Apparatus for manufacturing a disposable vacuum cleaner bag

The present invention relates to an apparatus and method of manufacturing vacuum cleaner bags with a unique tri-lock top and bottom seal. The paper end of at the end of the open bag length is sealed onto itself with seam-paste glue three times providing an extra strong seam to accommodate the ever increasing air pressure created by today's powerful cleaners.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates generally to vacuum cleaner filter bags and more 
particularly to a reinforced vacuum cleaner filter bag as well as a method 
of making same. 
This invention relates to a disposable vacuum cleaner bag for use with top 
loading upright vacuum cleaners and a fully automated method for forming 
such bags. 
2. Description of the Prior Art 
Vacuum cleaner filter bags are typically formed from a blank which contains 
fold lines and cut-outs. The blank is folded on the specified lines and 
adhesive is applied during the course of the folding process whereby the 
filter bag is completed. Typically, such filter bags are folded into a 
tubular shape having closed ends with access means formed in the tubular 
bag for permitting passage of air into the interior of the bag so that air 
can be filtered. 
The specific structure of the bag may vary depending upon the type of 
vacuum cleaner being utilized. For example, one typical filter bag is in 
the shape of a conventional page bag having a folded over edge on one end 
thereof and a bag bottom at the other end thereof. An opening is formed in 
the bag bottom which serves as the access means to permit the entry of air 
into the interior of the bag. The opening can then be connected to the 
vacuum cleaner outlet. Such a vacuum cleaner filter bag is described in 
U.S. Pat. No. 3,404,515. 
With the aforementioned bag, a blank sheet material is formed with the 
appropriate fold lines and cut-outs. Adhesive is placed along the 
longitudinal edge to permit formation of an overlapped seam and the sheet 
is folded around to form a tubular structure. Then, the bottom is formed 
by appropriately folding the material. After the material is folded 
partway during the formation of the bottom, glue is applied in stripes and 
the material is then folded over to complete formation of the bottom. 
Transverse stripes of glue are then applied at the other end and the 
tubular material is folded onto itself to close off and seal the other 
end. 
Another type of filter bag structure is the type having a long tubular body 
with both the upper and lower ends closed off by folding onto itself. An 
opening is formed in the tubular material and a separate connecting tube 
having an opening registered with the opening in the tubular body is 
connected. The connecting tube has its remote end available for connection 
to the vacuum cleaner outlet and the connecting tube serves as a 
passageway for the air into the filter bag. 
This type of vacuum cleaner filter bag is described in U.S. Pat. No. 
3,350,859 and wherein longitudinal fold lines are formed on the blank and 
the blank is folded around to form a tubular body having a front and rear 
panel and accordion side panels. Glue is provided in order to form an 
overlapping seam. Glue is also applied transversely at the upper and lower 
edges and the ends are then folded over onto itself to form a closed off 
cuff at the top and bottom portion. Adhesive is also placed around the 
registered openings to permit coupling of the connecting tube onto the 
tubular body. With both aforementioned types of vacuum cleaner filter 
bags, as well as with other types, although the filter bag is closed and 
appropriate adhesive is utilized for sealing and holding the bag closed, 
there is a tendency for rips and tears to occur at heavily stressed 
portions. Typically, tears will occur at the edges where the bag has been 
folded over in order to close off the bag. For example, at the folded over 
cuff portion, there will frequently occur tears or rips. Also, in the type 
of bag having a bottom, at the corners of the bottom, tears and rips tend 
to occur. Although additional adhesive can be applied, since the adhesive 
normally applied in stripes, it would necessitate applying a large amount 
of adhesive covering an excessive amount of area greater than the amount 
under stress. This would cause exposed adhesives which would be wet, 
tacky, and tend to stick to other adjacent bags during the course of 
processing. 
Disposable vacuum cleaner bags have been made which are comprised of a tube 
portion which leads air and collected dust into another large air previous 
tube, or collection chamber. The tube portion may be made from an air 
pervious or air impervious material, while the collection chamber is of an 
air previous material. These bags are inserted into a cloth, vinyl, felt 
or other outer bag attached to a sweeper tank and, when full, the inner 
bag may be disposed of without dust problems associated with cleaners 
which do not use disposable bags. 
Many upright cleaners which use such disposable bags are of a bottom 
loading design. Such bottom loading cleaners are disadvantageous in that 
the cleaner must force its air stream upwardly through previously 
collected dirt in the bag. In order to alleviate the problem, somewhat, 
with the bottom loading cleaners, vacuum cleaner bags have been developed 
which connect a transfer tube to the cleaner at a bottom connection, which 
transfer tube leads to a main collection bag compartment where the dirt is 
fed near the top and falls to the bottom of the collection compartment. 
In U.S. Pat. No. 3,322,041, for example a bottom connection, but top 
loading design is shown, wherein the two sections are attached together 
only along the apertures which are formed in the two sections for passage 
of air flow from the transfer chamber to an air pervious or dust 
collection section. Such a design is an improvement over bottom loading 
design because a cleaner air stream does not have to flow through 
previously collected dirt. Prevalent top loading, but bottom connection, 
bag designs have a transfer tube which attaches to the dirt inlet duct of 
the vacuum cleaner near the bottom of the cleaner. The dirty air stream 
then blows up the transfer tube and through a window area between the 
transfer tube and the collection bag and then falls down into the 
collection bag. There are, however, two fundamental problems associated 
with such a bag design. One is that there is a tendency for the flexible 
duct member in the cleaner itself to collapse and cause clogging; and, 
secondly, it is possible for the consumer to improperly attach the bag to 
the cleaner. Indeed, this occurs often and results in bag failure and 
cleaner malfunction. The improper attachment occurs when the consumer 
folds the transfer tube into a U-shape before installing the bag, thus 
placing the bag, into the carrier, upside down. 
In an attempt to overcome these problems associated with a bottom 
connection but top loading and top connection cleaners. Bags designed for 
use with such top loading cleaners overcame the above described problems, 
but also have caused problems of their own. Such bags require a transfer 
tube which attaches to the cleaner inlet duct and leads from the top of 
the bag to the cooperating apertures in the transfer tube and another 
section or collection bag. In order to produce the bags on fully automated 
equipment, the transfer tube must extend the full length of the collection 
bag. Since the window is near the top of the transfer tube, the entire 
lower section of the transfer tube would pack with dirt before dirt would 
flow through the window into the collection bag. In order to overcome this 
problem, the use of a short closed end bag or transfer tube was proposed, 
in combination with the collection bag, with the closed end bag having a 
hole in one wall communicating with the aperture in the wall of the 
collection bag. Use of such bags however, still left a small pocket below 
the windows which would fill with dirt. A further problem with such a 
short bag transfer tube collection bag combination, however, is that such 
a configuration requires three separate production operations. In one 
operation, the main bag body or collection bag is produced on one machine; 
in a second operation, the transfer tube or short bag section is produce 
and limits its availability. 
The present invention relates to a method of manufacturing an outer bag for 
an upright vacuum cleaner on an automatic assembly line whereby bag 
material, as well as zipper material, both in continuous rolls are fed 
into an assembly line wherein zipper lengths are sewn on opposite sides of 
the bag material, and the assembled product is cut in predetermined 
lengths whereby the separated bag is zipped together to form a tube. The 
tube is enclosed at one or both ends to form a finished upright vacuum 
cleaner outer bag assembly. 
The prior art method of manufacturing an outer bag is performed by either 
cutting the bag material to specified sizes and shapes, and attaching a 
finished assembled zipper to the sides of the cut panel by sewing or 
dielectric sealing means thereby forming a tube to be closed on one or 
both ends. Another method of manufacturing an outer bag for an upright 
vacuum cleaner is to cut the bag material into panels of specified sizes 
and shapes. Thereafter, one half of the zipper is attached to opposite 
sides of the panel by sewing or dielectric sealing methods. Then the sides 
with the zipper halves attached are zipped together causing the assembly 
to form a form a tube to be closed on one or both ends to form a bag. 
Either of the above prior art methods of manufacturing an outer bag with a 
zipper for an upright vacuum cleaner is slow and time consuming. 
Consequently, the present invention, which automatically feeds both bag 
and zipper material in long rolls, whereby a high speed production of 
vacuum cleaner outer bags with zipper type openings is accomplished. The 
present method of manufacturing vacuum cleaner outer bags includes the use 
of a double headed sewing machine to sew the left and right side zippers 
thereon simultaneously. Thereafter, the assembled product is then fed into 
a cutting press with an automatic incremental feed system which cuts the 
bottom of one panel and the top of the succeeding panel to Specified 
lengths and constitutes a marked improvement over the methods practiced by 
the prior art. 
Numerous innovations for the manufacture of vacuum cleaner bags have been 
provided in the prior art that are described as follows. Even though these 
innovations may be suitable for the specific individual purposes to which 
they address, they differ from the present invention as hereinafter 
contrasted. 
U.S. Pat. No. 5,009,633 shows an method of manufacturing the outer cloth 
bag for an upright vacuum cleaner in which the bag material of a 
predetermined width is unwound from a reel and fed through guides, 
material folders and a double headed sewing machine. At the same time 
zipper chains are fed from rolls on the right and left side of the moving 
bag material. The zippers are sewn on opposite side edges of the bag, the 
bag material is cut into predetermined sized panels, and thereafter the 
side edges of the panels are folded and the zipper halves zipped up to 
form a tube. At least one open end is closed to form a bag. 
U.S. Pat. No. 4,512,788 vacuum cleaner bag for use with top loading vacuum 
cleaner has a first collection tube and a second transfer tube, the tubes 
having communicating apertures near the top thereof, with a thermoplastic 
coating on the inner walls of the second transfer tube which is fused 
together to seal the second transfer tube adjacent the lower wall of the 
aperture thereof, the top and bottom of the first tube and bottom of the 
second transfer tube adhesively sealed; and method for automatically 
forming the bags by superimposing the two tubes, adhesively securing them 
together, heat sealing the inner walls of the second transfer tube 
together, below the aperture, and closing the ends of the tubes. 
U.S. Pat. No. 4,322,259 shows a vacuum cleaner filter bag formed from a 
blank including a sheet of air permeable filter paper, and which is folded 
to define a tubular container having closed ends with an access opening 
formed in the container for permitting the passage of air into the 
interior of the bag so that the air can be filtered. The bag is formed by 
folding the blank and applying adhesive material onto specific areas 
during the folding operation in order to form the bag. On the blank itself 
there is also pre-applied, by pre-printing or extruding, a heat, 
self-stick or pressure sensitive type of adhesive material on specified 
areas, these areas being susceptible to tears. After the bag is formed, it 
is passed through a heat or pressure applying station which activates the 
pre-printed or extruded adhesive material thereby providing reinforcement 
to the bag at the areas which tend to tear. 
U.S. Pat. No. 3,848,813 discloses a system in which urban waste, such as 
that collected from households in urban areas, is processed in the dry "as 
collected" state to recover ferrous metals, nonferrous metals, glass and 
paper fractions of suitable quality for sale and recycling. Waste is first 
shredded without balling or crushing tin cans and is thereafter subjected 
to a series of separations based upon differences in the physical 
properties of the waste materials. 
U.S. Pat. No. 5,078,668 discloses is a method of making garment protector 
that is of high quality, having an envelope structure made of cloth fabric 
with an easy access opening in one of its sides covered by a flap member. 
U.S. Pat. No. 4,322,259 discloses a vacuum cleaner filter bag formed from a 
blank including a sheet of air permeable filter paper, and which is folded 
to define a tubular container having closed ends with an access opening 
formed in the container for permitting the passage of air into the 
interior of the bag so that the air can be filtered. The bag is formed by 
folding the blank and applying adhesive material onto specific areas 
during the folding operation in order to form the bag. On the blank itself 
there is also pre-applied, by pre-printing or extruding, a heat, 
self-stick or pressure sensitive type of adhesive material on specified 
areas, these areas being susceptible to tears. After the bag is formed, it 
is passed through a heat or pressure applying station which activates the 
pre-printed or extruded adhesive material thereby providing reinforcement 
to the bag at the areas which tend to tear. 
Numerous innovations for the manufacture of vacuum cleaner bags have been 
provided in the prior art that are adapted to be used. Even though these 
innovations may be suitable for the specific individual purposes to which 
they address, they would not be suitable for the purposes of the present 
invention as heretofore described. 
SUMMARY OF THE INVENTION 
The present invention is for a specific apparatus and method of 
manufacturing vacuum cleaner bags. The apparatus and method prints, forms, 
cuts, folds, glues, finishes, and packages bags all in one line on a 
single machine in continuous operation. The apparatus has two custom 
designed aluminum segment folding cylinders, each completing a triple fold 
glued seal at the end of the bag with one folding cylinder. An adjustable 
rotary wheel forms with quick change mount and dismount. The bag length is 
altered by changing gear at feed rollers. The linear mounted shaft driven 
direct drive motor is placed in line with the apparatus as well as inboard 
drive shafts, gear boxes and torque limiter at motor unlike conventional 
bag manufacturing machinery having motor mounted transversely to machine 
with belt or chain drive. 
It is an object of the present invention to provide a novel vacuum cleaner 
bag for use with top loading upright vacuum cleaners. 
It is another object of this present invention to provide a fully automated 
method for producing vacuum cleaner bags for use with top loading upright 
vacuum cleaners. 
A vacuum cleaner bag for use with top loading upright vacuum cleaners 
comprises a first collection tube having closed ends and an aperture in a 
wall thereof, near top of collection tube, to serve as a collection bag, 
and a second narrower transfer tube having an aperture communication with 
the aperture of the first collection tube, serving as a feed tube. The 
second transfer tube has an open top end and a coating of thermoplastic 
material along the inner wall, at least adjacent the lower end of the 
aperture therein, and preferably completely over the inner wall, and a 
seal is formed between the inner walls of the second transfer tube by 
fusion of the thermoplastic material immediately below the aperture. The 
second transfer tube preferably extends the full length of the first 
collection tube and the bottom of the first collection tube to form a 
common closed end. 
The bags are formed on automated equipment by bring the first and second 
tubes together, with the apertures aligned with each other, adhesively 
securing the tubes together and sealing the second tube, which has the 
inner coating of thermoplastic material, immediately below the aperture 
therein by application of heat and pressure to fuse the thermoplastic 
coating together. The top of the first tube is then adhesively closed by 
folding, and the bottom of the first and second tube preferably closed 
together by applying adhesive and folding of the same. 
Accordingly, it is an object of the present invention to provide a vacuum 
cleaner filter bag which avoids the aforementioned problems of prior art 
filter bags. 
Another object of the present invention is to provide a reinforced vacuum 
cleaner filter bag. 
Still another object of the present invention is to provide a vacuum 
cleaner filter bag having pre-printed or extruded adhesive areas which are 
provided in locations which are tend to tear, and accordingly, provide 
reinforcement to the filter bag. 
Yet another object of the present invention is to provide a vacuum cleaner 
filter bag formed from a blank of air permeable filter sheet material 
which includes pre-printed or extruded heat, self-stick or pressure 
sensitive adhesives in specified areas which are susceptible to tears and 
rips, and accordingly, provides reinforcement to the filter bag. 
A further object of the present invention is to provide a vacuum cleaner 
filter bag formed by a blank of air permeable sheet material which 
includes a first type of adhesive utilized during the course of the 
folding and sealing operations and a second type of adhesive which is 
pre-printed or extruded onto the blank and is heat, self-stick or pressure 
sensitive. 
Another object of the present invention is to provide a vacuum cleaner 
filter bag formed from a blank of sheet material which utilizes quick 
setting, slow drying resin adhesive during the course of the folding and 
forming of the bag, as well as a heat, self-stick or pressure sensitive 
adhesive pre-printed or extruded on the blank for reinforcing specified 
areas of the filter bag. 
Another object of the present invention is to provide a blank for a vacuum 
cleaner filter bag having appropriate fold lines and cut-outs for forming 
the bag, and including pre-printed or extruded adhesive material on 
specified area of the blank. 
Still another object of the present invention is to provide a method of 
manufacturing a reinforced vacuum cleaner filter bag. 
A further object of the present invention is to provide a method of 
manufacturing a vacuum cleaner filter bag by utilizing a blank having 
pre-printed or extruded heat, self-stick or pressure sensitive adhesive 
areas on specified locations and by applying heat or pressure onto the 
filter bag after it is folded and sealed into its final form. 
Briefly, in accordance with the present invention, there is provided a 
vacuum cleaner filter bag which is formed from a blank of air permeable 
filter sheet material which is folded to define a tubular bag having 
closed ends. An excess means is formed in the tubular bag for permitting 
passage of the air to be filtered into the interior of the bag. A first 
adhesive material is applied onto specific areas of the blank for sealing 
the bag in its folded condition. A second, heat, self-stick or pressure 
sensitive adhesive material is pre-printer extruded onto the blank in 
other specified areas, and specifically adjacent to the ends, in order to 
prevent tears at the closed ends and provide reinforcement to the bags. 
The present invention also contemplates a blank for a vacuum cleaner filter 
bag, comprising a sheet of air permeable filter material which is provided 
with a pair of transverse edges and a plurality of elongated fold lines 
for defining therebetween a front panel, side panel,and a rear panel, when 
the blank is folded thereon. A cut-out section is formed on the blank for 
forming access means into the filter bag when it is folded. A heat, 
self-stick or pressure sensitive adhesive material is pre-printed or 
extruded in stripes on the blank adjacent the transverse edges for 
preventing tears at the edges of the bag, when it is in a folded 
condition. 
The invention also contemplates a method of manufacturing a vacuum cleaner 
filter bag comprising the steps of forming a blank air permeable filter 
material, having the necessary fold lines and cut-outs which are needed to 
form the desired filter bag configuration. A heat, self-stick or pressure 
sensitive adhesive material is printed or extruded onto the blank in 
specified areas which are susceptible to tears. The bag is folded and 
glued into its final form utilizing additional adhesives disposed on the 
other areas as needed. Heat or pressure is then applied to the folded 
filter bag in order to activate the heat, self-stick or pressure sensitive 
adhesive material, thereby providing g the extra reinforcement to the 
filter bag. 
The novel features which are considered characteristic for the invention 
are set forth in the appended claims. The invention itself, however, both 
as to its construction and its method of operation, together with 
additional objects and advantages thereof, will be best understood from 
the following description of the specific embodiments when read and 
understood in connection with the accompanying drawing. 
BRIEF LIST OF REFERENCE NUMERALS UTILIZED IN THE DRAWING 
6--shingle table 6 
8--collar section 8 
10--vacuum bag manufacturing equipment conveyor 10 
14--second tri-fold section 14 
16--turn around section 16 
18--first tri-fold section 18 
20--forwarding section 20 
22--rotary cutter 22 
24--motor and drive train 24 
26--quick change former section 26 
28--print press section 28 
30--paper roll 30 
DETAILED DESCRIPTION OF THE LIST OF REFERENCE NUMERALS UTILIZED IN THE 
DRAWING 
6--shingle table 6 stacks finished vacuum cleaner bags and receives 
processed vacuum cleaner bag material from collar section 8 
8--collar section 8 automatically locates and glues collars onto processed 
vacuum cleaner bags and receives processed vacuum cleaner bag material 
from conveyor 10 
10--conveyor 10 receives processed vacuum cleaner bag material from second 
tri-fold section 14 
14--second tri-fold section 14 folds and seals opposite end and receives 
processed vacuum cleaner bag material from turn around section 16 
16--turn around section 16 turns bag over end to end so that opposite end 
may be folded and sealed and receives processed vacuum cleaner bag 
material from first tri-fold section 18 
18--first tri-fold section 18 folds and seals opposite ends and receives 
processed vacuum cleaner bag material from forwarding section 20 
20--forwarding section 20 moves cut bag lengths from rotary cutter 22 to 
first tri-fold section 18 
22--rotary cutter 22 cuts vacuum cleaner material bag material which is 
received from quick change former section 26 and moves cut bag material to 
forwarding section 
24--motor and drive train 24 powers vacuum cleaner bag manufacturing 
apparatus 
26--quick change former section 26 utilizing quick change rotary wheels 
receives processed vacuum cleaner bag material from print press section 28 
28--print press section 28 receives vacuum cleaner bag material from paper 
roller 30 and feeds said vacuum cleaner bag material to quick change 
former section 26 after printing 
30--paper roller 30 feeds vacuum cleaner bag material to print press 
section 28

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Firstly, referring to FIG. 1 which is a diagrammatic representation of the 
vacuum cleaner bag manufacturing apparatus exhibiting the following 
features: shingle table 6 stacks finished vacuum cleaner bags and receives 
processed vacuum cleaner bag material from collar section 8; collar 
section 8 automatically locates and glues collars onto processed vacuum 
cleaner bags and receives processed vacuum cleaner bag material from 
conveyor 10; conveyor 10 receives processed vacuum cleaner bag material 
from second tri-fold section 14; second tri-fold section 14 folds and 
seals opposite end and receives processed vacuum cleaner bag material from 
turn around section 16; turn around section 16 turns bag over end to end 
so that opposite end may be folded and sealed and receives processed 
vacuum cleaner bag material from first tri-fold section 18; first tri-fold 
section 18 folds and seals one end and receives processed vacuum cleaner 
bag material from forwarding section 20; forwarding section 20 moves cut 
bag lengths from rotary cutter 22 to first tri-fold section 18; rotary 
cutter 22 cuts vacuum cleaner material bag material which is received from 
quick change former section 26 and moves cut bag material to forwarding 
section; motor and drive train 24 powers vacuum cleaner bag manufacturing 
apparatus; quick change former section 26 utilizing quick change rotary 
wheels receives processed vacuum cleaner bag material from print press 
section 28; print press section 28 receives vacuum cleaner bag material 
from paper roller 30 and feeds said vacuum cleaner bag material to quick 
change former section 26 after printing; and paper roller 30 feeds vacuum 
cleaner bag material to print press section 28. 
Now referring to FIG. 2 which is flow diagram representing the individual 
parts of the apparatus by which vacuum cleaner bags are manufactured 
exhibiting the following parts: stock paper roll; printing press; paper 
former; paper cutter; forwarding roller section; first tri-fold cylinder; 
turn around section; second tri-fold section; conveyor; collar section 
conveyor; and shingle table. 
Now referring to FIG. 3 which is a detailed flow diagram representing the 
method by which vacuum cleaner bags are manufactured exhibiting the 
following steps: 
a) forming vacuum cleaner bag material from paper stock roll; 
b) moving formed vacuum cleaner bag material to printing press then through 
former section utilizing quick change rotary wheels; 
c) cutting vacuum cleaner bag material in a rotary fashion; 
d) moving cut vacuum cleaner bag material to tri-fold in forwarding roller 
section; 
e) folding and gluing ends of formed and cut vacuum cleaner bag material 
using tri-fold cylinder; 
f) turning bag over end to end so that opposite end may be folded and 
sealed in turn around section in second tri-fold section; 
g) automatically locating and gluing collars through conveyor to collar 
section onto bags and feeding said bags onto shingle table for stacking 
purposes. 
It will be understood that each of the elements described above, or two or 
more together, may also find a useful application in other types of 
constructions differing from the type described above. 
While the invention has been illustrated and described as embodied in an 
apparatus and method of manufacturing, it is not intended to be limited to 
the details shown, since it will be understood that various omissions, 
modifications, substitutions and changes in the forms and details of the 
device illustrated and in its operation can be made by those skilled in 
the art without departing in any way from the spirit of the present 
invention. 
Without further analysis, the foregoing will so fully reveal the gist of 
the present invention that others can, by applying current knowledge, 
readily adapt it for various applications without omitting features that, 
from the standpoint of prior art, fairly constitute essential 
characteristics of the generic or specific aspects of this invention. 
What is claimed as new and desired to be protected by Letters Patent is set 
forth in the appended claims.