Method and Apparatus For Forming A Bag Template

Abstract

An apparatus 10 for forming a template for a bag, the apparatus being adapted to receive a material in a first, transport direction 5, for forming said template; the apparatus 10 comprising means 15 for forming first, second and third longitudinal fold lines in said material, said fold lines extending in said transport direction to form first, second, third and fourth longitudinal sections in said material and means 15 for providing first and second transverse fold lines in said material, said first and second transverse fold lines extending in a direction perpendicular to said first, transport, direction, to form upper, middle and lower transverse sections of said material, means for providing fold lines in the shape of first and second crosses 301, 302 in said material.

Description

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for forming a template for a bag. More particularly, the present invention relates to a method and apparatus for forming a template for a bag, which, when assembled, resembles a box and has the strength of a box.

BACKGROUND OF THE INVENTION

A bag is generally a container for storing and/or carrying items. Bags may be formed from many materials, such as plastic, paper, cartonboard etc. In particular, paper bags are preformed containers made of paper, usually with an opening on one side. It can be one layer of paper or multiple layers of paper and other flexible materials. The paper bag can be used for example, for carrying items from a store to a user's home. Whilst paper bags are useful for carrying items from place to place, they sometimes lack the rigidity that can, for example, be seen in a box.

Bags for carrying items can come in different shapes and sizes. Such bags are commonly made by a machine that feeds material through and cuts the material at certain points to then provide a template for forming a bag. The template may then folded along pre-formed lines or folds into the desired bag shape. This folding can be done manually or by machine.

SUMMARY OF THE INVENTION

The present invention is defined in the claims.

The invention focuses on ways of folding a bag along non-conventional lines, to form a bag that resembles, and has much of the strength of, a box, but has the lighter weight of a bag and is simpler to manufacture, e.g. using a modified paper-bag-making machine.

The present invention relates to a method for forming a template for a bag comprising the steps of providing a material for forming the bag and providing first, second and third longitudinal fold lines in the material, the fold lines extending in a first direction to form first, second, third and fourth longitudinal sections in said material. The method further comprises the steps of providing first and second transverse fold lines in the material to form upper, middle and lower transverse sections in the material, the transverse fold lines extending in a direction perpendicular to said first direction. The method further comprises the step of providing fold lines in the shape of a first and second crosses in the material.

In a preferred embodiment, the crosses are positioned in the upper transverse section of the material. In a further preferred embodiment, the first and second crosses are provided in alternating longitudinal sections. In other words, the crosses are not provided in adjacent longitudinal sections but are separated from each other by a further longitudinal section. In a preferred embodiment, the longitudinal section provided between the sections containing crosses itself has no crosses.

In a preferred embodiment, the material comprises an upper end or edge, a lower end or edge, a first side end or edge and a second side end or edge, and the first, second and third longitudinal fold lines are formed to extend in the first direction between the upper edge and the lower edge, to form the first second, third and fourth longitudinal sections in the material. In some embodiments, the fold lines extend all the way to the edge(s) of the material, and in other embodiments, the fold lines do not extend all the way to the edge(s).

In a preferred embodiment, the first and second transverse fold lines are formed to extend in the second direction between the first side edge and the second side edge, the crosses being positioned between the first transverse fold line, wherein the first transverse fold line is an upper fold line positioned closer to the upper edge than the second transverse fold line, and the upper edge of the material.

In a preferred embodiment, the method for forming the template involves producing the longitudinal fold lines in the material so that they overlap with the transverse fold lines to form a grid on the template. In the embodiment wherein there are three longitudinal fold lines and two transverse fold lines, each of the longitudinal sections comprises three subsections and each of the transverse sections comprise four subsections which are created by the overlapping of the longitudinal and transverse fold lines. These subsections of the template relate to the different parts of the finally assembled product, such as a tab for attachment (if a fourth longitudinal fold line is present), the base, the side and front and rear faces of the finally assembled bag and also the different parts of the lid of the bag.

In one embodiment, the method may comprise the step of providing diagonal fold lines that extend from the lower transverse section into the middle transverse section of the material. In one embodiment, the method may comprise the step of providing two of these diagonal fold lines so that they meet at a point in the middle transverse section. In a preferred embodiment, the point is halfway between the first and second transverse fold lines in the material. The diagonal fold lines may be used later, when the bag is finally assembled, to fold the bag so that the front and rear faces can lie flat against each other. In one embodiment, this is achieved by positioning the point at which the diagonal lines meet so that it is aligned longitudinally with the centre of the cross provided in the upper transverse section of the same longitudinal section.

In one embodiment, the method may comprise the step of forming holes in the material. These holes may then be used to apply inserts to the template, or alternatively, to allow closure means to be attached or connected to the template or bag. In one embodiment, the method may comprise the step of applying adhesive to the material so that the different sections of the template may be adhered to each other, or so that closure means may be adhered to the template or bag.

In a preferred embodiment, the method may comprise the step of applying and/or aligning inserts to the material, bag or template of the bag, for reinforcement of the bag's structure.

In a preferred embodiment, the method may further comprise the step of forming a fourth longitudinal fold line in the material, the fourth fold line being formed to extend in said the first, longitudinal, direction to form a fifth longitudinal section in the material. This section may then be used as an attachment means for attaching one side of the template to the other, to form a bag.

In a further aspect, the present invention relates to an apparatus for forming a template for a bag, the apparatus being adapted to receive a material in a first, transport direction for forming the template. The apparatus further comprises means for forming first, second and third longitudinal fold lines in the material, the fold lines extending in the transport direction to form first, second, third and fourth longitudinal sections in the material and means for providing first and second transverse fold lines in the material, the first and second transverse fold lines extending in a direction perpendicular to the first, transport, direction, to form upper, middle and lower transverse sections of the material, and means for providing fold lines in the shape of first and second crosses, in the material.

In a preferred embodiment, the apparatus may be configured to position the crosses in the upper transverse section. In a preferred embodiment, the apparatus may comprise means for providing the first and second crosses in alternating longitudinal sections as discussed above.

In one embodiment, the material may comprise an upper edge, a lower edge, a first side edge and a second side edge, and the apparatus may comprise means for forming the first, second and third fold lines to extend in the first direction from the upper edge to the lower edge, to form the first second, third and fourth longitudinal sections in the material and means for forming the first and second transverse fold lines to extend from the first side edge to the second side edge. The apparatus may further comprise means for positioning the crosses between the first transverse fold line, the first transverse fold line being closer to the upper edge than the second transverse fold line, and the upper edge of the material.

In one embodiment, wherein three longitudinal fold lines and two transverse fold lines are provided, the means for forming the longitudinal fold lines and the transverse fold lines is configured to provide the fold lines so that they overlap each other and form a grid such that each longitudinal section comprises three subsections and each transverse section comprises four subsections. In a preferred embodiment, these subsections ultimately form the different parts of the final bag such as the base, the faces and the lid.

In one embodiment, the apparatus comprises means for providing diagonal fold lines that extend from the lower transverse section into the middle transverse section of the material. In one embodiment, the diagonal fold lines are configured to meet at a point in the middle transverse section and in a further embodiment, the means for providing the diagonal fold lines is configured to position the point halfway between the first and second transverse fold lines in the material.

In one embodiment, the apparatus comprises means for forming holes in the material. In a further embodiment, the apparatus comprises means for applying adhesive to the material. In a further embodiment, the apparatus comprises means for applying inserts to the material. In one embodiment, the apparatus comprises means for aligning inserts with the material.

In a preferred embodiment, the apparatus may comprise means for forming a fourth longitudinal fold line in the material, the fourth fold line extending in the first direction to form a fifth longitudinal section in the material. This fifth longitudinal section may therefore be used as a tab for attaching one side of the template to the other side of the template when the bag is assembled. In some embodiments, this is achieved using adhesive that is applied to the tab, either by the apparatus or manually.

In one aspect, the present invention may also relate to a template for forming a bag, comprising a material comprising first, second and third longitudinal fold lines provided thereon, the fold lines extending in a first direction to form first, second, third and fourth longitudinal sections in the material, the material further comprising first and second transverse fold lines, the first and second transverse fold lines extending in a direction perpendicular to the first direction to form upper, middle and lower transverse sections in the material, and the material further comprising fold lines provided in the shape of first and second crosses.

In a preferred embodiment, the first and second crosses are provided in the upper transverse section. In a preferred embodiment, the first and second crosses are provided in alternating longitudinal sections.

In some embodiments, the material comprises an upper edge, a lower edge, a first side edge and a second side edge, and the first, second and third fold lines extend in the first direction from the upper edge to the lower edge, to form the first second, third and fourth longitudinal sections in the material, and the first and second transverse fold lines extend from the first side edge to the second side edge, and the crosses are positioned between the first transverse fold line, the first transverse fold line being closer to the upper edge than the second transverse fold line, and the upper edge of said material.

In some embodiments, the template further comprises diagonal fold lines that extend from the lower transverse section into the middle transverse section of the material and in some embodiments, the diagonal fold lines meet at a point in the middle transverse section. In some embodiments, the point is halfway between the first and second transverse fold lines in said material.

The template of the present invention may further comprise a fourth longitudinal fold line, the fourth fold line extending in the first direction to form a fifth longitudinal section in the material.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 depicts a creaser unit according to an aspect of the present invention.

FIG. 2 depicts a bag template as an exemplary embodiment.

FIG. 3 depicts an apparatus for forming a template for a bag, according to an aspect of the present invention

FIG. 4 depicts a pasting unit.

FIG. 5 depicts an assembled bag formed from the template and via a method and apparatus of the present invention.

FIG. 6A depicts a bag template with portions cut out to form a handle.

FIG. 6B depicts a closed bag with the handle protruding from the lid of the bag.

FIG. 6C depicts an alternative handle formation.

FIG. 6D depicts another alternative handle formation.

DETAILED DESCRIPTION OF THE INVENTION

A method for folding a bag is shown, in which the bag is folded along non-conventional lines to produce a bag that resembles a box when assembled. This is achieved by providing a bag that has four faces or sides 341, 342, 343, 344 (see FIG. 2 and FIG. 5, where only faces 342 and 343 can be seen in FIG. 5), a base, (371, 372, 373, 374 as shown in FIG. 2 but not shown in FIG. 5, as this lies underneath the bag), and an upper, open end. As shown in FIG. 5, the front and rear faces (342 being the front face) oppose each other and the two side faces (343 only shown in FIG. 6) oppose each other.

The method involves folding an upper part, 382, of the front, face, 342, inwards towards the opposing, rear, face, along a first fold line, 315, provided on the front face, and then folding an upper part of the rear face inwards towards the opposing front face along a fold line, 315, provided on the rear face, so that the upper parts of the front and rear faces then act as a kind of lid, closing the open end of the bag (see FIG. 5). In this way, the bag resembles a box with a closed lid.

This may be aided due to the fact that the bag may also comprise fold lines, 301, 302, 303, 304, provided on the upper part of both of the side faces, 341, 343. Preferably, these fold lines comprise at least a first diagonal line 301, 302, that may extend from the region of the fold line of the front face 342, towards the upper part of the rear face as shown in FIG. 2 (and preferably to the upper edge of the rear face). The diagonal line may extend the entire way from the fold line of the front face to the upper edge of the rear face, but does not necessarily have to. Due to the presence of this diagonal line, when folding the front face inwards, the upper parts of each of the side faces of the bag may also be folded along this diagonal fold line to allow the front face to fold neatly inwards to form a lid, or at least part of a lid, as shown in FIG. 6, whilst the rear face may still remain upright.

The method of folding then involves the step of folding the upper part, 384, of the rear face, 344, of the bag along a fold line, provided on the rear face, inwards, towards the front face, to complete the lid.

The side faces have a second diagonal fold line, 303, 304, that extends from the region of the fold line of the rear face towards the upper part of the front face (and preferably to the edge of the front face). The diagonal line may extend the entire way from the fold line of the rear face to the upper edge of the front face, but does not necessarily have to.

Due to these diagonal lines, it is therefore possible to neatly fold the front and rear faces of the bag inwards, on top of each other and to also fold the side faces of the bag in, (along the fold line, 315, of the side faces) underneath the lid formed by the rear face, to result in a bag that resembles a box with a closed lid. In this example, wherein these two diagonal lines are provided on the side faces of the bag, the diagonal lines on each side face may be provided in the form of a cross.

A template for a bag having non-conventional fold lines formed thereon is also shown. The bag may be a conventional bag that has one end open. However, fold lines are provided in a new configuration so that when the fold lines are folded at the open end, the open end provides rigidity to the bag by folding down to form an appearance of a lid to a box. This reinforces the bag and gives the bag the strength and rigidity more commonly found in a box.

The present application therefore also describes a template, 300, for such a bag and a method and apparatus, as shown in FIG. 2, for producing the template, 300, for the bag, which when assembled, may resemble a box.

A preferred example of a bag template is shown in FIG. 2. The template, 300, may be formed from a material such as paper, cardboard, or any other material that is sufficiently strong and pliable for forming the template and ultimately the assembled product.

The template can also use a 2 ply material. This can result in improved grease resistance in the finished product, or other advantageous properties such as making the material suitable for use in the oven, giving it a high gloss finish, or water-tight capability, for example. When using an apparatus to produce the bag, this can be achieved by running a second ply of material through the apparatus, for example, by installing a second web unwind before the first creasing unit, 15, as described below, and laminating the webs together. It has been found that conventional 2 ply adhesion is often not sufficiently accurate to ensure the accuracy of the creasing in production. If the fold lines are not accurate, then the bags will not fold correctly and the shape will ultimately collapse.

As mentioned above, the fold lines created in the bag are such that the material may be folded in such a way that the bag resembles a box. FIG. 2 shows an example of where these fold lines may be situated in the template for a bag. It is to be understood that these fold lines could be formed in other areas of the template for the bag.

As shown in FIG. 2, the template can comprise different subsections, each of which relate to the different parts of the bag described above. As shown in FIG. 2, the subsections labelled as 371, 372, 373, 374 relate ultimately to the base of the bag, the sub-sections labelled as 341, 342, 343, 344, relate to the faces of the bag (see also FIG. 5), with the side faces being 341 and 343. The subsections labelled as 371, 372, 373 and 374 relate to the upper parts of the faces of the bag which will ultimately be folded over to form the lid of the bag.

The fold line along which the front and rear faces of the bag is eventually folded to form the lid can be seen in FIG. 2 labelled as 315 (referred to below as the upper transverse fold line 315). The diagonal fold lines of the crosses provided in the upper parts of these side faces, as discussed above, can be seen in FIG. 2 labelled as 301, 302, 303 and 304.

The subsections 341 and 343 which form the side faces of the bag (not including the upper part that is eventually folded over) may have a transverse width (labelled as w1 in FIG. 2) that is twice that of its longitudinal height (labelled as h1 in FIG. 2). In a further embodiment, w1 and h1 may be the same.

A template will now be described in detail. As shown in FIG. 2, the template may comprise a first end (which in FIG. 2 is seen as an upper edge, 351), a second end, 352 (which in FIG. 2 is seen as the lower edge) and a first side, or longitudinal end, 353, and a second side, or longitudinal, end, 354 (which are shown as edges, 353, 354, in FIG. 2).

The template may further comprise first and second pre-formed horizontal or transverse fold lines, 315, 316, that extend across the template in the transverse direction. In one embodiment, these fold lines, or indeed any of the fold lines discussed herein are formed via perforations. In alternative embodiments, the fold lines are creases, or imprints in the material.

In one example, the fold lines extend from the first longitudinal side edge, 353, to the second longitudinal side edge, 343, i.e. in the transverse direction, 6, however, they need not extend all the way to and from the edges but may simply extend in that direction. These horizontal fold lines are spaced apart from each other in the longitudinal direction (i.e. in the direction or axis, 5, as shown in FIG. 2, which is perpendicular to the transverse direction or axis, 6). These fold lines therefore divide the template into three sections: an upper transverse section, 360, a middle transverse section, 370, and a lower transverse section, 380. As shown in FIG. 2, the middle transverse section is adjacent to and contacts both the upper and lower transverse sections.

The template, 300, may further comprise three or four further fold lines, 311, 312, 313, 314, that are provided extending in the direction perpendicular to the direction 5 shown in FIG. 2, hereafter referred to as the longitudinal direction. These form four longitudinal sections, 320, 330, 340, 350 of the template. These fold lines extend from the first, upper edge, 351, to the second, lower edge, 352, longitudinally across the material (i.e. in the transport direction of the apparatus, 5), however, as with the transverse fold lines, the lines need not extend all the way to and from the edges but may simply extend in that direction.

In one example, the longitudinal fold lines overlap with the transverse fold lines to form a grid such that each longitudinal section and each transverse section comprises a plurality of sub-sections created by the overlapping of the fold lines. For example, in the example depicted in FIG. 2, there are fifteen subsections in total, but a template could be produced that has a different number. For example, in an example where there are three longitudinal fold lines and two transverse fold lines, a template would be formed which had four subsections in each transverse section and three subsections in each longitudinal section, i.e. a total of twelve subsections. These sub-sections relate to the different parts of the finally assembled bag, as discussed above, e.g. the sub-sections 341 and 343 for example, will ultimately form the side faces of the bag and so on.

The template may further comprise first and second fold line patterns that are in the shape of first and second crosses, 301, 302, as shown in FIG. 2. These crosses are provided at the upper part of the template, in the upper transverse section, 360, between the first transverse fold line and the first, upper end or edge, 351, of the template. Each of the crosses may comprise first and second diagonal lines, 301, 302, 303, 305, the lower ends of which may extend towards the first transverse, horizontal line, 315. The lower ends of each of the fold lines of each of the crosses may contact the first transverse line, 315, however, this is not essential and the lines of the crosses may merely extend in that particular direction.

As can be seen in FIG. 2, the crosses are each provided in alternating longitudinal sections, 320, 340, but are different subsection of the same upper, transverse section of the template, and so are separated from each other by a further subsection of the same transverse section.

These crosses therefore correspond to the diagonal fold lines discussed above, which allow one of the front or rear faces to fold neatly in towards the other face while the other remains upright and to ultimately allow both the rear and front faces of the bag to fold neatly inwards towards each other to form the lid of the bag. The diagonal lines may therefore extend from the transverse fold line, 315, associated with the front face of the bag towards the upper part of the rear face of the bag and vice versa, to allow the bag to fold as described above.

As shown in FIG. 2, the upper ends of the diagonal lines, or crosses, meet the upper edge, 351, of the template, however, this is also not essential and the upper ends of the crosses may simply extend in the direction of the upper end or edge of the template.

The template may further comprise fold lines in the form of lines, 321, 322, which extend from the lower transverse section of the template up through and past the second, lower transverse, or horizontal line, 316. In one embodiment, these fold lines extend all the way from the lower end, or edge, 352, of the template, however, this is not essential and the fold lines may simply extend from somewhere within the lower transverse section.

As shown in FIG. 2, these lines are diagonal and two such diagonal lines, which extend from the lower transverse section or edge of the template, 352, may then meet at a point within the second transverse section of the template, i.e. somewhere between the first and second transverse lines, 315, 316. In a preferred example, they meet at a point that is halfway between the first and second transverse lines, 315, 316 in the longitudinal direction, as shown in FIG. 2. In a preferred example, the two diagonal lines meet at a point that is aligned longitudinally with the centre of the first and/or second cross, 301, 302, as shown in FIG. 2.

These fold lines provided in the lower and middle transverse sections of the template will ultimately span the base and part of the side faces of the assembled product and are useful in allowing the bag to be folded into a flat position when not in use.

The template may comprise a further, fourth, longitudinal fold line, 311, as shown in FIG. 2. This provides a further, fifth, longitudinal section in the template, 310. This section may be used as a tab for attaching, via adhesive, or other means, the longitudinal section of the template 320 on one side (in FIG. 2 shown as the left hand side) of the template to the longitudinal section 350 on the other side of the template (in FIG. 2 that shown on the right hand side).

The template can therefore be described as comprising four or five longitudinal sections 310, 320, 330, 340, 350, which are adjacent to each other and extend in a first direction (referred to herein as the transport, or longitudinal direction), 5 and three transverse sections, 360, 370, 380, i.e. an upper, middle and lower transverse section, which are adjacent to each other and which extend in a second direction (referred to herein as the transverse direction). The first and second directions are perpendicular to each other, as shown in FIG. 2, and so the sections extending in the first direction, or along the first axis, may overlap with the sections extending in the second direction, or along the second axis, to form a grid or pattern on the template each subsection of which relates to a different part of the finally assembled bag, such as the base, or side or rear face etc.

Each of the sub-sections may be therefore be described as being defined relative to, and distinguished from, each other by the edges, 351, 352, 353, 354, imprints, or fold lined lines/boundaries, 311, 312, 313, 314, 315, 316, discussed above.

When finally assembled, the middle sections, 341, 343, of the longitudinal sections of the bag containing the crosses will form the side faces of the bag so will be positioned opposite to each other and the sections adjacent and between these will form the front and rear faces of the bag and so will also be positioned opposite to each other.

As shown in FIG. 2, when the bag is assembled, the crossed fold lines, 301, 302, 303, 304, in the upper transverse section of the template, 300, as well as the transverse fold line, 315, may then be folded to result in a structure that resembles a lid for a box and, when the bag is closed, the bag may then resemble a box.

A method of folding the template to form the bag/box will now be described.

The template for the bag can therefore be folded to form a bag by folding the template in on itself, along the longitudinal fold lines 311, 312, 313, 314 so that the longitudinal section 310 at one side of the template is moved towards and contacts the longitudinal section 350 at the opposite side of the template. Section 310 may then be attached to the section 350, either directly, or via use of the optional longitudinal section, 310, which acts as a tab. The sections may be attached to each other by adhesive means, or by some other means. This therefore results in a kind of sleeve, or four-sided structure that comprises four faces, 341, 342, 343, 344, as shown in FIG. 2.

As described above, since the side faces, (which in the embodiment of FIG. 2 comprise the longitudinal sections containing the crosses), are positioned spaced apart from each other with a longitudinal section therebetween, then they will be positioned opposite each other, 341, 343, and the intervening (i.e. front and rear) faces (that, in this embodiment, do not contain a cross), will also be positioned opposite each other, as shown in FIG. 5. It is therefore advantageous that opposing faces are of similar size to each other. As shown in FIG. 2, if a bag is to be produced that is required to be long and thin, then the adjacent faces (e.g. side face 341 and front face 342) can be made to be of different lengths to each other. Alternatively, if a more uniform shape is desired, these lengths can be made more similar or identical.

In one example, which may be useful for producing bags that are suitable for carrying food or gifts, the transverse width of the side faces of the assembled and closed product is twice the height of the closed bag. In other words, the transverse width wt of the middle transverse section of the side face is twice its height, h1, as shown in FIG. 2.

In a further example, which may be useful for producing bags that are suitable for carrying hamper meals, the transverse width, w1, of the side face is the same as the height of the closed bag. In other words, the transverse width w1 of the middle transverse section of the side face is the same as the height h1 of the same middle transverse section. Of course, the transverse width is not necessarily the same or twice the height of the transverse section and may have differing widths in relation to the height of the transverse section.

The lower transverse section, 380, of the template (i.e. the base section) may then be moved inward, relative to section 370 (i.e., which remains as the faces or side walls of the bag, 341, 342, 343, 344) by folding along the lower transverse fold line fold line, 316, to form the base of the bag.

Of course, the bag could alternatively be formed by first folding the lower transverse section 380 to form the base and then folding the side ends of the template inwards to form the four sides or faces of the bag. The lower transverse section of the bag 380 therefore forms a base and is held in place relative to the faces of the bag via adhesive or other means.

A basic bag is therefore now formed from the template, the bag having a base, 380, and four side walls or faces, 341, 342, 343, 343 (formed from the middle transverse section). Each of the faces has a section of the upper transverse fold line, 315, that is associated with that face. This upper transverse line therefore corresponds to the fold lines for the rear and front faces, as discussed above, which enables the front and rear faces to be folded in towards each other to form a lid that can be closed.

In accordance with one example, the bag formed from the template may then be folded in such a way that the upper transverse section of each face of the bag is folded inward to result in a structure that resembles a box with a lid.

This is achieved by folding the upper portion of a first face, 342, (i.e. the front face) of the bag, which does not comprise a cross (but which has a cross provided in the longitudinal sections either side of it) along the upper transverse fold line 315, so that the upper transverse section associated with that face moves inwards towards the rear face. This may therefore lie in a plane that is generally perpendicular to the upright portion of the front face 342 as shown in FIG. 5. The rear face may remain upright during this. This is enabled by the fact that the crosses provided in the adjacent, side, faces of the bag each have a first diagonal fold line as discussed above that can be folded to allow the face 342 to lie flat, whilst the opposite, rear, face remains upright.

The rear face of the bag which is positioned opposite the front face of the bag can then be folded along the upper transverse fold line 315. The upper transverse fold line of the side walls can then be folded so that the side faces fold inwards, whilst the side walls are also folded along the second diagonal fold line of the crosses. In this way, the upper transverse section of the rear face, 344, as well as the side faces may be folded inwards so that they also lie in a plane perpendicular to the upright parts of the bag.

An assembled bag is shown in FIG. 5. It can be seen from this figure how, when assembled, the template essentially creates, for example, four top sections, 381, 382, 383, 384, (which are formed from the upper transverse section, as discussed above) wherein the sections 381, 383 may include the crosses formed from the apparatus described above and form the lid of the bag. One side face, 343 and the front face can also be seen. The base section 380 cannot be seen in this figure as it lies underneath the box.

From the template shown in FIG. 2, the upper transverse section, 360 of the bag may therefore provide, for example, a lid for the bag so that the bag resembles a box with its lid closed. It is to be understood, however, that the template may have more or less sections to provide alternatively shaped boxes.

In some examples, inserts can also be used with the bag and/or template of the bag.

The bag may also be used in conjunction with a plurality of different closure means. In one embodiment, the closure means may comprise a latex adhesive. In one embodiment, a peel and seal adhesive may be used. This may be applied to an upper insert prior to production and allows the user to close the box by removing the tape from a silicon-backed adhesive strip. Alternatively, a rope handle may be used with the bag, by threading the rope through holes provided in the upper transverse section of the bag. This type of handle is ideal for use with bags that are to be used for boutique sale carriers.

The bag may also be used in conjunction with a card handle that may be attached to a lower insert and pulled up through an upper insert. The card may have an overlap on one side of the handle which may lock over the upper insert and secure the bag. This type of handle is ideal for use with bags that are used for food containers, e.g. food hampers, fish and chips boxes etc. The bag may also be used with handles that are applied via heat seal, This is similar to the latex adhesive described above.

A bag/template as described herein could be folded and/or formed by hand. Alternatively, the bag/template could be folded and/or formed by a machine and the invention, in one aspect, relates to a new machine for forming the template. In one embodiment, the invention relates to a new machine for forming and folding the bag from the template.

An apparatus and method for forming the template will now be described with reference to the figures.

The invention essentially resides in a first creaser unit/fold line unit 15 in conjunction with an apparatus for forming a template as discussed below. The arrangement of the first creaser unit/fold line unit and the apparatus is shown together as an exemplary embodiment. It is to be understood, however, that the first creaser/fold line unit 15 can be added to existing template forming apparatus known in the art.

An apparatus for forming the template, 10, comprises a machine having a first end, 1, and a second end, 2, the first end, 1, being configured to receive the material for forming the template.

As described above, the material for forming the template may be paper, cardboard, or any other material that is sufficiently strong and pliable for forming the template and ultimately the assembled product.

When forming the template, the chosen material for forming the template may be fed into the apparatus, at the first end, 1, in a transport, or longitudinal direction, 5, (see FIG. 3), either by hand; or by another means, such as a feeding apparatus, for example. In a preferred embodiment, the material is fed from a reel stand.

The apparatus, 10, may comprise first material receiving/feeder/transporter means, 11, 12, 13, (FIG. 1) which receives the material being fed into the apparatus and transports the material in the transport direction, 5, (i.e. in the direction of the second end, 2, of the apparatus from the first end, 1). In a preferred embodiment, the material receiving means may comprise a roller, or a plurality of rollers, which may contact and/or grip the material and transport the material in the transport direction, 5 via rotation of the roller.

In one embodiment, the material receiving means comprises a first roller, 11, and a second roller, 12, located adjacent the first roller, the first roller, 11, contacting and/or gripping the material and transporting the material towards and into contact with the second roller. In one embodiment, a third roller may be located adjacent the second roller, as shown in FIG. 1, to aid in transporting the material further in the transport direction, 5.

The apparatus may further comprise a first creaser/fold line unit 15, as shown in FIG. 1. The first creaser unit may comprise a first creaser/imprint means, 16, for providing an imprint or crease of a first pattern onto the material that is being transported through the apparatus. These creases or imprints produced correspond to the fold lines discussed above with reference to the folding of the template and/or bag. In one embodiment, the imprint means achieves the imprint or fold line in the material by producing perforations. This imprint/perforations may be formed via pressure. The material can be maintained in an accurate printing position with a photocell and/or web control.

In one embodiment, the means for imprinting may be part of, attached to, or used in conjunction with a roller, 17, as shown in FIG. 1, so that as the material is transported through the apparatus, the rotation of the roller, 17, contacts the material and results in an imprint, or perforation of the material which corresponds to a pattern of the imprint means.

The roller may comprise a steel tube into which the imprint/fold liner/perforator means are bolted or alternatively, integrally formed therewith. In one embodiment, the means for imprinting/perforating the material may be a metal plate that is attached to, or integrally formed with, the roller, 17, as shown in FIG. 1, and which imprints the material due to pressure applied by the roller as it passes the roller. The plate may be attached to the first roller by fixing means, such as nuts, bolts, screws etc. The imprint means may then score onto a strengthened anvil roller made of chromed steel, for example, which is pressured in the centre to retain its integrity along the entire length of the shaft. The pressure applied may be retained by another roller provided behind the anvil, which may be made from plastic, for example.

In another embodiment, the imprint/perforation means of the fold liner unit, 15, may not comprise a roller but may instead comprise a press that uses pressure applied via another means, e.g. via a vertical stamp, to stamp the imprint/perforation onto/into the material as it passes the first fold liner unit. Any other form of imprint/perforation unit that is capable of producing an imprint or perforation in the material as it is being transported could also be used. Alternatively, the imprint means may be used by hand to imprint/perforate onto/into the material. The imprint means may comprise a fold liner unit, as described above, or a stamp, that can be used manually to produce an imprint or perforation.

The imprint means, 16, therefore contacts the material to form a fold line/imprint, or perforation in the material as it travels in the transport direction, 5, through the apparatus. This imprinted/creased pattern defines the fold lines along which the bag template is folded into its final assembled box shape. Also, the perforation of the material achieves the shape of the bag by weakening the fibres of the material.

In one embodiment, the first imprint means, 16, may provide a first horizontal imprint, crease or perforation, 315, in the material, (i.e. a fold line) which extends width wise along the material in the transverse direction, 6, as described above and as shown in FIG. 2. This imprint or fold line may extend from the first side end or edge, 353, to the second side end or edge, 354, of the material as also described above. This horizontal line therefore extends in the transverse direction and defines the boundaries between the first and second sections, 360, 370, of the template, referred to above as the upper and middle transverse sections of the material or template. As also described above, the first, upper transverse section, 360, will ultimately form the top section or lid of the bag, when assembled, whereas the second, middle transverse section, 370, will form the side front and rear faces of the bag, when assembled.

The first imprint means, 16, may also be configured to provide an imprinted or fold creased pattern in the material in the form of the first and second crosses, 301, 302, as described above. These may be positioned to one side of the horizontal fold line, 315, i.e. in the upper transverse section, as discussed above and in the embodiment shown in FIG. 2, are provided between the first transverse, horizontal fold line and the first, upper end or edge of the template, i.e. which ultimately forms the lid of the bag when assembled.

As described above, each of the crosses may comprise first and second diagonal lines, the lower ends of which may extend towards and in some embodiments, contact the first transverse line, 315. In one embodiment, the first and second crosses are each formed via first and second diagonal fold lines or perforations which are formed at 45°, of course the crosses could be formed at different angles, as desired, without departing from the scope of the present invention. In the embodiment shown in FIG. 2, the upper ends of the diagonal lines, or crosses, meet the upper edge, 351, of the template.

Different thicknesses of fold lines/imprints in the material can be used, depending on the requirements and size of the material and/or template/box being formed, however, in the preferred embodiment, the fold lines have a thickness of 2 mm as it has been found by the inventors that perforations or fold lines of approximately 2 mm in thickness produce the best result. This thickness of fold line or perforation allows the material to retain its integrity and withstand tearing as it is drawn through the machine and allows the template to be folded easily and conveniently into the final box shape, without it trying to return to its original shape.

In a preferred embodiment, such as that shown in FIG. 2, both of the crosses are positioned in the upper transverse section of the template, so that the first imprinted cross, 301, is positioned so as to be aligned in the transverse direction, with the second cross. In one embodiment, the crosses may also contact the horizontal line, 315, as discussed above.

The crosses, 301, 302, are not, however, provided in the same, or adjacent section in the transport/longitudinal direction, but are instead provided spaced apart in the transverse direction so that they are in separate longitudinal sections, with a further longitudinal section, 330, provided therebetween, separating the two crosses. See FIG. 2. The crossed sections, 301, 302, of the template, will ultimately form the top section or lid of the assembled bag, as shown in FIG. 6.

In the embodiment shown in FIG. 2, the crosses, 301, 302, are identical in size and shape to each other and have a longer longitudinal length than transverse width, however, other dimensions can be used, without departing from the invention, as discussed above. Although the crosses are described herein as being positioned in the upper transverse section, it is to be understood that the crosses could be applied to the lower transverse section, in an inverted manner.

There is also provided, in the apparatus, means for imprinting and/or perforating a second transverse fold line, 316, and diagonal fold lines 321 and 322 in the material, which are conventional lines in the art of making bags described herein.

After the material has been transported in the transport direction through the first creaser unit, 15, it is then preferably transported to a second creaser unit, 515, FIG. 3. The second creaser unit, 515, may have a similar structure to the first creaser unit, 15, and may include means for receiving/feeding the material as in the first creaser unit, 15. In the embodiment shown in FIG. 3, the second creaser unit is provided below the first creaser unit, 15, however the second creaser unit can be provided in any position relative to the first creaser unit, as long as it is able to receive the material after it has been passed from the first creaser unit. In one method, this could simply be done by transferring the material by hand from the first fold liner unit to the second creaser unit.

The second creaser/cutter unit, 515, may comprise second creaser/cutter means, 516, for creasing/imprinting into the material as it is transported through the unit. The second creaser unit, 515, may also provide means for cutting the material. Preferably, the means for creating a hole in the material comprises a cutting tool attached to a first roller provided in the second creaser/cutter unit, 515. The cutting tool may be arranged in various ways to provide different holes at different sections of the material when the material is passed through the second creaser/cutter unit and, in one embodiment, between a first roller and a second roller of the second unit.

In one embodiment, the second creaser/cutter unit, 515, may comprise means for cutting holes in the material, which would then match the correct position for providing card inserts, for reinforcement. The holes may be formed in any of the sections 310, 320, 330, 340, 350, 360, 370 and 380 of the template. The second creaser/cutting unit 515 may comprise a punching unit for punching holes into sections 310, 320, 330, 340, 350, 360, 370 and 380.

In another embodiment, holes may be cut to coincide with a position for a handle to carry the box once it is assembled. Such a handle may comprise wire, rope, paper, cardboard, for example. The handle may be attached by hand or in the final stages of preparing the box once the material has been transported to a conventional box or bag forming apparatus or section of the apparatus.

In a further embodiment, the second creaser/cutter unit, 515, may cut either section 330 or 350 to form a handle 710 within one of these sections, as shown in FIG. 6A. The handle may be formed as a trapezoidal handle, triangular handle, semi-circular handle and the like, as shown in FIGS. 6A, 6B and 6C. The second creaser/cutter unit, 515, also provides a slit to receive the handle, when the bag is in a closed position, into section 330 or 350, whichever has not had a handle formed therein.

In the exemplary embodiment shown in FIG. 6A, the template 300 has sections 330 and 350 as described above in FIG. 2. FIG. 6A shows the template after passing through a second creaser/cutter unit 515 described above. Section 330 has been cut to remove a portion of the template in order to form a handle portion 710.

Further, the creaser/cutting unit 515 also provides a slit in section 350 to receive the handle 710 when the bag is in a closed position (as shown in FIG. 6B).

In a preferred embodiment, the base of the handle 710 has a length l1, which corresponds to the length, l1, of the slit 720. The handle may, in a preferred embodiment, have opposite sides 701 that extend over length l1 to provide an interlockable engagement with section 350. When the bag is in a closed position (as shown in FIG. 6B), the handle 710 may be folded up to be perpendicular from section 330. Section 350 may then overlap section 330 to receive the handle 710 through the slit 720. As the handle 710 has portions that extend over length l1, the slit may be forced to receive the handle 710 such that the portions 701 overlap section 350. Therefore, the engagement between the handle 710 and the slit 720 provides a “lockable” lid to the bag in a closed position.

As shown in FIGS. 6A, 6C and 6D, the handle 710, 710′ and 710″ may be formed as a trapezoid, a semi-circle or a triangle respectively. Of course, the handle may take various sizes and shape that act as means for carrying the bag by a user.

Such a handle is preferable only. Other types of handle, e.g. a string or paper attachment may be provided, or even no handle at all.

In one embodiment, the inserts used for reinforcement comprise simple cut card, but reinforcements of other kinds or materials could also be used. In one embodiment, the inserts comprise two holes in the lower portion of the card and graduated slit in the upper portion thereof. In other embodiments, the inserts may be flat card, card with holes punched for rope handles, or card with card handles attached. The inserts may be applied to the material by a hopper and photocell, as is conventional in the art of producing bags as described herein.

As mentioned above, the punching unit punches holes in the material to coincide with the holes of the insert. This allows for placement of a handle, or allows a window to be installed into the material.

In one embodiment, where a window is desired in the bag, the second creaser/cutter unit, 515, provides a hole in the material via cutting or punching, or by any other means that results in a window in the material. Alternatively, the window could be formed by hand, by cutting a hole in the material using a cutting implement, such as scissors or knife, for example.

Additionally, the apparatus, 10, may further include a pasting unit, 610. In a preferred embodiment, the material is transported in the transport direction from the second creaser unit, 515, (or from the first creaser unit, 15, if the second creaser unit, 515, is not present) to the pasting unit, as shown in FIGS. 3 and 4. In the embodiment depicted in FIG. 3, the pasting unit is a top pasting unit, and is provided above both the first and second creaser units. Of course, the pasting unit need not be provided in this position and may be provided in any position where it is possible for the material to be transported from either or both of the first and second creaser units to the pasting unit, 610.

The pasting unit, 610, may comprise means for receiving the material, which in one embodiment, may be a roller, 611, or plurality of rollers. As the material is transported in the transport direction, through the pasting unit, 610, the pasting unit applies an adhesive to the material at certain sections, as required. The adhesive may be in the form of a coating, or may comprise the deposition of adhesive pads or other adhesive means.

In one embodiment, the adhesive is applied to the material at a position or positions that will match the position or positions of the inserts which are to be provided at a later point. The adhesive may be applied by the pasting unit, 610, or, alternatively, may be applied by hand using separate individual devices, such as a brush, glue gun, glue pen etc. In another embodiment, the adhesive may also be applied to portions of the material which are to be closed when the template is formed into a box, so as to seal the box. In this embodiment latex adhesive or peel and seal adhesive may be used. Therefore, the box can be opened and re-sealed as and when the user needs.

Following application of the adhesive means, the apparatus transports the material to an insert-application table, 620, where inserts may be aligned and applied to the material in the position of the previously applied adhesive. As discussed above, the inserts provide further reinforcement for the material and ultimately provide further strength to the final assembled box. The inserts may be applied by an automatic feeder to the area where the material is coated with adhesive. Alternatively, the inserts may be applied by a hopper and, again, to the area where the material has had adhesive or adhesive means applied. In another embodiment, the inserts may be applied by hand.

The template, now comprising the above described fold lines, cuts, adhesive and or insert, may then be removed from the apparatus for assembly at a later point, either by hand or by machine. Alternatively, the template may be transported to a conventional box or bag forming apparatus or section of the apparatus, where the box may be assembled into the final product. This may be achieved by, after the inserts are applied, running the material under a pressure roller and tapes, to meet a conventional bag or box forming section of the apparatus. The template is folded along the pre-formed fold lines into the desired shape.

The template may further be guillotined, to separate the plurality of templates formed in the material from each other and to form the upper and lower edges of the individual templates, as discussed above.

As seen above, in a preferred embodiment, the bags are imprinted/perforated, and made in various ways by an apparatus. It is to be understood, however, that any of the above methods of making the bag could be done manually by hand.

The bags can be produced in any size, as the apparatus and method of the present invention allow for the unit to be adapted to cater for multiple sizes of templates.

Claims

1. A method for forming a template for a bag comprising

providing a material for forming said bag,

providing first, second and third longitudinal fold lines in said material, said fold lines extending in a first direction to form first, second, third and fourth longitudinal sections in said material,

providing first and second transverse fold lines in said material to form upper, middle and lower transverse sections in said material,

said first and second transverse fold lines extending in a direction perpendicular to said first direction,

providing fold lines in the shape of first and second crosses in said material.

2. The method of claim 1 wherein said crosses are positioned in said upper transverse section.

3. The method of claim 1 wherein said first and second crosses are provided in alternating longitudinal sections.

4. The method of any of claim 1 wherein said material comprises an upper edge, a lower edge, a first side edge and a second side edge,

wherein said first, second and third longitudinal fold lines are formed to extend in said first direction between said upper edge and said lower edge, to form said first second, third and fourth longitudinal sections in said material,

wherein said first and second transverse fold lines are formed to extend in the second direction between said first side edge and said second side edge,

said crosses being positioned between said first transverse fold line, said first transverse fold line being an upper fold line positioned closer to the upper edge than said second transverse fold line, and said upper edge of said material.

5. The method of any of claim 1 wherein said longitudinal fold lines overlap said transverse fold lines to form a grid on said template, with each of said longitudinal sections comprising three subsections and each of said transverse sections comprising four subsections.

6. The method of any of claim 1 further comprising

the step of providing diagonal lines that extend from the lower transverse section into the middle transverse section of the material.

7. The method of claim 6 comprising providing two of said diagonal lines so that they meet at a point in the middle transverse section.

8. The method of claim 7 wherein the point is halfway between the first and second transverse fold lines in said material.

9. The method of any of claim 1 comprising the step of forming holes in said material.

10. The method of any of claim 1 comprising the step of applying adhesive to said material.

11. The method of any of claim 1 comprising the step of applying inserts to said material.

12. The method of any of claim 1 comprising

the step of forming a fourth longitudinal fold line in said material, said fourth fold line formed to extend in said first direction to form a fifth longitudinal section in the material.

13. An apparatus for forming a template for a bag,

the apparatus being adapted to receive a material in a first, transport direction, for forming said template; the apparatus comprising:

means for forming first, second and third longitudinal fold lines in said material, said fold lines extending in said transport direction to form first, second, third and fourth longitudinal sections in said material and

means for providing first and second transverse fold lines in said material, said first and second transverse fold lines extending in a direction perpendicular to said first, transport, direction, to form upper, middle and lower transverse sections of said material,

means for providing fold lines in the shape of first and second crosses in said material.

14. The apparatus of claim 13 wherein

said apparatus is configured to position said crosses in said upper transverse section.

15. The apparatus of claim 13 comprising

means for providing said first and second crosses in alternating longitudinal sections.

16. The apparatus of any of claim 13 wherein said material comprises an upper edge, a lower edge, a first side edge and a second side edge,

means for forming said first, second and third fold lines to extend in said first direction from said upper edge to said lower edge, to form said first second, third and fourth longitudinal sections in said material;

means for forming said first and second transverse fold lines to extend from said first side edge to said second side edge,

means for positioning said crosses between said first transverse fold line, said first transverse fold line being closer to the upper edge than said second transverse fold line, and said upper edge of said material.

17. The apparatus of any of claim 13 wherein

the means for forming said longitudinal fold lines and said transverse fold lines is configured to provide said fold lines so that they overlap each other and form a grid such that each longitudinal section comprises three subsections and each transverse section comprises four subsections.

18. The apparatus of any of claim 13 comprising

means for providing diagonal lines that extend from the lower transverse section into the middle transverse section of the material.

19. The apparatus of claim 18 wherein

the diagonal lines are configured to meet at a point in the middle transverse section.

20. The apparatus of claim 18 wherein

the means for providing said diagonal lines is configured to position said point halfway between the first and second transverse fold lines in said material.

21. The apparatus of any of claim 13 comprising means for forming holes in said material.

22. The apparatus of any of claim 13 comprising means for applying adhesive to said material.

23. The apparatus of any of claim 13 comprising means for applying inserts to said material.

24. The apparatus of any of claim 13 comprising means for aligning inserts with said material.

25. The apparatus of any of claim 13 further comprising

means for forming a fourth longitudinal fold line in said material,

said fourth fold line extending in said first direction to form a fifth longitudinal section in the material.