Duplex bag having a handle and method of making same

The present invention is directed to a duplex bag having a handle. The bag includes an inner and outer web of thermal plastic material. The outer web includes a front panel, a rear panel and a handle portion. The handle portion is integral with the front and rear panels and has a width less than the width of the front and rear panels. The inner web includes a front panel, a rear panel and a gusset portion. The gusset portion is integral with the front and rear panels and may have a line of perforations spaced from and parallel to the front and rear panels. All panels have about the same dimensions. The handle portion and the gusset portion may be adjacent one another at a top end of the bag. The front panel of the outer web overlies the front panel of the inner web and the rear panel of the outer web overlies the rear panel of the inner web. A side seam is formed at each lateral edge portion of said front and rear panels and seals the panels together.

BACKGROUND OF THE INVENTION 
1. Scope of the Invention 
The present invention is directed to a bottom loaded or side loaded duplex 
bag having a handle. Also disclosed is a method for making the bag. 
2. Background of the Invention 
U.S. Pat. No. 1,808,375 discloses a shopping bag. The shopping bag has a 
front and rear panels which are joined together by a handle portion. The 
lateral side edges and bottom are joined together. 
U.S. Pat. No. 3,580,486 discloses a plastic bag having an integral 
strap-like handle at its upper end and a bottom gusset or satchel bottom. 
The gusset unfolds under the weight of the items carried in the bag. 
U.S. Pat. No. 4,573,203 discloses a plastic bag having a gusset located at 
its upper most end adjacent a loop handle. The loop handle is welded to 
the bag adjacent the upper edge portion of the bag. 
SUMMARY OF THE INVENTION 
The present invention is directed to a duplex bag having a handle. The bag 
includes an inner and outer web of thermal plastic material. The outer web 
includes a front panel, a rear panel and a handle portion. The handle 
portion is integral with the front and rear panels and has a width less 
than the width of the front and rear panels. The inner web includes a 
front panel, a rear panel and a gusset portion. The gusset portion is 
integral with the front and rear panels and has a line of perforations 
spaced from and parallel to the front and rear panels. All panels have 
about the same dimensions. The handle portion and the gusset portion are 
adjacent one another at a top end of the bag. The front panel of the outer 
web overlies the rear panel of the inner web, and the rear panel of the 
outer web overlies the rear panel of the inner web. A side seam is formed 
at each lateral edge portion of said front and rear panels and seals the 
panels together. 
After the bag is filled, a bottom seam is formed at a bottom edge portion 
of the panels which seals the panels together. Additionally, a lip having 
a plurality of wicket holes may be located at the bottom edge portion of 
the bag. The lip having holes is used for holding the bag prior to filling 
and formation of the bottom seam. 
The present invention is also directed to a duplex bag comprising an inner 
bag for containing the product and an outer bag supporting the inner bag. 
The inner bag comprises opposing panels and at least one fold portion 
connecting the opposing panels. The outer bag comprises opposing panels 
and at least a handle portion connecting the opposing panels. As used 
herein, "handle" has its customary broad meaning and refers not only to a 
loop handle through which a person may slip an arm to carry the duplex bag 
of this invention but also to other means which one can grasp for the 
purpose of carrying the bag; for example, a portion of plastic with holes, 
openings, or surfaces which fingers can grasp. The handle portion of the 
outer bag straddles a fold portion of the inner bag and provides support 
for the inner bag, and the inner and outer bags have substantially 
co-extensive openings to facilitate introduction of product into the inner 
bag. The duplex bag of the invention is also directed to a duplex bag in 
which the four opposing panels of the inner and outer bags are sealed 
together along at least one common edge portion of the panels. 
The present invention is also directed to method of making a duplex bag. In 
one method of this invention a thermal plastic web is provided for an 
inner bag and at least one fold is provided in the web for the inner bag. 
A thermal plastic web is also provided for an outer bag and at least one 
fold is provided in the web for the outer bag, and a handle is formed in 
one fold portion in the outer web. The folded inner web and the folded 
outer web are then joined such that the inner web forms an inner bag with 
an open end portion and the outer web forms an outer bag with an open end 
portion, the handle portion of the outer web straddling the fold portion 
of the inner web.

DETAILED DESCRIPTION OF THE INVENTION 
Referring to the drawings where like numerals indicate like elements, there 
is shown in FIG. 1 a preferred embodiment of the duplex bag generally 
designated 10. 
Duplex bag 10 comprises an inner web 14 and an outer web 12. Outer web 12 
includes a handle portion 20. Inner web 14 preferably includes a gusset 
16. A line of perforations 18 is preferably formed at the apex of gusset 
16. The line of perforations 18 may be severed whereby materials within 
bag 10 may be retrieved or inserted. 
The webs 12 and 14 are made of thermal plastic material which is weldable. 
Webs 12 and 14 are welded together at lateral seams 22 and bottom seam 24. 
Seams 22 and 24 may be formed in any conventional manner such as but not 
limited to thermal welding, ultrasonic welding, electronic welding, etc. 
The seams and joints described herein may be glued, but this is not 
preferred. 
The outer web 12 may be made of low millage material. Regardless of the low 
millage material, the bag is still strong. The formation of seams 22 and 
24 about the periphery of the bag 10 allows the stress at the joining 
points of the handle 20 and panels of web 12 to be evenly distributed over 
the entire web 12. Accordingly, the bag can be used for such heavy items 
as charcoal, fresh potatoes, diapers or sanitary products, garden 
products, etc. 
Referring to FIGS. 4-6, the formation of inner web 14 is explained. Web 14 
is generally formed from a continuous web of thermal plastic material. The 
line of perforation 18 may bifurcate web 14 along the longitudinal axis. 
The web 14 is then folded over onto itself along the line of perforations 
18. See FIG. 5. Alternately, a plurality of wicket holes 26 may be 
disposed along a lateral edge portion or lip of web 14 parallel to the 
line of perforations 18. Wicket holes 26 are used for holding the bag 
loading. If the wicket holes 26 are used, then the line of perforations is 
offset from the longitudinal axis and the web 14 is folded at the line 18 
whereby a lip having the wicket holes 26 is formed. 
After web 14 has been folded over on itself as shown in FIG. 5, gusset 16 
is preferably formed along a line of perforations 18 at the folded portion 
of the bag. The line of perforations 18 is located along the apex of 
gusset 16. 
Referring to FIGS. 7-9, the formation of outer web 12 is disclosed. Web 12 
is formed from a continuous strip of thermal plastic material. See FIG. 7. 
Web 12 is folded over onto itself along the longitudinal axis or can be 
folded over folded web 14. See FIG. 8. Handle 20 is formed along the 
folded portion of web 12 preferably by diecutting. Of course other methods 
may be used for forming the handle 20. 
Referring to FIG. 10, there is an illustration of the orientation of the 
outer web 12 and the inner web 14 immediately prior to the welding/lateral 
seam formation operation. While the inner and outer webs are shown in FIG. 
10 to be exactly co-extensive, as mentioned above it is sufficient if they 
are substantially co-extensive. For example, in order to facilitate use of 
wicket holes, to utilize certain printing equipment, or for other reasons, 
the inner and outer webs may be offset as much as is necessary to achieve 
desired purposes. 
Longitudinal welds 33 and 35 are preferably made adjacent an opening 38 of 
bag 10. Weld 33 joins front and top panels 30, 34. Weld 35 joins rear and 
bottom panels 32, 36. Welds 33, 35 are made in any well known manner. 
Welds 33, 35 prevent materials, added to bag 10 during loading, from 
falling between the panels of the inner and outer panels. 
Web 12 includes a front panel 30 and rear panel 32 which are joined 
together by handle portion 20. Front panel 30 and rear panel 32 are 
preferably rectangular and have the same general dimensions. The handle 
portion 20 has a width which is preferably narrower than the width of the 
front and rear panels 30 and 32. 
Inner web 14 comprises a front panel 34, a rear panel 36 and the gusset 
portion 16. Gusset portion 16 is integral with and joins front and rear 
panels 34 and 36. Front and rear panels 34 and 36 are preferably 
rectangular and have the same general dimensions. 
Front and rear panels 30 and 32 and front and rear panels 34 and 36 all 
preferably have the same general dimensions. 
Front panel 30 overlies front panel 34. Rear panel 32 overlies rear panel 
36. Handle portion 20 and gusset portion 16 are adjacent a top portion of 
the bag. 
Lateral seams 22 are formed along seam line 28. Seam line 28 is generally 
perpendicular to perforated line 18. The welding operation which forms 
lateral seams 22 severs one bag 10 from the next and seals the panels 30, 
34, 36 and 32 together. 
FIG. 11 shows a preferred embodiment of the present invention prior to the 
formation of a bottom seam 24. Bag 10 includes a bottom opening 18. 
Materials are filled into bag 10 via opening 38. If the embodiment having 
the lip and wicket holes 36 is utilized, then during the formation of the 
bottom seal 26 the lip is severed from the bag 10. 
FIGS. 12 and 13 illustrate two alternate embodiments of the present 
invention in which a closure means 50 is attached adjacent to the gusset 
16. The closure means 50 includes a male member 52 and a female member 54. 
The male and female members 52, 54 may be joined together thereby forming 
a seal which closes the bag. Male and female members 52, 54 may be 
separated thereby allowing access to the bag. Male member 52 includes a 
longitudinal rib 56 which is adapted for a press-lock fit in a groove 58 
of female member 54. 
The embodiment illustrated in FIG. 12 has the closure means 50 straddling 
perforated line 18. The male member 52 is welded to a portion of the 
gusset 16 on one side of line 18 and female member 54 is welded to a 
portion of the gusset 16 on the other side of line 18. After the bag 10 is 
loaded and opening 18 is sealed, the closure means 50 can be opened and 
perforated line 18 separated. This allows access into the bag. The closure 
means 50 can be sealed, thereby closing the bag. The method of making the 
bag illustrated in FIG. 12 is generally the same as discussed above. 
However, the closure means 50 may be joined to the inner web 14 prior to 
the first folding step. (See FIG. 4a). The male and female members 52, 54 
are joined to web 14 on either side of the perforated line 18 in any 
conventional manner. 
The embodiment illustrated in FIG. 13 is generally the same as the 
embodiment of FIG. 12. However, the closure means 50 (the same as 
previously described) is adjacent the front (or rear) panel. The 
perforated line 18 is eliminated and new perforated line 18' is formed. 
One member of the closure means 50 is welded to a side 17 of gusset 16. 
The other member of the closure means 50 is welded to the panel of the 
inner web and is between panels of the inner and outer web. The method of 
making this embodiment is generally the same as the originally described 
method. However, the closure means 50 may be joined to the inner web after 
or with the formation of the gusset 16. (See FIG. 6a). 
The bag shown in FIGS. 14 to 21 has a handle for the outer bag generally of 
the kind shown in U.S. Pat. No. 4,252,269. As with other bags of this 
invention one can make the inner web have properties that are appropriate 
for holding the product, while making the outer web have different 
properties that are appropriate for supporting the product in the inner 
bag. In addition, the embodiment of FIGS. 14 to 21 eliminates a problem 
with the bags of U.S. Pat. No. 4,252,269. When bags of that patent are 
filled, stresses from the handle have a tendency to concentrate at the 
apex on the side seams where the center portion of the gusset meets the 
side. Since the outer bag web for the handle may be cut back from the side 
seams in the embodiment of FIGS. 14 to 21, those stresses do not form. 
The bag of FIGS. 14 to 21 comprises an inner web 114 and an outer web 112. 
The webs are made of thermal plastic and welded together at lateral seams 
122 and bottom seam 124. The duplex bag formed generally as shown in FIGS. 
4 to 10 except that, following the steps of U.S. Pat. No. 4,252,269, which 
is incorporated herein, the outer web 112 is sealed to itself at 119. In 
this embodiment of the invention, the portion of the outer web at "a" (see 
FIG. 14) is cut out from the outer web to the opposing panels 130 and 136. 
The inner web is then folded inward at fold 118, and the outer web is 
folded inward at fold 119 to form a gripping surface handle 120 that 
facilitates carrying the bag. The outer web thus makes up a bag having 
opposing panels 130 and 136, and the inner web makes up an inner bag 
having opposing panels 132 and 134. The outer bag handle 120 and handle 
piece 119A connect opposing panels 130 and 136 and straddle the folded 
portion 118 and 116 of the inner bag, comprising panels 132 and 134. The 
handle portion (120 and 119A) of the outer bag is longer than the fold 
portion (116 and 118) of the inner bag. 
In FIGS. 14 to 21, weld 133 joins front panels 130 and 134, and weld 135 
joins rear panels 132 and 136. Product may then be introduced into the bag 
through opening 138. In the embodiment of FIGS. 14 to 21 the web between 
opposing panels is sealed to itself at 119 to create two handle portions 
120 and 119A. The handle 120 portion may be provided with an opening 121 
to facilitate gripping and carrying the bag. If the distance "a" shown in 
FIG. 14 is about one-half the distance of the fold portion 116 between, 
its opposing panels, when the bag 110 is filled the first part of handle 
portion will cover most of the top portion of the inner bag. 
The bag of FIGS. 22 to 29 has the advantage of no filling seam on the 
bottom (the side opposite the handle). The only seams on the bottom or 
otherwise taking the stresses of carrying are seams made under controlled 
conditions at the time of or before manufacture of the bag, and such seams 
are stronger than seams made at the time of filling and packing. This 
provides better strength and weight carrying properties. The bag of FIGS. 
22 to 29 comprises an inner web 214 and an outer web 212. The webs are 
made of thermal plastic, formed into individual tubes at a seam not shown, 
and welded together at lateral seam 222. The duplex bag is formed 
generally as shown in FIGS. 4 to 10 except that they are formed into tubes 
with no opening in the area of welds 33 and 35. The inner web is folded 
inward at fold 218, and the outer web is formed into handle 220 that 
facilitates carrying the bag. The outer web thus makes up a bag having 
opposing panels 230 and 236, and the inner web makes up an inner bag 
having opposing panels 232 and 234. The outer bag handle 220 connects 
opposing panels 230 and 236 and straddles the folded portion 218 of the 
inner bag, comprising panels 232 and 234. During manufacture of the bag 
only one side seam (222) is sealed and the opposite side is left open to 
facilitate filling with product. Once filled, this opening 238 is closed 
and sealed to form seam 223. 
The duplex bags of this invention may be manufactured at high speed on 
automatic machinery. Because of the use of two layers and the stress 
distribution properties of the design, savings in raw materials are 
possible while at the same time permitting flexibility in packaging and 
the possibility of additional features. For example, a vacuum may be drawn 
on the inner bag, coupons may be placed between layers of the bag, and the 
inner web may have breathing holes for fresh produce without sacrificing 
strength in the outer supporting bag. The flexibility of this invention 
also permits the inner bag to have, for example, a reclosure as a 
convenience to the purchaser. 
A variety of perforation and opening arrangements is possible. In addition 
to the closure means of FIGS. 12 and 13, pressure sensitive tape or other 
recloseable sealing means may be used. Such recloseable means may be 
placed anywhere on the inner bag as may suit the product, and perforations 
may be arranged to provide primary seals that are tamper evident in the 
store but cover secondary seals (such as in FIGS. 12 and 13) which may be 
used by the purchaser at home for reclosure. Perforations may be placed on 
the folds 16, 116 and 216, as illustrated, but also in the side, front, or 
back panels. Perforations on the inside bag may be offset with respect to 
perforations on the outside bag and thereby provide both protection of the 
product and a degree of access to the product by manipulating a hand 
through two non-aligned openings without permitting the contents to fall 
freely from the bag. 
Sealing patterns may also be varied. While the bags described above are 
shown with continuous seals at seams between the inner and outer webs, 
spot sealing elsewhere on the panels to increase dimensional stability or 
registration of the two bags is also contemplated. The inner bag may have 
vents for fresh produce, to permit out-gassing, and/or to reduct trapped 
air. While continuous seals for the seams are shown, it will be understood 
that there may be circumstances where partial seals may be advantageous. 
Additionally, access to the space between the inner and outer bags may be 
arranged so that the bag can receive and carry additional items, such as 
coupons inserted by the manufacturer of the goods packaged in the bag, or 
bottles or other items inserted by the purchaser of the bag after the bag 
has been opened. Verticle and other seals between the inner and outer bags 
can create pockets for receiving such items, which facilitate this use. 
While the handle is shown in some figures without cut-outs, cut-outs to 
facilitate gripping may be used. Similarly, the width and the length of 
the handle may be varied to suit the user. We contemplate, for example, a 
handle that can be slipped over the arm either along the long axis of the 
package (as shown in FIG. 1) or, because of additional holes, finger 
grips, or the like at right angles to that axis 
The present invention may be embodied in other specific forms without 
departing from the spirit or essential attributes thereof and, 
accordingly, reference should be made to the appended claims, rather than 
to the foregoing specification, as indicating the scope of the invention.