US20140061191A1

US20140061191A1 - Web material for packaging

Info

Publication number: US20140061191A1
Application number: US13/598,423
Authority: US
Inventors: Christopher Ploessl
Original assignee: Exopack LLC
Current assignee: Coveris Flexibles US LLC
Priority date: 2012-08-29
Filing date: 2012-08-29
Publication date: 2014-03-06

Abstract

A web material for forming packaging may include front and back panels in addition to side panels or gussets that are used to form a single bag or packaging structure. The panels may be arranged on a web material in an efficient manner by accurately determining the dimensions of each of the panels.

Description

BACKGROUND

The present disclosure relates to web material for packaging.

BRIEF DESCRIPTION OF THE DRAWINGS

The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:

FIG. 1 is a perspective view of an embodiment of web material that is being unwound from a roll in a machine direction.

FIG. 2 is a plan view of a segment of another embodiment of web material.

FIG. 3 is a plan view of a segment of yet another embodiment of web material.

FIG. 4 is a plan view of a segment of a further embodiment of web material.

FIG. 5 is a plan view of a segment of a further embodiment of web material.

FIG. 6 is a perspective view of an embodiment of a bag formed from an embodiment of web material such as, for example, that shown in FIG. 1.

DETAILED DESCRIPTION

Certain embodiments disclosed herein relate to web material that may be used in forming bags and other packaging structures. The web material may be supplied in rolls and is often introduced and fed through various machines and systems during the manufacturing and processing of bags and other packaging structures. In some instances, for example, the webs may be introduced to systems that may print color and/or indicia onto a surface of the material and/or may provide the material with other or further desired characteristics. The web material may also be introduced into systems that may laminate or add additional layers of material onto the web. Additional features and/or characteristics may also be added to the web material through various processes including, for example, score line formation to provide the material with controlled tearing, addition of zipper closures, etc.
Web materials can be used for mass-producing bags or other packaging structures. Accordingly, in some instances, web material may include repeated segments. Each segment may comprise one or more components that may be used to form one or more bags or packaging structures. These components may include, for example, one or more front panels, one or more back panels, and two or more side panels or gussets. The repeated segments may be positioned adjacent to one another along the machine direction of the web.
In many instances, multiple rolls of web material are used to manufacture and process the various components of a bag or packaging structure. For example, a first web may be used to print or process the front and back panels while a second web may be used to print or process the side panels or gussets. The panels disposed on the separate webs may then be cut out or otherwise removed from the webs, and the individual panels may be adhered or otherwise joined together to form an individual bag or other packaging structure.
The present disclosure is directed to web materials from which all web-material components used in the formation of individual bag or packaging structures are obtained. For example, in some embodiments, each segment of a web may be configured to form one or more bags or packages. In certain of such embodiments, a single web material may include front and back panels as well as side panels or gussets, all of which can be used to form a single bag or packaging structure, two bags or packaging structures, or any other suitable number of bags or packaging structures. In some embodiments, a single segment is configured to be cut in such a manner as to form the various components (e.g., panels, gussets, etc.) of one or more bags without any waste, such that the segment is entirely reconfigured for inclusion as various components of the bag. In other embodiments, a single segment may provide for significantly reduced or minimal waste, with most of the material from cut portions being formed into one or more bags or packages, and with only minimal portions of material that are cut being discarded or recycled.
Using a single web material that includes each of the web-material components, such as individual panels, that are used to form a bag or packaging structure can have one or more advantages. For example, it can be easier to maintain consistent colors and/or indicia when printing on a single web, as compared with printing on multiple webs. In other or further instances, manufacturing and production costs may be reduced when using a single web material due to, for example, lower printing set-up costs and/or fewer waste scraps. Laminating costs and other processing costs may also be reduced when working with a single web material.
Some embodiments comprise individual web materials in which individual panels (e.g., front panels, back panels, and side panels or gussets) are efficiently arranged in patterns thereby eliminating or reducing the amount of material that is trimmed and wasted during the manufacturing and processing of bags and other packaging structures.
In some embodiments, a single web material may be divided into two webs following printing, laminating, or other processing steps. For example, the portion of the web material comprising the front and back panels may be divided from the portion of the web material comprising the side panels or gussets. The two separate web materials may then be used for further fabrication and production of the bags or packaging structures.
Various types of bags or packaging structures may be formed in accordance with the present disclosure. In some embodiments, a single web may comprise the panels used to form flat bottom bags or packages. In other embodiments, a single web may comprise the panels used to form fold over bottom bags or packages. In yet other or further embodiments, a single web may comprise the panels used to form sealed bags or packages. As can be appreciated from the present disclosure, additional types of bags or packaging structures may also be formed in accordance with the present disclosure.
Embodiments may be best understood by reference to the drawings. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments is not intended to limit the scope of the disclosure, but is merely representative of possible embodiments of the disclosure. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated. In some cases, well-known structures, materials, or operations are not shown or described in detail.
FIG. 1 depicts an illustrative roll 102 of web material 100 according to an embodiment of the present disclosure. In the illustrated embodiment, the web material 100 is shown being unwound from the roll 102 in a machine direction MD₁. In similar fashion, the web material 100 may be fed into various machines and systems for any suitable manufacturing and/or processing steps. The web material 100 may comprise repeated segments 105 disposed adjacent one another along the longitudinal, or machine direction MD₁, of the web 100. Each repeated segment 105 may comprise one or more components (e.g., 110, 120, 130) that may be used to form one or more bags or packaging structures; in some embodiments, the one or more components in a given segment 105 are used in the formation of a single bag or packaging structure. For example, each segment 105 may comprise one or more front panels 110, one or more back panels 120, and two or more side panels or gussets 130. The individual panels (e.g., 110, 120 and 130) disposed within a segment 105 may then be cut or trimmed during processing and at least one front panel 110, at least one back panel 120, and at least two side panels or gussets 130 may be joined or otherwise adhered to form a bag or packaging structure.
As discussed above, in some embodiments, the web 100 may be divided into two web materials during the manufacturing processes. Accordingly, as shown in FIG. 1, the components may be disposed on a segment 105 such that the one or more front panels 110 and one or more back panels 120 are disposed on a first section of the segment 105, while the two or more side panels or gussets 130 are disposed on a second section of the segment 105. The web 100 may therefore be cut along line 104 to divide the web 100 into two separate web materials, one of which comprises the front panels 110 and back panels 120 and the other of which comprises the side panels or gussets 130. In some embodiments, the two separate web materials may be further processed and/or subjected to various manufacturing processes. In some embodiments, the two web materials may be fed into machines that may cut out or otherwise remove the individual components from the web materials and the individual components 110, 120, and 130 may be adhered or otherwise joined together to form an individual bag or other packaging structure.
The web material 100 may be of any suitable variety. For example, in various embodiments, the web material 100 comprises one or more polymers or copolymers of one or more polyolefins, such as polyethylene, polyethylene terephthalate, polypropylene, ethylene vinyl acetate; one or more polymers or copolymers of one or more polyamides such as nylon; cellophane; paper materials; and/or combinations, blends, laminations, or other suitable arrangements thereof. In some embodiments, the web material 100 may comprise polyethylene and polyethylene terephthalate blends. In other embodiments, the web material 100 may comprise nylon and polyethylene blends. Any other suitable materials (e.g., materials known in the art and packaging industry) also may be used in accordance with the present disclosure.
Embodiments of the web material 100 may vary in thickness. For example, in various embodiments, the web material 100 may have a thickness of from about 1 mil to about 8 mils, from about 2.5 mils to about 5.5 mils, or from about 3 mils to about 5 mils. Other suitable thicknesses are also contemplated.
FIG. 2 depicts a single segment 205 of another embodiment of web material 200 that has multiple segments 205 situated adjacent to each other in a manner such as that depicted in FIG. 1 with respect to the segments 105. The web material 200 and the segment 205 can resemble the web material 100 and segments 105 discussed above with respect to FIG. 1. It will be appreciated that all the illustrated embodiments may have analogous features. Accordingly, like features are designated with like reference numerals, with the leading digits incremented to “2.” (For instance, the segment is designated 105 in FIG. 1, and an analogous segment is designated as “205” in FIG. 2.) Relevant disclosure set forth above regarding similarly identified features thus may not be repeated hereafter. Moreover, specific features of the segment and related components shown in FIG. 2 may not be shown or identified by a reference numeral or specifically discussed in the written description that follows. However, such features may clearly be the same, or substantially the same, as features depicted in other embodiments and/or described with respect to such embodiments. Accordingly, the relevant descriptions of such features apply equally to the features of the segment of FIG. 2. Any suitable combination of the features, and variations of the same, described with respect to the segment 105 and components illustrated in FIG. 1, can be employed with the segment 205 and components of FIG. 2, and vice versa. This pattern of disclosure applies equally to further embodiments depicted in subsequent figures and described hereafter.
As shown in FIG. 2, the segment 205 may comprise material that may be used to form one or more bags or packaging structures. For example, a segment 205 may comprise one or more front panels 210, one or more back panels 220, and two or more side panels 230. In the illustrated embodiment of FIG. 2, the segment 205 comprises two front panels 210, two back panels 220, and four side panels 230. Accordingly, the segment 205 depicted in FIG. 2 comprises components that may be used to manufacture two bags or packaging structures. Additional segments 205 comprising the same pattern of front panels 210, back panels 220, and side panels or gussets 230 may be disposed adjacent one another and repeated along the machine direction MD₂of the web 200.
Each panel (e.g., 210, 220 and 230) comprises at least four edges. For example, each front panel 210 comprises at least two side edges 212, a top edge 218, and a bottom edge 216. Similarly, each back panel 220 comprises at least two side edges 222, a top edge 228, and a bottom edge 226; and each side panel or gusset 230 comprises at least two side edges 232, a top edge 238, and a bottom edge 236.
The panels 210, 220, and 230 that are within the segment 205 may be arranged in efficient patterns to aid in minimizing or eliminating waste when cutting and trimming the individual panels 210, 220, and 230 during the manufacturing process. For example, in the illustrated embodiment of FIG. 2, the front panels 210 are disposed lengthwise along the transverse or cross direction CD₂of the segment 205. Similarly, the back panels 220 are disposed lengthwise along the transverse or cross direction CD₂of the segment 205. On the other hand, the side panels or gussets 230 are disposed lengthwise along the machine direction MD₂of the segment 205. Accordingly, the side edges 212, 222 of the front panels 210 and back panels 220 are oriented perpendicular to the side edges 232 of the side panels or gussets 230.
As further illustrated in the embodiment of FIG. 2, the two front panels 210 are disposed adjacent one another along the machine direction MD₂of the segment 205. More specifically, the two front panels 210 are disposed such that a side edge 212 of one front panel 210 is adjacent to and/or abuts a side edge 212 of an adjacent front panel 210. This pattern may then be repeated in each segment 205 along the machine direction MD₂of the web material 200.
The two back panels 220 also may be disposed in similar fashion. The two back panels 220 are disposed adjacent one another along the machine direction MD₂of the segment 210. Accordingly, the two back panels 220 are disposed such that a side edge 222 of one back panel 220 is adjacent to and/or abuts a side edge 222 of an adjacent back panel 220. This pattern may then be repeated in each segment 205 along the machine direction MD₂of the web material 200.
As further shown in FIG. 2, the one or more front panels 210 may be disposed adjacent to the two back panels 220 along the transverse or cross direction CD₂of the segment 205. More specifically, the top edges 218 of the front panels 210 may be disposed such that they are adjacent to and/or abut the top edges 228 of the back panels 220. Accordingly, the front panels 210 and back panels 220 may be disposed such that they are in an opposite orientation with respect to one another. In other embodiments, the front panels 210 and the back panels 220 within a segment 205 may be disposed such that they are not in an opposite orientation. Rather, the top edges 218 of the front panels 210 may be disposed such that they are adjacent to and/or abut the bottom edges 226 of the back panels 220. In other embodiments, the bottom edges 216 of the front panels 210 may be disposed such that they are adjacent to and/or abut the bottom edges 226 of the back panels 220. In yet other embodiments, the bottom edges 216 of the front panels 210 may be disposed such that they are adjacent to and/or abut the top edges 228 of the back panels 220. Accordingly, as can be appreciated, the front panels 210 and back panels 220 may be disposed on the segment 205 in a variety of ways.
In some embodiments, such as the illustrated embodiment, the front panels 210 may optionally comprise flaps 240. The flaps 240 may be disposed adjacent to the front panels 210 along the transverse or cross direction CD₂of the segment 205. In some embodiments, the flaps 240 may be disposed adjacent the bottom edge 216 of the front panels 210. In other embodiments, the flaps 240 may be disposed adjacent the back panels 220. For example, the flaps 240 may be disposed adjacent to the bottom edge 226 of the back panels 220.
In some embodiments, the flaps 240 may be integral with either the front panels 210 or back panels 220. For example, in the illustrated embodiment of FIG. 2, the flaps 240 are integral with the front panels 210. In such instances, the flaps 240 may be formed by folding the front panels 210 along a fold line 242. The fold line 242 may be physically marked on the web material 200, or it may be imaginary, such as shown in FIG. 2. In some embodiments, the flaps 240 may be used to form the bottom or base of a bag or packaging structure. In other embodiments, the flaps 240 may be used to close the bottom of a fold-over bottom bag or packaging structure.
The side panels 230 may be disposed adjacent one another along the transverse or cross direction CD₂of the segment 205. In the illustrated embodiment, four side panels or gussets 230 are disposed adjacent to one another along the transverse or cross direction CD₂of the segment 205, such that a side edge 232 of one side panel or gusset 230 is adjacent to and/or abuts a side edge 232 of an adjacent side panel or gusset 230.
In the illustrated embodiment, the four side panels or gussets 230 are disposed adjacent to the two back panels 220 along the transverse or cross direction CD₂of the segment 205. Accordingly, a side edge 232 of one of the side panels 230 is disposed adjacent to and/or abuts the bottom edges 226 of the back panels 220. Alternatively, in other embodiments the side edge 232 of one of the side panels 230 may be disposed adjacent to and/or abut the top edges 228 of the back panels 220.
In yet other embodiments, the side panels or gussets 230 may be disposed adjacent the front panels 210 along the transverse or cross direction CD₂of the segment 205. In such instances, a side edge 232 of one of the side panels 230 may be disposed adjacent to and/or abut the bottom edges 216 of the front panels 210. In yet other embodiments, a side edge 232 of one of the side panels 230 may be disposed adjacent to and/or abut the top edges 218 of the front panels 210. In other embodiments, the side panels or gussets 230 may be disposed adjacent the flaps 240.
As shown in FIG. 2, the front panels 210 and back panels 220 may be disposed on one section of the segment 205 while the side panels or gussets 230 are disposed on a second section of the segment 205 such that the web 200 may be easily cut and/or otherwise divided along line 204. Accordingly, the web 200 may be manufactured and processed using a variety of techniques, including techniques were two webs of material, a first web comprising the front panels 210 and back panels 220 and a second web comprising the side panels or gussets 230, are utilized. For example, in some embodiments, after printing, laminating or performing other processing steps, the web 200 may be divided into two separate webs for further manufacturing or processing procedures. In some embodiments, the two separate webs are fed into machines that cut components 210 and 220 out from the first web and components 230 out from the second web. The components 210, 220 and 230 may thereafter be adhered or otherwise joined together to form a bag or packaging structure.
In the illustrated embodiment, the edges of the panels 210, 220, 230 are shown spaced from each other, such that portions of web material 200 are positioned between the panels. When the panels 210, 220, 230 are removed from the web material 200, such as, for example, by cutting, the remnant portions can be discarded or recycled. In other embodiments, adjacent edges of the panels 210, 220, and adjacent edges of the panels 220 with a panel 230 may overlap, abut, be collinear, or otherwise coincide with one another such that a single cut line can separate a panel 210, 220 or 220, 230 from its adjacent panel. Stated otherwise, the various components (e.g., panels) that are to be removed from the segment 205 may be contiguous to one another. Such an arrangement may reduce material waste during a manufacturing process. Such an arrangement may also complicate the manufacturing process, in some instances, due to alignment of the boundaries of printed regions on the web material 200 with the cutting mechanism that is providing the unitary lines of cutting (e.g., blades, lasers, etc.).
As can be appreciated, arranging the panels 210, 220, and 230 disposed on the segment 205 in an efficient manner may further comprise accurately determining the dimensions of each of the panels 210, 220, and 230. For example, efficiently arranging the panels 210, 220, and 230 on a single web material 200 may benefit from having the length of the side panels or gussets 230 directly relate to the widths of the front panels 210 and back panels 220. Accordingly, the dimensions of each of the panels 210, 220, and 230 and the corresponding bag may be formed according to embodiments disclosed herein.
For example, in some embodiments, the height of bag made according to the present disclosure may be defined by the following equation:
H=N×W+D Equation (I)
where “H” represents the desired height of the bag, “N” represents the total number of bags or packaging structures that may be formed from the individual panels (e.g., 210, 220 and 230) disposed within one segment 205 of the web 200, “W” represents the desired width of the bag, and “D” represents the distance from the top of the bag to the start of side panels or gussets 230. In the embodiment shown in FIG. 2, “H” corresponds to the height of the front panels 210 measured from the top edges 218 to the bottom edges 216. Similarly, H also corresponds to the height of the back panels 220 measured from the top edges 228 to the bottom edges 226.
As noted above, the “N” in Equation (I) represents the total number of bags or packaging structures that may be formed from the individual panels (e.g., 210, 220 and 230) disposed within one segment 205 of the web 200. For example, the segment 205 depicted in FIG. 2 comprises two front panels 210, two back panels 220, and four side panels or gussets 230. Accordingly, two bags or packaging structures comprising one front panel 210, one back panel 220, and two side panels or gussets 230 may be formed from the individual panels (e.g., 210, 220, and 230) disposed within the segment 205, and therefore N is equal to 2. In some embodiments, N may be used to define the print repeat. Accordingly, N may be used to characterize the number around the print cylinder. In some embodiments, N may be between 1 and 3. In some embodiments, N is equal to 1. In other embodiments, N is equal to 2. In other embodiments, N is equal to 3. As can be appreciated, N can further be equal to 4 or greater depending on the size of the print cylinder, the desired size of the bags or packaging structures, and the size of the web materials 200.
As noted above, the “W” in Equation (I) represents the desired width of the bag. As shown in FIG. 2, W corresponds to the width of the front panels 210 measured between the two side edges 212. Similarly, W also corresponds to the width of the back panels 220 measured between the two side edges 222.
As noted above, the “D” in Equation (I) represents the distance from the top of the bag to the start of side panels or gussets 230. In some embodiments, this is the difference between the height of the front panels 210 (or back panels 220) and the height of the side panels or gussets 230. In some embodiments, D may be between about 0.2 inches and about 2.5 inches. In other embodiments, D may be between about 0.4 inches and about 2 inches. In some embodiments, D may be equal to about 0.4 inches. In other embodiments, D may be equal to about 1.75 inches. Accordingly, the length of D may vary depending on the desired characteristics of the bag. For example, bags that include a zipper closure may have a D that is relatively longer as compared to bags that do not include a zipper closure.
The length of each repeated segment 205 also relates to the size of the panels (e.g., 210, 220, and 230) that may be disposed within each individual segment 205. Accordingly, in some embodiments, the length of each repeated segment 205 may be characterized by the following equation:
L=N×W Equation (II)
The “L” in Equation (II) represents the length of each segment 205 along the machine direction MD₂of the web 200. The length of the segment 205 further defines the print repeat as adjacent segments 205 are repeated along the machine direction MD₂of the web 200. The “N” and “W” in Equation (II) are the same variables N and W described above with respect to Equation (I).
In some embodiments, it may be desirous to determine the volume of the bag that will be formed by adhering or otherwise joining the individual panels (e.g., 210, 220, and 230) that are disposed on each segment 205. Accordingly, in some embodiments, the volume of the bag to be formed may be characterized by equation (III):
V=H×W×GW Equation (III)
The “V” in Equation (III) represents the volume of the bag to be formed by adhering or otherwise joining the individual panels (e.g., 210, 220, and 230) disposed on each segment 205. The “H” and “W” in Equation (III) are the same H and W variables described above with respect to Equation (I). The “GW” in Equation (III) represents the width of the side panels of gussets 230.
Illustrative panel dimensions calculated using the above mentioned equations are set forth below in Table 1.

TABLE 1

Exemplary Panel Dimensions

		No.			Gusset	Segment
		of Bags	Height	Width	Width	Length
Example	“D”	(“N”)	(“H”)	(“W”)	(“GW”)	(“L”)
No.	(inches)	(inches)	(inches)	(inches)	(inches)	(inches)

1	1.75	2	17.75	8	3	16.0
2	1.75	2	16.75	7.5	3	15.0
3	1.75	2	15.75	7	3	14.0
4	1.75	2	14.75	6.5	3	13.0

FIG. 3 shows another embodiment of a web material 300 that includes another embodiment of a segment 305. As shown in FIG. 3, the segment 305 may comprise the panels (e.g., 310, 320, and 330) necessary to form three bags or packaging structures. In particular, in some embodiments, the segment 305 may comprise three front panels 310, three back panels 320, and six side panels or gussets 330. Accordingly, N is equal to 3 when applying Equations (I) and (II) to the illustrated embodiment of FIG. 3.
As further shown in FIG. 3, in some embodiments, the front panels 310 may optionally include a closure zipper such as a push-to-close zipper 360. The embodiment of FIG. 3 further includes illustrative indicia 350 that may be printed on one or more sides of the segment 305. The indicia 350 may be oriented in a variety of ways. In the illustrated embodiment, for example, the indicia 350 is printed such that the orientation of the indicia 350 on the front panels 310 and back panels 320 are directed oppositely relative to each other within the segment 305. As such, the top edges 318 of the front panels 310 and the top edges 328 of the back panels 320 are disposed adjacent to one another. In other embodiments, the indicia 350 may be printed such that the orientation of the indicia 350 on the front panels 310 and back panels 320 are not opposite one another while disposed on the segment 305 (e.g., the indicia may be oriented in the same direction for the front and back panels). As can be appreciated, in other embodiments, the indicia 350 may be printed on the front panels 310 and back panels 320 in any desired direction and orientation.
As further shown in FIG. 3, the indicia 350 on the side panels or gussets 330 is printed such that it is upside down relative to the direction the segment 305 is traveling (i.e., being unwound) along the machine direction MD₃of the web 300. Accordingly, the bottom edges 336 of the side panels or gussets 330 are downstream relative to the top edges 338 of the side panels or gussets 330 from the roll from which the web material 300 is being unwound. In other embodiments, the indicia 350 on the side panels or gussets 330 may be printed such that is not upside down relative to the direction the segment 305 is traveling (i.e., being unwound) along the machine direction MD₃of the web 300. As can be appreciated, in other embodiments, the indicia 350 may be printed on the side panels or gussets 330 in any desired direction and orientation.
As further shown in FIG. 3, the segment 305 may be devoid of flaps, such as the flaps 240 discussed above with respect to FIG. 2. In some embodiments, bags or pouches formed from components of the segment 305 may not have a flat bottom, such as may otherwise be accomplished via certain embodiments of such flaps. For example, in some embodiments, the front and back panels 310, 320 may be heat sealed to one another about their peripheral edges to form a pouch that does not have a flat bottom.
The web 300 may further be cut or otherwise divided along line 304 to form two webs, a first web comprising the front panels 310 and back panels 320 and a second web comprising the side panels or gussets 230.
FIG. 4 shows a segment 405 of a web material 400 according to another embodiment of the present disclosure. As shown in FIG. 4, the segment 405 may comprise one front panel 410, one back panel 420, and two side panels or gussets 430. Accordingly, N is equal to 1 when applying Equations (I) and (II) to the illustrated embodiment of FIG. 4.
As further shown in FIG. 4, in some embodiments, the front panel 410 may include one or more laser scores 465. In some embodiments, the laser scores 465 may be continuous across the face of the front panel 410. In other embodiments, the laser scores 465 may be discontinuous (or dashed) across the face of the front panels 410. In some embodiments, the back panel 420 may also optionally comprise one or more laser scores 465 that may be continuous or discontinuous. Laser scores may provide the bag or packaging structure with easy opening and/or controlled tear characteristics.
FIG. 5 shows a segment 505 of a web material 500 according to another embodiment of the present disclosure. As shown in FIG. 5, the segment 505 may comprise front panels 510, back panels 520, and side panels or gussets 530. As further shown in FIG. 5, in some embodiments, the segment 505 may comprise additional material 570 that may be used to create the bottom of a bag or packaging structure. The additional material 570 may be disposed adjacent the front panels 510 as illustrated in FIG. 5. In some embodiments, this additional material 570 may be integral with the front panels 510. In other embodiments, the additional material 570 may be disposed between the front panels 510 and back panels 520. In yet other embodiments, the additional material 570 may be disposed adjacent the bottom panels 520. In some embodiments, the additional material 570 may be integral with the bottom panels 520.
FIG. 6 shows an illustrative bag 680 made according to an embodiment of the present disclosure. As can be appreciated, the dimensions of the bag 680 of FIG. 6 may be calculated according to the Equations (I)-(III) set forth above. Additionally, as shown in FIG. 6, the bag 680 may comprise a front panel 610, a back panel 620, and two side panels or gussets 630. As further shown in FIG. 6, in some embodiments, the bag 680 may optionally comprise a push-to-close zipper 660 disposed on the face of the front panel 610. Alternatively, the bag 680 need not comprise a push to close zipper 660. Additionally, the bag 680 may optionally include indicia 650 as desired.
As further shown in FIG. 6, the bottom of the bag 680 may be composed of additional material 670. In some embodiments, this additional material may be integral with the front panel 610 or the back panel 620. In other embodiments, however, the front panel 610 and back panel 620 may be folded over using a flap. In other embodiments, the bag 680 may not comprise a bottom portion and the front panel 610 and back panel 620 may be sealed or otherwise adhered or joined together.
A web material, and corresponding segment thereof, from which the bag 680 is formed may be similar to the webs and segments discussed above with respect to FIGS. 1-5. Any suitable arrangements of the various features and components of those figures may be combined, as appropriate, to arrive at the bag 680, which includes a push-to-close zipper 660 and a bottom formed via a piece of additional material 670.
The present disclosure also relates to methods of manufacturing bags using a single web material. At an initial stage, a single roll of web material may be obtained. A print pattern for the web material may be configured such that the print pattern is repeated along a longitudinal direction of the web material. In some embodiments, the print pattern may comprise one or more front panels, one or more back panels, and two or more side panels. The one or more front panels may be disposed lengthwise along a transverse direction of the web material, the one or more back panels may be disposed lengthwise along the transverse direction of the web material, and the two or more side panels may be disposed lengthwise along the longitudinal direction of the web material.
The print pattern further may be configured such that a top edge of one or more front panels is disposed adjacent to a top edge of one or more back panels. In some embodiments, the two or more side panels may be disposed adjacent one another along the transverse direction of the web material such that a first side edge of a first side panel is disposed adjacent to a first side edge the second side panel and a second side edge of the first side panel may be disposed adjacent to a bottom edge of one or more back panels along the transverse direction of the web material. The side panels or gussets may also be oriented such that they are upside down relative to the unwinding direction of the web material.
Color and/or indicia may be printed on the web material. The web material may further be laminated and/or subjected to additional processing and manufacturing steps. In some embodiments, the web material may be divided into to a first web material and a second web material. In some embodiments, the first web material may comprise one or more front panels and one or more back panels, and the second web material may comprise two or more side panels. The individual panels may then be cut out of the first and second web materials. For example, at least one front panel and at least one back panel may be cut from the first web material, and at least two side panels may be cut from the second web material. The individual panels may thereafter be adhered or otherwise joined together to form a bag or packaging structure.
Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. The scope of the invention is therefore defined by the following claims.

Claims

What is claimed is:

1. A web material for use in forming one or more bags, comprising:

a plurality of repeated segments disposed along a longitudinal direction of a web material, each segment comprising:

a front panel disposed lengthwise along a transverse direction of the web material, the front panel comprising a top edge, a bottom edge, and two side edges;

a back panel disposed lengthwise along the transverse direction of the web material, the back panel comprising a top edge, a bottom edge, and two side edges; and

a first side panel and a second side panel disposed lengthwise along the longitudinal direction of the web material, each side panel comprising a top edge, a bottom edge, and two side edges, wherein a side edge of the first side panel is disposed such that it is adjacent to the bottom edge of the back panel.

2. The web material of claim 1, wherein the top edge of the front panel is disposed adjacent to the top edge of the back panel.

3. The web material of claim 2, wherein the first and second side panels are disposed adjacent to one another along the transverse direction of the web material such that a side edge of the first side panel is disposed adjacent to a side edge of the second side panel.

4. The web material of claim 1, wherein each repeated segment comprises material to form a single bag.

5. The web material of claim 1, wherein each repeated segment comprises material to form at least two front panels, at least two back panels, and at least four side panels.

6. The web material of claim 1, wherein each repeated segment comprises material to form at least three front panels, at least three back panels, and at least six side panels.

7. The web material of claim 1, wherein each repeated segment further comprises a flap.

8. The web material of claim 7, wherein the flap is disposed adjacent to the bottom edge of the front panel along the transverse direction of the web material.

9. The web material of claim 8, wherein the flap is integral with the bottom edge of the front panel.

10. The web material of claim 1, wherein each repeated segment further comprises additional material that may be used to form the bottom of a bag, wherein the additional material is disposed adjacent to the front panel.

11. The web material of claim 1, wherein the length of each repeated segment is approximately the same as the length of the side panels.

12. The web material of claim 1, wherein the width of the front panel and the back panel is approximately half of the length of the side panels.

13. The web material of claim 1, further comprising one or more laser score lines on the front panel.

14. The web material of claim 13, further comprising one or more laser score lines on the back panel.

15. The web material of claim 1, further comprising one or more zipper closures on the front panel.

16. The web material of claim 1, further comprising indicia printed on the front panel.

17. The web material of claim 16, further comprising indicia printed on the back panel and the first and second side panels.

18. A segment disposed on a single web material, wherein the segment comprises:

material to form a front panel, a back panel, a first side panel and a second side panel, wherein the panels are arranged in a pattern, the pattern comprising:

the front panel being disposed lengthwise along a transverse direction of a web material, the back panel being disposed lengthwise along the transverse direction of the web material, and the first and second side panels being disposed lengthwise along a longitudinal direction of the web material, wherein a side edge of the first side panel is disposed adjacent to the bottom edge of the back panel.

19. The segment of claim 18, wherein the segment is disposed adjacent to an additional segment along a longitudinal length of the web material, and wherein the additional segment comprises a pattern of panels that is identical to the pattern in claim 18.

20. The segment of claim 18, wherein the segment further comprises material to form a flap.

21. The segment of claim 20, wherein the flap is disposed adjacent to the bottom edge of the front panel along the transverse direction of the web material.