Abstract:
The present invention relates to articles such as bags and related methods. In an embodiment, the invention includes an article including a first sheet, a second sheet coupled to the first sheet defining an interior volume between the first sheet and the second sheet, and a handle region defining an aperture passing through the first sheet and the second sheet. The handle region including a first flap and a second flap, the first flap coupled to the first sheet and the second sheet along a first axis, the second flap coupled to the first sheet and the second sheet along a second axis, the first axis and second axis perpendicular to one another, the first flap and the second flap configured to flex away from the handle region. In an embodiment, the invention includes a method of forming a bag including coupling a first sidewall to a second sidewall to form a rectangular bag with four corners and forming a cut pattern through the first sidewall and the second sidewall to form a handle, the pattern outlining the shape of a plurality of flaps that can each flex along separate axes. Other embodiments are also included herein.

Description:
FIELD OF THE INVENTION 
     The present invention relates to articles such as bags and related methods. More specifically, the present invention relates to articles for holding a particulate product and related methods. 
     BACKGROUND OF THE INVENTION 
     Dry particulate products such as bird seed, grass seed, water softener salt, and pet food are often sold by retailers in prefilled bags. Such bagged products can be quite heavy depending on their volume, sometimes weighing 50 pounds or more. It can be difficult to grip such bags because of their shape and because they are often made of a relatively slick plastic material. As such, because of both weight and difficulty in gripping, it can be difficult for consumers to manipulate such bagged products. 
     Such bagged products can also be problematic for retailers because of their propensity to rupture, leading to messy spills of the product contained therein. The shear weight of the product contained therein places unique demands on bag construction that are quite distinct from that of other types of bags such as grocery bags or common retailer bags. 
     Unfortunately, cost constraints make it difficult to solve these issues. Even adding pennies of additional cost to a bag design can render it unfeasible for use with near-commodity bagged products sold in mass-market retailers. 
     Accordingly, a need remains for articles for holding dry particulate products. 
     SUMMARY OF THE INVENTION 
     The present invention relates to articles for holding a product and related methods. In an embodiment, the invention includes an article including a first sheet, a second sheet coupled to the first sheet defining an interior volume between the first sheet and the second sheet, and a handle region defining an aperture passing through the first sheet and the second sheet. The handle region including a first flap and a second flap, the first flap coupled to the first sheet and the second sheet along a first axis, the second flap coupled to the first sheet and the second sheet along a second axis, the first axis and second axis perpendicular to one another, the first flap and the second flap configured to flex away from the handle region. 
     In an embodiment, the invention includes a bag including a first sidewall, a second sidewall coupled to the first sidewall defining an interior volume between the first sheet and the second sheet, and a die-cut handle. The die-cut handle including a first flap and a second flap, the first flap coupled to the first sidewall and the second sidewall along a first axis, the second flap coupled to the first sidewall and the second sidewall along a second axis, the first axis and second axis perpendicular to one another. The first and second flaps configured to flex between a closed position where the flaps are substantially planar with the first and second sidewall and an open position where the flaps are not-planar the first and second sidewall. 
     In an embodiment, the invention includes a method of forming a bag including coupling a first sidewall to a second sidewall to form a rectangular bag with four corners and forming a cut pattern through the first sidewall and the second sidewall to form a handle, the pattern outlining the shape of a plurality of flaps that can each flex along separate axes. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a schematic view of an article in accordance with an embodiment of the invention. 
         FIG. 2  is an enlarged schematic view of the handle region of the article shown in  FIG. 1 . 
         FIG. 3  is a schematic view of the hand of a user manipulating an article in accordance with an embodiment of the invention. 
         FIG. 4  is an opposite side view of the embodiment shown in  FIG. 3 . 
         FIG. 5  is a cross-sectional schematic view of two flaps in a closed configuration. 
         FIG. 6  is a cross-sectional schematic view of a two flaps in an open configuration. 
         FIG. 7  is a schematic view of a handle region shown in accordance with another embodiment of the invention. 
         FIG. 8  is a cross-sectional view (not to scale) of an article as taken along line  8 - 8  of  FIG. 1 . 
         FIG. 9  is a cross-sectional view (not to scale) of an article as taken along line  9 - 9  of  FIG. 1 . 
         FIG. 10  is an exploded view of a support layer disposed between a first sheet and a second sheet in accordance with an embodiment of the invention. 
         FIG. 11  is an exploded view of a support layer disposed outside of a first sheet and a second sheet in accordance with an embodiment of the invention. 
         FIG. 12  is a schematic view of an article in accordance with another embodiment of the invention. 
         FIG. 13  is a schematic view of the handle region of an article in accordance with another embodiment of the invention. 
     
    
    
     While the invention is susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings, and will be described in detail. It should be understood, however, that the invention is not limited to the particular embodiments described. On the contrary, the intention is to cover modifications, equivalents, and alternatives falling within the spirit and scope of the invention. 
     DETAILED DESCRIPTION OF THE INVENTION 
     It can be difficult for customers to grip and manipulate bagged products, such as bagged bird seed or grass seed, because of the shape and weight of the filled bags, and also because the bags are often made of a relatively slick plastic material. 
     In some cases, handles have been attached to such bags in order to make them easier to manipulate for retail customers. However, because of the weight the bags, and because such handles generally result in concentrating the force of the bag weight over a small area of the hand, using handles can result in significant discomfort for bag users. 
     In addition, where bags have included handles, they are traditionally placed over the center of the bag. However, center placement is not an ideal placement of a handle for the purpose of pouring product, particularly a heavy product. A center-placed handle will increase the stress on the hand and wrist in the lifting and pouring of dry product, because the wrist must be cocked to approximately a 30 degree angle in order to elevate and handle packages with center-placed handles. 
     In some embodiments herein, a handle is formed in an article, such as a bag, in a manner so as to make the handle more comfortable for use. It has been observed that discomfort arises in an acute manner particularly where a cut edge of bag material is driven into the hand of the user by the overall weight of the bag and the product contained therein. In various embodiments herein, multiple flaps are used to make the handle more comfortable to use. Specifically, in various embodiments, the handle is formed such that flaps of bag material prevent a cut edge of bag material from contacting the hand of a user. The flaps of bag material can flex away from the plane of the package when a user inserts their hand into the handle, such that the edges of the flaps that are still connected to the rest of the package come in contact with the user&#39;s hand, instead of a cut edge of the bag. The use of flaps in this manner can lead to increased comfort on the part of the consumer picking up and/or carrying the bag, particularly in the context of bags loaded with a heavy product. 
     In some embodiments herein, two-layer laminate materials are used to construct articles, such as bags, that can be used to hold dry particulate products such as bird seed, grass seed, and the like. As such, some embodiments herein include an article as described herein in combination with a dry particulate product disposed within the article. Two-layer laminate materials can offer advantages in terms of product strength and/or product appearance. However, the use of such materials can be complicated by the varying properties each layer of the laminate. By way of example, a two-layer laminate of including a first layer of polyester, polyethylene, polypropylene or polyamide (e.g., nylon) and a second layer of polyethylene can be advantageous because it offers significant strength and can allow for an smooth and aesthetic outer surface while maintaining high strength. However, depending on the specific polymer or polymer alloy used in the laminate, the outer layer may not be conducive to heat-sealing. As such, use of such a laminate in a heat-sealed bag that has sufficient strength against rupture, particularly along seams or along tears or perforations in the structure, presents challenges. 
     However, embodiments of the invention herein include an article that incorporates a two-layer laminate into a heat-sealed bag in a manner that provides the advantages of two-layer laminates along with sufficient strength to resist ruptures along seams or along tears or perforations in the structure including in the area of the bag handle. 
     While not intending to be bound by theory, it is believed the bag can be made more ergonomic by placing the handle near a corner. Specifically, the placement of the handle near a corner of the package can make it easier to handle and pour the product. In some embodiments, the handle is positioned in a corner of the bag. 
     Various aspects of exemplary embodiments of the invention will now be described in greater detail. Referring now to  FIG. 1 , a schematic view of an article in accordance with an embodiment of the invention is shown. The article  100  includes a body  102  having a top edge  160 , a bottom edge  162 , a first side edge  164 , and a second side edge  166 . The article  100  also include a first corner  168 , second corner  170 , third corner  172 , and fourth corner  174 . In this embodiment, the body  102  of the article  100  is rectangular in shape. However, it will be appreciated that the body  102  can also take on other shapes such as semi-rectangular, square, semi-square, oblong, semi-rounded or the like. The article can include a handle region  104 . The handle region  104  can facilitate gripping of the article  102 . In some embodiments, the article  102  can also include a pouring region  106 . In some embodiments, the pouring region  106  can be defined by a scored line. The pouring region  106  can be adjacent to one end of the top edge  160 , while the handle region  104  can be adjacent to the opposite end of the top edge  160 . 
     Referring now to  FIG. 2 , an enlarged schematic view of the handle region  104  is shown. The handle region  104  can be configured to facilitate comfortable gripping of the article  102 . In some embodiments, the handle region  104  can include cut lines  138 ,  140 , and  142  that allow multiple flaps of material to flex away when a person&#39;s hand is inserted into the handle, creating a tactile feeling of increased comfort for the bag user. Cut lines  138 ,  140 , and  142  can allow flaps  122 ,  126 ,  130 , and  134  to move independently from one another. For example, when a person&#39;s hand is inserted, flap  122  can bend away from the plane of the body  102  along a first axis (line  124 ) and flap  126  can bend away from the body  102  along a second axis (line  128 ). In some embodiments, the first axis can be perpendicular to the second axis. Flap  130  can bend away from the body  102  along a third axis (line  132 ) and flap  134  can bend away from the body  102  along a fourth axis (line  136 ). In use, the weight of the bag will be supported by the user&#39;s hand through contact with the non-cut edge of the flaps that is still connected to the rest of the bag (e.g., the user&#39;s hand will support the weight by contact with the bag along one or more of the first axis, second axis, third axis, and fourth axis). In this manner, the flaps  122 ,  126 ,  130 , and  134  can serve to prevent the user&#39;s hand from supporting the weight of the bag through contact with a cut-edge of the material of the body  102 , thereby increasing comfort. 
       FIG. 3  is a schematic view of the hand  250  of a user manipulating an article in accordance with an embodiment of the invention. In this view, the article  200  includes a body  202  with a particulate product  252  disposed therein. The article  200  also includes a pouring region  206  that can include a perforation line to facilitate opening of the pouring region  206 . When a user&#39;s hand  250  is inserted into the handle region  204 , the article  200  is tilted with respect to the direction of gravity  254  because of the weight of the particulate product  252 . As such, when in a carrying position, the handle region  204  of the article  200  is disposed at the highest point of the article  200 . 
       FIG. 4  is an opposite side view of the embodiment shown in  FIG. 3 . This view shows the flaps  222 ,  226 ,  230  and  234  bent backward because of the insertion of the user&#39;s hand  250 . In this manner, pressure on the user&#39;s hand  250  exerted by the force of gravity acting on the weight of the particulate material  252  contained in the article  200  is distributed across the portion of the flaps that contacts the rest of the article  200  and is bent. In this particular carrying position, the weight of particulate material  252  would mostly be supported by the user&#39;s hand as it contacts flap  224  and flap  230 . As such, this configuration of the handle region  204  prevents the entire load being supported against the user&#39;s hand  250  through contact with a cut-edge, leading to increased comfort for the user. 
     Referring now to  FIG. 5 , a cross-sectional schematic view of a portion of a handle  260  is shown. The handle includes a first flap  262  and a second flap  264 . In this view, the first flap  262  and second flap  264  are in a closed configuration, substantially planar with the rest of the bag (not shown). As described above, the flaps can flex outwardly. Referring now to  FIG. 6 , a cross-sectional schematic view of a portion of the handle  260  is shown in an open configuration. In the open configuration, the flaps have flexed such that the cut ends ( 270  and  272 ) of the first flap  262  and second flap  264  are now pointed away from the region  274  in between the two flaps  262  and  264 . This can occur, for example, in response to a user inserting their hand into the region  274  in between the two flaps  262  and  264 . In the open configuration, a user&#39;s hand can support the weight of a bag through contact with the portions  266  and  268  of the flaps  262  and  264  connected to the rest of the bag. As such, in the open configuration, the user need not support the weight of a bag through contact with cut edges, thereby increasing comfort for the user. 
     It will be appreciated that the cut lines in the handle region can be formed in various ways including die-cutting, laser-cutting, thermal-cutting, and the like. It will also be appreciated that the precise pattern of cut lines can take on many different forms. Referring now to  FIG. 7 , a schematic view of a handle region is shown in accordance with another embodiment of the invention. In this embodiment, the handle region  304  includes a first flap  322  and a second flap  326 . The flaps  322 ,  326  are formed in part through a first cut line  340  and a second cut line  342 . The cut lines  340 ,  342  enable the flaps  322 ,  326  to flex along lines  324  and  328  respectively. In use, a user&#39;s hand (not shown) would be inserted into the handle region  304  and the weight of the article would be supported by the user&#39;s hand along flex line  324  of the first flap  322  and along flex line  328  of the second flap  326 . 
     In some embodiments of the invention, a reinforcing material is disposed in between two separate laminate sheets in order to provide extra strength in the handle region. Referring now to  FIG. 8 , a cross-sectional view (not to scale) of an article in accordance with an embodiment of the invention is shown as taken along line  8 - 8  of  FIG. 1 . In this view, a first laminate  172  and a second laminate  174  are configured such that the edges of the laminates are coupled to one another. This coupling can be achieved using various techniques including the use of adhesives, heat-sealing, sonic welding, and the like. Each laminate can include multiple layers of material. By way of example, first laminate  172  can include a first layer  146  and a second layer  148 . The first layer  146  can include polyester, polyethylene, polypropylene, polyamide, and/or alloys including the same and the second layer  148  can include polyethylene or polyethylene alloys. Similarly, second laminate  174  can include a first layer  152  and a second layer  150 . The first layer  152  can include polyester, polyethylene, polypropylene, polyamide, and/or alloys including the same and the second layer  150  can include polyethylene or polyethylene alloys. Together, the first layer  146  and the second layer  148  can define an interior volume  154 . It is within the interior volume  154  that the article can contain a product, such as a dry particulate material (not shown). 
     However, in the handle region, the article may include an additional layer of material in some embodiments. Referring now to  FIG. 9 , a cross-sectional view (not to scale) of an article is shown as taken along line  9 - 9  of  FIG. 1 . Cut line  142  is also shown in this cross-sectional view. In this view, a support layer  156  is disposed in between the first laminate  172  and the second laminate  174 . In some embodiments the support layer  156  can be composed of a material that can be heat sealed to both the second layer of the  148  of the first laminate  172  and the second layer  150  of the second laminate  174 . In this configuration, the support layer  156  can strengthen and reinforce the handle region, making it less likely to tear or rupture. This can be particularly important in the context of articles that have multiple cut lines, such as that shown in  FIG. 1  and  FIG. 7  since additional cut lines create additional points where a tear can begin. Reinforcement can be important as in some embodiments the bag may be configured to carry an amount of a product exceeding 10 pounds in weight. In some embodiments, the bag may be configured to carry an amount of a product exceeding 20 pounds in weight. In some embodiments, the bag may be configured to carry an amount of a product exceeding 30 pounds in weight. In some embodiments, the bag may be configured to carry an amount of a product exceeding 40 pounds in weight. 
       FIG. 10  is an exploded view of a support layer  456  disposed between a first sheet  472  and a second sheet  474 . In some embodiments, the first sheet  472  and the second sheet  474  can comprise laminates. The first sheet  472 , the support layer  456 , and the second sheet  474  can all be bonded together in order to make an article such as a bag for particulate material. 
     However, a support layer can also be disposed on the outside of the first sheet and the second sheet.  FIG. 11  is an exploded view of a support layer  556  disposed outside of a first sheet  572  and a second sheet  574 . The support layer  556 , the first sheet  572 , and the second sheet  574  can all be bonded together in order to make an article such as a bag for particulate material. 
     Embodiments of the invention can also include various other features in order to facilitate their use. By way of example referring now to  FIG. 12 , an article  600  is shown including a handle region  604 . The article also includes an opening strip  606  disposed across the top edge of the article  600 . The opening strip  606  can be removed in order to facilitate the opening of the article  600 . In some embodiments, the opening strip  606  can include a perforation line in order to facilitate removal of the opening strip  606 . In some embodiments, the article can also include a reclosure mechanism (not shown) such as a compression seal in order to facilitate reclosure of the article after removal of the opening strip  606 . In some embodiments, the article  600  can also be configured to include one or more gussets  610  in order to facilitate expansion of the interior volume of the bag in order to hold dry particulate matter. 
     It will be appreciated that handle regions having multiple flaps in accordance with embodiments herein can take on many different configurations. While not intending to be bound by theory, it is believed that there can be various manufacturing advantages associated with configurations wherein the flaps can be formed by die-cutting along lines that are not curved. For example, it can be easier to maintain the sharpness of a die that only needs to cut along straight line segments as opposed to curved line segments. Referring now to  FIG. 13 , an enlarged schematic view of the handle region  704  is shown in accordance with another embodiment herein. The handle region  704  can be configured to facilitate comfortable gripping of the article  702 . In some embodiments, the handle region  704  can include cut lines  738 ,  740 , and  742  that allow multiple flaps of material to flex away when a person&#39;s hand is inserted into the handle, creating a tactile feeling of increased comfort for the bag user. Cut lines  738 ,  740 , and  742  can allow flaps  722 ,  726 ,  730 , and  734  to move independently from one another. For example, when a person&#39;s hand is inserted, flap  722  can bend away from the plane of the body  702  along a first axis (line  724 ) and flap  726  can bend away from the body  702  along a second axis (line  728 ). In some embodiments, the first axis can be perpendicular to the second axis. Flap  730  can bend away from the body  702  along a third axis (line  732 ) and flap  734  can bend away from the body  702  along a fourth axis (line  736 ). In use, the weight of the bag will be supported by the user&#39;s hand through contact with the non-cut edge of the flaps that is still connected to the rest of the bag (e.g., the user&#39;s hand will support the weight by contact with the bag along one or more of the first axis, second axis, third axis, and fourth axis). In this manner, the flaps  722 ,  726 ,  730 , and  734  can serve to prevent the user&#39;s hand from supporting the weight of the bag through contact with a cut-edge of the material of the body  702 , thereby increasing comfort. 
     It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a compound” includes a mixture of two or more compounds. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     It should also be noted that, as used in this specification and the appended claims, the phrase “configured” describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration to. The phrase “configured” can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like. 
     All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference. 
     The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.