Abstract:
The present invention relates to improvements for the manufacturing of a wave-cut bag, more specifically a wave-cut bag with improved tie-flaps. Disclosed is a process for intermittently incrementally stretching and imparting a rib-like pattern to a collapsed tube of a blown film extrusion process. The incrementally stretched collapsed tube is particularly well suited for constructing wave-cut trash bags with a rib pattern on the tie-flaps of the trash bags. Further disclosed is a wave-cut trash bag with a rib pattern on its tie-flaps and surrounding area.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to improvements in bags made from polymeric film and processes for manufacturing polymeric film bags. 
         [0004]    2. Description of the Related Art 
         [0005]    Thermoplastic films are used in a variety of applications. For example, thermoplastic films are used in sheet form for applications such as drop cloths, vapor barriers, and protective covers. Thermoplastic films can also be converted into plastic bags, which may be used in a myriad of applications. The present invention is particularly useful to trash bags constructed from thermoplastic film. 
         [0006]    Polymeric bags are ubiquitous in modern society and are available in countless combinations of varying capacities, thicknesses, dimensions, and colors. The bags are available for numerous applications including typical consumer applications such as long-term storage, food storage, and trash collection. Like many other consumer products, increased demand and new technology have driven innovations in polymeric bags improving the utility and performance of such bags. The present invention is an innovation of particular relevance to polymeric bags used for trash collection and more particular for larger bags used for the collection of larger debris. 
         [0007]    Polymeric bags are manufactured from polymeric film produced using one of several manufacturing techniques well-known in the art. The two most common methods for manufacture of polymeric films are blown-film extrusion and cast-film extrusion. In blown-film extrusion, the resulting film is tubular while cast-film extrusion produces a generally planar film. 
         [0008]    The present invention is generally applicable to drawstring trash bags manufactured from a blown-film extrusion process resulting in tubular film stock. Manufacturing methods for the production of drawstring bags from a collapsed tube of material are shown in numerous prior art references including, but not limited to, U.S. Pat. Nos. 3,196,757 and 4,624,654, which are hereby incorporated by reference. 
         [0009]    In blown film extrusion, polymeric resin is fed into an extruder where an extrusion screw pushes the resin through the extruder. The extrusion screw compresses the resin, heating the resin into a molten state under high pressure. The molten, pressurized resin is fed through a blown film extrusion die having an annular opening. As the molten material is pushed into and through the extrusion die, a polymeric film tube emerges from the outlet of the extrusion die. 
         [0010]    The polymeric film tube is blown or expanded to a larger diameter by providing a volume of air within the interior of the polymeric film tube. The combination of the volume of air and the polymeric film tube is commonly referred to as a bubble between the extrusion die and a set of nip rollers. As the polymeric film tube cools travelling upward toward the nip rollers, the polymeric film tube solidifies from a molten state to a solid state after it expands to its final diameter and thickness. Once the polymeric film tube is completely solidified, it passes through the set of nip rollers and is collapsed into a collapsed polymeric tube, also referred to as a collapsed bubble. 
         [0011]    One common method of manufacturing trash bags involves segregating the collapsed polymeric tube into individual trash bags by forming seals which extend transversely across the entire width of the tube. Typically a line of perforations is formed immediately adjacent and parallel to each seal to facilitate separation of the trash bags one from another. After the trash bags are sealed and perforated, the trash bags can be twice-folded axially into a fractional width configuration. 
         [0012]    It is also known to provide wave-cut trash bags. A wave-cut trash bag has a wave or lobe-shaped configuration at its open end. This provides two or more lobes, which can be used to tie the trash bag in a closed configuration after it is filled. 
         [0013]    Wave-cut trash bags can be manufactured by providing closely spaced, parallel transversely extending seals at predetermined intervals along the collapsed polymeric tube. A transversely extending line of perforations is provided between the closely spaced, parallel seals. The collapsed polymeric tube is then separated longitudinally along a wave or lobe-shaped line located equidistant between the edges of the tube. 
         [0014]    The lobe-shaped features, or lobes, of a wave-cut trash bags, which may also be referred to as tie-flaps, provide a convenient user feature to tie and close the opening of the bag. The lobes are grasped and knotted to seal the bag opening. Representatives of wave-cut or “tie bags” can be found in the following prior art of U.S. Pat. Nos. 4,890,736, 5,041,317, 5,246,110, 5,683,340, 5,611,627, 5,709,641, and 6,565,794. 
         [0015]    In a further publication, U.S. Pat. Appl. Pub. 2008/0292222A1 discloses a bag having at least two “tie flaps” with gripping features embossed on at least one surface of the tie flaps. It is further disclosed that the bag may formed from a tube of thermoplastic material. However, the publication further discloses that the gripping feature is formed in a linear fashion along a length of a blown film bubble that is then slit lengthwise in a wave pattern. The bubble is then formed into bags after being collapsed with a collapsed edge forming a bottom of the bag. 
         [0016]    It has been determined, however, that the lobes of prior art wave-cut bags are often difficult to grasp and manipulate, especially if the lobes are contaminated with slippery trash contamination such as oil or grease or moist organic contaminants. Furthermore, wave-cut bags are often manufactured with thicker film than other types of trash bags since they often are intended for use with larger and heavier debris, such as yard debris and debris from home improvement projects. These thicker films used on larger wave-cut bags can be as thick as 3 mils and make it challenging for a user to manipulate the lobes of a wave-cut bag into a knot. Hence, it would be desirable to provide a wave-cut bag that has easier to grasp lobes that are also thinner than the rest of the bag. The present invention represents a novel solution to address this need. 
       SUMMARY OF THE PRESENT INVENTION 
       [0017]    In at least one embodiment of the present invention, a bag of polymeric film may be formed. To form the polymeric bag, a collapsed tube of polymeric film may be formed with a machine direction. The collapsed tube may be formed from a blown film extrusion process. Once the collapsed tube is formed, a pair of intermeshing rollers may intermittently engage the collapsed tube to form a plurality of incrementally stretched sections on the collapsed tube. Within each incrementally stretched section may be defined a plurality of thin and thick ribs that extend across a width of the collapsed tube. The plurality of thin and thick ribs may be parallel to each other and transverse to the machine direction of the collapsed tube. The pair of intermeshing rollers may stretch the collapsed tube in the machine direction. 
         [0018]    Once the collapsed tube is incrementally stretched, a bag converting operation may form the collapsed tube into a plurality of bags. Each one of the plurality of bags may have at least a fraction of one of the plurality of incrementally stretched sections. A wave-cutting operation may divide each of the incrementally stretched sections into two separate components. Each of the two separate components may be approximately one-half of an incrementally stretched section. One half of an incrementally stretched section may define an incrementally stretched portion on a first trash bag and a second half of an incrementally stretched section may define an incrementally stretched portion on a second trash bag. 
         [0019]    The bag converting operation may further comprise forming sets of closely spaced, parallel seals extending transversely across the entire width of the collapsed tube. Each set of closely spaced parallel seals may be at equally spaced intervals from each other. The bag converting operation may also form perforation lines extending transversely across the entire width of the collapsed tube with a perforation line located between each set of closely spaced, parallel seals. A plurality of wave-shaped perforations may also be formed in the collapsed tube. A location of each wave-shaped perforation may be equidistant from adjacent perforation lines. Each wave-shaped perforation may be centered within one of the plurality of incrementally stretched sections. 
         [0020]    The converting operation may further comprise a timing operation. The timing operation may detect the location of each perforation line and generate a timing signal. The location of each wave-shaped perforation and perforation line may be based upon the timing signal. The timing operation may be a standalone operation or may be integrated into the bag converting operation. 
         [0021]    The pair of rollers may counter-rotate in relation to each other so that the collapsed tube is fed through the pair of intermeshing rollers. A rotational axis of each of the pair of intermeshing rollers may be perpendicular to the machine direction of the collapsed tube. Each roller of the pair of intermeshing rollers may include a plurality of protruding ridges extending completely about a circumference of each roller. The plurality of protruding ridges may also only extend about a partial circumference of each roller. Each of the protruding ridges may be parallel to each other and parallel to the axis of rotation of each roller. Each of the protruding ridges may have a tip protruding radially outward from the axis of rotation of one of the pair of intermeshing rollers. The plurality of protruding ridges of one roller may intermesh with the plurality of protruding ridges of the other roller. The pair of intermeshing rollers may intermesh with each other only over a fraction of a circumference of each roller and only incrementally stretch the collapsed tube when the pair of intermeshing rollers are intermeshed. The pair of intermeshing rollers may be separated by a gap when the rollers are not intermeshed. 
         [0022]    The pair of intermeshing rollers may rotate at a constant speed so that a tangential (i.e. circumferential) speed of the rollers matches the linear speed of the collapsed tube. The rotational speed of the intermeshing rollers may also oscillate so that the tangential speed of the rollers match the linear speed of the collapsed tube when the rollers are intermeshed and when the rollers are not intermeshed the tangential speed of the rollers is slower than the linear speed of the collapsed tube. 
         [0023]    In a further embodiment of the present invention, a bag is formed form a collapsed tube of polymeric film. The bag may comprise a first panel and a second panel. The first panel and the second panel may be joined along a first side edge, a second side edge, and a bottom edge. The first side edge may be formed from a first edge of the collapsed tube and the second side edge may be formed from a second edge of the collapsed tube. The first panel may have a first top edge opposite the bottom edge and the second panel may have a second top edge opposite the bottom edge. The first top edge and second top edge may define an opening of the bag. A distal end of both the top edge and second top edge may have a wave-shaped profile and the wave-shaped profile may define a plurality of lobes. 
         [0024]    A plurality of ribs may be defined in the plurality of lobes. The plurality of ribs may be generally parallel to each other and each rib may extend from the first side edge towards the second side edge of the bag. Each rib may extend perpendicularly from the first side edge to the second side edge. A closure of the bottom edge may be formed from a seal extending transversely across the entire width of the collapsed tube. The wave-shaped profile may define a profile height and the plurality of ribs may extend below a bottom of the wave-shaped profile approximately one-half length of the profile height. The plurality of ribs may also extend below the bottom of the wave-shaped profile no more than a length of the profile height, or more than a length of the profile height. The plurality of ribs may result from incremental stretching of the polymeric film in the machine direction. The incremental stretching may be due to a pair of intermeshing rollers that intermittently incrementally stretch the collapsed tube. The pair of intermeshing rollers may have at least two rotational speeds. The pair of intermeshing rollers may rotate slower when incrementally stretching the collapsed tube than when not incrementally stretching the collapsed tube. 
     
    
     
       BRIEF DESCRIPTION OF THE RELATED DRAWINGS 
         [0025]    A full and complete understanding of the present invention may be obtained by reference to the detailed description of the present invention and certain embodiments when viewed with reference to the accompanying drawings. The drawings can be briefly described as follows. 
           [0026]      FIG. 1  depicts a perspective view of a first embodiment of the present invention. 
           [0027]      FIG. 2  depicts a partial perspective view of the first embodiment of the present invention. 
           [0028]      FIG. 3 a    depicts a perspective view of an incremental stretching operation of the first embodiment. 
           [0029]      FIG. 3 b    depicts a secondary perspective view of the incremental stretching operation of the first embodiment. 
           [0030]      FIG. 4 a    depicts a perspective view of an incremental stretching operation of a second embodiment of the present invention. 
           [0031]      FIG. 4 b    depicts a perspective view of an incremental stretching operation of a third embodiment of the present invention. 
           [0032]      FIG. 5  depicts a front view of a fourth embodiment of the present invention. 
           [0033]      FIG. 6  depicts another front view of the fourth embodiment of the present invention. 
           [0034]      FIG. 7  depicts a front view of a fifth embodiment of the present invention. 
           [0035]      FIG. 8  depicts another front view of the fifth embodiment of the present invention. 
           [0036]      FIG. 9  depicts a top planar view of an intermeshing roller of a sixth embodiment of the present invention. 
           [0037]      FIG. 10  depicts a front view of a trash bag of the sixth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0038]    The present disclosure illustrates several embodiments of the present invention. It is not intended to provide an illustration or encompass all embodiments contemplated by the present invention. In view of the disclosure of the present invention contained herein, a person having ordinary skill in the art will recognize that innumerable modifications and insubstantial changes may be incorporated or otherwise included within the present invention without diverging from the spirit of the invention. Therefore, it is understood that the present invention is not limited to those embodiments disclosed herein. The appended claims are intended to more fully and accurately encompass the invention to the fullest extent possible, but it is fully appreciated that certain limitations on the use of particular terms are not intended to conclusively limit the scope of protection. 
         [0039]    Referring initially to  FIG. 1  and  FIG. 2 , a process for forming wave-cut trash bags with incrementally stretched tie flaps or lobes is shown. The trash bags may be formed by a blown film extrusion process. The blown film extrusion process begins by molten polymeric resin being extruded through an annular die of an extruder  102  to form a bubble or tube of molten polymeric film  104 . The direction that the film is extruded out of the die is commonly referred to as the machine direction (MD). The direction of extrusion may also be referred to as the lengthwise direction of the bubble or polymeric film tube  104 . Hence, the length of the polymeric tube  104  extends parallel with the machine direction. The direction transverse to the machine direction is commonly referred to as the cross direction (CD). The blown film extrusion process is well known in the art and is further explained in U.S. Pat. No. 7,753,666, which is hereby incorporated by reference in its entirety. 
         [0040]    The polymeric resin used in the blown film extrusion process may vary. However, for forming polymeric bags, a polyethylene resin is commonly used. In the current state of the art for polymeric bags, a blend of various polyethylene polymers may be used. A polymer blend can have linear low-density polyethylene (LLDPE) as the primary component, but other polymers may be utilized including, but not limited to, other polyethylene resins such as high-density polyethylene (HDPE) or low-density polyethylene (LDPE). Typically, the primary component of the polymer blend, such as linear low-density polyethylene (LLDPE), will comprise at least 75% of the polymer blend. The remaining portion of the polymer blend may include additives including, but not limited to, coloring additives, anti-blocking agents, and/or odor control additives. The film utilized to form polymeric bags may also comprise multiple layers of blown film resin. The resultant multi-layer film may be formed by coextrusion, a lamination process, or other methods of forming a multi-layer film known in the art. In each layer, one or more of the above-discussed polymers may be used. 
         [0041]    As shown in  FIG. 1 , once the bubble  104 , or polymeric tube, of molten film solidifies, the bubble  104  is collapsed by a pair of nip rollers  108 , which results in a collapsed tube  110 . The collapsed tube  110  includes two opposing interconnected surfaces of film extending continuously in a lengthwise direction. This continuously extending surface of film may be referred to as a web. The nip rollers  108  are commonly elevated above the extruder  106  a considerable distance, since the molten bubble  104  is air-cooled and requires a relatively large vertical distance to cool and solidify before the bubble  104  is collapsed. 
         [0042]    As shown in  FIG. 2 , once collapsed, the collapsed tube  110  has a first edge  112  and second edge  114  defined in the opposing edges of the collapsed tube  110  extending the length of the collapsed tube  110 . The distance from the first edge  112  to the second edge  114  of the collapsed tube  110  can define a width of the collapsed bubble. Once the collapsed tube  110  returns from the cooling tower (not shown), the collapsed tube  110  can feed directly into an incremental stretching operation  120 ; hence the incremental stretching can be performed as an in-line process, synchronously, with the blown film extrusion. As shown in  FIG. 1  and more clearly in  FIG. 2 , the incremental stretching operation  120  can be configured to only intermittently stretch the collapsed tube  110 , leading to incrementally stretched partial lengths of the collapsed tube  110 . 
         [0043]    As shown in  FIGS. 3 a  -4 b   , the incremental stretching operation  120  can include a pair of intermeshing rollers  122   a ,  122   b . The diameter and length of each intermeshing roller  122   a ,  122   b  are equal in a preferred embodiment but may vary. As best shown in  FIG. 3 a   , the collapsed tube  110  can enter a nip  124  defined by the pair of intermeshing rollers  122   a ,  122   b . The rotational axes  128   a ,  128   b  of each roller  122   a ,  122   b  can be parallel to each other and transverse to the machine direction (MD) of the collapsed tube  110 . Each of the rollers  122   a ,  122   b  can have a plurality of protruding ridges  126  parallel to the axis of each roller  128   a ,  128   b  that extend around the entire circumference of each roller  122   a ,  122   b  at a constant spacing. The protruding ridges  126  of the rollers  122   a ,  122   b  can be configured to intermesh like gears. As the collapsed tube  110  enters the nip of the intermeshing rollers  122   a ,  122   b , the film of the collapsed tube  110  is stretched based upon the depth and spacing of the grooves  126 . 
         [0044]    As best shown in  FIG. 3 a   , the film of the collapsed tube  110  is stretched by each groove of the plurality of protruding ridges  126  in the machine direction, which results in a pattern of stretched and un-stretched lengths with each length extending along the width or cross-direction of the collapsed tube  110 . Examined closely, this pattern of stretched and un-stretched lengths results in a pattern of parallel thick ribs (un-stretched lengths) and thin ribs (stretched lengths) extending in the cross-direction of the collapsed tube  110  for each incrementally stretched section  116 . 
         [0045]    The preferred actual size and spacing of each of the plurality of protruding ridges  126  in relation to each of the rollers  122   a ,  122   b  is substantially exaggerated for ease of illustration in the figures. In one preferred embodiment, the spacing of the grooves can be 20 grooves per inch about the circumference of each roller  122   a ,  122   b , with each groove leading to a matching thin rib/thick rib extending along the width of the collapsed tube  110 . The spacing of the ribs in the film after stretching is greater than the groove spacing of the intermeshing rollers  122   a ,  122   b , since the stretching causes the ribs to spread away from each other. The pattern of thick and thin ribs is represented by a pattern of parallel and adjacent lines in the figures. 
         [0046]    Once again examining  FIG. 3 a    and  FIG. 3 b   , the incremental stretching operation  120  can be configured to only engage, and hence only incrementally stretch, the collapsed tube  110  intermittently. This intermittent engagement of the collapsed tube  110  leads to lengths of un-stretched sections  118  and lengths of incrementally stretched sections  116 . As illustrated in  FIG. 3 b   , the intermittent engagement of the collapsed tube  110  can be accomplished by the pair of intermeshing rollers  122   a ,  122   b  moving away from each other a certain distance G allowing the collapsed tube  110  to move past the incremental stretching operation  120  without being stretched by the intermeshing rollers  122   a ,  122   b . The gap G, as shown in  FIG. 3 b   , must be large enough to allow the collapsed tube  110  to pass through the nip  124  without interference from the intermeshing rollers  122   a ,  122   b.    
         [0047]    Shown in  FIG. 4 a    is an alternative method of intermittently incrementally stretching the collapsed tube  110 . Unlike the previous embodiment of the incremental stretching operation  120  shown in  FIGS. 3 a  and 3 b   , the rotational axes  128   c ,  128   d  of the pair of intermeshing rollers  122   a ,  122   b  are mounted stationary in relation to each other. However, the protruding ridges  126   a ,  126   b  extend only partially around the circumference of each roller  122   a ,  122   b  rather than about the entire circumference. The locations of the protruding ridges  126   a ,  126   b  on each roller  122   a ,  122   b  are spaced appropriately so that the protruding ridges  126   a ,  126   b  intermesh when the pair of rollers  122   a ,  122   b  revolve. Thus, the collapsed tube  110  is incrementally stretched only when the protruding ridges  126   a ,  126   b  intermesh and engage the collapsed tube  110 . The geometry of each roller  122   a ,  122   b  can be configured so that the collapsed tube  110  is not in contact with either of the rollers  122   a ,  122   b  when not engaged with the protruding ridges  126   a ,  126   b . In the alternative, the diameter of each roller  122   a ,  122   b , can be configured such that the surface of one or more of the rollers  122   a ,  122   b  is in contact with the collapsed tube  110  while the protruding ridges  126   a ,  126   b  are not intermeshed. One or more of the rollers  122   a ,  122   b  in contact with the collapsed tube  110 , when the protruding ridges  126   a ,  126   b  are not engaging the collapsed tube  110 , may assist in maintaining the desired tension in the collapsed tube  110 . 
         [0048]    The rollers of  FIG. 4 a    may rotate at a speed so that a tangential speed of each roller  122   a ,  122   b  matches a linear speed of the collapsed tube  110  passing through the nip  124 . In the alternative, the tangential speed of the rollers  122   a ,  122   b  may only match the speed of the collapsed tube  110  when the collapsed tube  110  is engaged by the protruding ridges  126   a ,  126   b . When the protruding ridges  126   a ,  126   b  are not engaged, the rotational speed, and hence the tangential speed, of the pair of rollers  122   a ,  122   b  can be decreased. In this instance, the diameter of each roller  122   a ,  122   b  must be configured such that the collapsed tube  110  is not in contact with the rollers  122   a ,  122   b  when not engaged with the protruding ridges  126   a ,  126   b , since the linear speed of the collapsed tube  110  is typically constant. Decreasing the speed of the rollers  122   a ,  122   b  when not engaged with the web has the advantage of allowing smaller diameter rollers than would be required if the rollers rotated at a constant speed. 
         [0049]    In one particular example, the incremental stretching operation  120  may be configured such that each incrementally stretched section  116  of the collapsed tube  110  is 15 inches in length after being stretched and each un-stretched section  118  is 85 inches in length. For rollers that rotate at a constant speed, the intermeshing rollers can be configured to stretch the collapsed tube approximately 15 percent such that the protruding ridges would extend about the circumference of each roller approximately 13 inches, stretching a length of 13 inches of the collapsed tube  110 , which results in a length of 15 inches after being stretched. The remaining smooth circumference of 85 inches would then be devoid of the protruding ridges, which results in a total circumference of approximately 98 inches and a diameter of approximately 31.2 inches for each roller  122   a ,  122   b.    
         [0050]    Unlike rollers that rotate at a constant speed, rollers  122   a ,  122   b  configured to run at an oscillating speed could have a smaller circumference and hence a smaller overall size. For instance, when not engaged, the rollers  122   a ,  122   b  could rotate with an average tangential speed of 50 percent of the linear speed of the web. The speed of the rollers  122   a ,  122   b  would not step down instantly to 50 percent. Thus, the rollers  122   a ,  122   b  would first decelerate, then rotate at a speed of less than 50 percent, and then accelerate prior to engaging the collapsed tube  110  again. This arrangement would only require a smooth partial circumference of one-half the previous smooth circumference of approximately 42.5 inches and a 13-inch partial circumference having protruding ridges  126   a ,  126   b  for a total circumference of approximately 55.5 inches and a diameter of approximately 17.7 inches for each roller  122   a ,  122   b . It also foreseeable that the rollers could rotate at an average tangential speed of much less than 50 percent when not engaged with the collapsed tube, such as 25 percent. 
         [0051]    Decreasing the diameter and hence the overall size of the rollers  122   a ,  122   b  offers several advantages. First, the cost to produce the rollers is decreased with rollers of decreased size. In addition, with smaller rollers, the time to manufacture the rollers may also be reduced. Smaller rollers lead to lighter weight rollers, which can lead to a mounting system for the rollers to be proportionally smaller and less expensive to construct. Lighter rollers may also lead to smaller, less expensive motors for driving the rollers. The use of smaller drive motors may also lead to less energy consumption. 
         [0052]    As shown in  FIG. 4 a   , the axes  128   a ,  128   b  of the rollers  122   a ,  122   b  can be located relative to the collapsed tube  110  so that the collapsed tube  110  passes equidistant from both rollers  122   a ,  122   b . However, in an alternative embodiment shown in  FIG. 4 b   , the collapsed tube  110  can be located slightly further away from the bottom roller  122   b  so that protruding ridges  126  may extend completely about the entire circumference of the bottom roller  122   b . In such an embodiment, the collapsed tube  110  passes over the lower protruding ridges  126  when not engaged by the upper protruding ridges  126   a . When the collapsed tube  110  is engaged by the upper protruding ridges  126   a , the collapsed tube  110  is pushed down into the lower protruding ridges  126  by the upper protruding ridges  126   a.    
         [0053]    In an alternative embodiment, the above-described incremental stretching operation  120  can be performed on a single layer web of polymeric film. For instance, the collapsed tube  110  may be slit along the first edge  112  so that the tube is open along the first edge  112 . The collapsed tube may then be spread out so that the two opposing layers of the collapsed tube  110  lie in the same plane adjacent to each other. The single layer web may then be intermittently incrementally stretched as described above. Once the stretching is complete, the web may be folded so that the two layers of the collapsed tube  110  once again oppose each other. The two layers of film adjacent to the first edge  112  may then be sealed together so that the collapsed tube  100  may still be used to form wave-cut trash bags. Performing the incremental stretching on one layer of film may prevent undesired binding of the two layers of film. 
         [0054]    In another alternative embodiment, rather than the incremental stretching operation  120  performed in-line and synchronously, as described above, with the blown film extrusion  102 , the incremental stretching  120  can be performed off-line from the blown film extrusion. For instance, once the polymeric bubble  104  is collapsed by the nip rollers  108 , the collapsed tube  110  can be rolled onto a master roll. The master roll can then be placed at a lead end of the incremental stretching operation  110  and the collapsed tube can be unrolled from the master roll. The collapsed tube  110  can then be fed into the incremental stretching operation  120 . 
         [0055]    Returning now to  FIGS. 1 and 2 , once the incremental stretching is complete, the collapsed tube  110  can enter a bag converter  140 . The bag converter  140  can form sets of closely spaced, parallel seals  142 . The sets of closely spaced parallel seals  142  can extend transversely to the machine direction and across the entire width of the collapsed tube  110 . As shown in FIGS.  5  and  6 , one seal of each set  142  can define a bottom seal  142   a  for each bag  154   a . As shown in  FIG. 2 , between each set of the closely spaced parallel seals  142 , the bag converter  140  can form perforation lines  144 . The perforation lines  144  can extend transversely to the machine direction, the cross direction, and across the entire width of the collapsed tube  110 . Each perforation line  144  can define the bag bottom  144   a  (shown in  FIG. 5 ) and separation point of adjoining bags  154 . 
         [0056]    Once again examining  FIG. 2 , once the sets of closely spaced parallel seals  142  and perforation lines  144  are formed, the bag converter  140  can fold the collapsed tube  110  one or more times, with each fold extending along the length of the collapsed tube  110  and parallel to the machine direction. In at least one particular embodiment, the collapsed tube  110  can be folded twice such that a width of the folded collapsed tube  110   a  is one-fourth the width of the un-folded collapsed tube  110 . Once folded, a first folded edge  112   a  and second folded edge  114   a  can be defined in opposing edges of each bag  154 . 
         [0057]    Once the collapsed tube  110  is folded, it can proceed into a wave-cutter  150 . The wave-cutter  150 , which may also be referred to as a wave-cutting operation, creates wave-cuts  152 . Wave-cuts  152  are wave-shaped perforations, extending across the width of the folded collapsed tube  110   a . The wave-cuts  152  can perforate the folded collapsed tube  110   a  in the shape of a one-half sine wave extending across the width of the folded collapsed tube  110   a . In one particular embodiment, the amplitude of the sine wave can be approximately 5 inches but may vary considerably. Due to the collapsed tube  110   a  being folded twice when each wave-cut  152  is made, when un-folded each wave-cut can have, in general, a shape of two full sine waves extending across the width of the collapsed tube  110 . 
         [0058]    The location of the wave-cut  152  in relation to the perforation line  144  can be controlled by a timing operation  160 . The timing operation  160  can detect the location of each perforation line  144 . The timing operation  160  can rely upon a laser beam, infrared light, a spark generator, or another form of an electromagnetic signal to detect each perforation line  144 . The detected location of each perforation line  144 , along with the fixed position of the timing operation  160  and the collapsed tube  110  traveling at a steady state, can be used to time the incremental stretching operation  120  and wave-cutting operation  150  so that each wave-cut  152  and incrementally stretched section  116  are placed at predetermined locations. The timing operation  160  may be a standalone operation or may be integrated into the bag converter  150 . 
         [0059]    In at least one preferred embodiment, each wave-cut  152  can be centered by the wave-cutter  150  about a height of an incrementally stretched section  116 , in relation to the machine direction. Thus, a distance from a bottom of a wave-cut  152  to a lower boundary of an incrementally stretched section  116 , the lower boundary separating an incrementally stretched section  116  from an un-stretched section  118 , can be equal to a distance from a top of the wave-cut  152  to an upper boundary of the incrementally stretched section  116 , the upper boundary opposite from the lower boundary. Each centered wave-cut  152  and incrementally stretched section  116  can be equidistant from adjacent perforation lines  144 . In this preferred embodiment, once the collapsed tube  110  is separated at wave-cuts  152  and perforation lines  144  to form bags  154   a , an approximate one-half length of an incrementally stretched section  116  is defined on each bag  154   a  (in relation to a mid-point or average of the waveform of the wave-cut  152 ). 
         [0060]    In a particular example of this embodiment, the perforation lines  144  can be 100 inches away from each other. Each incrementally stretched section  116  and wave-cut  152  can also be separated from adjacent incrementally stretched sections  116  and wave-cuts  152  by 100 inches. Since the sections  116  and wave-cuts  152  are aligned or centered, a mid-point of each section  116  and wave-cut  152  is located 50 inches away from adjacent perforation lines  144 . 
         [0061]    Once the collapsed tube is folded and the wave-cuts  152  are placed, the folded collapsed tube  110   a  may be separated at the perforation lines  144  and wave-cuts  152  into individual bags  154  with each bag having a height of approximately 50 inches. Each bag  154  may then be overlapped with an adjoining bag and rolled into a roll of bags as is known in the art. 
         [0062]      FIGS. 5 and 6  show in detail the structure of the trash bags  154  that may be formed from the above-described processes.  FIG. 5  shows that once adjacent perforation lines  144  are separated, a matching pair of interconnected trash bags  154  are defined. A boundary of each trash bag is defined by one of the wave-cuts  152 . An incrementally stretched section  116  is shown located on the two adjoining bags  154 . Further shown is first edge  112  and second edge  114  of the collapsed tube  110  defining two opposing sides of the two adjoining bags  154 . Two opposing perforation lines  144  are shown defining a bottom of each adjoining bag  154 . Once the perforated wave-cut  152  is separated, two separate trash bags result. One of the resultant trash bags  154   a  is shown in  FIG. 6 . 
         [0063]    As shown in  FIG. 6 , each wave-cut trash bag  154   a  can comprise a front panel and a rear panel formed from opposing sides of the collapsed tube  110 . The trash bag  154   a  can have a first side edge  112   b  defined by the first edge  112  of the collapse tube  110  and a second side edge  114   b  defined by the second edge  114  of the collapsed tube  110 . The trash bag  154  can further have a bottom seal  142   a  defined by one seal of the closely spaced sets of seals  142 . A bag bottom  144   a  can be defined by one of the perforation lines  144 . The bag top  152   a  can be defined by one of the wave-cuts  152 . The bag top  152   a  can have a wave-cut profile. The bag top  152   a  can be defined on both the front panel and back panel of the bag  154   a  and the bag top  152   a  can define a bag opening. 
         [0064]    As shown in  FIGS. 2, 5 and 6 , an incrementally stretched portion  158  of the trash bag  154   a  can be comprised of an incrementally stretched section  116  of the collapsed tube  110 . The incrementally stretched portion  158  can be a fractional length of one of the incrementally stretched sections  116 . Within the incrementally stretched portion  158 , a plurality of lobes  156  can be defined. The plurality of lobes  156  may also be referred to as tie-flaps. A wave-cut profile height H can be defined as a vertical distance from a top of the wave-cut profile to a bottom of the wave-cut profile, the wave-cut profile height H equal to an amplitude of the wave shape of the wave-cut profile. The incrementally stretched portion  158  can extend from the bag top  152   a  to at least the bottom of the wave-cut profile. However, at least in one embodiment, the incrementally stretched portion  158  can extend below the bottom of the wave-cut profile up to one-half the wave-cut profile height H. In an alternative embodiment, the incrementally stretched portion  158  can extend below the bottom of the wave-cut profile at least a distance equal to the wave-cut profile height H. The incrementally stretched portion  158  can define a plurality of ribs extending from the first side edge  112   b  to the second side edge  114   b  of the bag  154   a . The plurality of ribs can generally be parallel to each other and transverse to both the first side edge  112   b  and second side edge  114   b.    
         [0065]    In one particular example of the wave-cut trash bag  154   a , a height of the bag from the bag bottom  144   a  to the upper extent of the bag top  152   a  may be 50 inches. A width of the bag from the first side edge  112   b  to the second side edge  114   b  may be approximately 33 inches. The wave-cut profile height H may be 5 inches with the incrementally stretched portion  158  extending 2.5 inches below the bottom of the wave-cut profile. Thus, the incrementally stretched portion  158  may have a height of approximately 7.5 inches, resulting in the remaining 42.5 inches of bag height un-stretched. The incrementally stretched portion  158  may be stretched approximately 15%. Thus, if the film of the collapsed tube is formed with a thickness of 3 mil, the incrementally stretched portion  158  may have an average thickness of approximately 2.5 mil with the remaining portions of the bag having a thickness of 3 mil. 
         [0066]    Shown in  FIGS. 7 and 8  is an alternative embodiment of the invention. Rather than each incrementally stretched section  116  aligned with one of the wave-cuts  152 , each incrementally stretched section  116  can be offset from each wave-cut  152 . In this embodiment, each incrementally stretched section  116  is between adjacent perforation lines  140  and wave-cuts  152  so that a bag body  160  of each resultant bag  154  is incrementally stretched. The bag body  160  can be located between the lower extent of the bag top  152   a  and the bag bottom  144   a.    
         [0067]    In one particular example of the embodiment shown in  FIGS. 7 and 8 , the intermeshing rollers  122   a ,  122   b  can engage the collapsed tube  110  approximately 2.5 inches away from each side of each perforation line  142 . Each incrementally stretched section  116  can be approximately 40 inches long, which results in a length of approximately 7.5 inches of un-stretched film from the upper extent of the bag top  152   a  to a top of the incrementally stretched bag body  160  for a bag having a total length of 50 inches. The bag body  160  can be stretched approximately 17 percent so that an initial film thickness of 3 mil is stretched to approximately 2.5 mil within the bag body  160 . This embodiment allows less film to be used than an un-stretched bag. 
         [0068]    The embodiment shown in  FIGS. 7 and 8  may also be implemented on a wave-cut trash bag having typical dimensions of a kitchen trash bag. The bag body  160  can be stretched approximately 16 percent so that an initial film thickness of 0.7 mil is stretched to approximately 0.6 mil within the bag body  160 . 
         [0069]      FIG. 9  illustrates yet another embodiment of the incremental stretching operation. Shown in  FIG. 9  is a top planar view of an alternate embodiment of the outer surface of upper intermeshing roller  122   a . The closely spaced parallel lines of  FIG. 9  represent edges of each protruding ridge  126   a . Although not to the same extend as previous illustrations, the spacing between adjacent ridges is exaggerated for ease of illustration. For reference, shown in dashed lines is the outline of the intended corresponding placement of a wave-cut  152 . Within the plurality of protruding ridges  126   a  is shown a plurality of ridge voids  132 . Each ridge void  132  is a location from which a length of protruding ridges has been removed from the intermeshing roller  122   a . Each ridge void  132  defines a location where the intermeshing roller  122   a  will fail to stretch the collapsed tube  110  within each incrementally stretched section  116 . The ridge voids  132  are located about the intermeshing roller  122   a  such that an upper region of each lobe  156  of each bag  154  is left un-stretched. 
         [0070]      FIG. 10  illustrates the structure of bag  154   a  formed by the alternate embodiment of the incremental stretching operation as illustrated by  FIG. 9 . As a result of the plurality of ridge voids  132 , defined in an upper region of each lobe  156  is an un-stretched tip  132   a  that is devoid of any ribs that otherwise would have been formed by the incremental stretching operation. As shown in  FIG. 10 , a plurality of un-stretched tips  132  is defined on the bag  154 . In a likewise manner, the incrementally stretched portion  158  of the bag does not extend to the upper extent of the bag top  152   a . The remaining features of bag  154   a  remain unchanged from the embodiment illustrated in  FIGS. 5 and 6 . The un-stretched tips  132   a  may further improve the ease of tying the wave-cut trash bag versus the previously described embodiments. 
         [0071]    As previously noted, the specific embodiments depicted herein are not intended to limit the scope of the present invention. Indeed, it is contemplated that any number of different embodiments may be utilized without diverging from the spirit of the invention. Therefore, the appended claims are intended to more fully encompass the full scope of the present invention.