Abstract:
A method of manufacturing a biodegradable dry cleaning bag is disclosed, the method including loading an environmentally friendly slurry into a hopper, extruding the environmentally friendly slurry, passing the environmentally friendly slurry through a die, inflating the environmentally friendly slurry into a cylindrical shape, thereby creating a cylindrical member, passing the cylindrical member over a first roller, and rolling the cylindrical member onto a roll.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims the benefit of U.S. Provisional Patent Application No. 62/360,488, entitled “ENVIRONMENTALLY FRIENDLY DRY CLEANING BAGS,” filed Jul. 11, 2016, the entire contents of which are incorporated by reference herein. 
     
    
     BACKGROUND 
     Technical Field 
       [0002]    The present disclosure is directed generally to environmentally friendly bags. More specifically, the application relates to biodegradable environmentally friendly bags used to protect garments, and methods of making same. 
       Description of Related Art 
       [0003]    When it comes to protecting clothing, and particularly garments, from coming into contact with undesirable substances (e.g., dirt, water, etc.) during transportation or storage, clear plastic films are often used to enclose garments. These plastic films may be partially transparent and may further be used in a wide variety of applications, such as packaging or storage, of which typical examples are bags dry cleaning. 
         [0004]    Current plastic covers or bags permit an individual to protect the appearance of a garment by fitting over or surrounding at least a portion of the garment. These plastic bags may be cumbersome due to their construction and often are not easily recycled upon disposal. Specifically, existing plastic covers are often manufactured with non-recyclable materials such as polyethylene and other plastics. 
         [0005]    Many professional dry cleaners provide light weight plastic bags as a cover to protect freshly dry cleaned or laundered garments. The light weight plastic bags help keep the clean clothes isolated during transportation. These bags may present suffocation hazards, cause yellowing while in prolonged contact with garments, or otherwise stain or weaken the garment fibers. The yellowing and other changes in color is often caused by the presence of butylated hydroxyl tolune (BHT), an anti-oxidant used in the manufacturing of the plastic bag. When BHT comes in contact with moisture and air impurities, the BHT may cause a yellow pigment to be deposited onto the fabric. Further, the plastic bag may trap moisture against the garment and, if left in place for extended periods of time, may lead to the growth of mold or mildew. 
         [0006]    Dry cleaning bag users tend to discard dry cleaning bags once their garments are transported. Dry cleaning bags are not biodegradable and difficult to recycle since they are often made with low-density polyethylene (LDPE). This particular type of thin, clear plastic is often referred to as “film” in the recycling industry. However, these materials are not uniformly accepted as recyclable material, and as such, often are disposed of in the trash. Likewise, many consumers prefer not to recycle due to inconvenience, again leading to the disposal of the bags in the trash. Thus, there is a desire for disclosures related to dry cleaning bags which are biodegradable. 
       SUMMARY 
       [0007]    According to one aspect, the present disclosure relates to a method of manufacturing a biodegradable dry cleaning bag. The method includes loading an environmentally friendly slurry into a hopper, extruding the environmentally friendly slurry, passing the environmentally friendly slurry through a die, inflating the environmentally friendly slurry into a cylindrical shape, thereby creating a cylindrical member, passing the cylindrical member over a first roller, and rolling the cylindrical member onto a roll. 
         [0008]    According to aspects, the method includes loading an environmentally friendly slurry including organic fibers. 
         [0009]    In certain aspects, the method includes loading an environmentally friendly slurry including fibers derived from materials selected from the group consisting of trees, non-wood plants, cellulose based plants, wood, bagasse, miscanthus, wheat, grass, switchgrass, bamboo, eucalyptus, alfalfa, corn, barley, and combinations thereof. 
         [0010]    In some aspects, the method further includes processing fibers to remove lignin polymers. 
         [0011]    In aspects, the method further includes passing the cylindrical member over a second roller. 
         [0012]    According to aspects, passing the cylindrical member over the second roller includes the second roller having at least one protrusion which defines a predetermined pattern. 
         [0013]    According to certain aspects, passing the cylindrical over the second roller further includes the predetermined pattern forming a transverse line across the cylindrical member. 
         [0014]    In certain aspects, the transverse line forms a perforated line. 
         [0015]    In aspects, the predetermined pattern forms a plurality of transverse lines across the cylindrical member, defining a plurality of dry cleaning bags. 
         [0016]    In aspects, the method further includes passing the plurality of dry cleaning bags over a third roller, the third roller including a second pattern. 
         [0017]    In some aspects, passing the plurality of dry cleaning bags over the third roller includes forming a first and second shoulder on each of the dry cleaning bags. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and, together with a general description of the disclosure given above, and the detailed description of the embodiment(s) given below, serve to explain the principles of the disclosure. 
           [0019]      FIG. 1  is a plan view of a dry cleaning bag in accordance with the present disclosure; 
           [0020]      FIG. 2  is a plan view of an alternate embodiment of the dry cleaning bag of  FIG. 1 ; 
           [0021]      FIG. 3  is a system diagram of an apparatus for constructing the dry cleaning bag of  FIGS. 1 and 2 ; 
           [0022]      FIG. 3A  is a top plan view of the pair of rollers coupled to the bubble container of  FIG. 3 ; 
           [0023]      FIG. 3B  is a perspective of a roller including a pair of opposing flanges disposed circumferentially about a roller in accordance with aspects of the present disclosure; 
           [0024]      FIG. 3C  is a diagram of a pattern disposed along a roller in accordance with aspects of the present disclosure; and 
           [0025]      FIG. 3D  is a an alternate diagram of a pattern disposed along a roller in accordance with aspects of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    Embodiments of the present disclosure are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. 
         [0027]      FIG. 1  illustrates a dry cleaning bag in a first position, designated generally  10 . The dry cleaning bag  10  includes a shell having a front portion  11  and a back portion  12 , the front and back portions  11 ,  12  further including inner and outer surfaces, respectively. The front portion  11  and the back portion  12  are coupled along seams  14 . When coupled, the front and back portions  11 ,  12  partially enclose a cavity “C” therein. 
         [0028]    The dry cleaning bag  10  further includes a first opening  15  located along an upper portion of the dry cleaning bag  10 . The first opening  15  is dimensioned to receive a hook portion  16  of a hanger  17  therethrough. The dry cleaning bag  10  further includes a second opening  18  located along a lower portion of the dry cleaning bag  10 . The second opening  18  defines a diameter which is greater than a diameter defined by the first opening  15 . The second opening  18  is configured to receive garments (not shown) therein. Specifically, the dry cleaning bag  10  is configured to be placed over the hook portion  16  of a hanger  17 , and advanced over garments (not shown) disposed on the hanger  17 . The first opening  15  is in opposing relation to the second opening  18 . 
         [0029]    The dry cleaning bag  10  may include a plurality of perforations  11   a ,  12   a  disposed along the front surface  11  or back surface  12 . The plurality of perforations  11   a ,  12   a  may be disposed along the front surface  11  or the back surface  12 . The plurality of perforations  11   a ,  12   a  may further be disposed in patterned formations or randomly disposed along the front surface  11  and back surfaces  12 . The plurality of perforations  11   a ,  12   a  may be placed selectively so as to prevent the risk of suffocation by individual or animals. Additionally, the perforations  11   a ,  12   a  may allow for improved air flow between the front portion  11  and the back portion  12 , which may enhance biodegradability of the dry cleaning bag  10 . 
         [0030]    The lower portion of the dry cleaning bag  10  includes a fastener  13  configured to couple the front portion  11  and the back portion  12 , thereby sealing the bottom portion of the dry cleaning bag  10 . More specifically, the fastener  13  includes a first fastener  13   a  and second fastener  13   b . The first fastener  13   a  and second fastener  13   b  selectively couple to one another thereby permitting selective closure of the second opening  18  of the lower portion of the dry cleaning bag  10 . In alternative embodiments, the lower portion of the front surface  11  and the back portion  12 , which define the second opening  18 , may be coupled to each other sealing the second opening  18  during manufacturing. 
         [0031]    The dry cleaning bag  10  defines a pair of shoulders  19 ,  20  which taper upward from a left side  21  and a right side  22  toward the first opening  15 . The shoulders  19 ,  20  are configured to be in direct contact with a right and left portion of the hanger  17 , respectively. 
         [0032]    Referring now to  FIG. 2 , an alternative embodiment of a dry cleaning bag  10  is shown, and referred to generally as dry cleaning bag  10 ′. Similar to dry cleaning bag  10 , dry cleaning bag  10 ′ includes front portion  11  and a back portion  12 . The seams  14 ′ further define a crease or gusset  23  which extends toward the center of the dry cleaning bag  10 ′. The gusset  23  permits expansion of the dry cleaning bag  10 ′ when varying garments (not shown) are located therein. Additionally, a pair of detachable portions  24 ,  25  extends upward from the shoulders  19 ,  20  of the dry cleaning bag  10 ′. The detachable portions  24 ,  25  are coupled to the shoulders  19 ′,  20 ′, respectively, at along seams  26 . The seams  26  are perforated and configured to be detached when upward pressure is applied to the detachable portions  24 ,  25  and downward pressure is applied in an opposing direction to the dry cleaning bag  10 ′, more particularly, when downward pressure is applied to the first and second portion  11 ,  12  of the dry cleaning bag  10 ′. The seams defined by the shoulders  19 ′,  20 ′ are positioned downward relative to the detachable portions  24 ,  25 , respectively. 
         [0033]    The dry cleaning bag  10 ′ may be coupled to a plurality of dry cleaning bags  10 ′ at the upper and lower portions of the dry cleaning bags  10 ′. When coupled, the dry cleaning bags  10 ′ may be combined to form a roll  50  ( FIG. 3 ). The roll  50  includes a plurality of bags  10  coupled via a plurality of perforated or cut lines (not shown). The cut lines are configured to transversally seal the lower portion of a bag  10 ′ from roll  50 . 
         [0034]      FIG. 3  illustrates a system diagram of an apparatus for constructing the dry cleaning bags  10 ,  10 ′ of the present disclosure, the system referred to generally as  30 . The system includes a hopper  32 , an extruder  34 , a die  36 , an air ring  38 , a bubble container  40 , and rollers  42 . The hopper  32  is configured to receive an environmentally friendly slurry  33  (or slurry  33 ) which is described later in detail. Once processed, the environmentally friendly slurry  33  may be loaded into the hopper  32 , which feeds the environmentally friendly slurry  33  into the extruder  34 . The hopper  32  may be loaded with fresh slurry  33 , made of newly processed fibers, or a slurry  33  of partially or completely recycled fibers or recycled slurry  33 . The fibers used to form the environmentally friendly slurry  33  are preferably biodegradable, e.g., made from plant-based, polymeric-based (e.g., biodegradable plastics and/or polymers), or any combination of such materials thereof. In embodiments, it is contemplated that the environmentally friendly slurry  33  may be combined with non-biodegradable slurries or materials such as polyolefin or other thermoplastic fibers, or any combination thereof. Further, it is contemplated that the biodegradable slurry  33  may be combined with biodegradable plastics such as, without limitation, aliphatic polyesters. The slurry  33  may include an adhesive such as a water-based adhesive. When combined with the fibers of the slurry  33 , the adhesive binds the fibers into a finished sheet of film. 
         [0035]    The environmentally friendly slurry  33  is then fed into the extruder  34 . The extruder  34  forms the environmentally friendly slurry  33  into a sheet or film  35 . The film  35  is then passed from the extruder toward the die  36  which forms the film  35  into a tube shape. The die  36  may be an annular slit die, or any other suitable die capable of separating the film  35 . 
         [0036]    The film  35  is then fed into the air ring  38  which applies pressurized gas or air toward the film  35 . As air is directed toward the film  35 , the film  35  is pressed against the walls of the bubble container  40  while maintaining the tube shape. Further, as the film  35  passes through the air ring  38 , the film  35  come into contact with heated air which dries any liquid, including any included adhesive, found in the environmentally friendly slurry  33 , before passing the film  35  toward the bubble container  40 . Drying film  35  prevents the film  35  from coupling or folding over before being received by the rollers  42 . 
         [0037]    As the film  35  is then passed through the bubble container  40 , the film is advanced toward a pair of tapered surfaces  40   a ,  40   b . As the film  35  contacts the pair of tapered surfaces  40   a ,  40   b , respectively, the film  35  folds over to create a flat tube which is subsequently transferred to a pair of rollers  42 . The pair of rollers  42  coupled to the bubble container  40 , commonly referred to as nip rollers, (see  FIG. 3A ) may include a roller  42 ′ which has a first and second flange  42   a ,  42   b  disposed along opposing portions of an exterior surface of the roller  42 ′. As a result of passing between rollers  42 ,  42 ′, the left and right sides  21 ,  22  of the dry cleaning bags  10 , or left and right sides  21 ′,  22 ′ of the dry cleaning bag  10 ′, are formed. 
         [0038]    The rollers  42  may be positioned relative to one another such that a gusset  23  may be formed ( FIG. 2 ) along the sides of the extruded film  35  as the film is passed over the rollers  42 . The film  35  is then passed along additional rollers  42  which allow the film  35  to cool prior to being rolled about a tube  48  to form a roll  50 . Any of the rollers  42  may define varying diameters and may further include transverse flanges  42   c  ( FIG. 3C ). The transverse flanges  42   c  are disposed along the roller to form perforations between the dry cleaning bags  10 ,  10 ′. The transverse flanges  42   c  may be serrated or textured so as to perforate, cut, or otherwise act upon the film  35  as the film  35  passes over the rollers  42 . The transverse perforations formed by the rollers  42  may be spaced at predetermined distances, thereby forming uniform dry cleaning bags  10 ,  10 ′ prior to placing the dry cleaning bags  10 ,  10 ′ onto the tube  48 . Additionally, the transverse flanges  42   c  may be sharpened, or pointed, so as to cut the dry cleaning bags  10 ,  10 ′, thereby eliminating the need to roll the dry cleaning bags  10 ,  10 ′. It is contemplated that the rollers may have varying predetermined patters applied such that the dry cleaning bags  10 ,  10 ′ may take different forms (see  FIG. 3B , illustrating varying roller patterns). 
         [0039]    For a detailed discussion of the extrusion and formation of extruded plastic tubes, reference may be made to U.S. Pat. No. 3,157,720, and U.S. Pat. No. 7,556,762, the entire disclosures of which are hereby incorporated by reference. 
         [0040]    In alternative embodiments, the slurry  33  may be strained through a screen made of fine mesh in order to create a fibrous web. The fibrous web of the slurry  33  may then be pressed and allowed to dry. Pressure may be applied to the fibrous web so as to remove any remaining liquid or water. Once the fibrous web is dehydrated, the fibrous web may be cut to form sheets (not shown). The fibrous web may be partially dehydrated, such that the fibrous web may further be acted upon or processed as desired, e.g., to add colors, increase or reduce transparency by treating the fibrous web with chemicals, etc. The sheets may then be coupled via a water-based adhesive or other such suitable material to allow the sheets to remain in fixed relation relative to one another. The sheets are then cut as necessary to form individual dry cleaning bags  10 ,  10 ′. The combined sheets may also be dimensioned such that the sheets extend to a length suitable to be cut to form multiple dry cleaning bags  10 ,  10 ′. The extended sheet may then be formed in a roll, and cut by the end user, as desired. 
         [0041]    When used by end users or consumers, the roll  50  is placed on a dispenser (not shown). The end user may selectively remove bags, either by tearing one or more dry cleaning bags  10 ,  10 ′ along perforated edges, or by cutting the bags apart with sharp utensils, such as scissors. Once the dry cleaning bag  10 ,  10 ′ is separated from the roll, the dry cleaning bag  10 ,  10 ′ may be placed over one or more hangers holding garments ( FIGS. 1 and 2 ), so that the garments are covered. 
         [0042]    Referring generally to slurry  33  which may be used to form any of the components described, the slurry  33  is formed by mixing liquid and fibers, which form a pulp. The fibers are plant based (e.g., from trees, non-wood plants, or cellulose-based plants) or tree based (e.g., wood fibers, etc.). Additionally, the fibers may be made of bagasse (sugar cane),  miscanthus , wheat, grass, non-tree fibers, non-hardwood fibers, switchgrass, bamboo,  eucalyptus , alfalfa, corn, barley, or combinations thereof. These fibers may be broken down mechanically (e.g., crushing, ripping, grinding, etc.) or chemically so as to separate out the fibers. The separated fibers are then mixed with a liquid to form the pulp. The environmentally friendly slurry  33  herein is a slurry capable of creating a biodegradable dry cleaning bag which is fabricated from, at least in part, biodegradable materials in accordance with the present disclosure. 
         [0043]    Where fibers include lignin polymers, the lignin must be removed. If recycled materials are used to create the pulp, then removal of lignin polymers and other elements is not necessary. Once the lignin polymers are removed, the pulp may be treated with bleach so as to lighten the final film used to form the dry cleaning bags  10 ,  10 ′. The pulp is then further liquefied by diluting the pulp with water. 
         [0044]    It will be understood that various modifications may be made to the embodiments of the presently disclosed devices, systems, and methods. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. Additionally, components or elements of each of the described devices, systems, and methods may be interchanged by one skilled in the art to form devices, systems, and methods which are consistent with the present disclosure.