Abstract:
A novel bag for holding, transporting, and pouring a bulk product is provided. The bag comprises a perforated section extending the majority of the way (and preferably the entire way) horizontally across the bag. The bag can be opened by tearing along the perforations and separating the resulting two sections of the bag. The bag is typically formed of plastic, and can be used for salt, animal food, and other pourable products.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention is broadly concerned with the field of bags for holding pourable products such as salt, and more particularly bags having a perforated section that extends substantially, and preferably entirely, horizontally across the bag, for removal and pouring of the product from the bag. 
         [0003]    2. Description of the Prior Art 
         [0004]    Bag are commonly used to hold and transport pourable products (i.e., products comprising numerous small pieces). Such products include salt cubes or pellets, animal food, flour, and sugar, to name a few. These pourable products are typically sold in large quantities (e.g., 30-50 lbs.) and in bulk sizes that are difficult for the average person to handle. Even more difficult than carrying these bags is pouring the product from the bulky bag. That is, the consumer must open the bag, attempt to pick up the very heavy bag, and carefully pour the product in a controlled manner. This often results in spilling of the product, which goes from not coming out at all to rapidly falling from the bag and outside of the target area. There is a need for a bag that can be more easily opened at the point of use, as well as more easily poured with minimal or no spillage. 
       SUMMARY OF THE INVENTION 
       [0005]    In one embodiment, the invention provides a bag for holding a pourable product. The bag comprises front and back panels comprising first and second end portions presenting respective outermost edges and first and second side portions presenting respective outermost edges. The front and back panels and the end and side portions cooperate to form a chamber for holding the pourable product. There is a width “W,” defined as the shortest distance between the respective outermost edges of the first and second side portions. The perforations extend from at least one of the respective outermost edges of the first and second side portions at a distance of at least about 50% of “W,” towards the other of the respective outermost edges of the first and second side portions. 
         [0006]    In another embodiment, a method of using the above inventive bag is provided. The method comprises tearing the bag at the perforations to create an opening, and causing the pourable product to exit the bag from the opening, preferably by tilting the bag. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    FIG. ( FIG. 1  is a front elevation view of a bag according to the invention; 
           [0008]      FIG. 2  is a rear elevation view of a bag according to the invention; and 
           [0009]      FIG. 3  is a front elevation view illustrating the dimensions of a bag according to the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0010]    With reference to  FIGS. 1-3 , a bag  10  is illustrated. Bag  10  includes a front panel  12  and a back panel  14 . As shown, front and back panels  12 , 14  are flat to demonstrate their respective shapes before being filled with product. Front panel  12  and back panel  14  share a first end portion  16  and a second end portion  18 . 
         [0011]    Front panel  12  and back panel  14  further share a first side portion  20  and a second side portion  22 . First and second end portions  16 ,  18  and first and second side portions  20 ,  22  present respective outermost edges  24   a - d,  which define an outer boundary or periphery  26  of the bag  10 . Outermost edges  24   a  and  24   b  oppose, and are substantially parallel to, one another, while outermost edges  24   c  and  24   d  oppose, and are substantially parallel to, one another. Furthermore, outermost edges  24   c  and  24   d  are substantially perpendicular to outermost edges  24   a  and  24   b.    
         [0012]    Each of the first and second end portions  16 ,  18  intersects with first and second side portions  20 ,  22  at corners  28   a - d.  Front and back panels  12 ,  14 , first and second end portions  16 ,  18 , and first and second side portions  20 ,  22  cooperate to form a chamber for holding a pourable product. 
         [0013]    First end portion  16  comprises a first horizontal seam  30  spaced apart from outermost edge  24   a,  thus forming a flap  32  in first end portion  16 . First horizontal seam  30  has a thickness of from about 1/16 inch to about ¼ inch (and more preferably about ⅛ inch) and is substantially parallel to outermost edge  24   a.  Flap  32  comprises a handle  34  formed therein. Handle  34  comprises a patch  36  that is heat-sealed to the flap  32 . Patch  36  could be heat-sealed on either side of the flap  32  (i.e., on front panel  12  or on back panel  14 ), or on both sides if extra strength is required. Patch  36  can be any material typically used for bags carrying bulk products, including plastics such as linear low density polyethylenes (LLPDE). A C-shaped grip  38  is formed through patch  36  and flap  32  to form an opening, through which a user may place his or her fingers during carrying, pouring, etc. Outmost edge  24   a  of first end portion  16  is bisected by centerline  40  (see  FIG. 3 ). In a preferred embodiment, handle  34  is positioned such that some portion of the grip  38  falls upon the centerline  40 . Also, while it will be appreciated that the handle  34  is integrally formed with the bag  10  (and particularly with flap  32 ) as described above, one may also substitute an integrally formed handle with a separately formed handle that is then physically attached to the bag  10 . 
         [0014]    The bag  10  further comprises perforations  42  in front and back panels  12 , 14 . Perforations  42  provide an area where the front and back panels  12 ,  14  can be separated, creating an opening for pouring of product from the bag  10 . Ideally, perforations  42  form a pattern that is linear in nature, and substantially parallel to outermost edges  24   a,    24   b  and substantially perpendicular to outermost edges  24   c,    24   d.  The figures depict perforations  42  extending from outermost edge  24   c  to outermost edge  24   d,  however, in some embodiments, the perforations  42  do not extend entirely across the width “W” of the front and back panels  12 ,  14 , However, it is preferred that the perforations  42  extend at least about 50% of “W,” preferably at least about 75% of “W,” and more preferably about 100% of “W.” Furthermore, although the figures show the perforations  42  at a distance “D 3 ” from outermost edge  24   b,  it will be appreciated that the perforations  42  can be positioned anywhere along the length “L 1 ” of the front and back panels  12 ,  14 , provided perforations  42  are at least about 0.5 inches, and preferably at least about 1 inch, from first horizontal seam  30  and outermost edge  24   b.    
         [0015]    The bag  10  preferably has a side panel  44 . Side panel  44  is essentially a lay-flat fold whose width is defined by a turn axis  46 . Side panel  44  allows for expansion of the bag upon filling with the pourable product. 
         [0016]    Referring to  FIG. 3 , several dimensions of the inventive bag  10  have been defined. The ranges for those dimensions are shown in Table 1. 
         [0000]    
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Preferred Bag Dimensions 
               
             
          
           
               
                 Dimension 
                 Broad Range 
                 Preferred Range 
                 Most Preferred Range 
               
               
                 from FIG. 3 
                 (inches) 
                 (inches) 
                 (inches) 
               
               
                   
               
               
                 L 
                 about 20 to about 35 
                 about 24 to about 30 
                 about 26 to about 28 
               
               
                 W 
                 about 10 to about 24 
                 about 14 to about 20 
                 about 15 to about 18 
               
               
                 D 1   
                 about 2 to about 3.5 
                 about 2.2 to about 3 
                 about 2.4 to about 2.8 
               
               
                 D 2   
                 about 2 to about 4 
                 about 2.5 to about 4.5 
                 about 2.9 to about 3.2 
               
               
                 D 3 * 
                 about 0.5 to about 10 
                 about 2 to about 8 
                 about 4 to about 7 
               
               
                 L 1   
                 about 17 to about 30 
                 about 20 to about 28 
                 about 22 to about 26 
               
               
                 L 1 /D 3 * 
                 about 2 to about 15 
                 about 2 to about 10 
                 about 3 to about 7 
               
               
                   
               
               
                 *Distance from either outermost edge 24b or first horizontal seam 30. 
               
               
                 **Unitless 
               
             
          
         
       
     
         [0017]    The inventive bag  10  can be manufactured by various methods, but the preferred method is described herein. First, a tube or sleeve of plastic is cut to the desired length (represented by “L” in  FIG. 3 ). The plastic of which the inventive bag is formed can be any material typically used to form bags carrying bulk products. The plastic should be flexible and stretchable so that the bag collapses as the bulk product is poured from the bag. Preferably, the plastic of which the bag is formed stretches from about 1 to about 2 times at yield, and more preferably about 1.5 times at yield. Furthermore, it is preferred that the bag be formed of a plastic that stretches at least about 4 times, preferably at least about 5 times, and more preferably from about 5 to about 7 times at its break point. Thus, the preferred plastic has an ASTM D882 percent elongation of from about 200% to about 800%, preferably from about 400% to about 700%, and more preferably from about 500% to about 650%. The thickness of the preferred plastic is from about 2 mil to about 14 mil, preferably from about 4 mil to about 10 mil. and more preferably from about 6 mil to about 8 mil. The most preferred material is LLDPE. 
         [0018]    A heat seal is then applied at first end portion  16  in order to form horizontal seam  30 . A film (typically having a 10-mil thickness) is heat-sealed to flap  32  to form patch  36 . C-shaped grip  38  is then cut (e.g., die-cut) through the patch  36  and flap  32 , thus forming handle  34 , which serves as the primary carrying handle. The perforations  42  can be added at this time according to conventional methods. 
         [0019]    The manufactured bag can then be stored until needed, or immediately filled and sealed. Either way, after the bag  10  is filled to the desired level, a final heat seal is applied at second end portion  18  to create second horizontal seam  44 , making the filled bag  10  ready for distribution. It will be appreciated that the inventive bag  10  can be used to transport and store numerous types of pourable products, including cubes, pellets, tablets, powders, compacted pieces, and/or granules of those selected from the group consisting of: salt (e.g., water softening, pool treatment, deicing, etc.); animal food (e.g., bird seed, grain, dog or cat food); bulk flour or sugar; cement; seed (e.g., grass seed) and other lawn and garden products; fertilizers; ice; sand; rice; spices; soil (including soil mixtures); pesticides (e.g., fire ant treatments); industrial chemicals; mortar; plaster; marble dust; stones (including pebbles and gravel); and constructions products. Such products will typically cause the bags to weigh from about 20 lbs. to about 100 lbs., and more typically from about 40 lbs. to about 60 lbs. 
         [0020]    In use and before pouring, a user would tear the front and back panels  12 ,  14  at perforations  42  in order to separate (or at least partially separate) strip  48  from the remainder 50 of bag  10 . It will be appreciated that this allows for easy pouring of the product from the bag 10. 
         [0021]    This controlled pouring allows for fairly exact dispensing of the product, while preventing spillage and waste of the product. This type of opening is particularly advantageous in situations where the bag is being poured into a large opening. The user can just lay the bag on top of the large opening and use both hands to tear perforations  42  and separate strip  48  from remainder  50 , thus avoiding the need to hold and tilt a heavy bag during product removal.