Bag and method of making the same

Abstract

A bag includes a main body formed from a first sheet of material foldable to form front and rear panels, a pair of side panels, a bottom panel, and an interior space of the bag defined by the front, rear, side and bottom panels. The sheet of material includes a reinforcement section and at least one layering section for creating a two material design. The bag may also include a pair of handles formed from second and third sheets of material wherein engagement sections of the handles are fixedly attached to the reinforcement section of the bag. Stitching may be used to increase the strength and look of the bag.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a bag apparatus and method of making the same, and, in particular, to a new bag and handle design for enabling a bag made using a paper or paper-like product to handle greater weight.

[0003] 2. Description of the Related Art

[0004] Paper-based or paper-like bag products are known in the art. For instance, there are several types of store bags that are provided by a merchant to help a customer carry purchased merchandise. One famous example is the "Brown Bag" provided by Bloomingdale's outlets. Another example is the gift bags that one might get at a Hallmark store or Bed Bath & Beyond and similar stores.

[0005] In all of these bags, which are either paper-based or use a paper-like product, one of the weakest parts of the bag is where the handle is attached to the frame of the bag. Depending on the particular structure used by the manufacturer of the bag, if too much weight is applied or if the bag is held at an awkward angle, either the bag itself may tear or the handle may become disengaged from the bag frame. Other manufacturers have attempted to provide bags that utilize stronger materials such as cloth-based products, nylons, or other synthetics. However, these designs often greatly increase the cost of the bag, which must be kept low so that it makes economic sense for the manufacturer to sell them cheaply or provide them to customers for free.

[0006] Nylon or cloth-based duffle bags are also known in the art. However, these bags do not suffer from the problems associated with paper-based or paper-like bags in that the materials ensure a relatively strong bag. However, these bags are far more expensive than bags that use paper-based or paper-like materials and thus are not suitable for the purpose of providing gifts or being provided by a merchant after a purchase.

[0007] Thus, in light of the foregoing, there is a need for a new paper-based or paper-like bag or bag and method for making such bag in an economical manner that provides a cost-effective bag that is strong enough to reduce the risk of tearing when carrying relatively heavy articles.

SUMMARY OF THE INVENTION

[0008] In view of the above discussion, the shortcomings in known bags are overcome, at least in part, by a bag that comprises a frame constructed from a paper-based or paper-like product, at least one handle constructed from a paper-based or paper-like product and including an engagement portion having a first support component and a second support component wherein each of the first support component and a second support component is stitched to a portion of the frame. Further, a frame support may be included generally at the location of the portion of the frame where the engagement portion of the handle is stitched.

[0009] As used herein, the terms "paper-based" and "paper-like" refer to a material that includes paper, synthetic papers, plastics, and other materials that generally have the physical properties of natural paper.

[0010] As an additional feature of the invention, the frame of the bag may be constructed from a single sheet of material and folded so as to hide the point of engagement between the frame and the handle on the inside of the frame. Moreover, the bag may be additionally folded so as to give the bag the appearance that it is constructed from more than one material or sheet. Stitching may also be included to enhance this appearance.

[0011] In an embodiment of the handle, the handle is constructed from a single sheet and folded over itself such that the engagement portion of the handle is substantially flat whereas the upper portion of the handle is pinched. This advantageously increases the strength of the handle mechanism. The folded portions of the handle may be stitched and/or glued in place. To further increase the strength of the handle, a second support component, such as a piece of fabric may be layered on the first sheet forming the handle and folded within the first sheet so as to hide its existence. Stitching and/or an adhesive may be added to hold both the first sheet and the second support component in place.

[0012] Additional features and advantages of the system and methods of the invention are described further below.

BRIEF DESCRIPTION OF THE FIGURES

[0013] FIG. 1 is a perspective view of a bag with a frame and handle formed in accordance with a preferred embodiment of the present invention;

[0014] FIG. 2 is a perspective view of an alternate preferred embodiment of a bag with a frame and handle;

[0015] FIG. 3 is an illustration of the material of an embodiment of a portion of the bag handle in an unfolded state showing the preferred fold line and stitching layout;

[0016] FIG. 4 is an illustration of the material of an embodiment of a portion of the bag handle in an unfolded state showing the preferred fold line and stitching layout and further showing the inclusion of a support insert;

[0017] FIG. 5 is a perspective view of an alternate preferred embodiment of a bag with a frame and handle wherein the frame is folded to give the appearance of at least two components;

[0018] FIG. 6 is schematic of the material of an embodiment of a portion of the bag frame in an unfolded state showing the preferred fold line and stitching layout;

[0019] FIG. 7 is an enlarged schematic of the bag being folded to form a faux multi-material look in accordance with an embodiment of the invention; and

[0020] FIGS. 8a-8h each show an example of a bag design and constructed in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] With reference now to FIGS. 1-6 there will be shown and described several embodiments of an improved bag and handle assemble, and method of making the same. The improved bag and handle assembly advantageously provides increased strength to the bag and further enables the bag to be constructed such that it appears that the bag is made from multiple materials or parts.

[0022] With reference to FIG. 1, a perspective view of a first preferred embodiment of a bag and handle assembly 10 is shown. The assembly preferably includes a frame 15 having a front and rear panels 20, 22, two side panels 24, 26, and a bottom panel 28. As will be discussed further in connection with FIG. 6, the frame 15 is preferably, but not necessarily, formed from a single sheet that is folded so as to form the front and rear panels 20, 22, two side panels 24, 26, and a bottom panel 28. Interior space 17 and open end 19 are created by formation of the front and rear panels 20, 22, two side panels 24, 26, and a bottom panel 28 of the frame 15.

[0023] With further reference to FIG. 1, handle assembly 30 is fixedly attached to bag frame 15 via stitching 36 (as shown) or an adhesive (not shown), or any combination thereof. Handle assembly 30 preferably includes a pinched or folded handle 32 in combination with generally flat engagement portions 34. The construction of the handle assembly 30, and in particular engagement portions 34 is described further in connection with FIG. 3. As can be seen from the arrangement of FIG. 1, the handle assembly 30 is generally U-shaped and constructed such that engagement portions 34 extend a substantial way down side panels 20. For both design aesthetics and to increase the strength of the engagement of handle assembly 30 to frame 15, stitching 36 extends down the length of engagement portions 34. In an alternate embodiment, as shown in FIG. 2, engagement portions 34' does not extend a substantial way down the bottom of front panel 20.

[0024] It should be understood that although the foregoing discussion has focused on a single handle assembly 30 engaged with front panel 20, the bag assembly 10 preferably includes two such handle assemblies. The discussion with respect to one handle assembly applies equally to another such handle assembly engage with rear panel 22. The same is true with respect to support member 40, discussed below.

[0025] As further shown in FIG. 1, support member 40 may optionally be included to increase the strength of the connection between frame 15 and the engagement portions 34 of handle assembly 30. In a preferred embodiment, two support members 40 are positioned on the inside of front and rear panels at the location of engagement portions 34, as shown in FIG. 1. Support member 40 need not, buy may, extend towards bottom panel 28.

[0026] Like the embodiment shown in FIG. 1, the bag assembly 10' shown in FIG. 2 includes a frame 15' having front and rear panels 20', 22'. A pair of handle assemblies 30' with engagement portions 34' are fixedly attached to front and rear panels 20', 22' via stitches 36' in the manner described above. An adhesive (not shown) may be used in combination with the stitches 36'.

[0027] With reference now to FIGS. 3 and 3a-d, the construction of the handle assembly 300 will be shown and described. FIG. 3 depicts a laid open view of a portion of Handle assembly 300. Handle assembly 300 generally includes a grip section 302, which corresponds to folded handle 32 of FIG. 1, and a pair of engagement sections 350 (only of one of which is shown in FIG. 3). The section between the grip section 302 and the engagement sections 350 is referred to as transition section 352. Like frame 15, the handle assembly 300 is preferably constructed of a paper-based or paper-like material. As shown in FIG. 3, handle assembly 300 has a number of fold lines F1, F2, F3, F4, and F5 that permit the handle assembly 300 to be folded such that it creates a folded hand grip and a folded engagement section, which are each reinforced by the fact that the material is folded upon itself. Handle assembly 300 may also include flap section 354, which would get folded over engagement section 350 via fold line F6. A preferred manner of folding the handle assembly 300 will be described further in connection with FIGS. 3a-3d.

[0028] As further shown in FIG. 3, handle assembly 300 is stitched for both structural and design purposes. In the example shown, grip section 302' contains a single stitch S1 generally down the center of the folded grip section 302'. In the unfolded state, FIG. 3 shows the holes made by the stitching as S1a, S1b, S1c, and S1d. Similarly, engagement section 350' receives a generally square or rectangular stitch S2 to reinforce the connection of the handle assembly 300 to frame 15 (as further shown in FIGS. 1 and 2). In the unfolded state, this results in stitch holes S2a, S2b, S2c, S2d, S2e, S2f, and S2g.

[0029] With reference now to FIGS. 3a-3d, there will be shown and described a method of folding the handle assembly 300 so as to create a reinforced handle for attaching to bag frame 15. In FIG. 3a, a portion of grip section 302' is shown. Grip section 302' includes a pair of side flaps (a) and (b) and a pair of main flaps (c) and (d). As can be seen, side flaps (a) and (b) are folded inward and over main flaps (c) and (d). With reference to FIG. 3b, once side flaps (a') and (b') are folded completely over main flaps (c') and (d'), main flaps (c') and (d') are folded over one another to create the folded grip section 302'', which can then be stitched.

[0030] In FIG. 3c, there is shown a portion of engagement section 350'. Engagement section 350' includes side flaps (e) and (f), main flap (g), and bottom flap (h). Side flaps (e) and (f) are preferably folded over on another and also over main flap (g), as shown in FIG. 3d. Further, optional bottom flap (h) is then folded over side flaps (e) and (f) and main flap (g). It will be understood that bottom flap (h) is not used when the engagement portion 350' is intended to extend towards the bottom of bag frame 15 as shown in FIG. 1.

[0031] As shown in FIG. 4, handle assembly 400 may further include support member 475 placed inside handle assembly 400. Support member 475 may be constructed of any known material, but is preferably a thin and flexible material that has relatively strong elasticity. By way of example, a fabric or synthetic-based woven material can be both thin and flexible, while maintaining a high level of resistance to stretching. It is also preferred that support member 475 span both the grip section 402 and the engagement section 450, although the support member 475 may be substantially the same length as the entirety of handle assembly 400. In addition, it is preferred that support member 475 be wide enough so as to receive at least a portion of the stitching of handle assembly 400. Support member 475 may also be fixed inside of handle assembly 400 through use of an adhesive.

[0032] With reference now to FIG. 5, there is shown an alternate embodiment of the present invention in which bag 500 is constructed so as to appear to include two distinct materials. As shown in FIG. 5, bag 500 includes a frame 510 that appears to include two sections 515 and 520. Sections 515 and 520 are separated by interface 525, which may further include stitching 530 both to enhance the structural integrity of bag 500 and to further the design effect. Sections 515 and 520 may be colored so as to further the effect of making it appear that bag 500 is constructed of two different materials.

[0033] Structurally, as shown in FIG. 6, bag 600 is constructed from a single sheet 605--half of which is shown in FIG. 6. Sheet 605 is preferably cut such that includes a generally rectangular shaped main section 607 having a number of trapezoidal folded sections 609 at the bottom thereof. The length and width of the side of main section 607 will determine the final dimensions of the bag 600. For example, the width of sections A and C determine the width of the side panel of the bag (see side panel 26 of FIG. 1). Moreover, the width of section B determines the wide of the front and rear panels (see front and rear panels 20, 22 of FIG. 1). In order to form the rectangular box shape of the finished bag 600, the sheet 605 must be folded. A preferred embodiment of folding the bag is shown by fold lines F1-F12 of FIG. 6. To form the bag 600, sheet 605 is preferably first folded at fold line F5 so that section 620 is folded over section 610 so as to hide support member 640. The folding of section 620 over section 610 also advantageously increases the strength of the top of the bag and the portion of the bag to which engagement section 34 (see FIG. 1) is attached. Next, sheet 605 is folded at fold lines F6 and F7 so as to form the interface 525 (see FIG. 5), as shown in FIG. 7. FIG. 7 is an exaggerated and enlarged view of the preferred folding arrangement of sheet 605. In FIG. 7, it can be seen that the material (Z) of sheet 605 that lies between fold lines F6 and F7 overlaps a portion of support member 640. Moreover, the folding of fold lines F6 and F7 causes an interface line (see interface 525 in FIG. 5) to be formed between section 610 and section 615 on the outside of the bag. On the inside of the bag, section 620, as discussed previously, is folded at fold line F5 so as to overlap material (Z) as well as support member 640. Including optional support member 640, this creates a five-ply of material at the location where the engagement section of the handle assembly will be attached. Thus, in addition to making the look of the bag more desirable, the strength of the bag is also advantageously increased.

[0034] With reference again to FIG. 6, the sheet 605 is then folded at fold lines F2, F3, another fold line (not shown) at the leading edge of section (c). This brings all four sides of bag 600 together to form the internal space of bag 600. At this point the bottom of the bag can be formed, by folding sections 609 upon one another. In a preferred embodiment, flaps 660 and 664 are folded inward. Next, flap 662 and a mirror image of flap 662 (not shown) are folded one at a time over flaps 660 and 664 to form the bottom panel of the bag. A support member may be added to the inside of the bag to increase the strength of the bag at the bottom. As shown in FIG. 6, fold lines F1, F4 and F8-F11 are use to fold the bag flat when not in use.

[0035] With reference now to FIGS. 8a-8h there are shown eight different examples of bag designs constructed as described above. In FIGS. 8a-8c and 8f-8g, in particular, there are shown examples of bag designs wherein a dual faux material design is incorporated at the bottom of the bag. As described above in connection with FIGS. 5-7, the dual material look is created by incorporating an additional pair of fold lines (such as F6 and F7 in FIG. 6) at the bottom of the bag where the dual material design is desired to be located. A stitch line may also be included so as to strengthen the bag and to add to the faux dual material look.

[0036] Thus, while there have been shown and described fundamental novel features of the invention as applied to the exemplary embodiments thereof, it will be understood that omissions and substitutions and changes in the form and details of the disclosed invention may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.

Claims

1. A bag, comprising: a main body formed from a first sheet of material foldable to form front and rear panels, a pair of side panels, a bottom panel, and an interior space of the bag defined by the front, rear, side and bottom panels, the sheet of material including a reinforcement section and at least one layering section for creating a two material design, the reinforcement section including a first reinforcement sheet portion contiguous with the top of the front, rear, and side panels and a second reinforcement sheet portion contiguous with the first reinforcement sheet portion such that the first reinforcement sheet portion is folded over the second reinforcement sheet portion into the interior space of the bag, the layering section including a fold portion contiguous on a top side with the second reinforcement sheet portion in which the top side of the first fold sheet portion is folded up and onto at least a portion of the second reinforcement sheet portion in the interior space of the bag and in which a bottom side of the first fold sheet portion is folded down such that the remainder of the front, rear, and side panels extend downward forming the remainder of the interior space of the bag; a first handle being formed from a second sheet of material having a grip section and first and second engagement sections, the grip section of the second sheet of material being generally rectangular in shape and having sides that are substantially lengthier than the ends and the first and second engagement sections extending from the ends of the grip section and being wider than the grip section; the grip section formed by folding two side portions inward and over a center portion of the grip section and then folding the grip section again along a line substantially down the center of the grip section, the engagement sections including a pair of flaps and a central portion and wherein the engagement sections are each formed by folding the pair of flaps at least partially over one another and the central portion; and wherein the engagement sections of the first handle are each fixedly attached to the reinforcement section of the front panel of the bag.

2. The bag of claim 1, wherein the engagement sections of the first handle are generally rectangular in shape when the pair of flaps are folded at least partially over one another and the central portion.

3. The bag of claim 1, wherein the engagement sections are attached to the reinforcement section of the bag via stitching.

4. The bag of claim 1, wherein the reinforcement section further comprises a support member.

5. The bag of claim 4, wherein the support member is of a cardboard material.

6. The bag of claim 5, wherein the engagement sections of the first handle and the reinforcement section of the bag, including the support member, are attached via stitching.

7. The bag of claim 1, wherein the first handle further comprises a handle support member at least partially overlapping the grip section and the engagement sections.

8. The bag of claim 7, wherein the handle support member comprises two separate sections, a first of the two separate sections of the handle support member overlapping at least a portion of the grip section and a first of the engagement sections and a second of the two separate sections of the handle support member overlapping at least a portion of the grip section and a second of the engagement sections.

9. The bag of claim 1, wherein the fold portion of the layering section when folded is stitched to at least a portion of the reinforcement section.

10. The bag of claim 9, wherein the stitching through the layering section and the reinforcement section also passes through at least a portion of a support member in the reinforcement section.

11. The bag of claim 1, further comprising a second handle being formed from a third sheet of material having a grip section and first and second engagement sections, the grip section of the third sheet of material being generally rectangular in shape and having sides that are substantially lengthier than the ends and the first and second engagement sections extending from the ends of the grip section and being wider than the grip section; the grip section formed by folding two side portions inward and over a center portion of the grip section and then folding the grip section again along a line substantially down the center of the grip section, the engagement sections including a pair of flaps and a central portion and wherein the engagement sections are each formed by folding the pair of flaps at least partially over one another and the central portion; and wherein the engagement sections of the second handle are each fixedly attached to the reinforcement section of the rear panel of the bag.

12. The bag of claim 11, wherein each of the engagement sections of the first and second handles extends substantially towards the bottom of the bag when attached to the main body of the bag.

13. The bag of claim 1, wherein the bag is formed from paper.

14. The bag of claim 1, wherein the bag is formed of a paper-like material.

15. A method of forming a bag, comprising the steps: providing a first sheet of material to form a main body of the bag; folding the first sheet to form front and rear panels, a pair of side panels, a bottom panel, and an interior space of the bag defined by the front, rear, side and bottom panels; folding a first reinforcement sheet portion contiguous with the top of the front, rear, and side panels of the first sheet of material over a second reinforcement sheet portion and into the interior space of the bag to form a reinforcement section on the front and rear panels of the bag, providing a support member in between the first reinforcement sheet portion and the second reinforcement sheet portion; folding a fold portion of a layering section of the first sheet of material; attaching a first handle to the reinforcement section on the front panel of the bag; and attaching a second handle to the reinforcement section on the rear panel of the bag.

16. The method of claim 15, wherein the step of folding the fold portion of the layering section further comprises: folding a top side of the fold portion up and onto at least a portion of the second reinforcement sheet portion in the interior space of the bag; and folding a bottom side of the fold portion down such that the remainder of the front, rear, and side panels extend downward forming the remainder of the interior space of the bag.

17. The method of claim 15, wherein the first and second handles are formed from a second and third sheet of material, each of the first and second handles having a grip section and first and second engagement sections, the grip section of the second sheet of material being generally rectangular in shape and having sides that are substantially lengthier than the ends and the first and second engagement sections extending from the ends of the grip section and being wider than the grip section; the grip section formed by folding two side portions inward and over a center portion of the grip section and then folding the grip section again along a line substantially down the center of the grip section, the engagement sections including a pair of flaps and a central portion and wherein the engagement sections are each formed by folding the pair of flaps at least partially over one another and the central portion; and wherein the engagement sections of the first handle are each fixedly attached to the reinforcement section of the front panel of the bag.

18. The method of claim 15, wherein the layering section is adjacent the reinforcement section of the bag.

19. The method of claim 15, wherein the layering section is separated from the reinforcement section of the bag.