Abstract: A non-continuously laminated structure of thermoplastic films comprises thermoplastic films with differing material compositions and differing functional benefits. In particular, one or more embodiments comprise thermoplastic films that are co-extruded separately and then combined together by a post-extrusion bonding process. The differing composition of the various films of the non-continuously laminated structure of thermoplastic films and the post-extrusion bonding process, provide the structures with the functional benefits of the individual films.

Abstract: Methods of enhancing one or more physical properties of a thermoplastic film include incrementally stretching thermoplastic films in the machine direction and/or transverse direction. In one or more implementations, methods of incrementally stretching thermoplastic films include reducing the gauge of the films without reducing the films' machine-direction tear resistance. The methods can involve cold stretching the films and imparting rib patterns into the film. The linear ribs can have alternating thick and thin gauges. Incrementally stretched thermoplastic films can have a machine-direction tear resistance that is approximately equal to or greater than the machine-direction tear resistance of the film prior to stretching.

Abstract: A thermoplastic bag may include a sidewall that may have a plurality of first and second ribs formed therein. The first ribs may be longer in length but shorter in height than the second ribs. The second ribs may be arranged in discrete networks that appear superimposed over the first ribs. The second ribs may normally remain in a bent-over configuration. When a force is applied, the second ribs may expand the area of the sidewall so that the bag may easily accommodate large objects. To produce the bag, a thermoplastic web may be directed between opposing first and second rollers. One of the rollers may include ridges that may have first and second segments of differing heights that correspond to the differing heights of the first and second ribs. The formation of the first ribs may increase the width of the web.

Abstract: A thermoplastic bag may include a sidewall that may have a plurality of first and second ribs formed therein. The first ribs may be longer in length but shorter in height than the second ribs. The second ribs may be arranged in discrete networks that appear superimposed over the first ribs. The second ribs may normally remain in a bent-over configuration. When a force is applied, the second ribs may expand the area of the sidewall so that the bag may easily accommodate large objects. To produce the bag, a thermoplastic web may be directed between opposing first and second rollers. One of the rollers may include ridges that may have first and second segments of differing heights that correspond to the differing heights of the first and second ribs. The formation of the first ribs may increase the width of the web.

Abstract: Implementations described herein include films with maintained or decreased light transmittance despite a reduction in gauge. In particular, one or more implementations include a multi-layer film with each layer having differing opacity agents. The combination of the two different opacity agents in two different layers can have a synergistic effect that provide decreased light transmittance. Indeed, in one or more embodiments a multi-layer film with differing opacity agents in each layer has a decreased light transmittance despite a reduction in gauge and opacity agents.

Abstract: Multi-layer bags may be formed to include first and second sidewalls joined along a first side edge, an opposite second side edge, and a closed bottom edge. The first and second layers may be non-continuously laminated together in discrete sections to include bonded regions in which the layers are bonded and unbonded regions in which the layers are not bonded. Such a bag may be described as a “bag-in-a-bag” type configuration in which the inner bag is non-continuously bonded to the outer bag. The inventors have surprisingly found that such configurations of non-continuous bonding provides increased and unexpected strength properties to the multi-layer films and bags.

Abstract: Methods for forming a stock roll including a folded film within another folded film include combining the films and winding them into the stock roll. In particular, one or more implementations of a method of forming a stock roll involve combining films on an extrusion tower. Thus, implementations of the present invention can greatly reduce costs and space requirements, while allowing a single stock roll to feed a bag-making machine in order to produce bag-in-bag structures. One or more implementations further include stock rolls including a first folded film within another folded film.

Abstract: Apparatus and methods for creating multi-layered lightly-laminated provide films with increased or maintained strength. An increased level of strength is achieved by bonding adjacent layers of the multi-layer film together in a manner that the bond strength of the laminated layers is less than a strength of a weakest tear resistance of the individual first and second film layers. The inventors have surprisingly found that such a configuration of light bonding provides increased and unexpected strength properties to the multi-layer film as compared to a monolayer film of equal thickness or a multi-layer film in which the plurality of layers are tightly bonded together.

Abstract: Multi-layered thermoplastic films include intermittent stretched regions that are visually distinct from un-stretched regions. The stretched regions can be white, opaque, and non porous. The multi-layered thermoplastic films with visually-distinct stretched regions can be formed into bags for use as trash can liners or food storage. Additionally, methods of stretching thermoplastic films to create visually distinct stretched regions include incrementally stretching a plurality of film layers, at least one of which includes a thermoplastic material and a voiding agent.

Abstract: Thermoplastic films include intermittent stretched regions that are visually distinct from un-stretched regions. The stretched regions can be white, opaque, and non porous. The thermoplastic films with visually-distinct stretched regions can be formed into bags for use as trash can liners or food storage. Additionally, methods of stretching thermoplastic films to create non-porous, white, and opaque stretched regions include incrementally stretching a film of a thermoplastic material and a voiding agent.

Abstract: Crosslaminates of thermoplastic films have at least one of the films formed as a fluted structure, and two films are laminated to one another in such a manner that pockets are formed which contain gas. The pockets allow passage of gas between at least two adjacent flutes, whereby the product has an improved handle, and bags formed of the laminate have good stacking properties when filled with coarse particulates. The flute pitch is generally no more than 3 mm, while the pocket length is less than 50 mm. The bonding method involves spot bonding between the films, achieved by adhering the films together between crown portions of bosses on one film with molten material on the other film under a low pressure process, for instance achieved by provision of air pressure through adaptation of production apparatus, for instance die portions.

Abstract: In one example embodiment, a laminated film includes an extruded ribbed first film portion that includes multiple ribs, where consecutive ribs are separated by webs that are integral with the ribs. The laminated film also includes an un-ribbed second film portion, and a region of discontinuous lamination between the first film portion and the second film portion. The region of discontinuous lamination includes multiple regions where the first and second film portions are bonded together, and multiple regions where the first and second film portions are not bonded together.