Abstract: A light-weight side gusset for a bag includes a formed composite frame having a peripheral raised region and a depressed central region. An opening through the depressed central region forms a relatively narrow border portion around the inner periphery of the raised region. A central panel corresponding in configuration to the outline of the depressed region is attached to the border portion of the depressed region to cover the opening therethrough. The composite frame is made up of a moldable substrate, e.g. ethyl vinyl acetate foam, an outer layer wear-resistant material, e.g., high-denier nylon or poly/nylon combination, and, preferably, an inner adherent layer, e.g., the loop half of a hook-and-loop fabric. Methods of manufacturing the composite frame, a gusset including such frame, and a bag including such gusset are also disclosed.

Abstract: A light-weight side gusset for a bag includes a formed composite frame having a peripheral raised region and a depressed central region. An opening through the depressed central region forms a relatively narrow border portion around the inner periphery of the raised region. A central panel corresponding in configuration to the outline of the depressed region is attached to the border portion of the depressed region to cover the opening therethrough. The composite frame is made up of a moldable substrate, e.g. ethyl vinyl acetate foam, an outer layer wear-resistant material, e.g., high-denier nylon or poly/nylon combination, and, preferably, an inner adherent layer, e.g., the loop half of a hook-and-loop fabric. Methods of manufacturing the composite frame, a gusset including such frame, and a bag including such gusset are also disclosed.