Multi-layered bags and methods of manufacturing the same

• US 9,056,697 B2
• Filed: 12/15/2008
• Issued: 06/16/2015
• Est. Priority Date: 12/15/2008
• Status: Expired due to Fees

• Current Assignee: Coveris Flexibles US LLC (Coveris Management GmbH)
• Original Assignee: Exopack LLC (Coveris Management GmbH)
• Inventors: Smith, Allyson
• Primary Examiner(s): Weeks, Gloria R
• Application Number:
  US12/335,414
• Publication Number:
  US 20100150479A1
• Time in Patent Office: 2,374 Days
• Field of Search: 383/61.3, 383/109, 383/113, 383/116, 493/186, 493/267, 493/339, 493/927
• US Class Current: 1/1
• CPC Class Codes: B31B 2155/00 Flexible containers made from webs
• CPC Class Codes: B31B 2170/20 having multi-layered walls, e.g. laminated or lined
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/414 Translucent
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2307/702 Amorphous
• CPC Class Codes: B32B 2307/758 Odour absorbent
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2439/46 Bags
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 29/002 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B65D 31/02 : with laminated walls
• CPC Class Codes: B65D 33/18 : using adhesive applied to integral parts, e.g. to flaps
• CPC Class Codes: B65D 33/2508 : using slide fasteners with interlocking members having a substantially uniform section throughout the length of the fastener; Sliders therefor
• CPC Class Codes: B65D 33/26 : using staples or stitches B65D33/1641 takes precedence

Abstract

A bag can include walls formed of a material having multiple layers, one of which can be a layer of nonwoven material. A polyolefin layer can be joined to an outer face of the nonwoven layer. One or more films can be joined to an inner face of the nonwoven layer.

Claims

1. A bag comprising:

a body material that defines a front wall, a back wall, a first side wall, and a second side wall, the body material comprising a first layer, a second layer, and a third layer, wherein an inwardly facing surface of the first layer defines an innermost face of the body material that is configured to directly contact the contents of the bag when the bag is in a filled state and an outwardly facing surface of the first layer is laminated to an inwardly facing surface of the second layer, wherein the first layer consists of a single-layer, grease-impermeable nylon or polypropylene film that is configured to prevent grease from passing from the contents of the bag to the second layer, wherein the second layer comprises a web of nonwoven material, and wherein the third layer comprises a polyolefin film laminated to an outwardly facing surface of the nonwoven material; and

a closure at a first end of the bag, wherein the closure comprises a seal configured to prevent the contents of the bag from exiting the bag via the first end when the bag is in the filled state.

2. The bag of claim 1, wherein the web of nonwoven material comprises polymeric fibers.

3. The bag of claim 2, wherein the polymeric fibers comprise one or more of polypropylene fibers, polyethylene fibers, and polyester fibers sheathed in one or more of polyethylene, a co-polyester, and/or a copolymer of polyethylene.

4. The bag of claim 2, wherein the web of nonwoven material further comprises cellulosic fibers.

5. The bag of claim 2, wherein the web of nonwoven material is within a range of between about 10 and about 200 grams per square meter.

6. The bag of claim 1, wherein the web of nonwoven material comprises cellulosic fibers.

7. The bag of claim 1, wherein the web of nonwoven material is within a range of between about 10 and about 200 grams per square meter.

8. The bag of claim 1, wherein the third layer comprises printing.

9. The bag of claim 1, wherein the third layer is configured to prevent gases from entering the bag.

10. The bag of claim 1, wherein the bag further comprises a zipper closure that is heat sealed to the first layer at a second end of the bag.

11. The bag of claim 1, wherein the third layer comprises a heat-sealable material, and wherein the bag further comprises a zipper closure that is heat sealed to the third layer at a second end of the bag.

12. The bag of claim 1, wherein the closure at the first end of the bag comprises one of a sewn seam and a heat-sealed seam.

13. The bag of claim 1, wherein an edge of the body material overlaps a portion of the third layer to form a seam, and wherein the seam extends between the first end of the bag and a second end of the bag that is opposite the first end of the bag.

14. The bag of claim 1, wherein the third layer is treated with a coating on the outer face of the film.

15. The bag of claim 14, wherein the coating is oil, grease, and water resistant.

16. The bag of claim 1, wherein a second end of the bag comprises a portion of the front wall and a portion of the back wall, wherein the portion of the front wall extends beyond an end of the back wall such that the portion of the front wall may be folded to adheringly overlie the portion of the back wall to define an overlapping seam extending along substantially an entire transverse extent of the bag to closingly seal the second end of the bag.

17. The bag of claim 16, further comprising a hot melt adhesive, wherein the hot melt adhesive is configured to be positioned between the portion of the front wall that may be folded and the portion of the back wall to adhere the portions of the front and back wall to each other.

18. The bag of claim 1, wherein the single-layer, grease-impermeable nylon or polypropylene film is further configured to prevent mineral oils from passing from the contents of the bag to the second layer.

19. The bag of claim 1, wherein the single-layer, grease-impermeable nylon or polypropylene film is further configured to prevent solvents from passing from the contents of the bag to the second layer.

20. The bag of claim 1, wherein the single-layer, grease-impermeable nylon or polypropylene film is further configured to prevent acids from passing from the contents of the bag to the second layer.

21. A bag comprising:

a body material that defines a front wall, a back wall, a first side wall, and a second side wall, the body material comprising an outer layer and an inner layer, wherein the outer layer comprises a web of nonwoven material, and wherein the inner layer is laminated to an inwardly facing surface of the nonwoven material, the inner layer consisting of a single layer, grease-impermeable nylon or polypropylene film, wherein an inwardly facing surface of the film defines an innermost face of the body material that is configured to directly contact the contents of the bag when the bag is in a filled state, and wherein the film is configured to act as a barrier to grease; and

a closure at a first end of the bag, wherein the closure comprises a seal configured to prevent the contents of the bag from exiting the bag via the first end when the bag is in the filled state.

22. The bag of claim 21, wherein the web of nonwoven material is within a range of between about 10 and about 200 grams per square meter.

23. The bag of claim 21, wherein the bag further comprises a zipper closure that is heat sealed to the inner layer at a second end of the bag.

24. The bag of claim 21, further comprising a polyolefin film laminated to an outwardly facing surface of the web of nonwoven material.

25. The bag of claim 24, further comprising a zipper closure heat sealed to the polyolefin film that is laminated to the outwardly facing surface of the web of nonwoven material.

26. The bag of claim 24, wherein the polyolefin film that is laminated to an outwardly facing surface of the web of nonwoven material is printed.

27. The bag of claim 21, wherein a second end of the bag comprises a portion of the front wall and a portion of the back wall, wherein the portion of the front wall extends beyond an end of the back wall such that the portion of the front wall may be folded to adheringly overlie the portion of the back wall to define an overlapping seam extending along substantially an entire transverse extent of the bag to closingly seal the second end of the bag.

28. The bag of claim 27, further comprising a hot melt adhesive, wherein the hot melt adhesive is configured to be positioned between the portion of the front wall that may be folded and the portion of the back wall to adhere the portions of the front and back wall to each other.

29. A method of forming a bag, the method comprising:

providing a web of nonwoven material;

joining a grease-impermeable polyolefin film to the web of nonwoven material to form a body material, wherein the polyolefin film consists of a single-layer of nylon or polypropylene;

shaping the body material into a body having a front wall and a back wall such that the polyolefin film is oriented to be on the inwardly facing surface of the nonwoven material, wherein an inwardly facing surface of the polyolefin film defines an innermost face of the body material so that the polyolefin film provides a barrier to the passage of grease between an interior of the bag and the nonwoven material; and

joining an end of the front wall with an end of the back wall to form a closure.

30. The method of claim 29, wherein the web of nonwoven material is within a range of between about 10 and about 200 grams per square meter.

31. The method of claim 29, wherein the web of nonwoven material comprises polymer fibers.

32. The method of claim 29, wherein a second polyolefin film is joined to the web of nonwoven material on a side opposite the first polyolefin film.