Abstract:
A bag includes a main body formed from a first sheet of material foldable to form front and rear panels, a pair of side panels, a bottom panel, and an interior space of the bag defined by the front, rear, side and bottom panels. The sheet of material includes a reinforcement section and at least one layering section for creating a two material design. The bag may also include a pair of handles formed from second and third sheets of material wherein engagement sections of the handles are fixedly attached to the reinforcement section of the bag. Stitching may be used to increase the strength and look of the bag.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a bag apparatus and method of making the same, and, in particular, to a new bag and handle design for enabling a bag made using a paper or paper-like product to handle greater weight. 
         [0003]    2. Description of the Related Art 
         [0004]    Paper-based or paper-like bag products are known in the art. For instance, there are several types of store bags that are provided by a merchant to help a customer carry purchased merchandise. One famous example is the “Brown Bag” provided by Bloomingdale&#39;s outlets. Another example is the gift bags that one might get at a Hallmark store or Bed Bath &amp; Beyond and similar stores. 
         [0005]    In all of these bags, which are either paper-based or use a paper-like product, one of the weakest parts of the bag is where the handle is attached to the frame of the bag. Depending on the particular structure used by the manufacturer of the bag, if too much weight is applied or if the bag is held at an awkward angle, either the bag itself may tear or the handle may become disengaged from the bag frame. Other manufacturers have attempted to provide bags that utilize stronger materials such as cloth-based products, nylons, or other synthetics. However, these designs often greatly increase the cost of the bag, which must be kept low so that it makes economic sense for the manufacturer to sell them cheaply or provide them to customers for free. 
         [0006]    Nylon or cloth-based duffle bags are also known in the art. However, these bags do not suffer from the problems associated with paper-based or paper-like bags in that the materials ensure a relatively strong bag. However, these bags are far more expensive than bags that use paper-based or paper-like materials and thus are not suitable for the purpose of providing gifts or being provided by a merchant after a purchase. 
         [0007]    Thus, in light of the foregoing, there is a need for a new paper-based or paper-like bag or bag and method for making such bag in an economical manner that provides a cost-effective bag that is strong enough to reduce the risk of tearing when carrying relatively heavy articles. 
       SUMMARY OF THE INVENTION 
       [0008]    In view of the above discussion, the shortcomings in known bags are overcome, at least in part, by a bag that comprises a frame constructed from a paper-based or paper-like product, at least one handle constructed from a paper-based or paper-like product and including an engagement portion having a first support component and a second support component wherein each of the first support component and a second support component is stitched to a portion of the frame. Further, a frame support may be included generally at the location of the portion of the frame where the engagement portion of the handle is stitched. 
         [0009]    As used herein, the terms “paper-based” and “paper-like” refer to a material that includes paper, synthetic papers, plastics, and other materials that generally have the physical properties of natural paper. 
         [0010]    As an additional feature of the invention, the frame of the bag may be constructed from a single sheet of material and folded so as to hide the point of engagement between the frame and the handle on the inside of the frame. Moreover, the bag may be additionally folded so as to give the bag the appearance that it is constructed from more than one material or sheet. Stitching may also be included to enhance this appearance. 
         [0011]    In an embodiment of the handle, the handle is constructed from a single sheet and folded over itself such that the engagement portion of the handle is substantially flat whereas the upper portion of the handle is pinched. This advantageously increases the strength of the handle mechanism. The folded portions of the handle may be stitched and/or glued in place. To further increase the strength of the handle, a second support component, such as a piece of fabric may be layered on the first sheet forming the handle and folded within the first sheet so as to hide its existence. Stitching and/or an adhesive may be added to hold both the first sheet and the second support component in place. 
         [0012]    Additional features and advantages of the system and methods of the invention are described further below. 
     
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0013]      FIG. 1  is a perspective view of a bag with a frame and handle formed in accordance with a preferred embodiment of the present invention; 
           [0014]      FIG. 2  is a perspective view of an alternate preferred embodiment of a bag with a frame and handle; 
           [0015]      FIG. 3  is an illustration of the material of an embodiment of a portion of the bag handle in an unfolded state showing the preferred fold line and stitching layout; 
           [0016]      FIG. 4  is an illustration of the material of an embodiment of a portion of the bag handle in an unfolded state showing the preferred fold line and stitching layout and further showing the inclusion of a support insert; 
           [0017]      FIG. 5  is a perspective view of an alternate preferred embodiment of a bag with a frame and handle wherein the frame is folded to give the appearance of at least two components; 
           [0018]      FIG. 6  is schematic of the material of an embodiment of a portion of the bag frame in an unfolded state showing the preferred fold line and stitching layout; 
           [0019]      FIG. 7  is an enlarged schematic of the bag being folded to form a faux multi-material look in accordance with an embodiment of the invention; and 
           [0020]      FIGS. 8   a - 8   h  each show an example of a bag design and constructed in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0021]    With reference now to  FIGS. 1-6  there will be shown and described several embodiments of an improved bag and handle assemble, and method of making the same. The improved bag and handle assembly advantageously provides increased strength to the bag and further enables the bag to be constructed such that it appears that the bag is made from multiple materials or parts. 
         [0022]    With reference to  FIG. 1 , a perspective view of a first preferred embodiment of a bag and handle assembly  10  is shown. The assembly preferably includes a frame  15  having a front and rear panels  20 ,  22 , two side panels  24 ,  26 , and a bottom panel  28 . As will be discussed further in connection with  FIG. 6 , the frame  15  is preferably, but not necessarily, formed from a single sheet that is folded so as to form the front and rear panels  20 ,  22 , two side panels  24 ,  26 , and a bottom panel  28 . Interior space  17  and open end  19  are created by formation of the front and rear panels  20 ,  22 , two side panels  24 ,  26 , and a bottom panel  28  of the frame  15 . 
         [0023]    With further reference to  FIG. 1 , handle assembly  30  is fixedly attached to bag frame  15  via stitching  36  (as shown) or an adhesive (not shown), or any combination thereof. Handle assembly  30  preferably includes a pinched or folded handle  32  in combination with generally flat engagement portions  34 . The construction of the handle assembly  30 , and in particular engagement portions  34  is described further in connection with  FIG. 3 . As can be seen from the arrangement of  FIG. 1 , the handle assembly  30  is generally U-shaped and constructed such that engagement portions  34  extend a substantial way down side panels  20 . For both design aesthetics and to increase the strength of the engagement of handle assembly  30  to frame  15 , stitching  36  extends down the length of engagement portions  34 . In an alternate embodiment, as shown in  FIG. 2 , engagement portions  34 ′ does not extend a substantial way down the bottom of front panel  20 . 
         [0024]    It should be understood that although the foregoing discussion has focused on a single handle assembly  30  engaged with front panel  20 , the bag assembly  10  preferably includes two such handle assemblies. The discussion with respect to one handle assembly applies equally to another such handle assembly engage with rear panel  22 . The same is true with respect to support member  40 , discussed below. 
         [0025]    As further shown in  FIG. 1 , support member  40  may optionally be included to increase the strength of the connection between frame  15  and the engagement portions  34  of handle assembly  30 . In a preferred embodiment, two support members  40  are positioned on the inside of front and rear panels at the location of engagement portions  34 , as shown in  FIG. 1 . Support member  40  need not, buy may, extend towards bottom panel  28 . 
         [0026]    Like the embodiment shown in  FIG. 1 , the bag assembly  10 ′ shown in  FIG. 2  includes a frame  15 ′ having front and rear panels  20 ′,  22 ′. A pair of handle assemblies  30 ′ with engagement portions  34 ′ are fixedly attached to front and rear panels  20 ′,  22 ′ via stitches  36 ′ in the manner described above. An adhesive (not shown) may be used in combination with the stitches  36 ′. 
         [0027]    With reference now to  FIGS. 3 and 3   a - d , the construction of the handle assembly  300  will be shown and described.  FIG. 3  depicts a laid open view of a portion of Handle assembly  300 . Handle assembly  300  generally includes a grip section  302 , which corresponds to folded handle  32  of  FIG. 1 , and a pair of engagement sections  350  (only of one of which is shown in  FIG. 3 ). The section between the grip section  302  and the engagement sections  350  is referred to as transition section  352 . Like frame  15 , the handle assembly  300  is preferably constructed of a paper-based or paper-like material. As shown in  FIG. 3 , handle assembly  300  has a number of fold lines F 1 , F 2 , F 3 , F 4 , and F 5  that permit the handle assembly  300  to be folded such that it creates a folded hand grip and a folded engagement section, which are each reinforced by the fact that the material is folded upon itself. Handle assembly  300  may also include flap section  354 , which would get folded over engagement section  350  via fold line F 6 . A preferred manner of folding the handle assembly  300  will be described further in connection with  FIGS. 3   a - 3   d.    
         [0028]    As further shown in  FIG. 3 , handle assembly  300  is stitched for both structural and design purposes. In the example shown, grip section  302 ′ contains a single stitch S 1  generally down the center of the folded grip section  302 ′. In the unfolded state,  FIG. 3  shows the holes made by the stitching as S 1   a , S 1   b , S 1   c , and S 1   d . Similarly, engagement section  350 ′ receives a generally square or rectangular stitch S 2  to reinforce the connection of the handle assembly  300  to frame  15  (as further shown in  FIGS. 1 and 2 ). In the unfolded state, this results in stitch holes S 2   a , S 2   b , S 2   c , S 2   d , S 2   e , S 2   f , and S 2   g.    
         [0029]    With reference now to  FIGS. 3   a - 3   d , there will be shown and described a method of folding the handle assembly  300  so as to create a reinforced handle for attaching to bag frame  15 . In  FIG. 3   a , a portion of grip section  302 ′ is shown. Grip section  302 ′ includes a pair of side flaps (a) and (b) and a pair of main flaps (c) and (d). As can be seen, side flaps (a) and (b) are folded inward and over main flaps (c) and (d). With reference to  FIG. 3   b , once side flaps (a′) and (b′) are folded completely over main flaps (c′) and (d′), main flaps (c′) and (d′) are folded over one another to create the folded grip section  302 ″, which can then be stitched. 
         [0030]    In  FIG. 3   c , there is shown a portion of engagement section  350 ′. Engagement section  350 ′ includes side flaps (e) and (f), main flap (g), and bottom flap (h). Side flaps (e) and (f) are preferably folded over on another and also over main flap (g), as shown in  FIG. 3   d . Further, optional bottom flap (h) is then folded over side flaps (e) and (f) and main flap (g). It will be understood that bottom flap (h) is not used when the engagement portion  350 ′ is intended to extend towards the bottom of bag frame  15  as shown in  FIG. 1 . 
         [0031]    As shown in  FIG. 4 , handle assembly  400  may further include support member  475  placed inside handle assembly  400 . Support member  475  may be constructed of any known material, but is preferably a thin and flexible material that has relatively strong elasticity. By way of example, a fabric or synthetic-based woven material can be both thin and flexible, while maintaining a high level of resistance to stretching. It is also preferred that support member  475  span both the grip section  402  and the engagement section  450 , although the support member  475  may be substantially the same length as the entirety of handle assembly  400 . In addition, it is preferred that support member  475  be wide enough so as to receive at least a portion of the stitching of handle assembly  400 . Support member  475  may also be fixed inside of handle assembly  400  through use of an adhesive. 
         [0032]    With reference now to  FIG. 5 , there is shown an alternate embodiment of the present invention in which bag  500  is constructed so as to appear to include two distinct materials. As shown in  FIG. 5 , bag  500  includes a frame  510  that appears to include two sections  515  and  520 . Sections  515  and  520  are separated by interface  525 , which may further include stitching  530  both to enhance the structural integrity of bag  500  and to further the design effect. Sections  515  and  520  may be colored so as to further the effect of making it appear that bag  500  is constructed of two different materials. 
         [0033]    Structurally, as shown in  FIG. 6 , bag  600  is constructed from a single sheet  605 —half of which is shown in  FIG. 6 . Sheet  605  is preferably cut such that includes a generally rectangular shaped main section  607  having a number of trapezoidal folded sections  609  at the bottom thereof. The length and width of the side of main section  607  will determine the final dimensions of the bag  600 . For example, the width of sections A and C determine the width of the side panel of the bag (see side panel  26  of  FIG. 1 ). Moreover, the width of section B determines the wide of the front and rear panels (see front and rear panels  20 ,  22  of  FIG. 1 ). In order to form the rectangular box shape of the finished bag  600 , the sheet  605  must be folded. A preferred embodiment of folding the bag is shown by fold lines F 1 -F 12  of  FIG. 6 . To form the bag  600 , sheet  605  is preferably first folded at fold line F 5  so that section  620  is folded over section  610  so as to hide support member  640 . The folding of section  620  over section  610  also advantageously increases the strength of the top of the bag and the portion of the bag to which engagement section  34  (see  FIG. 1 ) is attached. Next, sheet  605  is folded at fold lines F 6  and F 7  so as to form the interface  525  (see  FIG. 5 ), as shown in  FIG. 7 .  FIG. 7  is an exaggerated and enlarged view of the preferred folding arrangement of sheet  605 . In  FIG. 7 , it can be seen that the material (Z) of sheet  605  that lies between fold lines F 6  and F 7  overlaps a portion of support member  640 . Moreover, the folding of fold lines F 6  and F 7  causes an interface line (see interface  525  in  FIG. 5 ) to be formed between section  610  and section  615  on the outside of the bag. On the inside of the bag, section  620 , as discussed previously, is folded at fold line F 5  so as to overlap material (Z) as well as support member  640 . Including optional support member  640 , this creates a five-ply of material at the location where the engagement section of the handle assembly will be attached. Thus, in addition to making the look of the bag more desirable, the strength of the bag is also advantageously increased. 
         [0034]    With reference again to  FIG. 6 , the sheet  605  is then folded at fold lines F 2 , F 3 , another fold line (not shown) at the leading edge of section (c). This brings all four sides of bag  600  together to form the internal space of bag  600 . At this point the bottom of the bag can be formed, by folding sections  609  upon one another. In a preferred embodiment, flaps  660  and  664  are folded inward. Next, flap  662  and a mirror image of flap  662  (not shown) are folded one at a time over flaps  660  and  664  to form the bottom panel of the bag. A support member may be added to the inside of the bag to increase the strength of the bag at the bottom. As shown in  FIG. 6 , fold lines F 1 , F 4  and F 8 -F 11  are use to fold the bag flat when not in use. 
         [0035]    With reference now to  FIGS. 8   a - 8   h  there are shown eight different examples of bag designs constructed as described above. In  FIGS. 8   a - 8   c  and  8   f - 8   g , in particular, there are shown examples of bag designs wherein a dual faux material design is incorporated at the bottom of the bag. As described above in connection with  FIGS. 5-7 , the dual material look is created by incorporating an additional pair of fold lines (such as F 6  and F 7  in  FIG. 6 ) at the bottom of the bag where the dual material design is desired to be located. A stitch line may also be included so as to strengthen the bag and to add to the faux dual material look. 
         [0036]    Thus, while there have been shown and described fundamental novel features of the invention as applied to the exemplary embodiments thereof, it will be understood that omissions and substitutions and changes in the form and details of the disclosed invention may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.