en) * | 2008-10-07 | 2010-04-08 | Misumaru Sangyo Co., Ltd. | Gift Bag with Double Wall Structure |
US20100266222A1 (en) * | 2009-04-15 | 2010-10-21 | The Glad Products Company | Bag |
US20110222797A1 (en) * | 2010-03-10 | 2011-09-15 | Maxwell Jason R | Bag |
US20110317945A1 (en) * | 2010-03-10 | 2011-12-29 | The Glad Products Company | Bag |
CN102849260A (en) * | 2011-06-30 | 2013-01-02 | 尤妮佳股份有限公司 | Packaging device |
US20130028542A1 (en) * | 2011-07-25 | 2013-01-31 | The Glad Products Company | Incrementally Stretched Films with Enhanced Properties and Methods for Making the Same |
US20130320019A1 (en) * | 2012-05-22 | 2013-12-05 | LaserSharp FlexPak Services, LLC | Process to manufacture Peel-Reclose packaging film using laser scoring and pressure sensitive labels |
US20150010252A1 (en) * | 2005-10-18 | 2015-01-08 | Innoflex Incorporated | Package having recloseable pour spout |
US9387618B2 (en) | 2011-07-25 | 2016-07-12 | The Glad Products Company | Incrementally stretched films with increased tear resistance and methods for making the same |
US20160272417A1 (en) * | 2015-03-17 | 2016-09-22 | Poly-America, L.P. | Polymeric bags |
US10947014B2 (en) * | 2015-10-09 | 2021-03-16 | Foresight Usa, Inc. | Bags with marks and systems of making same |
US20220135285A1 (en) * | 2019-01-29 | 2022-05-05 | The Glad Products Company | Thermoplastic bags with phased deformation patterns |
Families Citing this family (1)
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KR102151950B1 (en) * | 2019-05-02 | 2020-09-04 | 김수영 | Surface cutting device of Aluminum Disposable |
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Cited By (31)
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US20080260996A1 (en) * | 2002-12-20 | 2008-10-23 | The Procter & Gamble Company | Apparatus and process for producing a web substrate having indicia disposed thereon and elastic-like behavior imparted thereto |
US7938635B2 (en) | 2002-12-20 | 2011-05-10 | The Procter & Gamble Company | Apparatus for producing a web substrate having indicia disposed thereon and elastic-like behavior imparted thereto |
US9957361B2 (en) | 2002-12-20 | 2018-05-01 | The Procter & Gamble Company | Process for producing a web substrate having indicia disposed thereon and elastic-like behavior imparted thereto |
US9498794B2 (en) | 2002-12-20 | 2016-11-22 | The Procter & Gamble Company | Process for producing a web substrate having indicia disposed thereon and elastic-like behavior imparted thereto |
US20060228051A1 (en) * | 2005-04-07 | 2006-10-12 | Lg Electronics Inc. | Collapsible bag |
US20150010252A1 (en) * | 2005-10-18 | 2015-01-08 | Innoflex Incorporated | Package having recloseable pour spout |
US9315299B2 (en) * | 2005-10-18 | 2016-04-19 | Innoflex Incorporated | Package having recloseable pour spout |
US20090094943A1 (en) * | 2007-10-10 | 2009-04-16 | The Procter & Gamble Company | Absorbent article package with enhanced grip |
US20100086242A1 (en) * | 2008-10-07 | 2010-04-08 | Misumaru Sangyo Co., Ltd. | Gift Bag with Double Wall Structure |
US20100266222A1 (en) * | 2009-04-15 | 2010-10-21 | The Glad Products Company | Bag |
US20110317945A1 (en) * | 2010-03-10 | 2011-12-29 | The Glad Products Company | Bag |
US10265909B2 (en) * | 2010-03-10 | 2019-04-23 | The Glad Products Company | Bag |
US9272461B2 (en) * | 2010-03-10 | 2016-03-01 | The Glad Products Company | Bag |
US9272459B2 (en) * | 2010-03-10 | 2016-03-01 | The Glad Products Company | Bag |
US20110222797A1 (en) * | 2010-03-10 | 2011-09-15 | Maxwell Jason R | Bag |
CN102849260A (en) * | 2011-06-30 | 2013-01-02 | 尤妮佳股份有限公司 | Packaging device |
US9387618B2 (en) | 2011-07-25 | 2016-07-12 | The Glad Products Company | Incrementally stretched films with increased tear resistance and methods for making the same |
US10279537B2 (en) | 2011-07-25 | 2019-05-07 | The Glad Products Company | Incrementally stretched films with enhanced properties and methods for making the same |
US9216538B2 (en) * | 2011-07-25 | 2015-12-22 | The Glad Products Company | Incrementally stretched films with enhanced properties and methods for making the same |
US20130028542A1 (en) * | 2011-07-25 | 2013-01-31 | The Glad Products Company | Incrementally Stretched Films with Enhanced Properties and Methods for Making the Same |
US9522498B2 (en) | 2011-07-25 | 2016-12-20 | The Glad Products Company | Incrementally stretched films with enchanced properties and methods for making the same |
US20130320019A1 (en) * | 2012-05-22 | 2013-12-05 | LaserSharp FlexPak Services, LLC | Process to manufacture Peel-Reclose packaging film using laser scoring and pressure sensitive labels |
US10155614B2 (en) | 2012-05-22 | 2018-12-18 | LaserSharp FlexPak Services, LLC | Peel reclose package with laser features |
US9422080B2 (en) * | 2012-05-22 | 2016-08-23 | LaserSharp FlexPak Services, LLC | Process to manufacture peel-reclose packaging film using laser scoring and pressure sensitive labels |
US10138054B2 (en) * | 2015-03-17 | 2018-11-27 | Poly-America, L.P. | Polymeric bags |
US20190062045A1 (en) * | 2015-03-17 | 2019-02-28 | Poly-America, L.P. | Polymeric bags |
US20160272417A1 (en) * | 2015-03-17 | 2016-09-22 | Poly-America, L.P. | Polymeric bags |
US10611563B2 (en) * | 2015-03-17 | 2020-04-07 | Poly-America, L.P. | Polymeric bags |
US10947014B2 (en) * | 2015-10-09 | 2021-03-16 | Foresight Usa, Inc. | Bags with marks and systems of making same |
US20220135285A1 (en) * | 2019-01-29 | 2022-05-05 | The Glad Products Company | Thermoplastic bags with phased deformation patterns |
US11958660B2 (en) * | 2019-01-29 | 2024-04-16 | The Glad Products Company | Thermoplastic bags with phased deformation patterns |
Also Published As
Publication number | Publication date |
---|---|
JP2007521930A (en) | 2007-08-09 |
NZ548717A (en) | 2010-06-25 |
CN1918000A (en) | 2007-02-21 |
KR20060109993A (en) | 2006-10-23 |
EP1758731A2 (en) | 2007-03-07 |
KR100754545B1 (en) | 2007-09-04 |
JP2011068131A (en) | 2011-04-07 |
CA2556534A1 (en) | 2005-09-01 |
CA2556534C (en) | 2010-09-21 |
AU2005215773B2 (en) | 2008-04-10 |
AU2005215773A1 (en) | 2005-09-01 |
WO2005080071A3 (en) | 2005-12-01 |
ZA200606425B (en) | 2008-01-30 |
WO2005080071A2 (en) | 2005-09-01 |
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Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION |