Separable Bag Roll Design Eliminates Scrap Waste
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Solution Overview
Problem
The production of separable bags in rolls is inefficient due to significant waste material generation from cutouts and perforations, which interferes with the manufacturing process and is wasteful.
Innovation Solution
A roll of separable bags is designed with an outer and inner sheet portion, sealed at specific locations, and perforated to create bag separating lines and handle lines, allowing for easy tearing without generating scrap material, using a method that forms a tube from polymeric material with gussets and strategically placed seals and perforations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cutouts and perforations are used to form bag openings and separation lines, then bags can be separated and handles formed, but substantial waste material is generated that fouls machinery and reduces production efficiency
Solution Approach 1:
The bag structure is segmented into distinct functional zones: sealed portions for bag formation, perforated lines for separation, and handle portions with tear lines. This segmentation allows each zone to perform its specific function efficiently without generating waste, as materials are utilized in their intended locations without excessive removal.
Solution Approach 2:
Different regions of the bag structure have different properties optimized for their specific functions. The sealed portions provide structural integrity, the perforated lines enable clean separation, and the handle portions with tear lines facilitate easy handle formation. This local optimization eliminates the need for extensive material removal while maintaining functional performance.
2Ease of operation
If extensive cutouts are made to form bag openings, then functional bag structures are achieved, but production efficiency decreases due to material waste and machinery fouling
Solution Approach 1:
The bag structure is pre-configured with sealed portions, perforated lines, and handle portions during manufacturing. This preliminary arrangement of functional elements allows for easy bag separation and handle formation by the end user without requiring additional processing steps or generating waste during operation.
Solution Approach 2:
Instead of removing large amounts of material to create openings, the invention extracts only the minimal necessary material through strategic perforations and tear lines. The handle portions are formed by removing minimal material along predefined tear lines, and bag separation is achieved through perforated lines, both eliminating excessive waste generation.
3Ease of manufacture
If traditional manufacturing methods are used with significant material removal, then bag structures are formed, but operational interruptions occur due to scrap buildup fouling machinery
Solution Approach 1:
The manufacturing process parameters are changed from extensive material removal to minimal perforation and sealing. By altering the approach from cutout-based formation to seal-and-perforate methodology, the process generates negligible scrap, eliminating machinery fouling and operational interruptions while maintaining bag structure formation capability.
Data Source
AI summary
A roll of separable bags which leaves no scrap material and method of making a roll of separable bags which leaves no scrap material is disclosed herein. An elongated tube of material having a length and a width is laid flat, forming a web of material. The web of material comprises an outer and an inner sheet portion. First and second seals are formed widthwise across the outer and inner sheet portions. First and second bag separating perforation lines are formed widthwise across the outer and inner sheet portions. A user may tear one bag away from the roll of bags by using the bag separating perforation line. The user may then deploy the handles of the bag by tearing along the handle perforation lines.