Inner laminated packaging bag and automated methods of making and using the same

Abstract

A method of making and using composite bags. The bags include a multi-layered, inner laminated woven bag for consumer-facing bulk packaging of food products, particularly rice and grain products. The methods of making and using the bag can be partially or wholly automated.

1 . A composite food packaging bag comprising two first and second generally rectangular planar opposing sides operably connected along three edges and open along a fourth edge to define an opening between the first and second generally rectangular planar open sides to an interior portion of the bag, the opening being defined by unsealed edges of the bag, each of the generally rectangular planar opposing sides including:
 a) a base inner-barrier layer, the base inner-barrier layer including a continuous polymeric film layer;   b) a middle layer laminated to the base inner-barrier layer, the middle layer including a polymer woven layer forming a woven structure; and   c) a top outer layer laminated to the middle layer, wherein the top outer layer includes a polymer film;   wherein each of the base inner-barrier layer, the middle layer, and the top outer layer are formed as a laminated sheet having two parallel longitudinal edges that are sealed to each other in a sealing region to form a longitudinal seal from a bottom of the bag to a top of the bag.   
     
     
         2 . The composite food packaging bag of  claim 1 , wherein the longitudinal seal is formed by at least one of (i) the application of heat, (ii) the application of ultrasonic energy, (iii) stitching, and (iv) the application of adhesive. 
     
     
         3 . The composite food packaging bag of  claim 1 , wherein the laminated sheet is sealed to itself longitudinally by a lap joint formed by overlapping the two parallel longitudinal edges. 
     
     
         4 . The composite food packaging bag of  claim 3 , wherein the longitudinal seal bonds the base inner barrier layer along one of the two parallel edges to the top layer along the other parallel edge to form a lap seal. 
     
     
         5 . The composite food packaging bag of  claim 3 , wherein the longitudinal seal bonds the inside of the base inner barrier layer along one of the two parallel edges to the inside of the base inner layer along the other parallel edge to form a fin seal. 
     
     
         6 . The composite food packaging bag of  claim 1 , further comprising an anti-skid layer or coating. 
     
     
         7 . The composite food packaging bag of  claim 6 , wherein the base inner-barrier layer, the middle layer, and the top outer layer are laminated to each other over their entire extents. 
     
     
         8 . The composite food packaging bag of  claim 6 , wherein the base inner-barrier layer, the middle layer, and the top outer layer are laminated to each other over substantially their entire extents. 
     
     
         9 . A method of making a composite web of material suitable for making a composite bag suitable for food packaging, the method comprising:
 a) providing a base inner-barrier layer material web, said base inner-barrier layer including a continuous polymeric film layer;   b) providing a polymer woven layer material web;   c) laminating the base inner-barrier layer material web to a first face of the polymer woven layer material web to form a composite web of material having two longitudinal edges;   d) folding the longitudinal edges of the composite web of material toward each other to bring the longitudinal edges together; and   e) sealing the longitudinal edges of the composite web of material to each other to form a flat composite material suitable for making composite bags with a longitudinal channel defined therein.   
     
     
         10 . The method of  claim 9 , wherein the polymer woven layer material web of step b) is formed by longitudinally slitting a tubular woven fabric material and laying the material flat into a sheet form. 
     
     
         11 . The method of  claim 9 , further comprising laminating an outer layer material web to a second face of the polymer woven layer material web prior to forming the longitudinal seal to form the composite web of material having longitudinal edges. 
     
     
         12 . The method of  claim 9 , further comprising forming a seal from edge to edge of the flat composite material suitable for forming composite bags. 
     
     
         13 . A method of making a composite bag suitable for food packaging, the method comprising:
 a) providing a base inner-barrier layer material web, said base inner-barrier layer including a continuous polymeric film layer;   b) providing a polymer woven layer material web;   c) laminating the base inner-barrier layer material web to a first face of the polymer woven layer material web to form a composite web of material having two longitudinal edges;   d) folding the longitudinal edges of the composite web of material toward each other to bring the longitudinal edges together;   e) sealing the longitudinal edges of the composite web of material to each other to form a flat composite material suitable for making composite bags with a longitudinal channel defined therein; and   f) cutting the flat composite material to a desired length to form a composite bag with an open first end and an open second end.   
     
     
         14 . The method of  claim 13 , further comprising sealing one of the first end and the second end of the composite bag to form a sealed composite bag with a sealed closed end and an open end. 
     
     
         15 . The method of  claim 13 , further comprising laminating an outer layer material web to a second face of the polymer woven layer material web of step c) to form a composite web of material with a pair of longitudinal edges. 
     
     
         16 . A method of filling a bag suitable for food packaging, the method comprising
 a) providing a composite food packaging bag comprising two first and second generally rectangular planar opposing sides operably connected along three edges and open along a fourth edge to define an opening between the first and second generally rectangular planar open sides to an interior portion of the bag, the opening being defined by unsealed edges of the bag, each of the generally rectangular planar opposing sides including:
 a base inner-barrier layer, said base inner-barrier layer including a continuous polymeric film layer; and 
 a second layer laminated to the base inner-barrier layer, the second layer including a polymer woven layer forming a woven structure; 
   wherein each of the base inner-barrier layer and the second layer are formed as a laminated sheet having two parallel longitudinal edges that are sealed to each other in a sealing region to form a longitudinal seal from a bottom of the bag to the top of the bag;   b) positioning the bag with an open edge adapted to receive product;   c) moving the opposing sides away from each other to form the opening;   d) introducing the product through the opening; and   e) sealing the opening.   
     
     
         17 . A method of making a composite bag suitable for food packaging, the method comprising:
 a) providing a base inner-barrier layer material web, said base inner-barrier layer including a continuous polymeric film layer;   b) providing a polymer woven layer material web;   c) laminating the base inner-barrier layer material web to a first face of the polymer woven layer material web to form a composite web of material having two longitudinal edges;   d) folding the longitudinal edges of the composite web of material toward each other to bring the longitudinal edges together;   e) sealing the longitudinal edges of the composite web of material to each other to form a flat composite material suitable for making composite bags with a longitudinal channel defined therein;   f) sealing the composite web of material from edge to edge to form bag precursors; and   g) cutting the flat composite material from edge to edge adjacent the seal of step f) to form a composite bag with sealed end and an open end.