Gusseted Mesh Bag Bottom with Thermal Bonding
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Solution Overview
Problem
The challenge lies in creating a bottom-gusseted, multi-substrate bag with an all-mesh bottom that offers sufficient strength and aesthetic appeal, while eliminating the need for a sealing strip in the side seam, which was previously necessary due to the inability to heat seal mesh materials effectively and concerns about side seam failure.
Innovation Solution
A gusseted multi-substrate bag design featuring thermally bonded panels, including a mesh bottom with pleats and side seams that provide strength without the need for a sealing strip, using materials like Ultratech® or Meltac® for the mesh and film components, ensuring the side seams have a strength of at least 1.75 lbs (7.8 N) for secure storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mesh material is used to form the bottom of the bag, then ventilation and aesthetic appeal are improved, but side seam strength and reliability deteriorate due to inability to heat seal mesh effectively
Solution Approach 1:
The patent changes the physical parameters of the mesh material by incorporating thermally-bondable elements (such as thermoplastic coatings or laminates) that enable heat sealing. This allows the mesh to maintain its aesthetic appeal and ventilation properties while gaining the ability to be thermally bonded to itself and to film strips, thereby resolving the contradiction between aesthetic appeal and side seam strength.
Solution Approach 2:
The patent uses composite materials by combining mesh material with thermally-bondable components (such as film strips or coated mesh layers). This composite structure allows the bag bottom to maintain the aesthetic and functional properties of mesh while incorporating materials that can be reliably heat-sealed, thus improving side seam strength without sacrificing aesthetic appeal.
2Reliability
If a film strip or sealing strip is added to the side seam, then side seam strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the sealing function with the existing side seam structure by using thermally-bondable mesh material that can be directly heat-sealed to itself or to film strips. This eliminates the need for separate sealing strips or additional sealing mechanisms, thereby maintaining side seam strength while reducing manufacturing complexity and cost.
3Ease of manufacture
If the bottom is formed by folding a film strip, then the need for bottom seam is eliminated, but side seam failure risk increases and aesthetic appearance deteriorates
Solution Approach 1:
The patent changes the properties of the mesh material to enable thermal bonding, allowing the bottom to be formed by heat-sealing mesh panels together rather than folding film strips. This creates a more reliable side seam structure while maintaining manufacturing simplicity and improving aesthetic appearance through the gusseted design.
4Object-generated harmful factors
If mesh material is used throughout the bag, then ventilation is maximized, but dimensional stability and self-standing capability deteriorate
Solution Approach 1:
The patent applies local quality by using mesh material in specific locations (such as the bottom and lower portions) where ventilation is most needed, while using film or composite materials in other areas to provide dimensional stability. This allows the bag to maintain self-standing capability and structural integrity while maximizing ventilation where it is most beneficial.
Solution Approach 2:
The patent uses composite materials by combining mesh material with film strips or other stabilizing materials in a multi-substrate construction. This allows different regions of the bag to have different properties: mesh areas provide ventilation while film areas provide dimensional stability and self-standing capability, resolving the contradiction between maximum ventilation and structural stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of aesthetically pleasing, self-standing bags with enhanced dimensional stability and reduced manufacturing complexity, achieving the desired strength and capacity for storing perishable items like avocados, while maintaining the ventilation benefits of mesh material.
Implementation Method 1
opposed side edges of the first through fourth panels are thermally bonded directly to one another
Data Source
AI summary
A bottom gusseted bag includes first and second opposed walls that face one another, each of the first and second walls having an upper end and a lower end, and a gusseted bottom that connects the bottom ends of the first and second walls to one another. The gusseted bottom includes at least four panels that are formed from an open mesh material and that collectively form at least three pleats. Opposed side edges of all of the panels are thermally bonded directly to one another along first and second opposed seams extending at least the majority of the length of each of the panels. The gusseted bottom may have a side seam strength of at least about 1.lb (4.5 N). The first and second side walls are formed at least in part of material, such a film, that is thermally bondable to the mesh material.