Recyclable Bag Sewing Pattern for Insulation and Efficiency
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Solution Overview
Problem
There is a need for an efficient method to produce recyclable bags with excellent insulating properties from cellulosic materials, particularly those that can be easily manufactured and provide better orientation and closure within shipping cartons.
Innovation Solution
A process involving the alignment and sewing of three webs to form an inverted T-shaped structure, followed by folding and rotating to create a square bottom bag with a unique stitching pattern, allowing for automated production and easy closure, using cellulosic materials that can be embossed or creped, and incorporating additional layers for enhanced insulation and tear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to manufacture liners/bags, then production can be achieved, but manufacturing efficiency and insulating properties are insufficient
Solution Approach 1:
The bag is divided into three separate webs (bottom web, first side web, second side web) that are fed and sewn independently, allowing for optimized manufacturing of each component while maintaining overall production efficiency
Solution Approach 2:
The invention uses cellulosic material with insulating properties as the base material, combining it with specific stitching patterns and web configurations to achieve both manufacturing efficiency and excellent insulating performance
2Strength
If complex stitching patterns are used, then bag strength and structure are improved, but manufacturing complexity increases
Solution Approach 1:
The stitching is divided into distinct patterns for different regions: truncated triangle shapes for wing portions and flat-bottomed U shapes for the riser, allowing each pattern to be optimized independently for both strength and manufacturability
Solution Approach 2:
Different stitching patterns are applied to different parts of the bag: the truncated triangle pattern with tabs is used in wing portions where structural support is needed, while the flat-bottomed U pattern is used in the riser section, providing locally optimized strength without unnecessary complexity elsewhere
3Productivity
If automated production is implemented, then productivity increases, but manufacturing precision requirements increase
Solution Approach 1:
The bag construction is segmented into three separately fed webs that are aligned and sewn in a defined sequence, allowing automated systems to process each web independently while maintaining precise alignment through the standardized inverted T-shaped configuration
Solution Approach 2:
The webs are pre-configured into an inverted T-shaped arrangement with specific alignment requirements established before sewing begins, allowing automated equipment to maintain precision through consistent positioning rather than requiring complex real-time adjustment
Data Source
AI summary
A process for producing bags comprising:feeding a bottom web, a first side web and a second side web in a conversion process, each of the webs having a first side edge and a second side edge, wherein the first side edge of the first side web is aligned with the first side edge of the second side web, the second side edge of the first side web is aligned with the first side edge of the bottom web, and the second side edge of the second side web is aligned with the second side edge of the bottom web, thereby forming an inverted T-shaped web comprising a base having first and second wing portions and a riser, wherein the first wing portion comprises the bottom web and first side web, the second wing portion comprises the bottom web and the second side web, and the riser comprises the first and second side webs;sewing the first side web to the bottom layer in the first wing portion with a repeating pattern comprising a truncated triangle having a narrow portion and wider portion, and a tab separating the triangles, wherein the narrow portion of the triangle points toward the second side edge of the first side web;sewing the second side web to the bottom layer in the second wing portion with a repeating pattern comprising a truncated triangle having a narrow portion and wider portion, and a tab separating the triangles, wherein the narrow portion of the triangle points toward the second side edge of the second side web;contacting the first and second wing portions by folding them toward each other, thereby forming a folded web;rotating the folded web to the horizontal;sewing the first and second webs together in the riser with a repeating pattern comprising a flat-bottomed U shape with tabs separating the repeating U's, where the flat bottom of the U faces the first side edge of the first and second side webs, and the tabs separating the flat-bottomed U's are bisecting the tab separating the triangles in the first and second wing portions, thereby forming a web of sewn bags;cutting the web along the edge of sewn bags to remove the sewn portion corresponding to the flat bottom portion of the flat bottom U shape parallel to the edge, thereby forming a web of open top bags; andtransversely cutting the web of open top bags at the middle of the truncated triangles and bisecting the repeating U's, thereby forming separate, open bags, and optionally scrap material.