Patent ID: 12234075

DETAILED DESCRIPTION

Referring toFIG.1, a planar view of an embodiment of a substantially flat sheet of material from which a “step cut” bag1is to be formed is shown. Shown on the sheet are front wall2, rear wall3, seam4, first side wall5having gusset portion6, and second side wall7having gusset portion8. As shown inFIG.1, the bag1has a first or top end9and a second or bottom end10, and thus each of the front wall2, rear wall3, first side wall5and second side wall7has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends9and10are unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. Bag1is considered a “step cut” bag because the front wall2, the first side wall5and the second side wall7, and the rear wall3are cut so that the front wall2, the first side wall5and the second side wall7, and the rear wall3have different lengths on one end (or both ends) of the bag. As shown inFIG.1, the first side wall5and the second side wall7are cut to different lengths on either side of the gusset portion6and8, respectively. As shown inFIG.1the first end9of bag1has portions3aand3bof the rear wall3of the bag that extend further from the body of the bag1than do portions5aand7aof the first side wall5and second side wall7, respectively, which in turn extend further from the body of the bag1than do portions5band7bof the first side wall5and second side wall7, respectively, which in turn extend further from the body of the bag1than does the top end of the front wall2of the bag1. In addition, the bottom end of the front wall2at the second end10of bag1extends further from the body of the bag1than do portions5cand7cof the first side wall5and second side wall7, respectively, which in turn extend further from the body of the bag1than do portions5dand7dof the first side wall5and second side wall7, respectively, which in turn extend further from the body of the bag1than do portions3cand3dthe bottom end of the rear wall3of the bag1. Therefore, in the embodiment shown inFIG.1both of the ends of the bag1have a “step cut.” Also shown is weakened portion20, which in this embodiment is near the first end9of the bag1and comprises a plurality of perforations21extending from a first end21aon the front wall2of the bag1across the first side wall5of the bag1to a second end21bon the rear wall3of the bag1. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end9of the bag1. This weakened portion can be opened with less force than required to open or tear other portions of the bag1.

Referring toFIG.2, the upper portion of the bag1fromFIG.1is shown after sealing the first end9of the bag1. Visible inFIG.2is front wall2, back wall3having portions3aand3b, seam4, first side wall5having gusset portion6, and weakened portion20comprising a plurality of perforations21terminating at second end21b.

Bag1can be opened as shown inFIG.3throughFIG.6.FIG.3once again shows the upper portion of the bag1fromFIG.2, and visible is front wall2, back wall3having portions3aand3b, seam4, first side wall5having gusset portion6, and weakened portion20comprising a plurality of perforations21terminating at second end21b. Bag1is opened by initially pulling on the portions3′ and3″ of the rear wall3on both sides of the plurality of perforations21, which creates a tear in the weakened portion20of the bag1and begins separating the portions of the first side wall5that are separated by the gusset portion6. InFIG.4the portions3′ and3″ of the rear wall3on both sides of the plurality of perforations21are further pulled apart, resulting in the expansion of the tear in the weakened portion20toward the second end21bof the plurality of perforations21. Additionally visible inFIG.4are front wall2, back wall3having portions3aand3b, seam4, and first side wall5having gusset portion6. InFIG.5the portions3′ and3″ of the rear wall3on both sides of the plurality of perforations21are pulled completely apart, resulting in the expansion of the tear in the weakened portion20further toward the second end21bof the plurality of perforations21and to the first end21aof the plurality of perforations (not visible inFIG.5). This results in uncovering the top end6aof the gusset portion6of the first side wall5, which can then be pulled open. Additionally visible inFIG.5are front wall2, back wall3having portions3aand3b, and seam4. InFIG.6the plurality of perforations21are pulled completely apart, resulting in the expansion of the tear in the weakened portion20to the second end21bof the plurality of perforations21. This results in a large opening in bag1that can be used to pour out the contents of the bag1. Additionally visible inFIG.6are front wall2, back wall3having portions3a,3b,3′ and3″, seam4, first side wall5and gusset portion6having a top end6a.

Referring toFIG.7, the upper portion of the bag1fromFIG.1is shown after sealing the first end9of the bag1, with optional adhesive30located near the top end of the first side wall5, which serves to keep the top end of the first side wall5closed (see arrows). Although not visible inFIG.7, the optional adhesive can also be applied near the top end of the second side wall. Although shown as a spot inFIG.7, the adhesive can be applied in any manner that results in the closure of the top end of the first side wall5, for example as a strip that runs from the edge of the intersection of the first side wall5and the back wall3to the edge of the intersection of the first side wall5and the front wall2. Also visible inFIG.7is front wall2, back wall3having portions3aand3b, seam4, first side wall5having gusset portion6, and weakened portion20comprising a plurality of perforations21terminating at second end21b.

Once the bag1is sealed at one end, it can be filled with the desired materials. For example, it has been found that a bag1with dimensions of 16.5 inches by 6.5 inches by 39.5 inches can durably hold up to about fifty five (55) pounds of material without showing undue stress, undue tearing, undue breakage, undue deformation, or leakage or the like. It is believed that any bulk material can be contained by bag1, and in certain embodiments the contents can weigh up to 100 pounds or so without undue risk of tearing or damage to bag1. Once the bag1is filled, the second end typically needs to be sealed. The second end of the bag1can be sealed in a similar manner as that described above. Alternatively, the bag1can have its second end sealed by conventional means such as sewing. Still another approach is to stitch the second end, and then seal the second end in a manner like that described above (not shown). Although not shown, those skilled in the art will understand and appreciate that a second end of bag1can be sealed using any conventional technique once bag1has been filled with the selected amount of the desired material.

Referring toFIG.8, a planar view of an embodiment of a substantially flat sheet of material from which a “step cut” bag101is to be formed is shown. Shown on the sheet are front wall102, rear wall103, seam104, first side wall105having gusset portion106, and second side wall107having gusset portion108. As shown inFIG.8, the bag101has a first or top end109and a second or bottom end110, and thus each of the front wall102, rear wall103, first side wall105and second side wall107has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends109and110are unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. Bag101is considered a “step cut” bag because the front wall102, the first side wall105and the second side wall107, and the rear wall103are cut so that the front wall102, the first side wall105and the second side wall107, and the rear wall103have different lengths on one end (or both ends) of the bag. As shown inFIG.8, the first side wall105and the second side wall107are cut to different lengths on either side of the gusset portion106and108, respectively. As shown inFIG.8the first end109of bag101has portions103aand103bof the rear wall103of the bag that extend further from the body of the bag101than do portions105aand107aof the first side wall105and second side wall107, respectively, which in turn extend further from the body of the bag101than do portions105band107bof the first side wall105and second side wall107, respectively, which in turn extend further from the body of the bag101than does the top end of the front wall102of the bag101. In addition, the bottom end of the front wall102at the second end110of bag101extends further from the body of the bag101than do portions105cand107cof the first side wall105and second side wall107, respectively, which in turn extend further from the body of the bag101than do portions105dand107dof the first side wall105and second side wall107, respectively, which in turn extend further from the body of the bag101than do portions103cand103dthe bottom end of the rear wall103of the bag101. Therefore, in the embodiment shown inFIG.8both of the ends of the bag101have a “step cut.” In addition, the portions105aand105b,107aand107b,105cand105d, and107cand107dare not separated by a straight line, but rather an angled cut (see circles). Although inFIG.8this cut is shown as about 45°, the angle can vary in different embodiments (not shown). This angled cut serves to further prevent leakage of contents out of the bag, or infestation of organisms into the contents of the bag. Also shown is weakened portion120, which in this embodiment is near the first end109of the bag101and comprises a plurality of perforations121extending from a first end121aon the front wall102of the bag101across the first side wall105of the bag101to a second end121bon the rear wall103of the bag101. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end109of the bag101. This weakened portion can be opened with less force than required to open or tear other portions of the bag101.

Referring toFIG.9, a planar view of an embodiment of a substantially flat sheet of material from which a bag201is to be formed is shown. Shown on the sheet are front wall202, rear wall203, seam204, first side wall205having gusset portion206, and second side wall207having gusset portion208. As shown inFIG.9, the bag201has a first or top end209and a second or bottom end210, and thus each of the front wall202, rear wall203, first side wall205and second side wall207has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends209and210are unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. The top end209of bag201is has a “step cut” because the front wall202, the first side wall205and the second side wall207, and the rear wall203are cut so that the front wall202, the first side wall205and the second side wall207, and the rear wall203have different lengths. As shown inFIG.9, the first side wall205and the second side wall207are cut to different lengths on either side of the gusset portion206and208, respectively. As shown inFIG.9the first end209of bag201has portions203aand203bof the rear wall203of the bag201that extend further from the body of the bag201than do portions205aand207aof the first side wall205and second side wall207, respectively, which in turn extend further from the body of the bag201than do portions205band207bof the first side wall205and second side wall207, respectively, which in turn extend further from the body of the bag201than does the top end of the front wall202of the bag201. In the embodiment shown inFIG.9, the bottom end of the front wall202, the first side wall205, the second side wall207, and the rear wall203at the second end210of bag201each extend the same distance from the body of the bag201. Therefore, in the embodiment shown inFIG.9the bottom end210of the bag201has a “flush cut.” Although not shown, in certain embodiments the top end of the bag can be flush cut, and the bottom end of the bag can be step cut. Also shown is weakened portion220, which in this embodiment is near the first end209of the bag201and comprises a plurality of perforations221extending from a first end221aon the front wall202of the bag201across the first side wall205of the bag201to a second end221bon the rear wall203of the bag201. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end209of the bag201. This weakened portion can be opened with less force than required to open or tear other portions of the bag201.

Referring toFIG.10, a planar view of an embodiment of a substantially flat sheet of material from which a flush cut bag301is to be formed is shown. Shown on the sheet are front wall302, rear wall303, seam304, first side wall305having gusset portion306, and second side wall307having gusset portion308. As shown inFIG.10, the bag301has a first or top end309and a second or bottom end310, and thus each of the front wall302, rear wall303, first side wall305and second side wall307has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends309and310are unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. The top end309of bag301has a “flush cut” because the front wall302, the first side wall305and the second side wall307, and the rear wall303are cut to the same length. In the embodiment shown inFIG.10, the bottom end of the front wall302, the first side wall305, the second side wall307, and the rear wall303at the second end310of bag301each extend the same distance from the body of the bag301. Therefore, in the embodiment shown inFIG.10the bottom end310of the bag301also has a “flush cut.” Also shown is weakened portion320, which in this embodiment is near the first end309of the bag301and comprises a plurality of perforations321extending from a first end321aon the front wall302of the bag301across the first side wall305of the bag301to a second end321bon the rear wall303of the bag301. The weakened area is generally on or near the fold line (not shown) for closing or sealing the first end309of the bag301. This weakened portion can be opened with less force than required to open or tear other portions of the bag301.

Referring toFIG.11, a planar view of an embodiment of a substantially flat sheet of material from which a “step cut” bag401is to be formed is shown. Shown on the sheet are front wall402, rear wall403, seam404, first side wall405having first gusset portion406, and second side wall407having second gusset portion408. As shown inFIG.11, the bag401has a first or top end409and a second or bottom end410, and thus each of the front wall402, rear wall403, first side wall405and second side wall407has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends409and410are unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. Bag401is considered a “step cut” bag because the front wall402, the first side wall405and the second side wall407, and the rear wall403are cut so that the front wall402, the first side wall405and the second side wall407, and the rear wall403have different lengths on both ends of the bag. As shown inFIG.11, the first side wall405and the second side wall407are cut to different lengths on either side of the gusset portion406and408, respectively. As shown inFIG.11the first end409of bag401has portions403aand403bof the rear wall403of the bag that extend further from the body of the bag401than do portions405aand407aof the first side wall405and second side wall407, respectively, which in turn extend further from the body of the bag401than do portions405band407bof the first side wall405and second side wall407, respectively, which in turn extend further from the body of the bag401than does the top end of the front wall402of the bag401. In addition, the bottom end of the front wall402at the second end410of bag401extends further from the body of the bag401than do portions405cand407cof the first side wall405and second side wall407, respectively, which in turn extend further from the body of the bag401than do portions405dand407dof the first side wall405and second side wall407, respectively, which in turn extend further from the body of the bag401than do portions403cand403dthe bottom end of the rear wall403of the bag401. Therefore, in the embodiment shown inFIG.11both of the ends of the bag401have a “step cut.” However, the skilled artisan will readily appreciate that in other embodiments (not shown), one or both ends of the bag can be a different type of step cut, or another type of cut altogether, for example a flush cut end as described herein. As shown inFIG.11, the portions403aand405a,405band402a,402aand407b,407aand403b,403cand405d,405cand402c,402cand407c, and407dand403d, respectively, are separated from one another not by straight lines and right angles but by curved portions or edges, which inFIG.11are shown as radial (circular) elements. Although one particular size and shape of radial portion is shown inFIG.11, for the features between the foregoing portions, those skilled in the art will appreciate that in other embodiments (not shown), these radial portions can be as small or as large as desired. In addition, the portions405aand405b,407aand407b,405cand405d, and407cand407d, respectively, are not defined or separated by a radial portion or edge, but rather an angled portion or edge (see circles). Although inFIG.11this angled portion is shown as about 45° with respect to the top end of the front wall, the angle can vary in different embodiments (not shown). These radial and angled portions serve to further prevent breakage, leakage of contents out of the bag, or infestation of organisms into the contents of the bag, by providing extra material at one end of the bag that improves sealing. Further shown inFIG.11is cut-out411and corresponding tab412at opposing ends of the seam404. Since the bag401is formed from a continuous sheet of material, the formation of the cut-out411(removal of material) at one end of the bag401results in a tab412(extra material) at the other end of the bag401. The cut out411and tab412extend into the seam404, and also serve to further prevent breakage, leakage of contents out of the bag, or infestation of organisms into the contents of the bag. This is because since extra material can be present between the seam404of the bag and the edge of the rear panel403bof the bag that is not sealed, a hole can be present that can serve as an access point into or out of the sealed bag. But the presence of the cut-out411and the tab412ensures that the ends of any such hole will be sealed, preventing access into or out of the sealed bag. The cut-out411and tab412can be any depth/height desired, and can extend further into the seam as desired (not shown). Although inFIG.11the cut-out411and tab412are shown as extending from within the seam404to the edge of the rear panel403bof the bag, in other embodiments (not shown) the cut-out and tab can extend from within the seam404only a portion of the distance to the edge of the rear panel403bof the bag401. Furthermore, as shown, the tab and cut-out are illustrated as primarily rectangular in shape. It is understood that the shape is not limited to rectangles but can also be configured as an angular or rounded cut-out and matching tab as long as the configuration fits together to form a seal effective to prevent leakage or infestation. Additionally, in other embodiments (not shown), the bag can comprise an easy open or easy access feature, such as the weakened portion near the top of the bag as shown herein above (for example inFIG.8), or the easy open features detailed in United States Patent Application Publication Number US 2013/0206631 and United States Patent Application Publication Number US 2013/0209002, each of which is incorporated by reference herein in its entirety.

Referring toFIG.12, a planar view of the top portion of an embodiment of a substantially flat sheet of material from which a bag501is to be formed is shown. Shown on the sheet are front wall502, rear wall503, seam504, first side wall505having first gusset portion506, and second side wall507having second gusset portion508. As shown inFIG.12, the bag501has a first or top end509and a second or bottom end510(not visible inFIG.12), and thus each of the front wall502, rear wall503, first side wall505and second side wall507has a first or top end and a second or bottom end. It will be apparent, however, that the orientation of the bag ends509and510are unimportant and the “top” and “bottom” references are useful but may change depending upon the orientation from which one views the bag. The top end509of bag501has a “step cut” because the front wall502, the first side wall505and the second side wall507, and the rear wall503are cut so that the front wall502, the first side wall505and the second side wall507, and the rear wall503have different lengths. As shown inFIG.12, the first side wall505and the second side wall507are cut to different lengths on either side of the gusset portion506and508, respectively. As shown inFIG.12the first end509of bag501has portions503aand503bof the rear wall503of the bag501that extend further from the body of the bag501than do portions505aand507aof the first side wall505and second side wall507, respectively, which in turn extend further from the body of the bag501than do portions505band507bof the first side wall505and second side wall507, respectively, which in turn extend further from the body of the bag501than does the top end of the front wall502of the bag501. As shown inFIG.12, the portions503aand505a,505aand505b,505band502a,502aand507b,507band507a, and507aand503b, respectively, are separated not by straight lines and right angles but by curved portions or edges, such as radial (circular) portions as shown. Although one particular size and shape of the curved portions is shown inFIG.12, those skilled in the art will understand that in other embodiments (not shown) these curved edges can be of different shapes (e.g., elliptical, or different segments of a curve, etc.), and can be as small or as large as desired. These curved portions serve to further prevent breakage or leakage of contents out of the bag, or infestation of organisms into the contents of the bag. Further shown inFIG.12is cut-out511at one end of the seam504(corresponding tab512at the other end of the seam504is not shown inFIG.12). Since the bag501is formed from a continuous sheet of material, formation of the cut-out511(removal of material) at one end of the bag501results in a tab (extra material; not shown inFIG.12) at the other end of the bag501. The cut out511and tab (not shown inFIG.12) extend into the seam504, and also serve to further prevent breakage, leakage of contents out of the bag, or infestation of organisms into the contents of the bag. The cut-out511and tab (not shown) can be any depth/height desired, and can extend further into the seam as desired (not shown). Although inFIG.12the cut-out511(and corresponding tab, not shown) is shown as extending from within the seam504to the edge of the rear panel503bof the bag, in other embodiments (not shown) the cut-out (and tab) can extend from within the seam504only a portion of the distance to the edge of the rear panel503b of the bag. Additionally, in other embodiments (not shown), the bag can comprise an easy open or easy access feature, such as the weakened portion near the top of the bag as shown herein above (for example inFIG.8), or the easy open features detailed in United States Patent Application Publication Number US 2013/0206631 and United States Patent Application Publication Number US 2013/0209002, each of which is incorporated by reference herein in its entirety.

Referring toFIG.13A, shown is an outline of a portion of one end of a bag600with a step cut end, generally corresponding to a mirror image of the region marked as “A” inFIG.11, detailing an alternate embodiment with angled portions between the front panel602of the bag and the first section of the side wall607′, between the first section of the side wall607′ and the second section of the side wall607″, and between the second section of the side wall607″ and the back panel603of the bag, respectively, and a feature613at one end of the bag that extends into the seam. Since the bag600is formed from a continuous sheet of material, the feature613forms a cut-out611(removal of material; seeFIG.13B) at one end of the bag and a tab612(extra material; seeFIG.13C) at the other end of the bag.FIG.13Bshows an image of one end of the bag depicted inFIG.13Aupon sealing the seam604, showing cut-out611.FIG.13Cshows an image of the other end of the bag depicted inFIG.13Aupon sealing the seam604, showing the tab612.

Referring toFIG.14A, shown is an outline of a portion of one end of a bag700with a step cut end, generally corresponding to a mirror image of the region marked as “A” inFIG.11, detailing an alternate embodiment with a combination of radial and angled cuts between the front panel702of the bag and the first section of the side wall707′, between the first section of the side wall707′ and the second section of the side wall707″, and between the second section of the side wall707″ and the back panel703of the bag, respectively, and a feature713at one end of the bag700that extends into the seam. Since the bag700is formed from a continuous sheet of material, the feature713forms a cut-out711(removal of material; seeFIG.14B) at one end of the bag700and a tab712(extra material; seeFIG.14C) at the other end of the bag700.FIG.14Bshows an image of one end of the bag depicted inFIG.14Aupon sealing the seam704, showing cut-out711.FIG.14Cshows an image of the other end of the bag depicted inFIG.14Aupon sealing the seam704, showing the tab712.

Referring toFIG.51A, shown is an outline of a portion of one end of a bag5100with a step cut end, generally corresponding to a mirror image of the region marked as “A” inFIG.11, detailing an alternate embodiment with a combination of radial and angled cuts between the front panel5102of the bag and the first section of the side wall5106, between the first section of the side wall5106and the second section of the side wall5110, and between the second section of the side wall5110and the back panel5114of the bag, respectively, and a feature5116at one end of the bag5100that extends into the seam. Since the bag5100is formed from a continuous sheet of material, the feature5116forms a cut-out5118(removal of material; seeFIG.51B) at one end of the bag5100and a tab5122(extra material; seeFIG.51C) at the other end of the bag5100.FIG.51Bshows an image of one end of the bag depicted inFIG.51Aupon sealing the seam5120, showing cut-out5118.FIG.51Cshows an image of the other end of the bag depicted inFIG.51Aupon sealing the seam5120, showing the tab5122.

The step cut profile shown inFIG.51Aincludes angled step cuts of a variety of shapes and angles. A first step cut5104adjacent the front panel5102, includes an angled cut without a separate vertical portion, as shown inFIGS.14-14above. The first step cut5104is at a particular angle, variable over a large range of angles, for example between ten degrees and eighty degrees with respect to the top edge of front panel5102. A second step cut5108includes a curved cut5108aas well as an angled cut5108b. The curved cut5108amay be a cut having a constant radius, may be elliptical, parabolic, or otherwise curved. The angled cut5108bis positioned below the curved cut5108aand separated by a vertical portion of the second step cut5108. A third step cut5112, adjacent the back panel5114is shown with a single angled cut, similar to the first step cut5104. In some examples, the first step cut5104and the second step cut5112may include angled cuts at different angles, or may be at or about the same angle. Additionally, the length or distance traversed over the step cuts may vary, in addition to a spacing or distance between adjacent step cuts, such as by varying a width of the first section of the side wall5106and a width of the second section of the side wall5110. In some examples additional step cuts may be introduced between the first step cut5104and the third step cut5112. For example, a total of four or more step cuts may be included in the step cut profile. Additional step cuts may be included for purposes of including second, third, or fourth gussets to the side wall, thereby dividing the side wall into an additional third section, fourth section, and other sections as determined by the number and placement of additional gussets. Furthermore, the step cut profile shown inFIG.51Amay be used for one side of the top of the bag5100. In some examples, the left and right sides of the bag5100may include different step cut profiles, for example to accommodate different styles of bags and different opening panels, such as the easy open panels described herein.

Referring toFIG.52A, shown is an outline of a portion of one end of a bag5200with a step cut end, generally corresponding to a mirror image of the region marked as “A” inFIG.11, detailing an alternate embodiment with a combination of radial and angled cuts between the front panel5202of the bag and the first section of the side wall5206, between the first section of the side wall5206and the second section of the side wall5210, and between the second section of the side wall5210and the back panel5214of the bag, respectively, and a feature5216at one end of the bag5200that extends into the seam. Since the bag5200is formed from a continuous sheet of material, the feature5216forms a cut-out5218(removal of material; seeFIG.52B) at one end of the bag5200and a tab5222(extra material; seeFIG.52C) at the other end of the bag5200.FIG.52Bshows an image of one end of the bag depicted inFIG.52Aupon sealing the seam5220, showing cut-out5218.FIG.52Cshows an image of the other end of the bag depicted inFIG.52Aupon sealing the seam5220, showing the tab5222.

The step cut profile shown inFIG.52Aincludes angled and curved step cuts of a variety of shapes and angles. A first step cut5204adjacent the front panel5202, includes a first curved cut5204aand a second curved cut5204bhaving curves in two different directions, with a curvature in opposite directions. The curvature may be in different directions rather than opposite from one another in some examples. The first step cut5204is shown with two circular cuts that meet at a midpoint of the height of the first step cut5204. In some examples the first step cut5204may include a vertical portion, for example when the first curved cut5204aand the second curved cut5204bhave a radius of less than half the height of the first step cut5204. The first curved cut5204aand the second curved cut5204bmay each be a cut having a radius, may be elliptical, parabolic, or otherwise curved. A second step cut5208includes a curved cut5208aas well as an angled cut5208b. The curved cut5208ais at the top edge of the second step cut5208and is shown with a radius smaller than a radius of the cuts of the first step cut5204. The angled cut5208bis positioned below the curved cut5208aand separated by a vertical portion of the second step cut5208. A third step cut5212, adjacent the back panel5214is shown with a curved cut5212aand an angled cut5212b, similar to the second step cut5208, but is shown with the curved cut5212ahaving a larger radius than the radius of the curved cut5208aof the second step cut5208. Similar to the embodiment described above with respect toFIG.51, the length or distance traversed over the step cuts may vary, in addition to a spacing or distance between adjacent step cuts, such as by varying a width of the first section of the side wall5206and a width of the second section of the side wall5210. In some examples additional step cuts may be introduced between the first step cut5204and the third step cut5212. For example, a total of four or more step cuts may be included in the step cut profile. The introduction of additional step cuts may reduce a height of each step cut. In some examples, the heights of the step cuts may vary, for example with the first step cut5204at a first height and the second step cut5208at a second height, different from the first height. Additional step cuts may be included for purposes of including second, third, or fourth gussets to the side wall, thereby dividing the side wall into an additional third section, fourth section, and other sections as determined by the number and placement of additional gussets. Additional combinations of angled and curved cuts are envisioned, other than the specific embodiment shown and described with respect toFIG.52A-Cand are intended to be covered by this description.

Referring toFIG.53A, shown is an outline of a portion of one end of a bag5300with a step cut end, generally corresponding to a mirror image of the region marked as “A” inFIG.11, detailing an alternate embodiment with a combination of radial and angled cuts between the front panel5302of the bag and the first section of the side wall5306, between the first section of the side wall5306and the second section of the side wall5310, and between the second section of the side wall5310and the back panel5314of the bag, respectively, and a feature5316at one end of the bag5300that extends into the seam. Since the bag5300is formed from a continuous sheet of material, the feature5316forms a cut-out5318(removal of material; seeFIG.53B) at one end of the bag5300and a tab5322(extra material; seeFIG.53C) at the other end of the bag5300.FIG.53Bshows an image of one end of the bag depicted inFIG.53Aupon sealing the seam5320, showing cut-out5318.FIG.53Cshows an image of the other end of the bag depicted inFIG.53Aupon sealing the seam5320, showing the tab5322.

The step cut profile shown inFIG.53Aincludes angled step cuts of a variety of shapes and angles. A first step cut5304adjacent the front panel5302, includes an curved cut5304aas well as an angled cut5304b. In some examples the first step cut5304may include a vertical portion, for example when the curved portion5304aand the angled portion5304bdo not traverse the entire height of the first step cut5304. The curved cut5304amay be a cut having a radius, may be elliptical, parabolic, or otherwise curved. A second step cut5308includes a curved cut5308aas well as an angled cut5308b. The curved cut5308ais at the top edge of the second step cut5308and is shown with a radius smaller than a radius of the cuts of the first step cut5304. The angled cut5308bis positioned below the curved cut5308aand separated by a vertical portion of the second step cut5308. A third step cut5312, adjacent the back panel5314is shown with a curved cut5312aand an angled cut5312b, similar to the second step cut5308and the first step cut5304, but is shown with the curved cut5312ahaving a larger radius than the radius of the curved cut5308aof the second step cut5308and the radius of the curved cut5304aof the first step cut5304. The third step cut5312additionally may not include a straight vertical portion, but may, for example transition from the curved portion5312adirectly into the angled portion5312b. In some examples, the angled cut5312bmay be above the curved cut5312a, such that the top edge of the third step cut5312has the angled cut5312band the bottom of the third step cut5312includes the curved cut5312a. Similar to the embodiment described above with respect toFIGS.51-52, the length or distance traversed over the step cuts may vary, in addition to a spacing or distance between adjacent step cuts, such as by varying a width of the first section of the side wall5306and a width of the second section of the side wall5310. In some examples additional step cuts may be introduced between the first step cut5304and the third step cut5312. For example, a total of four or more step cuts may be included in the step cut profile. The introduction of additional step cuts may reduce a height of each step cut. In some examples, the heights of the step cuts may vary, for example with the first step cut5304at a first height and the second step cut5308at a second height, different from the first height. Additional step cuts may be included for purposes of including second, third, or fourth gussets to the side wall, thereby dividing the side wall into an additional third section, fourth section, and other sections as determined by the number and placement of additional gussets. Additional combinations of angled and curved cuts are envisioned, other than the specific embodiment shown and described with respect toFIG.53A-Cand are intended to be covered by this description.

Each of the step cut profiles shown inFIGS.1,8,9,11-14,51-53, and other such step cut profiles may be cut through the use of a laser. The laser may be guided by a computer numerical control (CNC) machine pre-programmed to cut the step cut profile. The step cut profiles can also be formed by punching, cutting, or by another suitable technique known to those in with skill in the art.

The step cut profile of the bag is cut while the substrate is in a flat configuration and subsequently folded and sealed to form the bag from the substrate. For example, with reference toFIG.12as an illustrative example, creases may be formed in the substrate at each of the step cuts of the top or bottom edges. The creases may, for example extend vertically from the top to the bottom of the bag and may be tangential to the step cut profile or may extend from a lower edge of each step cut profile. The creases form the first side wall505and the second side wall507and divide each side wall into a front side wall and a rear side wall. A crease between the front side wall and the rear side wall, may form the first gusset506. The gussets provide expansion to the bags when assembled. With reference to the step cut profiles and assembled views shown inFIGS.13-14and51-53, the seam on the front panel or back panel is used to seal couple opposite edges of the bag together to form a tube-like shape. Subsequently, the top and bottom profiles are folded, for example as shown and described with respect toFIGS.1-6and31-36.

A partial view of a bag with an easy open feature is shown inFIG.15A-C. InFIG.15A, bag800is an example of a bag with the disclosed sealing tape covered weakened area. The top or bottom end802is sealed inFIG.15Aby folding the top over to a seal line804and bonding to seal the opening. A cut out in the surface of the bag is shown to reveal the inner, woven polymer layer of a multi-layered bag as described herein, in which laminated bags can be composed of two or more layers including a woven polymer layer. In certain embodiments, the woven polymer layer includes woven strips of polypropylene, high density polyethylene, low density polyethylene, polyester, or combinations of any thereof. The polymer strips are understood to be flat, planar strips woven into a sheet by crossed strips referred to as warps and wefts, or woofs. In certain embodiments the strips are about ⅛ to ¼ inch wide flat strips. A second layer can include polypropylene, polyethylene, polyethylene terephthalate, polyamide, or any combination thereof, or it can include oriented polypropylene, biaxially-oriented polypropylene, oriented polyethylene, biaxially-oriented polyethylene, oriented polyethylene terephthalate, biaxially-oriented polyethylene terephthalate, oriented polyamide, biaxially-oriented polyamide, coated paper or any combination thereof, and can include a printed area thereon. In some examples, the second layer, and the first layer described herein, may consist essentially of any combination of one or more of the materials described above.

An easy open feature includes a sealing tape806covering a weakened area (visible inFIGS.15B and15C). The sealing tape includes two strings808affixed to the bottom or embedded in the sealing tape and running the length of the scaling tape and a tab812at one end. The tab area is not affixed to the surface of the bag, and in certain embodiments is free of adhesive and in certain embodiments is free of adhesive at least on the bottom surface. As seen inFIG.15A, the unsealed end814of the bag is step cut as described herein wherein the junctions818between the back wall816, the back820and front side walls824at the gusset fold lines822, and the junction826of the front side wall with the front wall830are curves, non-right angles or combinations of curves and non-right angles.

FIG.15Bis a view of the bag ofFIG.15Ain which the sealing tape has been partially raised in preparation for opening the bag by pulling up on the tab812separating the center section of the tape834along the line of the strings808and exposing the weakened area836in the front wall830of the bag.FIG.15Cshows a bag in which the center section of the sealing tape is further removed, exposing more of the weakened area. In the embodiment shown the weakened area is a line of perforations. When the center portion of the sealing tape is removed, the bag can be easily opened by pushing or running a finger along the line of perforations. The easy open feature that is composed of a line of perforations or cuts836is visible below the area where the tape has been lifted off the surface of the bag. InFIG.15Cthe tape has been further removed revealing more of the weakened area836.

A partial view of a bag with an easy open feature is shown inFIG.16A-C. InFIG.16A, bag900is an example of a bag with a sealing tape covered weakened area. The top or bottom end,906which is nearer to the easy open feature, is sealed inFIG.16Aby folding the top over to a seal line904and bonding to seal the opening. An easy open feature includes a sealing tape902covering a weakened area. The sealing tape includes a narrower strip of tape910affixed to the surface of the bag or to the bottom or top surface of the sealing tape and running the length of the sealing tape. The sealing tape includes a tab912at one end. The tab area is not affixed to the surface of the bag, and in certain embodiments is free of adhesive and in certain embodiments is free of adhesive at least on the bottom surface.FIG.16Bis a view of the bag ofFIG.16Ain which the narrower strip of tape910down the center of the sealing tape902has been lifted by the tab end in which the tab912is shown not to be adhered to the surface of the bag.FIG.16Cis a view of the bag in which the tape has been lifted by the tab end to partially reveal the weakened area914in the surface of the bag below the tape.

FIGS.17A and17Bare partial views of a bag with an easy open feature as described for the bags shown inFIGS.15A-Cand/or16A-C in which the sealing tape has not been applied. The weakened area shown inFIG.17Ais a line of perforations1036extending across the face of the front or rear wall of the bag in a line substantially parallel to the sealed top or bottom edge1002of the front or back wall of the bag. The bag is sealed by folding over the edge to a seal line1004and bonding the folded portion to the face of the front or back wall to seal the bag. The bag shown inFIG.17Bis similar, including a top edge1002and seal line1004. In the embodiment shown inFIG.17B, the weakened area1036includes a curve near the center of the weakened area that serves as a thumb tab1038. It is understood that a weakened area can include alternate configurations of perforations or cuts, including but not limited to2rows of cuts or perforations, either in parallel or crossing to form an “X”, or cuts or perforations that extend from the center of the weakened area in a downward or upward direction relative to the closest end of the bag.

In certain embodiments of the disclosure, the disclosed bags can be laminated woven sacks or bags. In certain embodiments the bags are composed of two or more laminated layers including an inner layer comprised of woven polymer strips. Polymer strips can be extruded polyethylene or polypropylene cut into flat strips of about ⅛ to ¼ inch in width and woven to produce a continuous woven sheet that is then cut into individual bag blanks. The woven layer can be laminated to a polymer film such as a polyester or polypropylene film, and the two layers can be laminated by a third polyethylene or polypropylene film that laminates the first two layers. The second layer of polymer film can also include graphics printed thereon including reverse printed graphics in order to provide an attractive display for commercial purposes. There are certain advantages to providing all three layers in the same polymer such as polypropylene or polyethylene, in that such bags are more easily recycled, for example. For example, a bag having its walls comprise a laminate which has two or three (or more) layers, wherein each of the bag wall layers comprises or consists essentially of the same polymer (such as polypropylene or polyethylene), may not use an adhesive material and thus is a non-adhesive laminate, is easy to recycle. In some examples, polyethylene bags, or bags that consist essentially of polyethylene may include up to ten percent polypropylene without interfering with the recyclability of the polyethylene, and polypropylene up to that threshold may be introduced for various purposes without compromising the recyclability. Moreover, any scrap or unusable bags resulting from manufacturing can be recycled as well.

The woven strips create a bag with the requisite strength to hold large amounts of material under stress and are typically not used in smaller bags, holding ten pounds or less because of the increased cost and complexity of producing heavy duty bags. An inner layer of woven flat polymer strips is shown inFIG.15Aas inset832.

It should be understood that the perforations may include or may be replaced with cuts which are longer, and may include cuts in various shapes in addition to the thumb tab, and the bags of the present disclosure may have both cuts and perforations. In addition, the cuts and/or perforations may extend entirely through all layers of the bag wall, or may extend through one or more of the bag wall and not through one or more other layers. For example, the perforations may extend through one or more outer film layers and partially but not entirely through the woven layer. In addition, it is noted that the cuts and/or perforations may include one or more cuts and/or perforations which extend through all three bag layers and others which do not, and may include cuts and/or perforations which extend deeper through one or more layers than other cuts and/or perforations. It is further noted that the cuts and/or perforations may vary in size and/or in shape, such that, for example, one or more cuts or perforations are greater in length and/or width (and/or depth) than one or more other cuts and/or perforations.

The sealing tape and/or fibers may comprise polymers, such as polypropylene, polyethylene, or combinations thereof, and can include woven polymers or woven polymer strips. A bag may include two, three, or possibly more layers, as well as the tape and fibers, which may all comprise a single material composition, thus making it much easier to recycle a bag or scrap for manufacturing purposes and also to minimize the costs of the bag. For example, the bag wall layers (whether two, three, four, or more layers) may comprise a non-adhesive laminate which is made of a single polymer (such as polyethylene or polypropylene), with the strings and tape also made of the same material or combination thereof as the bag wall layers. In one embodiment, the strings may themselves comprise a braided or woven string with one or more separate fibers or strings braided together (or woven together) to provide greater strength.

In still another embodiment (not shown), a sealing tape and substantially parallel strings may be added to the interior surface of the bag wall. In such an embodiment, a pull tab is provided which extends from the tape and from the exterior surface of the bag wall, or a pull tab can be added to the tape. In such an embodiment, a customer can pull the pull tab and the tape may pull the bag wall defined by the cuts and/or perforations (i.e., the weakened area of the bag wall) with the tape, thus providing an opening for access to the bag contents.

Referring toFIG.18, the front side view of an embodiment of a “flush cut” bag2001ais shown. Bag2001ahas a front wall2010, a back wall2011, a first side wall2012, a second side wall2013, a top end2014, and a bottom end2015. It is noted, however, that the orientation of the bag ends2014and2015may be relative, while the “top” and “bottom” references may change depending on the orientation that the bag is viewed. Bag2001ais considered a “flush cut” bag because the front wall2010and the back wall2011are cut so that the ends of the front wall2010and the back wall2011are essentially “flush” with one another; they have substantially the same length. Bag2001aalso comprises an easy open feature2020near the top end2014of the bag2001a, which in this embodiment comprises a full cut2021in a rectangular shape having a first end2021aand a second end2021bthrough the front wall2010of bag2001a, a first row of perforations2022extending from the first end2021aof the cut2021, a second row of perforations2023extending from the second end2021bof the cut2021, an optional third row of perforations2024connecting the end of the first row of perforations2022and the second row of perforations2023, tape2025covering the cut and the rows of perforations, and a pull tab2026attached to the tape2025. Although in this embodiment the easy open feature2020is located near the top end2014of the bag2001aand the pull tab is located close to the second side wall2013, it is noted that the easy open feature2020could also be in the opposite orientation, with the pull tab located closer to the first side wall2012, reside in either orientation near the bottom end2015of the front wall2010of bag2001a, or reside in either orientation near the top end2014or bottom end2015on the back wall2011of the bag2001a. The full cut2021can be formed by punching, cutting, or through the use of a laser, or by another suitable technique. The easy open feature2020(in this embodiment the cut2021and/or first2022or second2023row of perforations) provides a portion of bag2001athat is weakened. This weakened portion can be opened with less force than applied to open or tear other portions of the bag2001a.

Bag2001acan be opened by pulling the pull tab2026, which removes the tape2025and the portion of bag2001adefined by the cut2021and the first, second, and third row of perforations2022,2023, and2024, respectively. Although not shown in this embodiment, it is noted that the full cut2021can be larger or smaller, and can extend to a greater or lesser extent, and the first and second rows of perforations2022and2023, respectfully, can extend any distance from the first end and second end, respectively, of the cut toward the opposite side wall of the bag, for example 50%, 75%, 90% or about 100% of the distance from the ends of the cut to the opposite side of the bag. In addition, although not shown in this embodiment, the tape2025can cover less than the full extent of the first and second rows of perforations, whatever distance the rows of perforations extend across the front wall of the bag, and in certain embodiments covers only the full cut portion of the easy open feature2020. Additionally, the pull tab2026can comprise black and white and/or color printing (not shown), for example a coupon (not shown), and can also be used to reclose the bag.

Referring toFIG.19, the front side view of another embodiment of a flush cut bag2001bis shown. Bag2001balso has a front wall2010, a back wall2011, a first side wall2012, a second side wall2013, a top end2014, and a bottom end2015. Bag2001balso comprises an easy open feature2020, which in this embodiment is near the bottom end2015of the bag2001band comprises a full cut2021in a triangular or carat shape having a first end2021aand a second end2021bthrough the front wall2010of bag2001b, a first row of perforations2022extending from the first end2021aof the cut2021, a second row of perforations2023extending from the second end2021bof the cut2021, an optional third row of perforations2024connecting the end of the first row of perforations2022and the second row of perforations2023, tape2025covering the cut and the rows of perforations, and a pull tab2026attached to the tape2025.

Referring toFIG.20, the front side view of yet another embodiment of a flush cut bag2001cis shown. Bag2001ealso has a front wall2010, a back wall2011, a first side wall2012, a second side wall2013, a top end2014, and a bottom end2015. Bag2001ealso comprises an easy open feature2020, which in this embodiment is near the top end2014of the bag2001cand comprises a full cut2021in a semi-circular shape having a first end2021aand a second end2021bthrough the front wall2010of bag2001c, a first row of perforations2022extending from the first end2021aof the cut2021, a second row of perforations2023extending from the second end2021bof the cut2021, an optional third row of perforations2024connecting the end of the first row of perforations2022and the second row of perforations2023, tape2025covering the cut and the rows of perforations, and a pull tab2026attached to the tape2025.

Referring toFIG.21, an alternate embodiment of tape2025and pull tab2026is shown, where tape2025covers the full cut2021in a semi-circular shape having a first end2021aand a second end2021b, but does not cover the full extent of the first row of perforations2022and the second row of perforations2023, and does not cover the third row of perforations2024. In this embodiment, the pull tab2026includes instructions to open the bag, but can also comprise black and white and/or color printing (not shown), for example a promotional coupon (not shown).

Referring toFIG.22, the front side view of still another embodiment of a flush cut bag2001dis shown. Bag2001dalso has a front wall2010, a back wall2011, a first side wall2012, a second side wall2013, a top end2014, and a bottom end2015. Bag2001dalso comprises an easy open feature2020, which in this embodiment is near the bottom end2015of the bag2001dand comprises a full cut2021in a rectangular shape having a first end2021aand a second end2021bthrough the front wall2010of bag2001d, a first row of perforations2022extending from the first end2021aof the cut2021, a second row of perforations2023extending from the second end2021bof the cut2021, an optional third row of perforations2024connecting the end of the first row of perforations2022and the second row of perforations2023, tape2025covering the cut and the rows of perforations, and a pull tab2026attached to the tape2025.

Referring toFIG.23, the front side view of one embodiment of a “pinch cut” bag2100ais shown. As shown inFIG.23, the bag2100ahas a first or top end2105and a second or bottom end2110. Once again, it is noted, however, that the orientation of the bag ends2105and2110may be relative, while the “top” and “bottom” references may change depending on the orientation that the bag is viewed. Bag2100ais considered a “pinch cut” bag because one of the front wall2108or the back wall2106are cut so that one of the ends of the front wall2108or the back wall2106is longer than the other; they have different lengths. In the embodiment shown inFIG.23both of the ends of the bag2100ahave a “pinch cut.” The bag2100ahas a front wall or surface2108with top end2116, a rear wall or surface2106, and two side walls2102and2103. It is noted that conventional techniques can be used to provide side gussets in the bag2100afor each of sides2102and2103during this forming process. The first end2105of bag2100ahas portions2112aand2112bof the rear wall or surface2108of the bag that extend further from the body of the bag2100athan do portions2114aand2114bof the material of bag2100aforming the side gussets for sides2102and2103. In addition, the portions2114aand2114bof the side gussets extend further from the body of the bag2100athan the top end2116of the front wall2108of the bag2100a. As shown inFIG.23, the front wall2108of the bag2100ahas an end portion2116at the first end2105of the bag that does not extend as far from the body of the bag2100aas the end portions2114aand2114bof the side gussets or the end portions2112aand2112bof the rear wall of the first end2105of the bag2100a. Bag2100aalso comprises an easy open feature2120near the top end2105of the bag2100a, which in this embodiment comprises a full cut2121in a rectangular shape having a first end2121aand a second end2121bthrough the front wall2108of bag2100a, a first row of perforations2122extending from the first end2121aof the cut2121, a second row of perforations2123extending from the second end2121bof the cut2121, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, tape2125covering the cut and the rows of perforations, and a pull tab2126attached to the tape2125.

Referring toFIG.24, the front side view of another embodiment of a pinch cut bag2100bis shown. As shown inFIG.24, the bag2100bhas a first or top end2105and a second or bottom end2110. The bag2100bhas a front wall or surface2108with top end2116, a rear wall or surface2106, and two side walls2102and2103. The first end2105of bag2100bhas portions2112aand2112bof the rear wall or surface2108of the bag that extend further from the body of the bag2100bthan do portions2114aand2114bof the material of bag2100forming the side gussets for sides2102and2103. In addition, the portions2114aand2114bof the side gussets extend further from the body of the bag2100bthan the top end2116of the front wall2108of the bag2100b. As shown inFIG.24, the front wall2108of the bag2100bhas an end portion2116at the first end2105of the bag that does not extend as far from the body of the bag2100bas the end portions2114aand2114bof the side gussets or the end portions2112aand2112bof the rear wall of the first end2105of the bag2100b. Bag2100balso comprises an easy open feature2120, which in this embodiment is near the bottom end2110of the bag2100band comprises a full cut2121in a rectangular shape having a first end2121aand a second end2121bthrough the front wall2108of bag2100b, a first row of perforations2122extending from the first end2121aof the cut2121, a second row of perforations2123extending from the second end2121bof the cut2121, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, tape2125covering the cut and the rows of perforations, and a pull tab2126attached to the tape2125.

Referring toFIG.25, a planar view of an embodiment of a substantially flat sheet of material from which a bag2100cis to be formed is shown. Shown on the sheet are front wall2108, rear wall2106, first side2102having gusset portion2114a, second side2103having gusset portion2114b, seam2104, top end2105and bottom end2110. Also shown is easy open feature2120, which in this embodiment is near the bottom end2110of the front wall2108of the bag2100cand comprises a full cut2121in a rectangular shape having a first end2121aand a second end2121bthrough the front wall2108of bag2100c, a first row of perforations2122extending from the first end2121aof the cut2121across the front wall2108of bag2100a, a second row of perforations2123extending from the second end2121bof the cut2121across the front wall2108of bag2100c, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, tape2125covering the cut2121and the rows of perforations, and a pull tab2126attached to the tape2125.

Referring toFIG.26, a planar view of another embodiment of a substantially flat sheet of material from which a bag2100dis to be formed is shown. Shown on the sheet are front wall2108, rear wall2106, first side2102having gusset portion2114a, second side2103having gusset portion2114b, seam2104, top end2105and bottom end2110. Also shown is easy open feature2120, which in this embodiment is near the top end2105of the front wall2108of the bag2100dand comprises a full cut2121in a rectangular shape having a first end2121aand a second end2121bthrough the front wall2108of bag2100d, a first row of perforations2122extending from the first end2121aof the cut2121across the front wall2108of bag2100d, a second row of perforations2123extending from the second end2121bof the cut across the front wall2108of bag2100d, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, tape2125covering the cut2121and the rows of perforations, and a pull tab2126attached to the tape2125.

Referring toFIG.27, a planar view of another embodiment of a substantially flat sheet of material from which a bag2100eis to be formed is shown. Shown on the sheet are front wall2108, rear wall2106, first side2102having gusset portion2114a, second side2103having gusset portion2114b, seam2104, top end2105and bottom end2110. Also shown is easy open feature2120, which in this embodiment is near the top end2105of the second side2103of the bag2100eand comprises a full cut2121in a carat shape having a first end2121aand a second end2121bthrough the second side2103of bag2100e, a first row of perforations2122extending from the first end2121aof the cut2121across the second side2103of bag2100e, a second row of perforations2123extending from the second end2121bof the cut2121across the second side2103of bag2100e, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, and a pull tape2127covering the cut2121and a small portion of the first row of perforations2122and second row of perforations2123.

Referring toFIG.28, a planar view of another embodiment of a substantially flat sheet of material from which a bag2100fis to be formed is shown. Shown on the sheet are front wall2108, rear wall2106, first side2102having gusset portion2114a, second side2103having gusset portion2114b, seam2104, top end2105and bottom end2110. Also shown is easy open feature2120, which in this embodiment is near the top end2105of the second side2103of the bag2100fand comprises a full cut2121in a carat shape having a first end2121aand a second end2121bthrough the second side2103of bag2100fa first row of perforations2122extending from the first end2121aof the cut2121across the second side2103, front wall2108, first side2102and rear wall2104of bag2100fa second row of perforations2123extending from the second end2121bof the cut2121across the second side2103, front wall2108, first side2102and rear wall2104of bag2100fan optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, and a pull tape2127covering the cut2121and a small portion of the first row of perforations2122and second row of perforations2123.

Referring toFIG.29, a planar view of another embodiment of a substantially flat sheet of material from which a bag2100gis to be formed is shown. Shown on the sheet are front wall2108, rear wall2106, first side2102having gusset portion2114a, second side2103having gusset portion2114b, seam2104, top end2105and bottom end2110. Also shown is easy open feature2120, which in this embodiment is near the top end2105of the second side2103of the bag2100gand comprises a full cut2121in a carat shape having a first end2121aand a second end2121bthrough the second side2103of bag2100g, a first row of perforations2122extending from the first end2121aof the cut2121across the second side2103, front wall2108and into the first side2102of bag2100g, a second row of perforations2123extending from the second end2121bof the cut2121across the second side2103, front wall2108and into the first side2102of bag2100g, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, and a pull tape2127covering the cut2121and a small portion of the first row of perforations2122and second row of perforations2123.

Referring toFIG.30, a planar view of another embodiment of a substantially flat sheet of material from which a bag2100his to be formed is shown. Shown on the sheet are front wall2108, rear wall2106, first side2102having gusset portion2114a, second side2103having gusset portion2114b, seam2104, top end2105and bottom end2110. Also shown is easy open feature2120, which in this embodiment is near the top end2105of the front wall2108of the bag2100hand comprises a bidirectional full cut2121in a square shape having a first end2121a, a second end2121b, a third end2121cand a fourth end2121dthrough the front wall2108of bag2100, a first row of perforations2122extending from the first end2121aof the cut2121across the front wall2108and into the first side2102of bag2100h, a second row of perforations2123extending from the second end2121bof the cut2121across the front wall2108and into the first side2102of bag2100, an optional third row of perforations2124connecting the end of the first row of perforations2122and the second row of perforations2123, a fourth row of perforations2122aextending from the third end2121cof the cut2121across the front wall2108and into the second side2103of bag2100h, a fifth row of perforations2123aextending from the fourth end2121dof the cut2121across the front wall2108and into the second side2103of bag2100h, an optional sixth row of perforations2124aconnecting the end of the fourth row of perforations2122aand the fifth row of perforations2123a, and a pull tape2127covering the cut2121and a small portion of the first row of perforations2122, second row of perforations2123, fourth row of perforations2122aand fifth row of perforations2123a.

Referring toFIG.31, the back side view of yet another embodiment of a pinch cut bag2100jis shown. As shown inFIG.31, the bag2100jhas a first end2105and a second end2110. It is useful to think of first and second ends2105and2110as the top and bottom ends of the bag2100j, respectively. The bag2100jhas a front wall or surface1208, a rear wall or surface2106, and two side walls2102and2103. The bag2100jalso has a seam2104on the back side, or rear wall or surface. The seam2104may be made when the bag2100is formed using conventional methods. Using such conventional methods, a material from which a bag2100jis to be formed (such materials are discussed in detail below) is provided in a substantially flat sheet (seeFIG.25throughFIG.30). The sheet is then directed and formed so that a portion of one side of the sheet is disposed on top of the other side of the sheet, such as in forming a tube. The overlapping portion is then secured and sealed together, forming the seam2104. It is noted that conventional techniques can be used to provide side gussets in the bag2100jfor each of sides2102and2103during this forming process.

The bottom (as shown inFIG.31) of the first end2105of bag2100jhas portions2112a and2112bof the front wall2108or surface of the bag that extend further from the body of the bag2100jthan do portions2114aand2114bof the material of bag2100J forming the side gussets for sides2102and2103. In addition, the portions2114aand2114bof the side gussets extend further from the body of the bag2100jthan the top end2117of the rear wall2106of the bag2100j. As shown inFIG.31, the rear wall of the bag2100jhas a top end2117that does not extend as far from the body of the bag2100jas the end portions2114aand2114bof the side gussets or the end portions2112aand2112bof the front wall2108of the bag2100j.

Now referring toFIG.32, a top side view of bag2100kis provided. For ease of reference, the same numerals are used in the Figures to denote the same features of bag2100k. As shown inFIG.32, the bag2100kcomprises multiple layers of materials2220,2222and2224. The first layer2220is preferably a woven polymeric material, such as polypropylene, polyester, high-density polyethylene, or polyethylene. The woven plastic layer2220can be made of woven strips of plastic made of film to provide great strength from relatively lightweight materials, and can also be stretched to provide greater strength.

Still referring toFIG.32, the layer2222is a coating or a lamination, preferably a polypropylene film. Layer2224is preferably an oriented polypropylene film with reverse printing. The layer2224can comprise reverse printing of various labels, advertising, warnings, and other information as may be desired, such as the cover2130shown inFIG.32. Although not shown, it is noted that the top side, back side, and sides2102and2103of the bag2100may all contain such pictures, patterns, or information as may be desired. It is noted that the reverse printing of layer2224can be achieved with conventional techniques, and with various conventional plastic films. An advantage of printing the bottom portion of the front and/or back panels is the provision of information that remains visible when the bag is on a display shelf in a store.

Still referring toFIG.32, the bottom side (as shown inFIG.32) of the bag2100kextends outward from the body of the bag2100kat the second end2110of the bag2100k. As shown inFIG.32, the top side of the bag2100khas an end portion2140extending along the width of the bag2100k. The side gussets of the sides2102and2103of the bag2100keach have portions2142aand2142bwhich extend further towards the second end2110of the bag2100kthan the end portion2140of the top side of bag2100k. In addition, the bottom side of the bag2100khas an end portion2110that extends further from the end portions2142aand2142bof the side gussets. The end portion2110of the bag2100kincludes portions2144aand2144b. As shown inFIG.32, the second end portion of the bottom side of the bag2100kextends along the entire width of the bag2100k. Also shown is seam2104.

Still referring toFIG.32, the exposed end portions2144aand2144bof the bottom side of the bag2100kcan be coated with a durable adhesive. The adhesive can be applied to selective surface areas, such as portions2144aand2144b, or can be applied in a line extending across the bottom side of the bag2100kalong the second end portion2110, including portions2144aand2144b. After the adhesive is applied, preferably the sides2102and2103of the bag2100, together with the bottom side of the bag2100kare folded so that at least a portion of the interior surface of the bottom side of the bag2100kextends over the top surface of the top side of the bag2100k. In some cased, the portions2142aand2142bof the side gussets may be folded over and attached to the top surface of the top side of the bag2100k, as well as portions2144aand2144bof the second end2110of the bottom side of the bag2100k. The coating then seals the second end2110of the bag2100ktogether. The first end2105of the bag2100kcan be sealed in a similar fashion if desired. Alternatively, the first end2105or second end2110of the bag2100kcan be sealed using a hot melt technique or another suitable technique.

Referring now toFIG.33, a detailed cross-sectional view of an end portion of the bag2100is provided. As shown inFIG.33, at least a portion of the front side2130of bag2100is now covered by the lowest edge portion2110of the back side of bag2100, the extending portions2142a,2142bof side2102of the bag2100, as well as a portion of the front side2130of bag2100including end portion2140. Once these portions are folded over, heat and pressure can be applied as appropriate to obtain and ensure that the bottom end2110of bag2100is durably sealed, such as with a conventional heat sealable adhesive.

Once the bag2100is sealed at one end, it can be filled with the desired materials. It has been found that a bag2100with a height of41inches and a width of 28 inches can durably hold at least about fifty (50) pounds of material without showing undue stress, tearing, breakage or the like. It is believed that any bulk material can be contained by bag2100, and the contents can weigh up to 100 pounds or so without undue risk of tearing or damage to bag2100. Once the bag2100is filled, the second end typically may be sealed. The second end of the bag2100can be sealed in a similar manner as that described above for the bottom end2110. Alternatively, the bag2100can have its second end sealed by conventional means such as sewing. Still another approach is to seal the second end in a manner like that described for the bottom end2110of the bag2100, and then stitching one of the two ends (not shown). Although not shown, it is noted that a second end of bag2100can be sealed with conventional techniques once bag2100has been filled with the selected amount of the desired material.

Referring now toFIG.34, an isometric view of bag2100bis provided. As shown inFIG.34, the bag3700includes a front panel3701, a first side panel with gussets3709, a second side panel with gussets (not visible inFIG.34), a top end3703, and a bottom end3705. The bag3700is a pinch cut bag like those described previously, with both a pinch cut top end3703and a pinch cut bottom end3705. The bag3700preferably has a weakened area (not shown inFIG.34) or other easy open feature on at least one surface (not shown inFIG.34). As shown inFIG.34, the bag3700has been filled and sealed and contains one or more materials. Although the contents of the bag3700may be food, animal food, other bulk items, the contents may also contain liquids or mixtures. It is noted that the bag3700, once formed in accordance with the present disclosure, may be filled and then either the top end3703or the bottom end3705or both may be sealed as described previously. As shown inFIG.34, the bag3700, once filled, presents a bottom panel3707on the bottom end3705thereof and a top panel on the top end thereof (not visible inFIG.34). The bag3700may be stacked on top of similar or different bags, such as at a grocery store, pet store, or other display location, such that panel3707is easily visible to a consumer. As shown inFIG.34the front panel3701, the first side panel3709and the bottom panel3707includes printing (and can also include graphics), and it is noted that the top panel, the rear panel, and the second side panel of bag3700, which are not visible inFIG.34, can also include graphics and/or printing. Thus bag3700has six discrete areas for printing and/or graphics, each formed by a discrete surface area of the bag3700. Additionally, the printing and/or graphics can extend across more than one panel, or any combination of the six panels (not shown). The panel3707may include graphics and/or printing so that a consumer is able to quickly, readily and easily identify the brand of the contents in the bag, such as the brand name for the pet food therein if the bag3700contains pet food. Alternatively, or in addition, the printing or graphics on the panel3707may contain information such as price, composition, expiration date, and the like. In another embodiment, the panel3707may contain printing or graphics that provide a coupon or other price discount or other offer, either on the contents of the bag3700or some other product.

In one embodiment of the present disclosure, a bag is provided that has a peelable, easy open feature. Such as bag is illustrated inFIGS.35and36. The bag has a front or first wall and an opposing back or second wall. The bag may have side walls, and the side walls may have gussets, all as described above in connection with the various embodiments described, or the bag may instead comprise a laminated bag, such as a bag having two or more laminated layers, or any other type of consumer goods packaging. In the following description, a laminated, woven bag is described as a specific example of a bag, but is provided only as an example. In the example of a woven bag as a particular embodiment, the bag has a top or first end, and a bottom or second end, with the first end of the back wall extending beyond the first end of the front wall. This extension of the top end of the back wall beyond the top end of the front wall may be anywhere from a fraction of an inch to four inches, six inches, eight inches, ten inches, or more, as may be desired. Each of the bag walls has an exterior surface and an interior surface. The bag walls may have a woven polymeric layer and one or more polymeric film layers, such as any of those described above in connection with the various bags described herein. The bag wall layers may comprise any one or more materials, including any type of polymer, polypropylene, polyethylene, high density or low density polyethylene, polyester, nylon, polyethylene terephthalate, polyester, polyamide, oriented polypropylene, biaxially-oriented polypropylene, oriented polyethylene, biaxially-oriented polyethylene, oriented polyester, biaxially-oriented polyester, nylon, oriented or biaxially-oriented nylon, oriented polyethylene terephthalate, biaxially-oriented polyethylene terephthalate, oriented polyamide, biaxially-oriented polyamide, coated paper, or any combination thereof In some examples, the first layer may consist essentially of polypropylene, high density polyethylene, low density polyethylene, polyester, and combinations thereof. In some examples, the second layer may consist essentially of polypropylene, polyethylene, polyethylene terephthalate, polyamide, or any combination thereof or paper.

A portion of the exterior surface of the front bag wall, the interior surface of the back bag wall, or both, may be treated to provide a preferential peelable, easy open area as described in more detail below. The treated portion of the surface(s) of the front and/or back bag wall(s) may be treated with a polyamide ink, a urethane-based ink, a nitrocellulose ink, or a combination of any of the foregoing, and may be treated in a particular pattern, such as a rectangular area, an elliptical area, a triangular area, or the like. It should be appreciated that the interior of the back wall and/or the exterior of the front wall may be treated with two or more inks or a combination of one or more inks and one or more treatments. For example, a first portion of the overlay portion can be treated with a first type of ink or subject to a first treatment, and a second portion of the overlay portion can be treated with a second, different ink and/or subject to a second, different treatment. Depending on the material selected for one or more of the bag layers, one or more different inks or treatments may be selected to provide the desired sealing strength control at the desired locations of the bag. For example, a polyamide resin or polyamide-based ink may provide less scaling strength than a nitrocellulose- or polyurethane-based ink or resin.

The treated portion of the surface(s) of the front and/or back bag wall(s) is determined so that it is preferably proximal the top end of the front bag wall, such as within the top one, two, or three inches from the top end of the front bag wall when the back bag wall is folded over the top end of the bag and brought into contact with a portion of the exterior surface proximal the top end of the front bag wall. The treated portion may extend all or partially across the width of the front and/or back bag walls. For example, if it is desired to control the sealing strength so that the seal is stronger on the left hand side of the bag (as shown inFIGS.35and36) than the right hand side, more ink may be used on the right hand side of the bag wall and/or no ink may be used on the left hand side. Alternatively, the ink may be applied to an area that extends across 10%, 20%, 30%, 50%, or 100% of the bag's width from one side.

Once the front and/or back bag wall(s) have been treated, and a portion of the extending portion of the back bag wall has been folded over and brought into contact with a portion of the front bag wall proximal the top end of the bag, the overlaying portions of the front and back bag walls may be sealed, such as by applying heat and/or pressure in desired amounts for a desired time period, or by any of the sealing techniques described above in connection with any of the other embodiments described herein. This sealing may be done by passing the overlaying portions of the front and bag walls past a nozzle blowing heated air at or above a predetermined temperature or within a predetermined temperature range, or by applying heated clamps to opposing exterior surfaces of the overlaying portion of the front and bag walls, with the clamps applying a predetermined amount of pressure and at a predetermined temperature or above or within a predetermined temperature range. It is noted that the front and back bag walls may be sealed without the use of an adhesive, or, as described above, one or more adhesives may be used to seal the bag end.

In addition, the sealing of the overlaying portions of the front and back bag walls may be done selectively, such that a portion of the back bag wall is not sealed to the front bag wall and forms a flap. The flap may extend along the width of the bag wall, or may extend for only a portion of the width of the bag wall. The flap and sealing of the front and back bag walls as described provides an easy open feature such that a consumer can grip the flap, such as at one side of the bag, and pull the flap upwards and/or away from the front wall of the bag. Because the strength of the seal has been controlled at the overlay portion of the front and back bag walls as desired, the consumer should be able to open the bag without a knife or for scissors. The flap may include one or more pull tabs to assist the consumer in gripping and pulling the flap, and may include printing and/or graphics to instruct and assist the consumer in how to open the bag.

Referring now toFIGS.35and36, an example of one type of bag with a peelable, easy open feature of this type is illustrated. InFIG.35, a bag3500with a peelable, easy open feature is shown. The bag3500has a front wall3501and an opposing back wall (not shown), which are joined by side walls. The bag3500further has a top end3510and a bottom end3505. The bottom end3505can be of any type, including a stepped-cut bag, a pinch bag, a pouch bag, or other type, and can be sealed using any of the sealing techniques described herein, or may include a peelable, easy open feature or other type of easy open feature. As illustrated inFIG.35, a portion3515of the back wall is folded over and forms the top end3510of the bag3500. At least a portion of the portion3515located above the line3525is sealed to the front wall3501of the bag3500. In this particular illustration, the interior surface of the portion3515of the back wall is sealed to the exterior surface of the front bag wall. It is noted that the extending portion of the back wall can be double-folded if desired so that an exterior surface of the back bag wall is scaled to the exterior surface of the front wall. It can be seen that a flap3520of the end of the back bag wall is not sealed to the front bag wall below the line3525. This flap3520can be gripped by a consumer and pulled to open the bag3500easily.

Referring now toFIG.36, the exemplary bag3500is shown with a portion of the top end3510opened on the right hand side of the bag. The top end3530of the front wall3501of the bag3500is shown. It can be seen inFIG.36that the left-handed portion3535of the top end of the back wall is still sealed to the exterior surface of the front wall3501. It should be appreciated that a consumer can grip the flap3520(as shown inFIG.35) at the right-hand side of the bag and pull upwards and/or away from the bag front wall3501to open the bag3500. It should also be appreciated that the selective treatment of a portion or portions of the front and/or back bag walls as described herein allow for a controlled sealing area proximal the top end of the bag3500, such as to create one or more areas in which the front and back bag walls are sealed with a stronger seal than other areas, and/or one or more areas in which the front and back bag walls are sealed with a seal which is more easily separated, all without the use of an adhesive (although, as noted, an adhesive may be used to seal the top end of the bag3500if desired). By selectively controlling the area(s) treated with one or more inks, and by controlling the heat, pressure, and/or duration of the application of heat and pressure to selected areas of the overlaying portions of the front and back bag walls, a selective and more precise control of the location of the seal between the front and back bag walls as well as the local strength of such seals, may be attained. The local strength of the seal may vary, but yet provides sufficient strength to pass the applicable drop test, peel test, and the like and provides a strong, durable seal. In some examples, the layers and construction of the bag are such that the bags as described herein must pass a drop test wherein the bag is filled with up to twenty to eighty pounds of material and dropped at a height of two to ten feet without bursting a seam or tearing the bag.

Referring now toFIGS.37through48, various different examples of easy open features are shown. The views inFIGS.37through48show a wall of the bag that includes an easy open feature in a vertical orientation and a corresponding diagonal orientation. It is noted that various different types of orientations of the easy open feature are contemplated herein.

InFIG.37a view of a bag3750with an easy open feature3752is shown. As shown, easy open feature3752is intended to represent a weakened line, such as at least one cut or perforation, as discussed previously, that includes a curved portion3754centrally located that may function as a tab for opening bag3750. By pressing on curved portion3754, a preferential tear may occur at easy open feature3752to enable opening of bag3750. Easy open feature3752also includes end curves3758at each respective end that enable the opening to form small flaps and prevent tearing while the contents of bag3750are poured out. Accordingly, easy open feature3752may be used with or without a sealing tape that covers easy open feature3752. It is further noted that a depth of easy open feature3752may vary in different embodiments. For example, easy open feature3752may include cuts, including perforations, that penetrate all layers of bag3750, in some embodiments. In various embodiments, easy open feature3752may include cuts or perforations through or partially through selected one or more layers of bag3750, but without cuts or perforations in at least one layer of bag3750, for example. In other embodiments, various types of weakening methods may be used to form easy open feature3752, such as, but not limited to, at least one of heat, pressure, punctual force, and cutting (including perforating). Easy open feature3752is shown oriented substantially vertically with respect to bag3750inFIG.37, as indicated by arrow3756, which points upward in the vertical direction with respect to bag3750. Although shown vertically oriented, easy open feature3752may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag3750.

Similarly, a bag3800shown inFIG.38includes an easy open feature3802. As shown, easy open feature3802is intended to represent a weakened line, such as a cut or a perforation, as discussed previously, that includes a curved portion3854centrally located that may function as a tab for opening bag3800, as well as end curves3858. Easy open feature3802is substantially similar to easy open feature3752inFIG.37, but easy open feature3802is oriented diagonally with respect to bag3800inFIG.38. It is noted that bag3800inFIG.38is shown alongside bag3750inFIG.37in the same orientation with respect to arrow3754. As shown, easy open feature3802is oriented at about a 45° angle with respect to the top edge (or the bottom edge) of bag3800. Easy open feature3802can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge and still be diagonally oriented.

InFIG.39a view of a bag3900with an easy open feature3902is shown. As shown, easy open feature3902is intended to represent a portion of tape3904that covers a cut or opening (not visible) made into the bag wall of bag3900. Within tape3904, an H-shaped weakened line3906, such as a cut or a perforation, as discussed previously, is centrally located and may function as a tab for opening tape3904. By pressing on H-shaped weakened line3906, tape3904may be released by puncturing the cut or perforation, and may enable tape3904to be at least partially pulled to enable opening of bag3900. In other embodiments, various types of weakening methods may be used to form H-shaped weakened line3906in easy open feature3902, such as, but not limited to, at least one of heat, pressure, force, and cutting (including perforating). Easy open feature3902is shown oriented substantially vertically with respect to bag3900inFIG.39, as indicated by arrow3908, which points upward in the vertical direction with respect to bag3900. Although shown vertically oriented, easy open feature3902may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag3900.

Similarly, a bag4000shown inFIG.40includes an easy open feature4002. As shown, easy open feature4002that is substantially similar to easy open feature3902inFIG.39. Accordingly, easy open feature4002includes a portion of tape4004and an H-shaped weakened line4006, such as a cut or a perforation, as discussed previously. Easy open feature4002is substantially similar to easy open feature3902inFIG.39, but easy open feature4002is oriented diagonally with respect to bag4000inFIG.40. It is noted that bag4000inFIG.40is shown alongside bag3900inFIG.39in the same orientation with respect to arrow3908. As shown, easy open feature3902is oriented at about a 45° angle with respect to the top edge (or the bottom edge) of bag3900. Easy open feature3902can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge and still be diagonally oriented.

InFIG.41a view of a bag4100with an easy open feature4102is shown. As shown, easy open feature4102is intended to represent a portion of tape4108that covers an opening4104formed into the bag wall of bag4100. Along with tape4108is a release tab4106that may function as a tab for releasing tape4108in order to expose opening4104to open bag4100. Opening4104is shown as a cut entirely through the wall of bag4100in a rectangular shape. It is noted that various shapes may be used for opening4104in different embodiments. Release tab4106may be attached to at least one side of tape4108and may accordingly enable tape4108to be at least partially pulled to enable opening of bag4100. In other embodiments, various types of release tabs4106or tape releasing features may be included in easy open feature4102. It is noted that a force used to pull release tab4106may be lower than a force used to open a seal of the walls of bag4100, such as seals formed at the ends of bag4100upon filling and sealing bag4100. Easy open feature4102is shown oriented substantially vertically with respect to bag4100inFIG.41, as indicated by arrow4110, which points upward in the vertical direction with respect to bag4100. Although shown vertically oriented, easy open feature4102may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag4100.

Similarly, a bag4200shown inFIG.42includes an easy open feature4202. As shown, easy open feature4202that is substantially similar to easy open feature4102inFIG.41. Accordingly, easy open feature4202includes a portion of tape4208that covers an opening4204and a release tab4206, as discussed above. Easy open feature4202is substantially similar to easy open feature4102inFIG.41, but easy open feature4202is oriented diagonally with respect to bag4200inFIG.42. It is noted that bag4100inFIG.41is shown alongside bag4200inFIG.42in the same orientation with respect to arrow4110. As shown, easy open feature4202is oriented at about a 45° angle with respect to the top edge (or the bottom edge) of bag4200. Easy open feature4202can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge and still be diagonally oriented.

InFIG.43a view of a bag4300with an easy open feature4302is shown. As shown, easy open feature4302includes a cover on the exterior surface of bag4300over a plurality of cuts, such as perforations. The cover may be a tape4306that covers a weakened line4304formed into the bag wall of bag4300. Weakened line4304, such as a cut or a perforation, as discussed previously, may be substantially similar to weakened line3752discussed above with respect toFIG.37. By pressing on weakened line4304, or by pulling on a tab4310of a release strip4308, a preferential tear may occur at easy open feature4302to enable opening of bag4300. Tape4306may include release strip4308that preferentially separates from the remaining portions of tape4306and is centrally oriented to cover weakened line4304. For example, release strip4308may have tab4310to enable removal of release strip4308from tape4306to expose weakened line4304that may be used to open bag4300. After removal, release strip4308may be discarded. It is further noted that a depth of weakened line4304may vary in different embodiments. For example, weakened line4304may include cuts, including perforations, that penetrate all layers of bag4300, in some embodiments. In various embodiments, weakened line4304may include cuts or perforations through or partially through selected one or more layers of bag4300, but without cuts or perforations in at least one layer of bag4300, for example. In other embodiments, various types of weakening methods may be used to form weakened line4304, such as, but not limited to, at least one of heat, pressure, force, and cutting (including perforating). In other embodiments, various types of release tabs or tape releasing features may be included in easy open feature4302. It is noted that a force used to pull release strip4304may be lower than a force used to open a seal of the walls of bag4300, such as seals formed at the ends of bag4300upon filling and sealing bag4300. Easy open feature4302is shown oriented substantially vertically with respect to bag4300inFIG.43, as indicated by arrow4312, which points upward in the vertical direction with respect to bag4300. Although shown vertically oriented, easy open feature4302may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag4300.

Similarly, a bag4400shown inFIG.44includes an easy open feature4402. As shown, easy open feature4402that is substantially similar to easy open feature4302inFIG.43. Accordingly, easy open feature4402includes a portion of tape4406that covers an opening4404and a release strip4408having a tab4410, as discussed above. Easy open feature4402is substantially similar to easy open feature4302inFIG.43, but easy open feature4402is oriented diagonally with respect to bag4400inFIG.44. It is noted that bag4400inFIG.44is shown alongside bag4300inFIG.43in the same orientation with respect to arrow4312. As shown, easy open feature4402is oriented at about a 45° angle with respect to the top edge (or the bottom edge) of bag4400. Easy open feature4402can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge and still be diagonally oriented.

InFIG.45a view of a bag4500with an easy open feature4502is shown. As shown, easy open feature4502is intended to represent a portion of tape4506that covers a weakened line4504formed into the bag wall of bag4500. Weakened line4504, such as a cut or a perforation, as discussed previously, may be similar to weakened line3752discussed above with respect toFIG.37. As shown, weakened line4504is a straight line without a tab formed therein. Easy open feature4502also includes end curves4509at each respective end of weakened line4504that enable the opening to form small flaps and prevent tearing while the contents of bag4500are poured out. In some implementations, weakened line4504may be weakened further than weakened line3752and may open relatively easily once tape4506is removed. After removing tape4506and then by pressing on weakened line4504, a preferential tear may occur at easy open feature4502to enable opening of bag4500. Additionally, tape4506may include a tab4508to enable removal of tape4506to expose weakened line4504that may be used to open bag4500. After removal, tape4506may be discarded. In some embodiments, tape4506may be resealable or may be reattached to cover and at least partially seal the opening at weakened line4504. It is further noted that a depth of weakened line4504may vary in different embodiments. For example, weakened line4504may include cuts, including perforations, that penetrate all layers of bag4500, in some embodiments. In various embodiments, weakened line4504may include cuts or perforations through or partially through selected one or more layers of bag4500, but without cuts or perforations in at least one layer of bag4500, for example. In other embodiments, various types of weakening methods may be used to form weakened line4504, such as, but not limited to, at least one of heat, pressure, force, and cutting (including perforating). In other embodiments, various types of release tabs or tape releasing features may be included in easy open feature4502. It is noted that a force used to pull tape4504may be lower than a force used to open a seal of the walls of bag4500, such as seals formed at the ends of bag4500upon filling and sealing bag4500. Easy open feature4502is shown oriented substantially vertically with respect to bag4500inFIG.45, as indicated by arrow4510, which points upward in the vertical direction with respect to bag4500. Although shown vertically oriented, easy open feature4502may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag4500.

Similarly, a bag4600shown inFIG.46includes an easy open feature4602. As shown, easy open feature4602that is substantially similar to easy open feature4502inFIG.45. Accordingly, easy open feature4602includes a portion of tape4606having a tab4608that covers a weakened line4604, as discussed above, as well as end curves4609. Easy open feature4602is substantially similar to easy open feature4502inFIG.45, but easy open feature4602is oriented diagonally with respect to bag4600inFIG.46. It is noted that bag4600inFIG.46is shown alongside bag4500inFIG.45in the same orientation with respect to arrow4510. As shown, easy open feature4602is oriented at about a 45° angle with respect to the top edge (or the bottom edge) of bag4600. Easy open feature4602can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge and still be diagonally oriented.

InFIG.47a view of a bag4700with an easy open feature4702is shown. As shown, easy open feature4702is intended to represent a portion of tape4706that covers a weakened line4704formed into the bag wall of bag4700. Weakened line4704, such as a cut or a perforation, as discussed previously, may be substantially similar to weakened line3752discussed above with respect toFIG.37. Easy open feature4702also includes end curves4709at each respective end of weakened line4704that enable the opening to form small flaps and prevent tearing while the contents of bag4700are poured out. In some implementations, weakened line4704may be weakened further than weakened line3752and may open relatively easily once tape4706is removed. After removing tape4706and then by pressing on weakened line4704, a preferential tear may occur at easy open feature4702to enable opening of bag4700. Additionally, tape4706may include a tab4708to enable removal of tape4706to expose weakened line4704that may be used to open bag4700. After removal, tape4706may be discarded. In some embodiments, tape4706may be resealable or may be reattached to cover and at least partially seal the opening at weakened line4704. It is further noted that a depth of weakened line4704may vary in different embodiments. For example, weakened line4704may include cuts, including perforations, that penetrate all layers of bag4700, in some embodiments. In various embodiments, weakened line4704may include cuts or perforations through or partially through selected one or more layers of bag4700, but without cuts or perforations in at least one layer of bag4700, for example. In other embodiments, various types of weakening methods may be used to form weakened line4704, such as, but not limited to, at least one of heat, pressure, force, and cutting (including perforating). In other embodiments, various types of release tabs or tape releasing features may be included in easy open feature4702. It is noted that a force used to pull tape4704may be lower than a force used to open a seal of the walls of bag4700, such as seals formed at the ends of bag4700upon filling and sealing bag4700. Easy open feature4702is shown oriented substantially vertically with respect to bag4700inFIG.47, as indicated by arrow4710, which points upward in the vertical direction with respect to bag4700. Although shown vertically oriented, easy open feature4702may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag4700.

Similarly, a bag4800shown inFIG.48includes an easy open feature4802. As shown, easy open feature4802that is substantially similar to easy open feature4502inFIG.45, but is shaped according to easy open feature3752, discussed above with respect toFIG.37. Accordingly, easy open feature4802includes a portion of tape4806having a tab4808that covers a weakened line4804, as discussed above, as well as end curves4809. Easy open feature4802is substantially similar to easy open feature4702inFIG.47, but easy open feature4802is oriented diagonally with respect to bag4800inFIG.48. It is noted that bag4800inFIG.48is shown alongside bag4700inFIG.47in the same orientation with respect to arrow4710. As shown, easy open feature4802is oriented at about a 45° angle with respect to the top edge (or the bottom edge) of bag4800. Easy open feature4802can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge and still be diagonally oriented.

Referring now toFIG.49, a bag4902is shown with an easy open feature4904. Easy open feature4904is shown as a generic feature that may be any of the features depicted with respect toFIGS.38through47. As shown, easy open feature4904is located at a side wall of bag4902and is vertically oriented. Although shown vertically oriented, easy open feature4904may also be oriented within an angular range of about 80° to 100° with respect to the top edge or the bottom edge of bag4900. Although the easy open feature4904as shown inFIG.49indicates a tape covering one or more cuts or perforations through or partially through one or more of the bag wall layers of the bag side wall, it should be noted that such cuts and/or perforations (such as those described above) can be provided with or without a tape covering.

Referring now toFIG.50, a bag5002is shown with an easy open feature5004. Easy open feature5004is shown as a generic feature that may be any of the features depicted with respect toFIGS.38through47. As shown, easy open feature5004is located at a side wall of bag5002and is diagonally oriented. Easy open feature5004can be oriented within an angular range of about 30° to 60° with respect to the top edge or the bottom edge of bag5002and still be diagonally oriented. Although the easy open feature5004as shown inFIG.50indicates a tape covering one or more cuts or perforations through or partially through one or more of the bag wall layers of the bag side wall, it should be noted that such cuts and/or perforations (such as those described above) can be provided with or without a tape covering.

In one particular example of a bag which is from 2.0 to 20.0 inches in width with a peelable, easy open feature like that shown and described herein, the bag walls may comprise or consist of two or more layers, including a first layer comprising woven strips of oriented polyethylene, polyester, or polypropylene and a second layer comprising a film layer comprising oriented polyethylene, polyester, or polypropylene. The second layer may be laminated to the first layer, such as without an adhesive, and may be laminated to the first layer by a third layer comprising a film layer comprising polyethylene, polyester, or polypropylene. The first, second and third layers may all comprise the same material, and may be polyethylene, polyester, and polypropylene, or a combination thereof. The top end of the back wall may extend 0.25 to 6.0 inches or so beyond the top end of the front bag wall. A polyamide ink, urethane ink, nitrocellulose ink, or combination thereof, may be applied to the exterior or interior surface of the front bag wall in an area extending across the width of the front bag wall and from the top end of the front wall to 0.25 to 6.0 inches below the top end of the bag wall. The top end of the back wall may be folded over the top end of the front wall and a portion of the interior surface of the back wall may be placed into contact with a portion of the exterior surface of the front wall to form an overlaying portion of the front and back walls. The overlaying portion may extend lengthwise across the width of the bag wall and may be from 2.0 to 20.0 inches in width. The overlaying portion may be sealed by passing it by a nozzle blowing heated air at a temperature of from 360 F. to 1800 F. or so, at a speed of about 20 to 3,000 inches per minute, to form a seal at the top end of the bag. In addition, an unsealed flap of about 0.125 to 2.0 inches or so in width may extend lengthwise across the width of the bag, wherein the flap is formed from the portion of the top end of the back wall that is not scaled to the front wall of the bag. It has been observed that such a bag is adapted to hold anywhere from 1.5 pounds, ten pounds, twenty pounds, thirty pounds, forty pounds, fifty pounds, sixty pounds, to seventy pounds of a filling material once filled, and provides a strong, durable seal that is rugged and can hold such contents without the risk of spilling or contamination, yet can be easily opened by a consumer without a knife or scissors by pulling the tab upwards and/or outwardly from the front wall of the bag. In this particular example, the bag's second layer may comprise printing and/or graphics on at least one side, which may be done with reverse printing or surface printing, and the ink coating may be applied to the second bag layer (e.g., the film layer) on the second layer's printed side. The ink coating may be applied to the film layer after the film layer has had the printing and/or graphics printed thereon.

Those skilled in the art will understand and appreciate that the bag according to the invention may vary in size, dimensions, and shape without departing from the scope of the invention, and that the foregoing description of the preferred embodiments is not intended to limit the scope of the invention as defined by the claims. For example, those skilled in the art will understand and appreciate that the bags shown and described in the various embodiments can have sealed and sewn ends in a tubular bag with side gussets as shown, or a block bottom and top, or a combination thereof, although not shown. Those skilled in the art will also appreciate that a weakened portion or area can be provided in a number of ways that may vary from those expressly described and shown, such as by stressing portions of the bag wall with or without deforming or perforating same, as well as varying the size, number, depth, and/or pattern of perforations and/or deformations in a bag wall. Similarly, those skilled in the art will understand that the bags shown and described in the various embodiments may be provided with a re-usable opening (not shown). Such features are conventional with prior art bags. Similarly, those skilled in the art will appreciate that terms such as “front” and “rear,” and “top” and “bottom,” are useful in describing a bag, but essentially depend on a bag's orientation when such terms are used, and are therefore not limiting as to a bag's orientation. Similarly, those skilled in the art will appreciate that the material compositions may consist essentially of any combination described herein, with the term “consisting essentially of” may include impurities and limited amounts of other items or materials that do not interfere with properties of the bags described herein, interfere with the easy-open capability, or interfere with the recyclability of the product.