Flat-bottom gusseted bag made from multi-layer sheet

A method of forming a bag, the method comprising:

• providing a first web and a second web;
• pattern applying an adhesive to an adhesive-region of the first web;
• laminating the first web to the second web via the adhesive;
• forming a blank from the laminate, the blank defining:
• a front panel;
• a left side panel joined to a left side edge of the front panel;
• a right side panel joined to a right side edge of the front panel;
• a rear panel joined to one of the left side panel or right side panels;
• a plurality of bottom panels respectively joined to lower edges of the front panel, left side, right side, and rear panel;
• and
• fold lines respectively formed at each juncture between the panels;
• wherein the pattern applied adhesive is not applied to a plurality of adhesive-free fold line regions,
• wherein each adhesive-free fold line region:
• extends substantially along the length of a fold line, between a bottom panel and the single respective front, left side, right side, or rear panel joined therewith,
• without covering a juncture between any of the following panels:
• the front panel,
• the left side panel,
• the right side panel, and
• the rear panel, and
• extends at least partially above and below each fold line;
• sealing the rear panel to the unattached left side panel or the right side panel;
• sealing a bottom portion of each of the plurality of bottom panels together, defining a bag with an open top side.

A method of forming a bag, the method comprising:

• providing a series of blanks having a first web laminated to a second web by an adhesive, each of the blanks comprising:
• a plurality of serially connected side wall panels;
• and
• a plurality of bottom panels respectively connected to the plurality of side wall panels, each of the plurality of bottom panels being connected to a respective one of the plurality of side wall panels at a fold line;
• wherein the adhesive is a patterned adhesive defining a plurality of adhesive-free fold line regions, wherein each adhesive-free fold line region:
• extends substantially along the length of a fold line, between a bottom panel and the single respective front, left side, right side, or rear panel joined therewith, and
• extends at least partially above and below each fold line;
• and
• wherein the at least one adhesive region is disposed on at least one juncture between any of the following panels:
• the front panel,
• the left side panel,
• the right side panel, and
• the rear panel;
• sealing the rear panel to either the left side panel or the right side panel;
• and
• sealing a bottom portion of each of the plurality of bottom panels together, defining a bag with an open top.