Abstract:
A manufacturing method for producing a plurality of polymeric drawtape bags, the method including: a) dispensing a film of polymeric pliable material; b) producing a web of folded and sealed polymeric panels from the film, the web including a plurality of polymeric bags having a pair of drawtapes added into a pair of hems proximate a bag opening with a series of notches produced near lateral edges of each of the hems exposing the drawtapes with a series of lateral seals applied to the exposed drawtapes within the notches; c) measuring a relative placement of the series of notches with respect to the seals; and d) providing feedback to a notch production system to improve placement of the series of lateral seals of the exposed drawtapes within the notches by accurately locating the series of notches produced along the web.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/449,591, filed 4 Mar. 2011, the contents of which are hereby expressly incorporated in its entirety by reference thereto for all purposes. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to polymeric bags, and more specifically, but not exclusively, to polymeric elastic drawtape trash bags and methods of their manufacture. 
         [0003]    Polymeric trash bags are a common household product and have been so for many years. Common trash bags include a variety of polymeric materials, sizes, thicknesses, colors, counts, and closure formats. Polymeric trash bags are used not only for collection, containment, and disposal of trash and garbage, but also for long term storage of items such as clothing and the like. With the constant growing use of polymeric trash bags, manufacturers are always researching new manufacturing materials and methods to enhance consumer experience while at the same time providing options to generate less waste, enhance sustainability, and improve profitability. 
         [0004]    The closure method of polymeric trash bags differ in design. A common polymeric bag design can be as simple two bag panels sealed along opposing sides creating what is commonly called an ‘open top’ bag. This style of bag is inserted into a trash container with the upper edges of the bag rolled over the container rim to provide a means to hold the bag to the container. When the bag is filled, the bag is removed by pulling the bag from the trash container, spinning the top of the bag shut, and then applying a twist-tie (or other closure system) to hold the bag shut. Two specific inherent frustrations apply to this design: (1) The bags tend to fall into the trash container while filling as the bag does not provide a feature to secure the bag to the top of the container; and (2) Consumers have expressed concern that the tie devise sometimes become lost thus requiring the consumer to (try to) tie a knot in the bag which can be difficult in the event there is not enough material remaining in the bag body once filled. 
         [0005]    To overcome the ‘open top’ bag closure frustrations, manufacturers developed a polymeric trash bag commonly called “drawtape” and/or “drawstring” trash bags. A typical drawtape (or drawstring) bag feature includes a pair of polymeric strips enclosed in a formed hem in the top of each bag panel. When polymeric drawtape trash bags are used by a consumer, the drawtape feature provides a method for removal of the trash bag from the container as the drawtape acts as a handle for gripping and lifting the bag. Once the bag has been lifted from the container, the polymeric drawtape strips can be tied to each other to secure the bag shut and then provide a carrying mechanism to transport the bag to its desired location. Throughout the existence of drawtape style polymeric trash bags, this design style has become a common product used in households and business. 
         [0006]    Because of the variety of polymeric drawtape trash bag sizes and trash container sizes, a common unsatisfactory experience expressed by consumers when using a polymeric drawtape trash bag in a container is the bags do not always remain secured to the top of the container consequently when the bag is filled, the bag tends to pull/drop inward into the container which then results in trash and garbage not completely being captured by the bag thus the trash container is subject to becoming soiled and unsanitary. When this condition occurs, the consumer has to reach into the container and through trash to locate the top of the trash bag—more specifically locate and grip the drawtape pull feature. When the bag fails to remain in place, the outcome defeats the purpose of using a bag to provide a barrier between the trash and trash container. 
         [0007]    Consumers are always seeking the latest and greatest feature to enhance a product experience. With this in mind, manufacturers began researching new materials and methods that offer stretchable drawtape strips in trash bags. The advantage of a stretchable drawtape is simple—when the top section of a polymeric drawtape trash bag is folded over the container rim, the bag tends to stay in place thus allowing the bag panels to act as a liner overcoming the need for consumers having to reach into a trash container to reattach the bag to the container rim and having to clean the container interior. 
         [0008]    Elastic drawtape polymeric trash bags are manufactured by several companies all of which utilize a variety of manufacturing techniques, methods, materials, and processes. Following are two product description examples and corresponding consumer experiences. 
         [0009]    1. One product design utilizes an elastic polymeric drawtape enclosed in individual hems along the top of the polymeric trash bag. A dedicated heat seal attaches the drawtape ends to the bag hem panels on each side of the bag. The dedicated drawtape seals extend further into the bag body panel width than the main bag panel seals thus creating a reduced bag opening size (circumference) when measured against the bag panel interior size (circumference). This reduced opening provides a means to secure the bag to a container rim. This bag design includes a centralized semicircular cutout in the top of the bag to allow bag closure when the drawtape strips are pulled through the cutouts. A descriptive reference for this product is found in US Pub No. 2010/0111452-A1 entitled REDUCED OPENING ELASTIC DRAWSTRING BAG filed 30 Oct. 2008. 
         [0010]    This product design requires the consumer to stretch the upper portion of the bag body hem panels while in the same motion stretching the elastic drawtape strips in order to secure the top of the bag around the container rim. Stretching both the bag body hem panels and elastic drawtape in one motion requires additional pulling force and strength from the consumer when compared to product #2 described in the next section below. Furthermore, when having to pull the drawtape strips from a centralized hole, the experience can lead to cinching/gathering of the bag hem panels upon closure thus making it difficult to fully close the bag. Depending on the consumer, products that require an extra force to use a trash bag may lead to frustration and tendency to purchase other products. 
         [0011]    2. One product design utilizes a polymeric drawtape material that is not of an elastic material in design however the drawtape strips have been designed in a manner to include looped sections which have an elastic adhesive strip attached to the looped sections. The elastic adhesive strips are adhered to the polymeric drawtape strips to allow the drawtape to react in an elastic manner when pulled. There is one drawtape strip enclosed in each of the two individual bag body hems along the top of the polymeric bag. In this design, the bag has a pair of notch cutouts on the top of the bag with one located on each side of the bag. The drawtape is sealed to each other (strip  1  to strip  2 ) while remaining separate of being sealed to the bag body panels and hem sections. The notch cutouts allow the drawtape to extend outside of the bag body panels. This design requires less force when the drawtape is pulled by the consumer as the consumer only has to stretch the drawtape strips around the container rim to secure the bag to the container. A descriptive reference for this product is found in U.S. Pat. No. 6,059,458 entitled ELASTIC TOP DRAWTAPE BAG AND METHOD OF MANUFACTURING THE SAME filed 5 Feb. 1999. 
         [0012]    Depending on the consumer and pulling force exerted during closure, the adhesive strips on the looped drawtape can break free from the non-elastic drawtape strips thus rendering the stretchable capability unusable. Furthermore, it was discovered during visual product analysis that the notch proximity to the edge of the bag panels varied in dimension and the shape was of a rectangular shape vs. a half semicircular shape as noted in the aforementioned patent document drawings. Depending on the pulling force exerted on the bag during closure, the notches tend to enlarge thus creating openings at the drawtape closure points which could subject the bag contents to pests and other environmental conditions. 
         [0013]    What is needed is an improved design and manufacturing method for polymeric elastic drawtape bags that addresses the limitations of existing bags. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    Disclosed is an improved design and manufacturing method for polymeric elastic drawtape bags that addresses the limitations of existing bags. The following summary of the invention is provided to facilitate an understanding of some of technical features related to polymeric bags and manufacturing processes thereof, and is not intended to be a full description of the present invention. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole. 
         [0015]    A drawtape bag includes a body having a pair of pliable opposing polymeric body panels joined together with a pair of lateral body seals along a pair of opposing lateral sides and a bottom bridging and closing the pair of pliable opposing polymeric body panels producing a polymeric bag with an open mouth end at a top end, the body panels each forming a hem extending along the open mouth end, each the hem including a pair of lateral notches at the opposing lateral sides; and a pair of pliable polymeric elastomeric drawtapes moveably disposed without attachment within the hems, one drawtape within each hem wherein opposing lateral sides of the pair of drawtapes are exposed within the notches and joined together with a pair of lateral drawtape seals to form a single closed drawtape loop extending around a perimeter of the open mouth end wherein the single closed drawtape loop is configured to be drawn through one or both of the pair of lateral notches to close the open mouth end; wherein the lateral notch has a length in a direction along the hem about 1.625 inches or less wherein the body has a width about 24 inches or less and a length about 27 inches or greater. 
         [0016]    A method of manufacturing a drawtape bag includes a) directing a pair of overlying polymeric film panels in a machine direction wherein the pair of polymeric film panels are joined together at a bottom edge and open at a top edge opposite of the bottom edge to form a single polymeric film, with the panels being separable from each other along a mouth end formed opposite the bottom edge; b) producing a pair of hems along the top edges of the film panels of the single polymeric film; c) producing drawtape notches in each hem of the pair of hems at regular distance intervals corresponding to a desired width of the drawtape bags; d) adding a pair of pliable polymeric drawtape into the pair of hems, a drawtape disposed into each hem; e) sealing the panels to each other using body seal structures generally transverse to the machine direction to create individual drawtape bags; and f) sealing the drawtapes to each other using drawtape seal structures within the drawtape notches to form, for the drawtape bag, a single closed drawtape loop disposed around a perimeter of the mouth end. 
         [0017]    A manufacturing system for producing polymeric drawtape bags, the system including a plurality of manufacturing stations to dispense polymeric pliable material and to produce a web of folded and sealed polymeric panels forming a plurality of polymeric bags having a pair of drawtapes added into a pair of hems proximate a bag opening with a series of notches produced near lateral edges of each of the hems exposing the drawtapes with a series of lateral seals applied to the exposed drawtapes within the notches; and a notch registration system, coupled to one or more stations of the plurality of manufacturing stations, measuring a relative placement of the series of notches with respect to the seals and providing feedback to a notch production system of the plurality of manufacturing stations to improve placement of the series of lateral seals of the exposed drawtapes within the notches by accurately locating the series of notches produced along the web. 
         [0018]    A manufacturing method for producing a plurality of polymeric drawtape bags, the method including: a) dispensing a film of polymeric pliable material; b) producing a web of folded and sealed polymeric panels from the film, the web including a plurality of polymeric bags having a pair of drawtapes added into a pair of hems proximate a bag opening with a series of notches produced near lateral edges of each of the hems exposing the drawtapes with a series of lateral seals applied to the exposed drawtapes within the notches; c) measuring a relative placement of the series of notches with respect to the seals; and d) providing feedback to a notch production system to improve placement of the series of lateral seals of the exposed drawtapes within the notches by accurately locating the series of notches produced along the web. 
         [0019]    Although the production lines used to manufacture polymeric drawtape trash bags utilize industry standard technologies, the process has an inherent variation in the placement of the drawtape notch cutout. The variation is partially the result of the pliable characteristic of the film and web tension variables. One component of a bag manufacturing line is referred to as “The Dancer” (a downstream component) also contributes to notch placement variation as the Dancer tends to oscillate in response to film tension variables thus offsetting the notch placement. One feature of our invention includes technologies to control and limit the notch placement variations. 
         [0020]    Other features, benefits, and advantages of the present invention will be apparent upon a review of the present disclosure, including the specification, drawings, and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention. 
           [0022]      FIG. 1  illustrates a storage system including a receptacle and a polymeric bag sized for use with the receptacle; 
           [0023]      FIG. 2  illustrates a front view of a first type of a polymeric drawtape bag; 
           [0024]      FIG. 3  illustrates a front view of a second type of a polymeric drawtape bag; 
           [0025]      FIG. 4  illustrates an overview of a manufacturing process producing the first type of polymeric drawtape bag; 
           [0026]      FIG. 5  illustrates an overview of a manufacturing process producing the second type of polymeric drawtape bag; and 
           [0027]      FIG. 6  illustrates an overview of the control components of the manufacturing process. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0028]    Embodiments of the present invention provide an improved design and manufacturing method for polymeric elastic drawtape bags that addresses the limitations of existing bags. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. 
         [0029]      FIG. 1  illustrates a storage system  100  including a receptacle  105  and a polymeric bag  110  sized for use with the receptacle. Storage system  100  is ubiquitous and implemented in a wide variety of formats. The present invention is most conveniently described in a specific context, but it is understood that it may be adapted for implementation in many other contexts as well. 
         [0030]    The specific preferred context includes bag  110  as a nominally 13 gallon (49.21 liters) drawstring bag with “gripping” technology and having side hole notch for accessing the drawstring, hereafter referred to as a 13 gallon bag. A nominal 13 gallon bag is configured for receptacle  105  as a nominally 13 gallon receptacle, but there is a very wide variation in dimensions. For example, even though referred to as a 13 gallon receptacle, the actual gallon equivalent of receptacle  105  can range from about 9 gallons to about 14 gallons. Receptacle  105  may have representative dimensions ranging from a top rim circumference of about 46.5 inches to about 49 inches while a depth dimension varies in a range of about 19 inches to about 24 inches. For a limited sampling of receptacles, receptacle  105  is, on average, about 12.4 gallons with a circumference of about 48 inches and a depth of about 22 5/9 inches. Any sampling will show variation from these values. 
         [0031]    Any manufacturer of bag  110  desirably provides dimensions for bag  110  that will provide usefulness to as great a number of people of possible, in as simple and efficient manner as possible. Ultimately for any particular implementation of manufacturing for bag  110 , specific bag dimensions are chosen in contemplation of a range of useful receptacle sizes. For a “grip” feature, it is contemplated that the circumference of the gripper feature of bag  110  will be smaller than the smallest circumference of the set of receptacles, with elastic “stretching” to provide the grip. There is a limit to the amount of stretching that can occur before deformation destroys the elasticity, which defines an effectively upper bound for the circumference for receptacle  105 . For a particular design of bag  110 , the present invention is used to improve the usefulness to the end-user. 
         [0032]      FIG. 2  illustrates a front view of a first type of a polymeric drawtape bag  200 . Bag  200  includes a polymeric film  205  with a first fold  210  at a bottom and a pair of lateral edge seals  215  to produce an opening  220  at a top. At the top a pair of second folds  225  and a pair of top seals  230  create a pair of hems  235  enclosing a pair of drawtapes  240  that are sealed together at a pair of lateral edge seals  245  to produce a single closed loop  250  extending through both hems  235 . Loop  250  is captured within hems  235 , but is otherwise unattached to polymeric film  205  so loop  250  moves independently and freely within hems  235 . A set of lateral notches  255  in hems  235  expose lateral edge seals  245  of loop  250 . 
         [0033]    Several important aspects of the present invention relate to the dimensions of the bag, the seals, the notches and the interplay of these dimensions in the context of use with receptacle  105  shown in  FIG. 1 . As noted above, dimensions of notches  255  affect the size of “holes” in the top of bag  200  after loop  250  is pulled closed and tied. Notches  255  are used to allow a user to conveniently access loop  250  and to remove bag  200  from receptacle  105  so they are necessary but can, when not appropriately addressed, produce such undesirable effects. Heretofore Applicant is unaware that bag manufacturers have manufactured an apparatus such as bag  200 , much less addressed specifically problems associated with enlargement of lateral notches  255  in bag  200 . 
         [0034]    Specifics of bag manufacture vary from one bag format to another. As noted, there are different ways of providing a reduced circumference opening, not all of which include an independent closed loop drawtape accessed by lateral notches with the closed loop drawtape providing the sole gripping function. Important dimensions for bag  200  include Bag Width1  and Bag Length1  which define the useful capacity of bag  200 . Lateral side seals  215  each have a width shown as Body Seal1  defining a width of the bag opening therebetween. Lateral edge seals  245  each have a width shown as Loop Seal1  defining a width, Loop Length1 , therebetween. Notches  255  have a nominal length dimension shown as Notch Length1 . Loop Seal1  is greater than Body Seal1  and as explained in more detail herein, Notch Length1  is a factor related to Bag Width1  and is desirably reduced when possible, while preserving other important characteristics of bag  200 . 
         [0035]      FIG. 3  illustrates a front view of a second type of polymeric drawtape bag  300 . Bag  300  includes a polymeric film  305  with a first fold  310  at a bottom and a pair of lateral edge seals  315  to produce an opening  320  at a top. At the top a pair of second folds  325  and a pair of top seals  330  create a pair of hems  335  enclosing a pair of drawtapes  340  that are sealed together at a pair of lateral edge seals  345  to produce a single closed loop  350  extending through both hems  335 . Loop  350  is captured within hems  335 , but is otherwise unattached to polymeric film  305  so loop  350  moves independently and freely within hems  335 . A set of lateral notches  355  in hems  335  expose lateral edge seals  345  of loop  350 . 
         [0036]    Several important aspects of the present invention relate to the dimensions of the bag, the seals, the notches and the interplay of these dimensions in the context of use with receptacle  105  shown in  FIG. 1 . As noted above, dimensions of notches  355  affect the size of “holes” in the top of bag  300  after loop  350  is pulled closed and tied. Notches  355  are used to allow a user to conveniently access loop  350  and to remove bag  300  from receptacle  105  so they are necessary but can, when not appropriately addressed, produce such undesirable effects. Heretofore Applicant is unaware that bag manufacturers have manufactured a drawtape bag such as bag  300 , much less addressed specifically problems associated with enlargement of lateral notches  355  in bag  300 . 
         [0037]    Specifics of bag manufacture vary from one bag format to another. As noted, there are different ways of providing a reduced circumference opening, not all of which include an independent closed loop drawtape accessed by lateral notches with the closed loop drawtape providing the sole gripping function. Important dimensions for bag  300  include Bag Width2  and Bag Length2  which define the useful capacity of bag  300 . Lateral side seals  315  each have a width shown as Body Seal2  defining a width of the bag opening therebetween. Lateral edge seals  245  each have a width shown as Loop Seal2  defining a width, Loop Length2 , therebetween. Notches  255  have a nominal length dimension shown as Notch Length2 . Loop Seal2  is equal to Body Seal2  with Bag Width2  less than Bag Width1  and Bag Length2  greater than Bag Length1  (to make the capacity of the bag  300  essentially the same as bag  200 ), Notch Length2  is less than Notch Length1 , and as explained in more detail herein, Notch Length2  is a factor related to Bag Width2  and is desirably reduced when possible, while preserving other important characteristics of bag  300 . 
         [0038]    For example, Notch Length1  is at least about 1.625 inches (and may be increased in some implementations if variation in notch cutting risks having a lateral edge seal  345  sealed to hems  335 ). Loop Seal1  is about 0.625 inches greater than Body Seal1 . For other bag designs having lateral cutouts accessing an enclosed elastic-type drawstring, notch lengths are significantly larger and can be about 2.25 inches to about 2.5 inches. As further discussed below, use of a novel manufacturing process enables the notch length to be reduced. For example, Notch Length2  is about 1 inch, with Loop Seal2  about equal to Body Seal2 . 
         [0039]      FIG. 4  illustrates an overview of a manufacturing process  400  producing the first type of polymeric drawtape bag  200  shown in  FIG. 2 . Process  400  includes three manufacturing stations, a dispensing station  405 , a first forming station  410 , and a second forming station  415 . Station  405  holds a roll  420  of polymeric pliable material (aka polymeric film)  425 . Roll  420  is manufactured in a blown film extrusion process in the shape of a tube that is flattened into a web format, then cut on one side and then wound into a finished roll  420 . Film  425  drawn off roll  420  includes a fold  430  at a bottom edge while a top edge is open, which creates a front panel (shown) and a back panel (not shown). Station  405  delivers film  425  to station  410  and then to station  415  for further processing. 
         [0040]    Station  410  pulls film  425  over a set of folding plates where a section of both the front and back film panels at the top end are each folded back over a pair of elastomeric (e.g., formed of a polymeric material to be elastic for expanding, gripping receptacle openings to hold bag upright) drawtapes  432 . A top seal  435  is applied to both the front and the back film panels to form a pair of hems  440  and the bag opening therebetween (only the front drawtape  432 , seal  435 , and hem  440  are shown for clarity). Specifically, a cutter (aka—Servo Cutter or the like) periodically cuts a pair of notches  445 , one notch  445  into each panel, to expose periodic openings in the top edge. Film  425  continues downstream over a set of folding bars where the individual front and back bag are separated and hem  440  is then formed respectively in each panel. At this point, a single strip of polymeric elastic drawtape  432  is inserted into each hem  440  (a first strip inserted into a front hem  440  and at the same time a second strip inserted into a back hem  440 ). Film  425  continues downstream where the respective top seals  435  are applied to both the front and back panels, thus creating hems  440 , one in each panel, with each hem  440  enclosing one polymeric elastic drawtape  432 . 
         [0041]    Film  425  continues from station  410  in this format downstream into station  415  for further processing. Film  425  travels through a web tensioning device (aka—a Dancer), and continues downstream around a sealing drum where periodic bag panel seals  450  and drawtape seals  455  are made. Seals  450  are made from primary seal bar mechanisms secured in the sealing drum. Seals  450  are made from seal bars that are secured to the primary seal bars however the sealing variables are controlled separate of the primary seal bar. Film  425  continues over a series of folding bars for folding the sealed film into a folded web format. 
         [0042]    The folded web then travels through a perforation knife cutting station where periodic perforations  460  are made to folded web which provides a mechanism to separate the sealed web format into individual bags in a downstream machine (e.g., a folder, winder, or the like—not shown). Bag  200  may be thus made by process  400  and provides good results for a range of products. A controller  465  using a feedback system  470  is optional in process  400  for notch placement, but its use as further described herein could improve notch placement and permit narrower notches to be employed and thereby improving bag  200  by reducing the notch hole enlargement issue described herein. 
         [0043]    Process  400  includes a considerable length of film  425  throughout the manufacturing line. For example, a distance between the Servo Cutter at station  410  and a web perforation device at a downstream end of station  415  is about fifty feet. This equates to about 25 bags thus any variation in a tension of film  425  tension typically results in oscillations in the Dancer which in turn creates an expansion or retraction of the web path in the machine direction. These oscillations cause the notch cutout placement to move proportionally to the web expansion/retraction. In the event the notch cutout  445  moves upstream or downstream as the result of the web movement, notch  445  may be positioned in the immediate area of the drawtape seal  450  thus becoming sealed to either end of hem  440  thus rendering the elastic characteristic of drawtape  432  to not function as designed. In order to provide a means of compensation for the web expansion/retraction and to ensure a precise placement of notch  445  and its registration to the bag panel side seals  450  and drawtape seal  450 , controller  465  and feedback system  470  are used and the tighter these registration requirements (e.g., smaller notches), the more useful is controller  465  and feedback system  470 . Thus, for process  500  described below in  FIG. 5  for production of bag  300 , the controller and feedback system are desirably included. 
         [0044]      FIG. 5  illustrates an overview of manufacturing process  500  producing the second type of polymeric drawtape bag  300  shown in  FIG. 3 . As further described below, process  500  is similar to process  400  except that bag  300  is produced instead of bag  200 . Thus process  500  makes a bag that is narrower, longer, and has a smaller notch, primarily by controlling registration better using a controller and a feedback system. Process  500  includes three manufacturing stations, a dispensing station  505 , a first forming station  510 , and a second forming station  515 . Station  505  holds a roll  520  of polymeric pliable material (aka polymeric film)  525 . Roll  520  is manufactured in a blown film extrusion process in the shape of a tube that is flattened into a web format, then cut on one side and then wound into a finished roll  520 . Film  525  drawn off roll  520  includes a fold  530  at a bottom edge while a top edge is open, which creates a front panel (shown) and a back panel (not shown). Station  505  delivers film  525  to station  510  and then to station  515  for further processing. 
         [0045]    Station  510  pulls film  525  over a set of folding plates where a section of both the front and back film panels at the top end are each folded back over a pair of drawtapes  532 . A top seal  535  applied to both the front and back film panels to form a pair of hems  540  and the bag opening therebetween (only the front drawtape  532 , seal  535 , and hem  540  are shown for clarity). Specifically, a cutter (aka—Servo Cutter or the like) periodically cuts a pair of notches  545 , one notch  545  into each panel, to expose periodic openings in the top edge. Film  525  continues downstream over a set of folding bars where the individual front and back bag are separated and hem  540  is then formed respectively in each panel. At this point, a single strip of polymeric elastic drawtape  532  is inserted into each hem  540  (a first strip inserted into a front hem  540  and at the same time a second strip inserted into a back hem  540 ). Film  525  continues downstream where the respective top seals  535  are applied to both the front and back panels, thus creating hems  540 , one in each panel, with each hem  540  enclosing one polymeric elastic drawtape  532 . 
         [0046]    Film  525  continues from station  510  in this format downstream into station  515  for further processing. Film  525  travels through a web tensioning device (aka—a Dancer), and continues downstream around a sealing drum where periodic bag panel seals  550  and drawtape seals  555  are made. Seals  550  are made from primary seal bar mechanisms secured in the sealing drum. Seals  550  are made from seal bars that are secured to the primary seal bars however the sealing variables are controlled separate of the primary seal bar. Film  525  continues over a series of folding bars for folding the sealed film into a folded web format. 
         [0047]    The folded web then travels through a perforation knife cutting station where periodic perforations  560  are made to folded web which provides a mechanism to separate the sealed web format into individual bags in a downstream machine (e.g., a folder, winder, or the like—not shown). Bag  300  may be thus made by process  500  and provides good results for a range of products just as is true for bag  200 , with bag  300  providing a smaller notch-induced hole. A controller  565  using a feedback system  570  is preferred in process  500  for accurate notch placement to reduce notch length. 
         [0048]      FIG. 6  illustrates an overview of a notch registration control system  600  useful in the manufacturing processes described herein, specifically as the “optional” components in process  400  and the “preferred” components in process  500 . Of course a control system exists for processes  400  and  500  and the notch registration control system is an add-on (or integrated) function for a preferred system of achieving a goal of reduced notch length for any bag format using a manufacturing process generally similar to those described herein. Thus not all control and feedback systems and components used in processes  400  and  500  are described herein. 
         [0049]    Control system  600  includes components that are preferably integrated into station  510  (and optionally station  410 ) and station  515  (and optionally into station  415 ) as shown. Components of control system  600  included in station  510  are an operator programmable interface  605 , a web encoder  610 , a servo controller  615 , and a servo cutter motor  620 . Interface  605  is used for the initial registration set point value as entered by an operator. Web encoder  610  generates a web speed feedback signal used at station  515 . Servo controller  615  initiates a control sequencing of servo cutter motor  620 . Servo cutter motor  620  actuates a notch cutter through the polymeric film as described herein. 
         [0050]    Components of control system  600  included in station  515  include a motion controller  625 , a dancer and roller assembly  630 , and a dancer oscillation position feedback device  635 . Dancer and roller assembly  630  provide real-time feedback of motion of the film as it travels through the stations of process  500 . Rotary oscillations of dancer and roller assembly  630  are converted into linear oscillations by dancer oscillation position feedback device  635  and then into a dancer oscillation signal. Motion controller  625  is a central coordination point for process and feedback communication regarding notch registration. Motion controller  625  receives the web speed signal from web encoder  610  and the dancer oscillation signal from dancer oscillation position feedback device  635 . Additionally, there is a notch registration feedback signal indicating current downstream notch registration as described below. 
         [0051]    The notch registration feedback signal is obtained from capturing a parameter of the film as it relates to where the system is placing the notch in relation to the body and loop seals. Preferably system  600  uses a vision capture system at a vision capture point between two bags downstream of station  515 . Preferably this vision capture point is a distance between a bag perforation  560  and a vertical trailing edge  640  of each notch cutout  545 . This vision capture point is the same point on each bag during line operation. 
         [0052]    System  600  includes, for a vision system, an imager  645  (e.g., feedback system  570 ) and a vision feedback processor  650  (e.g., controller  565 ). Imager  645  includes a digital capture imaging sensor that inspects a placement of edge  640  with respect to perforation  560 . Imager  645  works in cooperation with feedback processor  650  to send a notch registration feedback signal to motion controller  625  so motion controller  625  can set precise registration of notch  545 . 
         [0053]    Description of Systems Control: 
         [0054]    Upon start-up of the manufacturing line, an initial notch registration offset is set by a programmed value entered into interface  605  by an operator as determined by a visual measurement of a placement of notch  545  and its relation to perforation  560 . During line operation, a trigger signal is generated from the bag machine perforation drum and is relayed to motion controller  625 . Motion controller  625  uses feedback from three interface sources: web encoder  610  that measures web speed, feedback processor  650  providing the notch registration feedback signal based on a pixel count of stored images against a live image capture from imager  645  during operation, and dancer oscillation position feedback device  635 . As the line continues to run, motion controller  625  calculates notch registration adjustments based on real time feedback from the web encoder, vision and dancer feedback systems. Motion controller  625  maintains registration by outputting a signal to servo controller  615  at every sequence of the perforation drum. 
         [0055]    The improved manufacturing process can be implemented under program control of a plurality of machine code instructions accessed from a memory and executed by a controller or processor. Some or all of the inventive aspects of certain ones of the embodiments of the present invention may be implemented in such non-transitory program instructions stored in a memory. 
         [0056]    As noted herein, the system and process are most preferably implemented in a polymeric bag used for collection and storage of materials. The system and methods above has been described in general terms as an aid to understanding details of preferred embodiments of the present invention. Other preferred embodiments of the present include the described application for improved polymeric trash bags. In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. The preferred embodiments include specific physical processing devices and steps, such as cutters for notches and inserters for placing drawtapes into formed hems. The preferred invention encompasses other devices and methods for producing notches, e.g., punches, lasers, and other processing equipment and methods, to yield the desired structures. 
         [0057]    One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention. 
         [0058]    Reference throughout this specification to “one embodiment”, “an embodiment”, or “a specific embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention and not necessarily in all embodiments. Thus, respective appearances of the phrases “in one embodiment”, “in an embodiment”, or “in a specific embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments of the present invention described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the present invention. 
         [0059]    It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. 
         [0060]    Additionally, any signal arrows in the drawings/Figures should be considered only as exemplary, and not limiting, unless otherwise specifically noted. Furthermore, the term “or” as used herein is generally intended to mean “and/or” unless otherwise indicated. Combinations of components or steps will also be considered as being noted, where terminology is foreseen as rendering the ability to separate or combine is unclear. 
         [0061]    As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. 
         [0062]    The foregoing description of illustrated embodiments of the present invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention, as those skilled in the relevant art will recognize and appreciate. As indicated, these modifications may be made to the present invention in light of the foregoing description of illustrated embodiments of the present invention and are to be included within the spirit and scope of the present invention. 
         [0063]    Thus, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of embodiments of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular terms used in following claims and/or to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention is to be determined solely by the appended claims.