Note: Descriptions are shown in the official language in which they were submitted.
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A RESILIENT PACKING PRODUCT AND
METHOD AND APPARATUS FOR PRODUCING THE SAME
The present invention relates to a method and apparatus
for making a resilient packing product or the like. More
particularly, this invention relates to apparatus and methods
for resiliently folding and crimping shredded sheets of sheet
material into selected lengths of interlocking, bulk packaging
material.
Styrofoam pellets or peanuts are commonly used within the
wholesale and retail industries as bulk packaging material.
The peanuts are used to position a product away from the
interior sides of a container and fill the empty space located
therebetween. The peanuts are intended to protect the
packaged product against the impact of a blow or other
mistreatment.
Dispensing styrofoam peanuts does not require a great
degree of sophistication. The peanuts are simply gravity fed
from large retainer bins into the empty spaces within a
packaging container.
Use of styrofoam peanuts, however, has many drawbacks.
For example, if styrofoam peanuts are used to protect a heavy
object placed within a container, and such package is jostled
and shaken, the object usually gravitates toward the bottom of
the container and the peanuts float upward. Eventually the
object comes to rest against the base or side of the container
and damage to the object may occur. The light weight of the
Styrofoam peanuts also allows them to be easily blown by the
wind and scattered.
Of particular concern, styrofoam peanuts are extremely
difficult to dispose of and destroy after use. In fact,
because of the extensive use of this nonbiodegradable product,
which emits toxic gases if burned, styrofoam peanuts present a
major threat to the environment and are being banned from an
increasing number of communities.
Styrofoam peanuts are also dangerous to children and to
wildlife who often mistake them as food and consequently
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ingest them. Styrofoam peanuts are not digestible and cause a
major source of tracheal blockage in children.
Other packaging filler materials, such as shredded paper,
have also been used. Shredded paper, however, usually lays
S flat within the container and a very large amount of paper is
required to provide the bulk needed to fill the voids and to
protect the contained object. To provide such a large amount
of shredded paper is often cost prohibitive and, following its
use, such voluminous amounts of paper must be disposed. In
addition, the shock absorbency of flat shredded paper is
minimal.
A number of patents are directed to the folding or
crumpling of large sheets of materials. Specifically, U.S.
Patent Nos. 2,668,573; 3,150,576; and 4,012,932 are directed
to the corrugation or pleating of large sheets of paper
material.
Complicated sheet creeping, crinkling or folding is
disclosed in U.S. Patent Nos. 1,680,203 and 3,501,565.
However, U.S. Patent No. 3,501,565 simply includes preliminary
steps prior to the stretching of plastic sheet material or the
like.
Other patents discuss the crumpling of sheet paper
material or the like for the formation of filters. U.S.
Patent No. 2,786,399 includes such crumpled sheet paper
material and employs a cutter for the formation of small
blocks of such material. U.S. Patent No. 2,924,154 is
directed to filter material and employs a gate means during
the advancement of the sheet material to assist in the
formation of the crumpled blocks of material.
Various methods and apparatus for forming dunnage are
disclosed in several patents which include the folding or
funnelling of sheet paper or material into a compact elongated
form. U.S. patent Nos. 3,509,797; 3,613,522; and 3,650,877
include such elongated dunnage material which is twisted and
compressed to provide a helical shape. U.S. Patent Nos.
4,085,662; 4,650,456; and 4,699,609 disclose additional
devices for the folding and collapsing of elongated sheet
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material. Some of these patents directed to dunnage include
cutter means at the outlets in order to provide predetermined
lengths of the dunnage material.
U.S. Patent Nos. 3,754,498 and 4,201,128 generally
disclose shredding machines which are used in conjunction with
compacters or bailers.
U.K. Patent No. 771,877 and U.S. Patent No. 3,217,988
disclose cutting discs for producing a longitudinal cut of
sheet material to form longitudinal strips. Outlet support
means is provided for supporting the longitudinal strips
during a transverse cut to form smaller pieces.
U.S. Patent Nos. 2,621,567; 2,686,466; and 2,770,302
disclose shredding devices which include a comber
configuration for imparting a bend or kink to the strips which
are cut thereby.
It is felt that the known prior art taken alone or in
combination neither anticipate nor render obvious the present
invention. These citations do not constitute an admission
that such disclosures are relevant or material to the present
claims. Rather, these citations relate only to the general
field of the disclosure and are cited as constituting possible
prior art for consideration.
In U.S. Patent No. 2,537,026, there is disclosed an
apparatus for producing a sheet comprising ribbons of zig-zag
material attached by their longitudinal edges to one or more
sheets of backing material. The apparatus includes cutting
discs for cutting a sheet of paper into a plurality of strips
and a drive mechanism for driving the strips singly into a
compression chamber including a guide arm. This action
corrugates the strips to produce the packaging product, but
the apparatus of U.S. Patent No. 2,537,026 has a number of
disadvantages.
Firstly, the fact that the strips are advanced singly
means that output of the apparatus is slow unless it is
provided with multiple compression chambers. However, it is
believed that the complexity, power consumption and
maintenance requirements of such a machine would, in practice,
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mean that the apparatus could not be operated on a commercial
scale.
Moreover, the strip by strip operation of the apparatus
of U.S. Patent No. 2,537,026 means that mingling of the strips
does not take place to an acceptable extent.
U.S. Patent No. 2,271,180 discloses a packing product
similar to the kind that can typically be produced using the
apparatus of U.S. Patent No. 2,537,026.
It is therefore a general object of the invention to
provide apparatus and methods for rapidly folding large
quantities of shredded strips or strands of sheet material
into continuous or segmented lengths of folded and crimped,
interlocking, bulk packaging material, such apparatus being:
sturdy and durable in design; compact; easily constructed;
inexpensive to manufacture; and economical and simple to
operate.
An advantage is to provide one embodiment of the
invention including apparatus and methods for producing large
quantities of folded and crimped, shredded strips of sheet
material which: avoid interference with the otherwise normal
operation of conventional shredding device; does not require
permanent modification of the shredding device's structure, or
defacement or mutilation thereof; and may be used on any
commercial shredding device, irrespective of its design or
general configuration.
A still further advantage is to provide apparatus and
methods for a commercial shredding device which allows for
quick and easy adjustment of the device to selectively extend
or shorten the length of the shredded, folded, and crimped
strips of sheet material into segment lengths which would
otherwise be commercially impossible, and to do so without
requiring modification of the device's mechanics, or any
careful or critical attention by the operator.
Another advantage is to produce a series of folded
interlocking strips of bulk packaging material which are
produced from colored sheet material and may be made from a
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large variety of different colors or controlled combinations
of colors.
Another advantage is to produce the folded, interlocking
strips from biodegradable pulp materials such as from paper,
cardboard, and the like, the composition of which may be
edible and is approved by the U.S. Federal Food and Drug
Administration (FDA) for use in packaging edible products.
It is also an advantage of the present invention to
provide another preferred machine which is particularly
adapted for and capable of producing the desired packing
product.
It is also an object to provide such a machine which
feeds sheet material to a cutting section for the sequential
folding of longitudinal strip means formed in the cutting
section.
It is a further object of the invention to produce the
strip means of material having a natural resilience so that
the sequential folding causes the strip means to be
longitudinally compressed and capable of resilient expansion
during use.
It is yet another object of the invention to provide an
overall packing product comprising a plurality of intertwined
and intermixed strip means which have been longitudinally
compressed in order to provide overall resilience and
resistance to compression of the packing product.
The present invention achieves these general and specific
objects and presents new apparatus and methods for producing a
bulk packaging material which incorporates therein the
beneficial features of both Styrofoam peanuts and shredded
paper. The present invention also overcomes each of the
previously mentioned disadvantages.
In short, this invention provides apparatus and methods
for rapidly producing large quantities of bulk packaging
material comprising folded and crimped, interlocking strips of
sheet material which may: (a) be used as a resilient padding
to cushion and prevent heavier objects from gravitating toward
the bottom and/or sides of a container, such padding requiring
6
a lesser amount of raw material to form a greater amount of
interlocking bulk packaging material than was previously
available; (b) be produced with selectable lengths, smaller
lengths capable of being gravity fed into a container to fill
the void left by the banning of styrofoam peanuts, larger
lengths capable of being wrapped around a product to provide a
secure protective cushion; (c) be produced in selectable
colors and/or controlled color combinations for decorative and
aesthetic purposes; (d) be manufactured from biodegradable
material, such as pulp material (i.e., paper, cardboard, or
the like); and (e) be edible and/or approved by the U.S.
Federal Food and Drug Administration (FDA) for use in
packaging edible products.
In accordance with one aspect of the present invention
there is provided a method of producing a paper product from a
substantially continuous web of paper, said method comprising
the steps of: transversely cutting the web of paper to define
a leading sheet portion, separating the leading sheet portion
from the rest of the web of paper, longitudinally slitting the
leading sheet portion into a plurality of strips, advancing
the plurality of strips through a common discharge chute, and
sequentially folding each of the plurality of strips into an
accordion shape; wherein the sequential folding step is
accomplished only by restricting the forward advancement of
the plurality of strips in the discharge chute in such a
manner that the natural resilience of the paper produces
substantially uniform adjacent opposite folds thereby causing
each of the strips to assume substantially the same accordion
shape.
In accordance with another aspect of the present
invention there is provided an apparatus for producing a paper
product from a substantially continuous web of paper
comprising: a transverse cutter which cuts a leading sheet
portion of the web of paper, a separating device which
separates the leading sheet portion from the rest of the web
of paper, a slitting device which slits the leading sheet
portion into a plurality of strips, and a common discharge
,~.y.
chute through which the plurality of strips are advanced;
wherein the discharge chute includes means for restricting the
forward movement of the plurality of strips in such a manner
that this means along with the natural resilience of the paper
alone produces substantially uniform adjacent opposite folds
thereby causing each of the strips to assume substantially the
same accordion shape; and wherein the separating device
separates the leading sheet portion prior to the strips being
folded whereby the plurality of strips are of the same
unfolded length.
In accordance with yet another aspect of the present
invention there is provided a packing product comprising:
a plurality of narrow, elongated strip means of flat,
substantially planar material; each of said strip means
including a plurality of folds along a length thereof; and
said plurality of said strip means being intertwined and
interconnected to form a resilient mass of said packing
product.
In accordance with still yet another aspect of the
present invention there is provided a packing product
comprising: a plurality of intertwined and interlocking strip
means of flat, substantially planar material; each of said
strip means including a plurality of folds with said material
having been compressed at each of said folds; and said
plurality of said intertwined and interlocking strip means
with said folds having been compressed therein combining to
provide a resilient mass of said packing product.
In accordance with still yet another aspect of the
present invention there is provided a packing product
comprising: a plurality of narrow, elongated strip means of
flat, substantially planar material; said material having a
natural resilience; and each of said strip means including a
plurality of transverse folds against said natural resilience
to form a longitudinally compressed said strip means; wherein
said longitudinally compressed strip means are intertwined and
interconnected.
~a _
In accordance with still yet another aspect of the
present invention there is provided a packaging product
comprising: a plurality of narrow, elongated strip means of
flat, substantially planar material; said material having a
natural resilience tending to oppose folding thereof; each of
said strip means including a plurality of relatively uniform
folds to be generally accordion shaped; and said plurality of
said strip means being generally compacted against each other
at said folds in opposition to said resilience; wherein said
longitudinally compressed strip means are intertwined and
interconnected.
In accordance with still yet another aspect of the
present invention there is provided a compacted material in a
confined area, said compacted material for being used as a
packing product when released from said confined area, said
compacted material comprising: a plurality of elongated strip
means being formed from a flat, substantially planar material;
each of said strip means having a plurality of folds to be
compacted against itself and against other said strip means of
said plurality of said strip means; and said folds of said
strip means being relatively uniform to form a mass of said
strip means which has an accordion shape; wherein said
plurality of said strip means are intertwined and interlocking
and said mass of said strip means is resilient.
In accordance with still yet another aspect of the
present invention there is provided a compacted material in a
confined area, said compacted material for being used as a
packing product when released from said confined area, said
compacted material comprising: a plurality of elongated strip
means being formed from a flat, substantially planar material;
each of said strip means having a plurality of folds to be
compacted against itself and against other said strip means of
said plurality of said strip means; said folds of said strip
means being relatively uniform to form a mass of said strip
means which has an accordion shape; and said each strip means
including at least two layers of said flat, substantially
planar material.
_ ~b _
In accordance with still yet another aspect of the
present invention there is provided a compacted material in a
confined area, said compacted material for being used as a
packing product when released from said confined area, said
compacted material comprising: a plurality of elongated strip
means being formed from a flat, substantially planar material;
each of said strip means having a plurality of folds to be
compacted against itself and against other said strip means of
said plurality of elongated strip means; and said folds of
said strip means being relatively uniform to form a mass of
said strip means which has an accordion shape; wherein said
each strip means include adjacent longitudinal portions at
respective opposite sides of each of said folds of said
plurality and said adjacent portions extend generally parallel
from said each fold therebetween; each of said adjacent
longitudinal portions is substantially planar; said each strip
means includes at least two layers of said flat, substantially
planar material and said at least two layers within said each
adjacent longitudinal portion are generally parallel.
In accordance with still yet another aspect of the
present invention there is provided a packing product
comprising a strip segment; the strip segment comprising a
plurality of strips made from a paper sheet material; the
paper sheet material having a natural resilience; at least
some of the strips having a compressed zig-zag shape formed
from a plurality of transverse folds against the natural
resilience of the material; and the strips being attached
together to form the strip segment; wherein the plurality of
strips are positioned side by side in the strip segment.
In accordance with still yet another aspect of the
present invention there is provided a packing product
comprising a strip segment; the strip segment comprising a
plurality of strips made from a paper sheet material; the
paper sheet material having a natural resilience; at least
some of the strips having a compressed zig-zag shape formed
from a plurality of transverse folds against the natural
resilience of the material; and the strips being attached
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together to form the strip segment; wherein the strips are
attached together at corresponding forward ends and terminal
ends; wherein the plurality of strips are positioned side by
side in the strip segment.
In accordance with still yet another aspect of the
present invention there is provided a packing product
comprising a strip segment; the strip segment comprising a
plurality of strips made from a paper sheet material; the
paper sheet material having a natural resilience; at least
some of the strips having a compressed zig-zag shape formed
from a plurality of transverse folds against the natural
resilience of the material; and the strips being attached
together to form the strip segment; the strips being attached
together at corresponding forward ends and terminal ends;
wherein the sheet of material comprises multiple layers and
wherein the ends of at least some of the layers are bonded
together.
One embodiment of the invention can comprise an
attachment for a commercial shredding machine or device. Such
an attachment can be a simple, compact, rugged, inexpensive,
movable barrier which is easily attached and employed. In
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this embodiment, the present invention does not necessarily
require the defacement or alteration of the shredding device's
structure. In essence, the attachment modifies the shredding
device to cause a sheet material, such as mylar, paper,
cardboard, or the like, which is fed therethrough, to be
impacted or impelled against a barrier after having passed
through a series of cutting blades in the shredding device.
The barrier causes the shredded sheet material to become
controllably jammed between the barrier and the cutting
blades. The continued rotation of the cutting blades forces
additional amounts of sheet material into the shredding
machine and cutting blades. As a result, each shredded strip
of sheet material is folded against itself in a relatively
controlled manner, thereby, repetitively folding and crimping
or creasing each strip and compacting it within a confined
space or area against a remaining dam of jammed shredded
strips. The resulting effect is the folding or crimping of
each cut strip into an accordion-shaped mass.
The confined area preferably is located near an exit
opening of the shredding device through which the shredded
strips pass.
As pressure builds up behind the confined mass of
shredded strips, a pressure sensitive gate, in one embodiment,
opens to allow the escape of a portion of the jammed strips.
The gate controllably maintains the confinement of a remaining
portion of jammed strips within the confined area. The gate
thus allows the continuation of additional lengths of shredded
sheet material to be folded and pressed against the remaining
dam of jammed strips without the modified device actually
becoming jammed to the point of requiring servicing.
This means for controllably jamming the paper within the
confined area may comprise a simple, movable barrier which is
placed near the exit opening of the shredding device. The
barrier causes the shredded strips of sheet material to
temporarily remain within a confined area located between the
barrier and the cutting blades of the shredding device.
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The confined area may be of a fairly small or large
volume, the boundaries of which are initially defined by the
barrier, the cutting blades, and possibly a lower, upper, and
side support elements. After a partial dam of shredded strips
S has been achieved, the dam itself further limits the volume of
space remaining within the confined area. As long as a
partial dam of shredded strips remains within the confined
area, such shredded strips serve the purpose of the movable
barrier, and may even eliminate the need for continued use of
IO the gate barrier.
In its simplest form, the barrier comprises a movable
gate which is urged toward a closed position. The gate serves
to hinder the exit of the shredded strips and to confine the
strips into a partially jammed state. As additional amounts
15 of sheet material are fed or pulled into the shredding device,
the expelling force of the shredding device forces the
shredded strips into the confined area. Once the pressure
forcing the jammed strips into the confined area overcomes the
means for urging the gate into a closed position, the gate is
20 urged open to allow a portion of the folded and crimped strips
to escape.
Various methods and apparatus may be used to urge the
gate toward its closed position and thereby retain the
shredded strips within the confined area. For example, a
25 weighted, hinged gate may be used. Other embodiments include
the use of a pivotal gate which is urged toward its closed
position by a spring or by a hydraulic or pneumatic piston.
Once the folded and crimped strips of sheet material are
formed, the strips may be deposited within a receiving bin.
30 Alternatively, upon leaving a confined area, located
immediately adjacent to the cutting blades, the compressed
state of the folded and crimped strips may be maintained by
forcing the strips to travel through a confined conduit. A
second cutting device or shearing device may be located at
35 some point along the length of the confined conduit or at the
end thereof. The shearing device may be engaged to cut or
shear the compacted, folded and crimped strips into segments.
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Continued insertion of additional lengths of sheet
material into the shredding device at a regulated rate
naturally causes the folded strips to exit the shredding
device at a similar regulated rate. If the strips are passed
through the confined conduit and a shearing device is used,
the shearing device may be activated at preselectable time
intervals to shear, cut, or dissect the compressed, crimped
strips travelling within the confined conduit into various
segment lengths. This process enables the formation of
crimped strips of material having any desired length from 100
foot lengths or greater to segments of one or two inches or
smaller.
If a plurality of layers of sheet material are passed
through the shredding device at one time, the shearing device
forces each layer against an adjacent layer with a tremendous
force. This force is necessary to cause the multiple layers
of sheet material to shear. Such compression, however, has an
added benefit of sealing together or partially bonding the
sheared ends of the juxtaposed and sheared strips. The
bonding of each overlapping layer of sheet material to the
proximately juxtaposed sheet material assists in maintaining
the structural integrity the interlocking folded and crimped
strips. Thus, a plurality of layered, shredded, folded and
crimped strips of sheet material may be cut into short
segments that are bonded at each terminal end thereof. These
shorter segments serve very well to replace the use of
Styrofoam peanuts. Such shorter segments may also be used in
existing gravity feed systems.
Longer lengths of the shredded, folded and crimped strips
may be used for decorative effects at parties and/or windcw or
room displays.
The longer lengths of the folded strips may also be used
as bulk padding and packing material. When so used, the
object to be protected may be liberally and literally wrapped
within multiple lengths of interconnecting and interlocking
folded and crimped, shredded strips.
2 X7214 7
Because the ridges of the paper strips interlock with one
another, the strips hold their form and greatly increase the
volume of space they occupy. Thus, the use of a smaller
amount of paper is required to protect a particularly packaged
object. The shock absorbency of the packing material is also
substantially increased, since the impact of a blow is
dispersed throughout each interacting ridge or web of the
interconnecting folded strips. The folded and crimped status
of the strips of the present invention allows for a
substantially greater degree of interlocking effect and shock
absorbency than do the kinked strips described in U.S. Patent
Nos. 2,621,567; 2,686,466; and 2,770,302.
If paper sheet material is used, the longer lengths of
crimped, shredded strips may be placed within a retainer bin
or hopper and a selected amount of bulk packaging material may
be torn therefrom. This enables an operator to use an exact
amount of desired packaging material, and thereby reduce
waste.
Another important, added benefit of the present invention
is the ability to use a variety of colors in the production of
the shredded, folded and crimped strips. This enables the
inventor to produce bulk packaging material of the present
invention having the chosen colors of a particular store,
company, or corporation. This is accomplished by simply using
a sheet material having the desired color.
A combination of colors may also be used. Two or more
differently colored sheets of material may be passed into the
shredding machine to produce a variety of color combinations.
The only limiting factor is the capacity of the shredding
machine. For example, a first percentage of one color (such
as 230 of dark blue) and a second percentage of another color
(such as 770 of light blue) may be used. Thus, folded and
crimped strips of packaging material may be produced with any
number of colored sheet material combinations.
Printed, embossed, or any other means of identification
may also be affixed to the sheet material which is shredded.
Preferably, such printing locates the printed matter
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longitudinally along each length of shredded strip. Thus, a
store, company or corporation may have its name, logo,
trademark, or other subject matter, listed along each
individually crimped strip.
Another important benefit is that recyclable,
biodegradable sheet material may be used. By using pulp
materials, such as paper and/or cardboard which breakdown and
decompose quickly, the detriment to the environment by
disposal of such material is minimized.
Depending upon the composition of the sheet material, the
environment may even be enhanced by the discarding of such
packaging material. For example, fertilizers or other
beneficial additives may be incorporated into the sheet
material. These benefits are in stark contrast to the damage
caused by the disposal of Styrofoam peanuts.
Existing apparatus and methods for packaging food
products often cause substantial damage to the very products
they are intended to protect. For example, existing apparatus
and method for packaging flash frozen fish often cause
scarring to appear on the fish. This difficulty is greatly
overcome by the present invention because when the folded and
crimped strips of the present invention are made from paper
and are exposed to moisture, the folded strips conform to the
contour of the object being packaged. This provides a more
uniform and larger support framework for the object and
scarring is eliminated, or at least substantially reduced.
Edible sheet material and sheet material which has been
approved by the U.S. Food and Drug Administration (FDA) for
use in packaging edible, or at least consumable, products may
also be used. Thus, the wholesale and retail food industries
are now provided with apparatus and methods for packaging food
products which have been hence unavailable.
Additional uses for the crimped sheet material include
using it as bulk material for starting worm composts and/or
animal bedding.
The apparatus which produces such a universal bulk
packaging material is inexpensive, and is easily manufactured.
2U72147
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Operation of the apparatus is also extremely simplistic and
may be accomplished by an unskilled worker.
The various advantages of the invention are provided by a
method of producing a paper product from a sheet of paper,
said method comprising the steps of: feeding the sheet of
paper in a longitudinal direction; cutting the sheet of paper
into a plurality of strips, whereby to form a body of such
strips, said cutting being performed by rotating at least two
sets of cutting discs; and sequentially folding each of the
strips into a zig-zag shape, characterized in that said
sequentially folding step is accomplished by advancing the
plurality of strips against a restricting means acting on the
body of strips in such a manner that the natural resilience of
the paper produces substantially uniform adjacent opposite
folds thereby causing each of the strips to assume
substantially the same zig-zag shape.
The sequential folding can occur adjacent the outer
surface of the corresponding one of the cutting discs in a
first of the two sets and between adjacent cutting discs in a
second of the two sets. The sequential folding is preferably
against a natural resilience of the material of the strip
means.
The sequential folding produces a plurality of folds of
the strip means with adjacent folds being in opposite
directions. The sequential folding of the plurality of folds
is against natural resilience of the material to produce
biasing at each of the folds tending to separate adjacent
longitudinal portions of the strip means which are adjacent to
each fold. The sequential folding of each strip means
produces a longitudinally compressed strip means. The method
further includes primarily collecting a plurality of the
longitudinally compressed strip means between the two sets of
cutting discs after the cutting and sequential folding. The
method further includes additional collecting of an additional
plurality of the longitudinally compressed strip means in a
discharge chute remote from the two sets of cutting discs.
The additional collecting produces resistance to movement of
-w 2 ~ 7 214 7
_ 1a_ _
the plurality of longitudinally compressed strip means from
the collecting and the collecting of the longitudinally
compressed strip means causes the restricting of each strip
means to cause the sequential folding.
The feeding includes simultaneously feeding a plurality
of the sheets of material, the cutting of each strip means
produces layers of strips of the material in the strip means,
and the sequential folding causes substantially aligned folds
of the plurality of folds respectively in each strip of the
layers of strips.
The method includes the feeding which includes directing
the material from a roll toward the two sets of cutting discs
and transversely cutting the material in a direction which is
transverse to the first direction to provide each of the at
least one sheet of material prior to the cutting. The
directing includes simultaneously directing a plurality of
layers of the material and the transverse cutting forms a
plurality of sheets of the material for the cutting.
The various advantages are also provided by apparatus for
producing a paper product from a sheet of paper, said
apparatus comprising: means for feeding the sheet of paper in
a longitudinal direction; and means for longitudinally cutting
the sheet into a plurality of strips, whereby to form a body
of such strips, said means for cutting including at least to
rotating sets of cutting discs, characterized by the inclusion
of means for advancing the plurality of strips against a
restricting means acting on the body of strips in such a
manner that the natural resilience of the paper produces
substantially uniform adjacent opposite folds in each of the
strips thereby causing the strips to assume substantially the
same zig-zag shape.
The means for feeding can include means for initially
directing the material from a supply of the material and means
for transversely cutting the material to form the at least one
sheet of material. The means for feeding can be for feeding a
plurality of layers of the material in the at least one sheet
2'D72147
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of material. Each of the cutting discs can include a
cylindrical outer surface.
The preferred means for cutting includes a plurality of
combers, each of the combers of the plurality being
respectively aligned with each of the cutting discs, each
comber having a facing end which is adjacent the strip means
after formation thereof by the means for cutting, and the
facing ends of the combers defining an area of passage of the
strip means through the means for cutting. The facing ends of
the combers can be substantially parallel.
The means for restricting each strip means includes a
discharge chute extending from the means for cutting. The
apparatus can further include means for adjusting the means
for restricting each strip means. The discharge chute can
include wall means and the means for adjusting can include
means for angularly adjusting the wall means of the discharge
chute. The combers can include extensions for directing each
strip means substantially in the first direction into an
interior of the discharge chute.
A packing product manufactured in accordance with the
invention comprises: a plurality of narrow, elongate strip
means of material, the material having a natural resilience;
and each of the strip means including a plurality of
transverse folds against the natural resilience to form a
longitudinally compressed strip means, the longitudinally
compressed strip means being interlocked and biased to expand
longitudinally. A majority of the folds includes an acute
angle. The material of the longitudinally compressed strip
means can include a plurality of layers. The longitudinally
compressed strip means are biased to longitudinally expand.
The longitudinally compressed strip means are intertwined and
interlocked to combine and form a resilient mass of the
packing product. Each of the longitudinally compressed strip
means includes substantially planar portions adjacent to each
of the folds of the plurality of folds. Each longitudinally
compressed strip means can include a predetermined width
dimension and a majority of the planar portions can include a
-w 2 ~7 214 7
- 16 -
length dimension which is between the predetermined width
dimension and twice the predetermined width dimension.
There now follows a description of preferred embodiments
of the invention, by way of example, with reference being made
S to the accompanying drawings in which:
FIG. 1 is a simplified, partial, cross-sectional, side
elevational view of one preferred embodiment of the present
invention wherein a hinged gate is shown located in a closed
position to serve as a barrier.
FIG. 2 is a simplified, partial, cross-sectional, side
elevational view of the apparatus shown in FIG. 1, wherein the
gate is urged away from its closed position.
FIG. 3 is an enlarged, partial, cross-sectional, side
elevational view of the gate in its closed position.
rFIG. 4 is an enlarged, fragmentary, cross-sectional,
front elevational view taken along line IV-IV in FIG. 1.
FIG. 5 is an enlarged, fragmentary, isometric view of the
preferred embodiment shown in FIG. 1.
FIG. 6 is a simplified, isometric view of a plurality of
bonded segments of folded, crimped, interlocking strips of
shredded. sheet material which is a product of the present
invention.
FIG. 7 is a simplified, isometric view of a plurality of
folded, crimped, interlocking strips of shredded sheet
material as produced by the present invention.
FIG. 8 is a side elevational view of another preferred
embodiment including various features of the present
invention.
FIG. 9 is a fragmentary, sectional view of the embodiment
of FIG. 8.
FIG. 10 is a fragmentary, top view of the discharge
section of the preferred embodiment of FIGS. 8 and 9.
FIG. 11 is an enlarged, fragmentary view of the cutting
area of the embodiment of FIGS. 8, 9 and 10.
FIG. 12 is a fragmentary, sectional view as seen along
line XIII-XIII of FIG. 10.
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FIG. 13 is a fragmentary, sectional view as seen along
line XIV-XIV of FIG. 10.
FIG. 14 is a fragmentary, side view of a generally
compressed preferred strip of material including various
features of the invention which can, for example be made by
the embodiment of FIGS. 8, 9 and 10.
FIG. 15 is a fragmentary, side view of a generally
compressed acceptable strip of material including various
features of the invention which, for example, can also be made
by the embodiment of FIGS. 8, 9 and 10.
FIG. 16A is a fragmentary, side view of a single-faced or
one-sided corrugated cardboard material in sheet form or being
supplied, for example, to the feeding section of the
embodiment of FIGS. 8, 9 and 10.
FIG. 16B is a fragmentary, side view of a generally
compressed strip of the invention formed of the material of
FIG. 16A.
FIG. 17 is a fragmentary, isometric view of a narrow
section of the sheet material including another feature of the
invention to be made, for example, by the embodiment of
FIGS. 8, 9 and 10.
One should understand the drawings are not necessarily to
scale and the elements are sometimes illustrated by graphic
symbols, phantom lines, diagrammatic representations, and
fragmentary views. In certain instances, the drawings have
omitted details which are not necessary for an understanding
of the present invention or which render other details
difficult to perceive. For example, the preferred embodiment
of Figures 1 and 2 typically includes cutting blades which are
mounted for rotation on two parallel shafts and which have
serrated cutting edges, neither of which are specifically
shown in the drawings. Additionally, the embodiment of
Figures 1 and 2 generally employs the type of cutting or
shredding machine which typically includes comb teeth,
spacers, combers or strippers between the cutting blades on
each rotating shaft but have also been eliminated to simplify
the drawings.
._ , 2D721~7
- 18 -
Referring to the drawings and particularly to Figure 7,
wherein like numerals indicate like parts, the prior art
generally teaches that sheets of paper may be cut into
elongated strips 20. Strips 20, however, do not provide very
much resiliency or forgiveness when subjected to a blow or
other mistreatment. A large number of strips 20 are required
to fill a given empty space.
Figure 8 illustrates a plurality of shredded, elongated,
interconnecting strips 22 which have been folded and crimped
using the apparatus and methods as taught herein. The folds
within crimped strips 22 interlock with one another to form a
resilient mass of intertwined and interconnected strips of
decorative or bulk packaging material. The folds also form a
variety of differently angled flanges and/or webbing which
distribute any blow or impact received in a dispersed manner
throughout each interconnecting fold of the interlocked
crimped strips 22. Such folds also cause crimped strips 22 to
occupy a greater volume of space, using a smaller amount of
sheet material, than would otherwise be required.
Figure 6 illustrates a plurality of shredded, elongated,
interconnecting strips 22 which have been folded, crimped, and
sheared into strip segments 23. Strips 22 have also been
bonded together at a forward terminal end 24 and a rearward
terminal end 26 thereof to form strip segment 23.
Figure 1 illustrates one preferred embodiment of a
crimping apparatus 30 which may be attached to a readily
available commercial shredding device 32 which is shown in
simplified form. In one embodiment of the invention, any
appropriate shredding device 32 may be used.
Various shredding devices 32 are well known in the prior
art and need not be further described herein except to mention
that sheet material 34 is fed into a plurality of parallel
cutting blades 36 and 38 which rotate therein, cutting sheet
material 34 into a plurality of strips 20.
A conveyor belt 40 may be used to support and urge sheet
material 34 into cutting blades 36 and 38. Conveyor belt 40
may be free rolling or be powered by a motor (not shown).
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Preferably, in the embodiment of Figures 1 and 2, the
cutting blades 36 and 38 are serrated cutting blades which
facilitate easy shredding of sheet material 34 and which
assist in pulling sheet material 34 into shredding device 32
once sheet material 34 engages cutting blades 36 and 38.
When passed between cutting blades 36 and 38, sheet
material 34 is cut into elongated strips 20 which are then
directed toward, and expelled outwardly from, an exit opening
42 of shredding device 32. Strips 20 are generally expelled
through exit opening 42 at a very rapid rate. In this
preferred embodiment, strips 20 are expelled from exit opening
42 along a path generally indicated by arrow 43 at a rate of
about 125 feet (38.1 meters) per minute.
Crimping apparatus 30 is primarily a simple, durable,
easily constructed, and inexpensive attachment for shredding
device 32 which may be easily attached and employed.
Attachment of crimping apparatus 30 to or near shredding
device 32 may be accomplished by any appropriate means, and
does not necessarily require permanent modification or
defacement of shredding device 32. For example, crimping
apparatus 30 may be attached or secured to an elevated stand
or support member 44, which is attached to an underlying
structure (not shown) and/or has sufficient weight to resist
movement. The bulk of the weight of crimping apparatus 30 may
rest upon support member 44. Thus attached, crimping
apparatus 30 may be properly positioned near exit opening 42
without even being attached to shredding device 32.
Alternatively, crimping apparatus 30 may be physically
secured to shredding device 32. For example, crimping
apparatus 30 may be removably attached to a structural
framework 45 of shredding device 32 by any appropriate support
means. As shown in Figures 1 and 2, crimping apparatus 30 is
removably attached to the enclosure of shredding device 32,
such as to a rear wall 46, by means of a supporting bracket
47, such as a section of angle iron. Means for removably
attaching supporting bracket 47 to crimping apparatus 30 and
to structural framework 45 of crimping apparatus 32 may
2~ - 2 D72 i 4 7
comprise a plurality of removable screws 48, bolts, or the
like. If used as an optional or retrofit attachment, crimping
apparatus 30 is positioned adjacent to exit opening 42. If
space within shredding device 32 allows, a forward end 50 of
crimping apparatus 30 is positioned immediately adjacent to an
expulsion side of cutting blades 36 and 38.
Shredding device 32 may also be specifically designed to
incorporate therein the subject matter of this invention,
alleviating the need for an attachment.
Crimping apparatus 30 modifies shredding device 32 to
cause sheet material 34, which may be made of mylar, paper,
cardboard, or the like, and is fed therethrough, to be
initially impacted or impelled against a barrier 60 after
passing between cutting blades 36 and 38. Barrier 60 causes
the shredded strips 20 to assume a partially jammed state
within a compression chamber or confined area 62 located
between barrier 60 and cutting blades 36 and 38.
Continued shredding of additional sheet material 34 by
shredding device 32 forces additional elongated strips 20 into
confined area 62 forming a dam or temporarily jammed strips
20. Once a dam of shredded strips 20 is formed, the front of
the dam, which is located most closely to cutting blades 36
and 38, serves itself as a barrier 60'. As additional amounts
of sheet material 34 are fed or pulled into shredding devices
32, the expelling force exerted by cutting blades 36 and 38
forces strips 20 into confined area 62. As strips 20 are
forced against barriers 60 or 60', strips 20 are confined
within confined area 62 and are forced to fold against
themselves in a relatively controlled manner. Such folding
and further insertion of strips 20 into confined area 62,
causes the folded strips to become compacted against
themselves and each other, thereby creating crimped strips 22.
The compaction of strips 20 within confined area 62 causes
strips 20 to be crimped at each fold. Continued insertion of
strips 20 into confined area 62 against barrier 60 or 60'
repetitively, and relatively uniformly folds and crimps each
strip 20 into an accordion-shaped mass of crimped strips 22.
2'672141
- 21 -
The function of crimping apparatus 30 is to serve as a
pressure sensitive barrier 60 which is capable of temporarily
damming the passage of strips 20 which are expelled from
shredding device 32. Toward this end, crimping apparatus 24
is provided with a means for urging barrier 60 toward a closed
position.
In its preferred embodiment, barrier 60 comprises a
compression door or gate 70 having a closed position located
within a generally vertical plane, and an open position,
located within a generally horizontal plane. Figures 1 and 3
illustrate gate 70 in a closed position. Figure 2 shows gate
70 in an open position.
Initially gate 70 is urged towards its closed position by
an urging means 72. Urging means 72 may comprise a spring, a
weight, or a pneumatically or hydraulically controlled piston
74 which is connected to gate 70 by a linkage means 76. The
farce exerted by urging means 72 upon gate 70 may be
controlled by either the type of characteristics of the spring
that is used, or by a valve means 78 that is attached to
piston 74. If piston 74 is used, a fluid or air pressure
reservoir 80 may also be provided and appropriately connected
to the piston by means of a hose 82. Electronic pressure
sensors may also be used to determine the amount of pressure
which is being exerted upon gate 70 and to activate and/or
release urging means 72 when needed.
Figures 3 and 4 illustrate the attachment and function of
gate 70, linkage means 76, and piston 74. Gate 70 spans the
width of confined area 62 and is attached to a compression
door shaft or pivotal rod 84. Pivotal rod 84 allows gate 70
to rotate between its open and closed position. Pivotal rod
84 may pass through side walls 86 and 88 which help define
confined area 62. Pivotal rod 84 may be operationally secured
to linkage means 76 by a key element 90 which is placed within
a keyway 92 provided within pivotal rod 84 and linkage means
76. Linkage means 76 may comprise an angle arm as illustrated
in Figures 1 through 5. Linkage means 76 is secured to
pivotal rod 84 by means of a locking nut 94 having a cotter
2D72147
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pin 96 located therein to prevent loosening of locking nut 94.
Linkage means 76 is then connected to a second rod 98 or
connector rod by means of a pair of nuts 99 and 99'. Second
rod 98 is attached to a first end 100 of piston 74. A second
end 102 of piston 74 is connected to either the structure of
crimping apparatus 30 itself, or to any'other element which
will facilitate the operation of piston 74. Figure 3
illustrates second end 102 of piston 74 being attached to an
upper wall 104, which further defined confined area 62, by
means of a pin 106 and support brace 108.
A recess 110 may be provided within upper wall 104
adjacent to pivotal rod 84 so that gate 70 may be retained
therein when located in its open position. Thus, pivotal rod
84 and gate 70 do not obstruct the flow of crimped strips 22
when gate 70 is located in its open position.
In this preferred embodiment, confined area 62 is defined
by gate 70, side walls 86 and 88, upper wall 104, and lower
wall 112, and by cutting blades 36 and 38. However, once a
dam of partially jammed crimped strips 22 are located within
confined area 62, the frictional resistance between crimped
strips 22 and the interior surfaces of upper wall 104, lower
wall 112, and side walls 86 and 88, provides sufficient
retaining force to eliminate the need for gate 70. At this
point, gate 70 may be automatically or manually raised to its
open position as shown in Figure 2. The remaining dam of
crimped strips 22 serves the function of gate 70. Therefore,
the use of gate 70 is required only temporarily, until a
sufficiently large dam of partially jammed crimped strips 22
are contained within confined area 62.
Given the above statements, barrier 60 may comprise any
obstacle which will cause a sufficiently large amount of
crimped strips 22 to become partially jammed within confined
area 62 to the point that the frictional resistance along the
interior sides of confined area no longer require the use of
barrier 60. Therefore, an alternative embodiment of barrier
60 may be a simple board or other object which temporarily
simulates the occurrence of a jammed state. For example, a
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- 23 -
segment of wood, cardboard, or anything else that temporarily
fills the void within confined area 62 will serve this
function. A board may be used for this purpose. Or,
alternatively, a given amount of previously produced strips 20
or 22 may be forced into confined area 62 to begin the above
described process.
In addition, if it is desirable to increase the amount of
frictional resistance between the crimped strips 22 and the
interior side, upper, and lower walls of confined area 62, the
volume of confined area 62 may be reduced. Thus the same
amount of sheet material 34 would be forced through a smaller
area of confined area 62. This may be accomplished by
providing lower wall 112 with a means 114 for raising lower
wall 112 with respect to upper wall 104 and to side walls 86
and 88. For example, as shown in Figures 1 and 2, support
member 44 may be provided with a vertically oriented bolt
extending therefrom which may be rotated to force lower wall
112 upward with respect to the remaining elements of crimping
apparatus 30.
In the preferred embodiment, upper, lower and side walls
104, 112, 86, and 88 are made from aircraft LEXAN (Trade
Mark), which is a very workable transparent material that
enables an operator to view the status crimping apparatus 30
as a glass. Other materials such as steel, aluminum, wood,
plastic, or the like may also be used.
Once crimped strips 22 have been formed they may pass
through confined area 62 and be deposited with a receiving bin
116. If needed, a chute or ramp 118 may be used to facilitate
the movement of crimped strips 22 toward and into receiving
bin 116.
The length of crimped strips 22 may also be limited. For
example, if sheet material 34 has a limited length, then once
such sheet material 34 passes through shredding device 32 and
crimping apparatus 30, the crimped strips 22 that are formed
will necessarily have a limited length.
Alternatively, continuous lengths of sheet material 34
may be passed through shredding device 32 and crimping
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- 24 -
apparatus 30. The compacted state of the folded, crimped, and
compressed strips 22 may be maintained through crimping
apparatus 30 by means of requiring crimped strips 22 to travel
along a path having a generally confined area. A cutting,
chopping, or shearing device 120 may then be engaged at
preselected intervals to cut the compressed strips 22 into
strip segments 23. As shown in Figures 1 and 2, shearing
device 120 may utilize a blade 122 to cut compressed crimped
strips 22.
The length of crimped strips 22 may be controlled by:
regulating the rate of passage of strips 22 through crimping
apparatus 30; and/or regulating the rate or time interval
between which blade 122 cuts strips 22. Thus, crimped
strips 22 may be produced with lengths exceeding 100 feet
(30.48 meters) or more or with lengths of less than one inch
(2.54 cm) .
As has been explained above, the chopping or shearing of
multiple layers of crimped strips 22 may compress such layer
so strips 22 against one another to an extent that bonding
between the strips 22 occurs. Thus strip segments 23 may be
produced.
The preferred method of producing crimped strips 22
comprises the following steps: (a) passing shredded sheet
material 34 in strip form into confined area 62; (b)
controllably preventing the exit of the strips of sheet
material 34 from confined area 62; and (c) passing additional
strips of sheet material 34 against a portion of the
previously confined strips of sheet material 34 to cause such
strips of sheet material 34 to fold against itself and thereby
become folded and crimped into a generally accordion-shaped
strip.
An additional step may comprise the step of cutting
crimped strips 22 into various segments.
As seen in Figures S to 11, another preferred embodiment
of the invention is provided in the form of a machine 200 for
forming the preferred packing product. The preferred machine
200 includes a feeding section 202, a cutting section 204 and
- 25 - 2072147
a discharge section 206. The feeding section 202 is provided
to feed one or more sheets of material to the cutting section
204 to be longitudinally cut thereby. The strip means cut by
the cutting section 204 are then discharged from the cutting
section 204 to the discharge section 206.
To provide basic power to the machine 200, a feeding
motor 208 is included in the feeding section 202. The feeding
motor 208 has an associated reduction gear section 210 with a
reduction gear output in the form of a drive sprocket 212.
For powering the cutting section 204, a cutting motor 214 is
provided with an associated reduction gear section 216. The
output of the reduction gear section 216 is in the form of a
drive sprocket 218.
To initiate the operation of the machine 200, a base
material for forming the preferred packing material is
preferably supplied in roll form (not shown) to provide cne or
more layers of the material to the feeding section 202. As
seen in Figure 8, the material is initially directed for
alignment through redirecting rollers 219. Although not
specifically duplicated in Figure 9, three layers of the
material are preferred.
As seen in Figure 9, the feeding section 202 is
configured for advancing the material in a first direction A.
However, the preferred machine 200 is different from the
embodiment shown in Figures 1 and 2. It has been determined,
for machine 200, that it is advantageous to provide pre-cut
sheets of the material rather than transversely cutting the
packing material after it is formed. Accordingly, a first
drive roller 220 feeds the material to a transverse cutting
component 222. The transverse cutting component 222 includes
four rotating cutting blades 224 which are mounted for
rotation on a shaft 225. A backup cylinder 226 is in
alignment with the shaft 225 and includes neoprene sections
228 for specific alignment and cooperation with the blades
224.
Although not shown in the Figures, each of the blades 224
includes a generally serrated edge but also includes several
- 26 - 2~72i 4l
gaps along the lengths thereof in order to provide only a
partial cut of the material as it is transferred thereunder.
With the material being only partially cut, it is advanced to
a second drive roller 230 for further direction to the cutting
section 204. To maintain the material in position for
advancement to the transfer cutting component 222, the first
biased roller means 221 is biased toward and in alignment with
the first drive roller 220. A second biased roller means 231
is biased toward and in alignment with the second drive roller
230.
The first drive roller 220, the backing cylinder 226 and
the second drive roller 230 all rotate at the same rotational
speed. Each of the components in the feeding section 202 are
preferably greater than 15 inches (38.1 cm) wide in order to
provide the material to the cutting section 204 which, as will
be seen, is also capable of accommodating material 15 inches
wide. The first drive roller 220 is preferably knurled or
rough to provide sufficient friction for advancing the
material therethrough while the second drive roller 230 is
preferably smooth. Additionally, the second drive roller 230
has a slightly larger diameter than the first drive roller 220
in order to keep the material tight for proper partial cutting
by the transverse cutting component 222. Because of the
smooth surface for roller 230, the additional tension created
by the slightly larger second drive roller 230 is not
sufficient to actually tear or separate the resulting sheets
238 of material simply by the action of the drive rollers 220,
230.
The means for providing the rotation of the first drive
roller 220, the cutting blade shaft 225, the backing cylinder
226, and the second drive roller 230 is shown in Figure 8.
With the basic power being provided by the feeding motor 208,
the second drive roller 230 includes a driven sprocket 232
rigidly mounted on the end thereof for driving connection with
a chain drive 213 from the drive sprocket 212. A gear 232a on
the shaft of the second drive roller 230 is in engagement with
and rotates a first idler gear 233 mounted on the side housing
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of the feeding section 202. The first idler gear 233 is in
turn in engagement with a gear 234 associated with the backing
cylinder 226. The gear 234 is in engagement with a second
idler gear 236 and with a larger gear 238 connected to the
rotating shaft 225 of the cutting blades 224. The gear 238
has a diameter which is twice that of the gear 234 in order to
produce rotation of the shaft 225 at one half of the speed of
the backing cylinder 226. Consequently, the four cutting
blades 224 are brought into alignment with the two neoprene
sections 228 of the backing cylinder 226 as they rotate at
correspondingly different speeds. The second idler gear 236
is in engagement with and rotates the drive gear 237 on the
end of the first drive roller 220. With the directional
rotation of each sprocket and gear as indicated by the small
arrows on Figures 8 and 9, it can be seen that the roll of
material will be fed towards the cutting section 204 by the
feeding section 202.
In the preferred machine 200, the feeding motor 208 is a
variable speed, five horsepower motor with the reduction gear
section 210 having a reduction gear ratio of ten to one. The
motor 208 is preferably set to produce a feeding of the
material having a width of between 8 inches (20.32 cm) to
about 15 (38.1 cm) inches at a speed of about 360 feet
(109.73 meters) per minute. The spacing of the cutting blades
224 around the shaft 225 is such that the partial cut is
produced every 4.4 inches (11.18 cm) along the length of the
material. Accordingly, the preferred sheets 238 to be fed to
the cutting section are 15 inches (38.1 cm) wide and 4.4
inches (11.18 cm) long.
The cutting section 204, as best seen in Figures 8, 9, 10
and 11, includes an upper and lower set of overlapping cutting
discs 240, 242. The upper cutting discs 240 are fixedly
mounted for rotation on a shaft 241 while the lower cutting
discs 242 are fixedly mounted for rotation on a shaft 243.
The lower shaft 243 includes a driven sprocket (not shown) and
is connected by a chain 219a to the drive sprocket 218 of the
cutting motor 214. The shafts 241, 243 are coupled by
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- 28 -
matching gears (not shown) for corresponding rotation in the
opposite direction as generally indicated by the arrows B.
The overlapping and interengagement of the discs 240, 242 are
such that adjacent cutting discs 240, 242 on their respective
shafts 241, 243 are separated one from the other for receipt
of a cutting disc 242, 240 on the other shaft 243, 241
therebetween. The array of overlapping cutting discs 240, 242
are capable of receiving therebetween each sheet 238 of the
material, whether there is one or more layers, from the
feeding section 202. Once directed between the cutting discs
240, 242, the sheets 238 are longitudinally cut, in the
direction A, into strip means with each strip means including
a corresponding number of layers as the original sheets 238
supplied by the feeding section 202.
The sheets 238 are generally cut to form elongated strip
means associated with each cutting disc 240, 242. The cuts
are produced between the side edges of each cutting disc 240
and the adjacent side edges of the adjacent cutting disc 242.
The strip means produced by the cutting discs 240, 242 are
generally maintained in alignment for passage through the
cutting section 204 by an array of combers 244 associated with
each set of cutting discs 240, 242.
Each comber 244 includes a central opening 245 for
receipt of the corresponding shaft 241, 243 therethrough. The
combers on one shaft 241, 243 are laterally or transversely
aligned with corresponding cutting discs 242, 240 on the other
shaft 243, 241. Each comber 244 is mounted on and supported
by transverse bars 246 extending across the cutting section
204 through corresponding holes in the end of the comber 244.
Despite the support by the rods 246, the preferred combers 244
are capable of limited movement along the shafts 241, 243 in
the same manner as the cutting discs 240, 242.
Most significantly, each of the combers 244 includes an
end face 248 in alignment with the corresponding cutting disc
240, 242 on the opposite shaft 241, 243. The configuration of
cutting discs 240, 242 and aligned end faces 248 of the
combers 244 produces a general region for restricted movement
2 p72 ~ 47
- 29 -
of the strip means formed by the cutting section 204 as the
sheets 238 pass therethrough. The aligned end face 248
terminates at an extension 250 of each comber 244 at the
discharge side of the cutting section 204. The purpose of the
extensions 250 will be discussed hereinbelow.
The cutting section 204 is powered by the motor 214 which
is preferably fifteen horsepower with variable speed control
and includes the reduction gear 216 with a six to one
reduction ratio. Each of the cutting discs 240, 242 is about
1/8 of an inch (.32 cm) wide. Accordingly, each cutting shaft
241, 243 includes at least sixty cutting discs 240, 242
thereon to provide a total of at least one hundred and twenty
cutting discs 240, 242 for the two sets to produce the desired
cutting of the sheets which are 15 inches (38.1 cm) wide.
Preferably, the speed of the motor 214 is adjusted to provide
a speed at the outer cylindrical surface of each cutting disc
240, 242 of about 380 feet (115.82 meters) per minute. In
other words, the cutting discs 240, 242 are rotating at a
linear speed faster than the second drive roller 230. As a
result, the faster speed of the cutting discs 240, 242 causes
them to grab the sheets 238 as they enter therebetween and
causes each sheet to be pulled from its following adjacent
sheet 238 to separate the partially cut sheets for advancement
through the cutting section 204. As seen in Figure 10, the
separation has not yet occurred and tends to occur as the
sheet 238 is leaving the second drive roller 230. It is
desirable for the drive roller 230 to maintain contact with
the following adjacent sheet 238 in order to maintain the
tension on the material for transverse cutting. Consequently,
each sheet 238, whether having a single or multiple layer of
material, will be longitudinally cut in the cutting section
204 prior to the entrance of the next available sheet 238 into
the cutting section 204.
It should be clear, from the discussion of the embodiment
of Figures 1 and 2, that the preferred machine 200 must also
include some means for restricting the movement of the strip
means after their formation in the cutting section 204.
2~72i ~7
- 30 -
Accordingly, the discharge section 206 is aligned with the
cutting section 204 and primarily includes a discharge chute
260. The discharge chute 260 is maintained in position by
framing 258 which is secured at opposite sides of the cutting
section 204. The preferred discharge chute 260 is primarily
formed of plexiglass or some other durable clear plastic
material such as that described for the embodiment of
Figures 1 and 2.
The discharge chute 260 includes a lower wall 262 and an
upper wall 264 with two side walls 266 therebetween. To
generally support the discharge chute 260, a pair of lower
brackets 268 are secured to the framing 258 to receive and
support the lower wall 262 thereon. The leading end of each
side wall 266 is movably secured between the lower wall 262
and the upper wall 264 by bolt means 276. To apply pressure
to the lower wall 262 and the upper wall 264 for complete
retention of the side walls 266 therebetween, there is
provided adjustable bracketing at the top of the framing 258
for creating a downward force on the upper wall 264.
Specifically, brackets 270 extend across the top surface of
the upper wall 264 and are maintained in place by adjustable
bolt means 274 which extend through a rigid bar 272 secured
between the side framing 258. Basically, the bolt means 274
are intended, through the brackets 270, to apply reinforcing
pressure to the upper wall 264 and the lower wall 262 while
also providing significant frictional force on the upper and
lower surfaces of the side walls 266.
This means of applying pressure to the side walls 266 is
significant when it is understood that the preferred discharge
chute 260 can be adjusted to accommodate sheets of material
having different widths as the strip means formed thereby are
discharged from the cutting section 204. In other words, the
discharge section 206, as shown in Figure 11, is intended to
receive the strip means formed from sheets of material which
are about 15 inches wide. However, the feeding section 202
and the cutting section 204 could reasonably accommodate
sheets of material as narrow as 8 inches (20.32 cm). However,
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1
to provide for proper discharge through the discharge section
206, the preferred chute 260 must be adjusted for producing
sufficient resistance to the strip means discharged from the
cutting section 204. To provide for increased resistance in
the discharged section 206, the mounting of the side walls 266
by the bolt means 276 allows the trailing end of each side
wall 266 to be rotated to cause the discharge chute 260 to
have a narrowing profile: Specifically, if the side walls 266
are to be configured with a narrower profile for the
fabrication of strip means from narrower sheets of material,
the bolts 274 can be loosened to reduce the pressure between
the brackets 268, 270. With the force reduced on the upper
wall 264 and the lower wall 262, each side wall 266 can be
rotated about its respective bolt means 276. To provide
proper adjustment to the side walls 266, each frame 258 is
provided with adjustable bolt means 278 for controlled
positioning of the side walls 266 about the bolt means 276.
Although the side walls 266 are shown to be parallel in
Figure 11, for the accommodation of sheets of material which
are about 15 inches (38.1 cm) wide, if the sheets of material
were as narrow as 8 inches (20.32 cm) the bolts 278 could be
inwardly adjusted to cause the trailing end of the discharge
chute 260 to be significantly narrowed to about 8 inches
(20.32 cm). The resulting narrowing profile can create a
reduced volume for the collecting of strip means therein and
for providing significant restrictions on all of the strip
means being discharged therethrough.
Further restriction to the passage of strip means through
the discharge chute 260 can be provided by the adjustable gate
280 at the output end thereof. The gate 280 is hingedly
coupled to the upper wall 264. Bracketing 286 at the opposite
ends of the gate 280 can be used for manual or automatic
control means (not shown) for the proper positioning of the
gate 280. As mentioned for the embodiment shown in Figures 1
and 2, the gate 280, during continued production of the
packing product of the present invention, need not always be
in a closed and restricting position. In other words, once
2~D1214l
- 32 -
the gate 280 is closed to produce sufficient collecting of the
packing product within the interior of the discharge chute
260, the general friction created by the packing product
through the discharge chute 260 may be sufficient to cause
adequate restrictions at the discharge of the cutting section
204 to produce the desired characteristics to the strip means
as described hereinbelow.
The preferred chute means 260 has an internal height H of
about 2 inches (5.08 cm) and internal width W which can be
varied between 8 and 15 inches (20.32 and 38.1 cm). Because
of the significant pressure and forces which are generated
within the discharge chute 260, the lower wall 262 and the
upper wall 264 have a thickness of about 3/4 of an inch
(1.91 cm) while each of the side walls 266 have a thickness of
about 1 1/2 inches (3.82 cm). While the preferred length of
the discharge chute is abut 12 inches (30.48 cm), the length
could be altered depending on the type of material being
employed to produce the preferred packing product. The height
of 2 inches (5.08 cm) allows the extensions 250 of each comber
244 to be loosely positioned within the interior of the chute
260 to produce a better transition from the cutting section
204 to the discharge section 206.
As shown in Figures 8, 9 and 10, the preferred embodi-
ment, in the form of machine 200, does not include any
representation of the packing product being formed thereby.
However, the enlarged fragmentary view of Figure 11 includes a
representation of what is felt to occur within the interior of
the cutting section 204. It should be understood that the
preferred machine 200 produces an extremely packed and tight
array of strip means which basically comprises the preferred
packing product prior to expansion, relaxation and intermixing
in the discharge chute 260 and after leaving the discharge
chute 260. The plurality of tightly mixed and interconnected
strip means produces the packing product in such a compacted
form that actual identification of the orientation and
configuration of the various strip means within the cutting
section 204 and discharge section 206 is quite difficult.
2072347
- 33 -
However, the best understood representation of the packing
product, as it is being formed in the machine 200, is provided
in a schematic form in Figures 11, 12 and 13.
Generally, it should be recognized that all of the base
material for the formation of the preferred packing product
includes a natural resilience with a tendency to resist
folding. Whether the material is paper, cardboard, mylar or
any other material in sheet form, the material includes a
tendency to remain in a straightened form and to resist any
folds or bends thereof. This principle can be readily
observed by simply taking a small sheet of paper and trying to
fold it in half. If one attempts to apply pressure to the
fold to impart a folded memory to the sheet material, it is
not uncommon for the fold to "relax" as the two halves of the
paper tend to naturally separate because of the original
"memory" in the paper tending to resist the fold. The same
principle can also be observed if several layers are also
folded at the same time.
Throughout the remainder of the description provided
hereinbelow, it should be noted that each of the folds
produced in the preferred strip means are, at least initially,
quite tight so that the adjacent longitudinal portions of the
strip means tend to lie in close contact. However, as will be
seen, as pressure on each of the strip means is relaxed, the
folds will have a natural tendency to expand or relax to cause
the portions adjacent to folds to angularly separate.
As seen in Figure 11, the sheets 238, as they advance
between the cutting wheels 240, 242, are initially cut at the
side edges thereof to form initial strip means 300a which tend
to lie along the smooth, outer cylindrical surface 240c, 242c
of the respective cutting wheels 240, 242. The initial strip
means 300a is constantly being advanced, at least partially,
by the rotating surface 240c, 242c toward the discharge side
of the cutting section 204.
However, as with the embodiment shown in Figures 1 and 2,
significant resistance to each of the initially formed strip
means 300a is provided by a collection of previous formed
2012141
- 34 -
strip means in the discharge section 206 which will be
discussed hereinbelow. It is sufficient initially to
understand that a plurality of previously formed strip means
are tightly collected at the discharge side of the cutting
S section 204. Consequently, as each initially formed strip
means 300a is advanced through the cutting section 204 by each
of the cutting discs 240, 242 applying frictional force
thereto, the resistance at the end thereof causes the
initially formed strip means 300a to be sequentially folded to
provide a longitudinally compressed strip means 300b. The
longitudinally compressed strip means 300b is formed
inherently within the cutting section 204 by previously formed
and fully longitudinally compressed strip means 300b
collecting at the discharge side thereof. It is impossible to
stop the machine 200 to see the exact location of the fully
longitudinally compressed strip means between the cutting
discs 240, 242 and the combers 244. However, it is expected
that they will tend to collect to the discharge side of a
connecting line between the centers of the shafts 241, 243.
As a result, it is possible that the initially formed strip
means 300a will be relatively shorter than shown in rigure 11.
The sequential folding of each strip means may begin as each
strip means is being longitudinally cut. However, with all
the cutting discs 240, 242 rotating toward the discharge side,
it would appear that the frictional force created on each
fully longitudinally compressed strip means 300b would tend to
cause them to collect toward the discharge end of the cutting
section 204 rather than toward the connecting line of the
cutting section 204.
The moving collection of fully longitudinally compressed
strip means 300b is maintained in position for discharge by
the aligned end faces 248 of each of the combers 244 and the
extensions 250. As indicated above, the view shown in
Figure 11 represents the best understanding of the type of
collection of the fully longitudinally compressed strip means
300b within the cutting section 204 at the discharge side
thereof. While the outer cylindrical surface 240c, 242c does
272141
- 35 -
impart some compressive force on each of the initial strip
means 300a as the fully longitudinally compressed strip means
300b are being formed, it should also be understood that the
side surfaces 240s and 242s of each cutting wheel 240, 242
also apply side frictional forces to each of the fully
longitudinally compressed strip means 300b during and after
its formation.
It should be noted that the preferred machine 200 differs
from the embodiment shown in Figures 1 and 2 by the inclusion
of the smooth cylindrical outer surfaces 240c and 242c of the
cutting discs 240 and 242. The cutting discs of the
embodiment shown in Figures 1 and 2 preferably include a
serrated or tooth configuration which could grip material
provided thereto and could tend to insure proper longitudinal
cutting of the material for the formation of strip means.
However, it has been found that one feature of the invention
is improved by the inclusion of the smooth outer cylindrical
surfaces 240c, 242c because of the type of longitudinal
compacting of the various strip means which occurs within the
cutting section 204 of the machine 200. The smooth outer
cylindrical surfaces 240c, 242c do not tend to tear the
material and significantly reduce the possibility of dust and
other fine particles being produced. Further, as seen in
Figure 11, with the tight collection of the fully
longitudinally compressed strip means 300b at the outlet side
of the cutting discs 240, 242, the smooth edges of the outer
surface of the cutting discs can freely rotate by the
previously collected fully longitudinally compressed strip
means 300b without any side ripping or tearing thereof.
It should now be clear that the general force provided,
by the rotation of the cutting discs 240, 242, to create the
fully longitudinally compressed strip means 300b also
continues to impart force to each previously formed strip
means to cause migration and movement in a direction toward
the discharge section 206. Depending on the thickness of the
material and the number of folds produced, it would not be
uncommon for the fully longitudinally compressed strip means
2O1214l
- 36 -
300b, formed of 4.4 inch (11.18 cm) strip means, to be only
about 1/2 inch (1.27 cm) to about 1 inch (2.54 cm) long in the
cutting sections 204.
As seen in Figure 12, the strip means, according to the
best observation possible, appear to collect in some type of
wave form near the entrance end of the discharge chute 260 as
tightly longitudinally compressed strip means 300c advance
through the discharge chute 260. While the tightly
longitudinally compressed strip means 300c have very tight
folds therein, it is not expected that their folds will be
quite as tight as those of the fully longitudinally compressed
strip means 300b as initially formed within the cutting
section 204. Clearly, the resistance produced in the
discharge chute 260 tending to cause the sequential folding of
each of the initial strip means 300a will be greater within
the cutting section 204 than at subsequent positions along the
discharge chute 260. The restricting force is greater at the
discharge side of the cutting section 206 than at further
locations along the discharge chute 260 because of the added
effects of the frictional resistance of the various strip
means as they tend to slide along the internal surface of the
discharge chute 260. Accordingly, Figure 13 is only a
schematic representation of what appears to be occurring at
the inlet end of the discharge chute 260 and the waves are
probably not as uniform or as evenly positioned. However, the
strip means 300c should still be quite tightly longitudinally
compressed but not to the same extent as the fully
longitudinally compressed strip means 300b. This tendency to
be less longitudinally compressed is fully consistent with the
resilient nature of the material used to form the strip means
which comprises the basic packing product.
As seen in Figure 13, at a location within the discharge
chute 260 which is more remote from the cutting section 204,
there is included a mixed array of less longitudinally
compressed strip means 300d. As the pressure on the less
longitudinally compressed strip means 300d tends to reduce,
because of the opening at the discharge end of the discharge
2D72147
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chute 260, the natural resilience of each strip means tends to
cause them to expand and to be relatively repositioned within
the discharge chute 260. There is a significant volumetric
expansion of the strip means 300d with clear intermixing and
reposition of all of the less longitudinally compressed strip
means 300d as they are approaching the end of the discharge
chute 260.
With the description provided for Figures 11, 12 and 13,
it should be clear that the basic force required to form the
longitudinally compressed strip means is produced by the
rotating cutting discs 240, 242 against the resistance of the
previously formed longitudinally compressed strip means
tending to collect throughout the length of the discharge
chute 260. The natural resilience of each longitudinally
compressed strip means causes them to generally longitudinally
expand as they proceed toward the end of the discharge chute
260 and, once released from the discharge chute 260 into a
container (not shown), further expansion of each strip means
will occur. Consequently, it should now be clear that the
preferred machine 200 does not include simply a shredding
machine configuration for forming a collection of strip means
which is compressed to form a packing product. Instead, the
preferred packing product is composed of a plurality of
individually longitudinally compressed strip means which tend
to expand in an interlocking and resilient manner to provide
the resulting packing product with individual strip means
having natural resilience, a tendency to longitudinally
expand, and a tendency to resist lateral or side forces.
As seen in Figure 14, a fragmentary section of a
typically longitudinally compressed strip means 300 would
include a plurality of folds 310 with generally planar
longitudinal sections 320 therebetween. The folds extend
substantially transverse to the longitudinal direction of the
strip means. One planar section 320 extends in a second
direction, generally transverse to the longitudinal direction,
to terminate at a fold 310. The next planar section 320
extends away from the fold 310 in a third direction which is
2b72141
- 38 -
also transverse to the longitudinal direction and is
substantially opposite the second direction of the previous
planar section 320.
It has been found that, with proper resistance
S established in the discharge chute 260, a majority of planar
sections or portions will have a length P of about 1/8 of an
inch (.32 cm) to about 1/4 of an inch (.64 cm) for the
longitudinally compressed strip means 300 formed in the
preferred machine 200 having cutting discs 240, 242 with a
width of 1/8 of an inch (.32 cm). In other machines similar
to the preferred machine 200, in which cutting discs having a
width of about 1/4 of an inch (.64 cm), it is not uncommon for
the majority of the planar sections 320 to have a length of
about 1/4 inch (.64 cm) to 1/2 inch (1.27 cm). In any case,
with at least fifty percent of the longitudinally compressed
strip means being formed as generally seen in Figure 14, the
preferred packing product includes an overall, combined
resilience as desirable. The longitudinally compressed strip
means 300, formed of 4.4 inch (11.18 cm) strip means, would
2o typically be only about 1 1/2 inch (3.82 cm) to about 2 1/2
inches (6.35 cm) long.
As mentioned above, the general configurations shown in
Figures 11, 12 and 13 are rather schematic and idealized.
Because of the tight compaction of the various strip means
formed therein, clearly all of the strip means do not have the
preferred, generally even folding as shown in Figure 14. For
example, as seen in Figure 15, it is not uncommon for some of
the longitudinally compressed strip means 300x to have a
varying configuration of folds and generally longitudinal
planar sections therebetween. As can be best determined, a
significant number of such longitudinally compressed strip
means 300x may be formed because of individual gaps which may
occur near the cutting discs 240, 242 as the previously formed
fully longitudinally compressed strip means 300b are being
formed and shifted toward the discharge of the cutting section
204. The longitudinally compressed strip means 300x may have
smaller longitudinal planar sections with a length P1 which
39 _ 2~72147
are as small as 1/64 of an inch (.04 cm) and larger
longitudinal planar sections with a length P2 as large as an
inch (2.54 cm).
In any case, while the various longitudinally compressed
strip means 300, 300x have natural resilience and are
generally biased along the length thereof, it should also be
noted that the resistance created by the folds 310 tend to
provide significant lateral or side strength to each strip
300, 300x as they are intermixed and interconnected throughout
the preferred packing product. Further, as the longitudinally
compressed strip means 300, 300x tend to expand the initially
formed folds having a zero angle between the longitudinal
planar sections 320, the partially relaxed angles of the folds
could typically vary from as small an angle as 5 or 10 degrees
to larger angles of about 90 degrees. A very low percentage
of individual folds may be completely straightened to about
180 degrees as the various longitudinally compressed strip
means 300, 300x bend, curve, and intermix together to form the
interlocking array of the desired packing product. In fact,
the intermixing and interconnection of all of the various
strip means of the preferred packing product are so
complicated and intertwined that representation in a drawing
is virtually impossible. In any case, from the description
provided hereinabove, it should be clear that the primary
features provided to the preferred packing product, similar to
that shown in schematic form in Figures 6 and 7 are produced
by the individual characteristics of each of the
longitudinally compressed strip means of which the preferred
packing product is composed.
As shown in Figures 14 and 15, the strip means 300, 300x
are preferably formed of the three layers of the sheet
material as initially provided by the feeding section 202.
The layers are shown separated for emphasis but would normally
be in close contact throughout the length. Again, not only is
side resilience and strength provided by each of the folds
310, but additional side resistance and strength is provided
- 4~ - 2D72147
by the inclusion of the multilayers of the material in each of
the longitudinal sections or portions 320.
As seen in Figure 16A, the preferred machine 20o can also
be utilized to provide a significantly sturdier packing
product by the introduction of one-sided corrugated cardboard
238a thereto. The corrugated cardboard 238a has a planar side
238b to which is joined at transverse portions therealong the
corrugated side 238c which is also formed of a cardboard
material. The feeding of the one-sided corrugated cardboard
238a to the cutting section again produces strip means which
are longitudinally compressed but with a generally less
uniform configuration than seen in the strip means 300, 300x
of Figures 14 and 15. The planar portion 238b, as seen in
Figure 16B, is converted to have a plurality of folds 336
generally separated by planar sections 338. The corrugated
side 238c is converted to have multiple sections and folds 334
depending on the resistance created as the strip means are
generally discharged from the cutting discs 240, 242. In any
case, the resulting product shown in Figure 16B is
longitudinally compressed while providing even greater side or
lateral strength and resistance to collapsing to provide
overall rigidity and resilience to the packing product formed
thereby.
As seen in Figure 17, a small, approximately 1/2 inch
(1.27 cm) wide portion of another preferred sheet 238p is
shown. While the entire sheet 238p may again have a width of
about 15 inches (38.1 cm), the smaller section is shown in
Figure 17 for demonstration purposes. With proper printing or
embossing or the like on the sheet 238p, a company name, logo,
or trade mark may be provided at 340 which will, with proper
alignment, be present when the various strips 300p are
initially formed to produce the desired packing product.
While the initially formed strip means 300p are only 1/8 of an
inch (.32 cm) wide, the overall machine 200 allows the
printing to be provided in a simplified manner before the
strip means are formed which would not normally be expected
for such small strip means of the packing product.
2~?72 ~ 47
- 41 -
From the description provided, it should be clear that
the present invention includes a method of producing a packing
product includes the steps of: providing a plurality of
narrow, elongated strip means of material, each of which has a
small width dimension and a substantially larger length
dimension; advancing each strip means of the material in a
first direction generally parallel with the length dimension
of each strip means; and sequentially folding each strip means
of the material generally on itself during the advancing. The
sequential folding is for causing adjacent longitudinal
portions of each strip means of the material at each side of
the folding to respectively extend in a second direction and
in a generally opposite third direction, which second and
third directions are substantially transverse to the first
direction. The sequential folding causes each of the adjacent
longitudinal portions to be generally planar. The sequential
folding produces a plurality of folds which are respectively
between each of the adjacent longitudinal portions and the
folding of the material at each of the folds produces tension
in the material. The sequential folding is produced by
restricting each strip means of material after the advancing
in the first direction. The restricting can be provided by
collecting the strip means of material downstream of the
advancing and the sequential folding.
Preferably, the collecting of the strip means is between
generally parallel wall means which extend in the first
direction and are disposed at opposite sides of a region of
the advancing and the sequential folding. The collecting of
the strip means of material produces at least some friction on
the wall means in opposition to the advancing.
Each strip means can include a plurality of layers of the
material and the advancing and the sequential folding of each
strip means can occur simultaneously for each layer of the
material in the strip means.
The advancing of each strip means can include
simultaneous advancing of the plurality of strip means with
each strip means being in a side edge-by-side edge
2072147
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relationship with adjacent strip means. The providing of the
plurality of strip means can include: feeding at least one
sheet of material in the first direction; cutting the at least
one sheet of material into the plurality of strip means; the
S cutting being performed by rotating two sets of alternating
overlapping cutting discs; the feed of the at least one sheet
of the material being between the two sets of cutting discs;
and the advancing of each strip means is provided at least
partially by the rotating of a cutting surface of a
corresponding one to the cutting discs cutting each strip
means as the cutting surface moves in the first direction.
The providing of the plurality of strip means can further
include printing information on at least one side of the sheet
of material prior to the feeding of the sheet of material.
The feeding can include a plurality of sheets of the material
for forming each strip means to include a plurality of layers
and the sequential folding of the plurality of layers of each
strip means occurs simultaneously. The plurality of layers of
each strip means can include aligned folds and substantially
aligned adjacent longitudinal portions respectively at each
side of the aligned folds. The sequential folding of each
strip means can initially occur adjacent the cutting surface
of a corresponding one to the cutting discs. The sequential
folding can occur adjacent a discharge of the two sets of the
cutting discs. The feeding of the plurality of sheets can
include the sheets having at least two different colors for
producing the packing product to include the strip means with
at least two different colors.
The present invention also includes apparatus for
producing a packing product including means for advancing each
strip means of a plurality of strip means of material in a
first direction, each strip means of the material having a
small width dimension and a substantially longer length
dimension which length dimension extends in the first
direction; and means for sequentially folding each strip means
of material generally on itself downstream of the means for
advancing. Each strip means can include a plurality of layers
2072147
_ a_ 3 _
of the material, the means for advancing can simultaneously
advance the layers of each strip means, and the means for
sequentially folding each strip means can include
simultaneously correspondingly folding each of the layers of
each strip means. The means for sequentially folding causes
adjacent longitudinal portions of each strip means of the
material to respectively extend in a second direction and a
generally opposite third direction, and the second direction
and the third direction are substantially transverse to the
first direction. Each of the adjacent longitudinal portions
is substantially planar. The means for sequentially folding
produces a plurality of folds which are respectively between
each of the adjacent longitudinal portions and the folds
produce tension on the material at each of the folds. The
I5 means for sequentially folding can include means for
restricting each strip means of the material downstream of the
means for advancing in the first direction.
Preferably, the means for restricting each strip means of
the material can include collecting each strip means of
material between generally parallel wall means which extend in
the first direction and are disposed at opposite sides of a
region downstream of the means for advancing each of the strip
means. The means for collecting the strip means of material
produces at least some friction on the wall means in
opposition to the means for advancing the plurality of strip
means of material.
The means for advancing the plurality of strip means can
include means for simultaneously advancing the strip means of
the plurality with each strip means being in a side edge-by-
side edge relationship with adjacent strip means of the
plurality. The apparatus can also include means for cutting
at least one sheet of the material for simultaneously
providing the plurality of strip means of the material. The
at least one sheet of material can include printed information
on at least one side thereof prior to being advanced to the
means for cutting. In the apparatus, the means for cutting
includes two sets of alternating, overlapping cutting discs;
272147
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the two sets of cutting discs respectively rotating in
opposite directions; and each of the cutting discs providing
the means for advancing a corresponding strip means which
corresponding strip means is produced by the cutting of the
S cutting disc. The means for cutting includes a plurality of
the sheets of material for cutting each strip means to~ include
a plurality of layers and the means for sequentially folding
producing simultaneous folding of each layer of each strip
means. The plurality of layers of each strip means includes
aligned folds and substantially aligned longitudinal portions
respectively at each side of the aligned folds. The means for
sequentially folding of each strip means causes initial
folding in an area adjacent each cutting disc. The means for
sequentially folding of the plurality of strip means causes
initial folding adjacent a discharge of the two sets of
cutting discs. The plurality of sheets includes the sheets
having at least two different colors to cause the packing
product to include the strip means with at least two different
colors.
From the description provided, it should also be clear
that the present invention includes a compacted material in a
confined area, which compacted material for being used as a
packing product when released from the confined area. The
compacted material includes a plurality of elongated strips of
material; each of the strips having a plurality of folds to be
compacted against itself and against others of the plurality
of strips; and the folds to the strips being relatively
uniform to form a mass of strips having an accordion shape.
The mass of strips is under pressure. The strips are
intertwined and interlocking and the mass of strips is
resilient. The material includes at least one of
biodegradable material, pulp material, paper, cardboard, and
mylar.
Further, each strip could include at least two layers of
the material. The at least two layers of material could
respectively include at least two colors to provide the two
272147
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colors to the compacted material. Alternatively, each strip
could include printing on at least one surface thereof.
The method and apparatus of the invention are such as to
produce, e.g. a packing product including a plurality of
narrow, elongated strip means of material; each of the strip
means including a plurality of folds along a length thereof;
and the plurality of strip means being intertwined and
interconnected to form a resilient mass of the packing
product. The adjacent folds of each strip means are disposed
in generally opposite directions. Each strip means includes
portions between the adjacent folds which are substantially
planar. The material includes a natural resilience and the
natural resilience tends to oppose folding at the folds of
each strip means. The material of each strip means at a
majority of the folds forms a generally acute angle.
The packing product includes a plurality of intertwined
and interlocking strip means of material; each of the strip
means including a plurality of folds with the material having
been compressed at each of the folds; and the plurality of
intertwined and interlocking strip means with the folds having
been compressed therein combining to provide a resilient mass
of the packing product. The folds have been compressed by
compacting of each strip means at least against itself. The
folds are relatively uniform to provide each strip means with
a general accordion shape. Adjacent folds of each strip means
are directed to generally opposite directions. Each strip
means includes portions between the adjacent folds which are
substantially planar.
Still further, the invention can result in the production
of a packing product including a plurality of narrow,
elongated strip means of material; each of the strip means
having a small width dimension and a substantially longer
length dimension; each strip means having a plurality of
substantially transverse folds; each strip means including
adjacent longitudinal portions at respective opposite sides of
each of adjoining folds; and a majority of the adjacent
longitudinal portions extending from the adjoining fold
2'072147
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generally with an acute angle therebetween. Each of the
adjacent longitudinal portions is substantially planar.
Additionally, the invention may result in the production
of a packing product including a plurality of narrow,
elongated strip means of material; the material having a
natural resilience tending to oppose folding thereof; each of
the strip means including relatively uniform folds to be
generally accordion shaped; and the plurality of strip means
being generally compacted against each other at the folds in
opposition to the resilience. The natural resilience of the
plurality of strip means is for tending to longitudinally
expand each of the strip means with time. The plurality of
strip means of material having the folds therein are capable
of generally expanding under the natural resilience by
generally unfolding the folds.
In all the embodiments described, the packing product can
include material which includes at least one of biodegradable
material, pulp material, paper, cardboard, and mylar. Each
strip means can include at least two layers of the material.
The at least two layers of the material can respectively
include at least two colors to provide the two colors to the
packing product. Further, each strip means could include
printing on at least one surface thereof.
The means and construction disclosed herein are by way of
example and comprise primarily the preferred form of putting
the invention into effect. Although the drawings depict a
preferred and alternative embodiment of the invention, other
embodiments have been described within the preceding text.
One skilled in the art will appreciate that the disclosed
device may have a wide variety of shapes and configurations.
Additionally, persons skilled in the art to which the
invention pertains might consider the foregoing teachings in
making various modifications, other embodiments, and
alternative forms of the invention.
It is, therefore, to be understood that the invention is
not limited to the particular embodiments or specific features
shown herein. To the contrary, the inventor claims the
'~ 2072147
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invention in all of its forms, including all alternatives,
modifications, equivalents, and alternative embodiments which
fall within the legitimate and valid scope of the appended
claims, appropriately interpreted under the Doctrine of
Equivalents.
For example, other cutting discs and comber
configurations may be employed to produce wider strip means
and/or for cutting even wider sheets of material to
simultaneously produce more of the packing product.
Similarly, other means could be employed to feed and/or create
different lengths of sheets for cutting to produce longer
strip means for the packing product. Clearly, the discharge
chute could be altered to provide different means for
collecting compressed strip means therein to vary the
resistance on the cutting section without departing from the
invention as claimed.
The folding and crimping apparatus, and method for use
thereof, as described herein may be used to fold and crimp
shredded strips of sheet material into selected lengths of
interlocking, bulk packaging and/or decorative material. The
shredded, folded, crimped, interlocking strips may serve as a
resilient padding and/or wrapping material having various
desired lengths. The crimped strips may be produced in a
variety of colors or combination of colors and may have
printing appearing thereon. The crimped strips are preferably
made of recyclable, biodegradable material, and may also be
made of edible material or of a material which is approved by
the U.S. Federal Food and Drug Administration for use with
edible products. The apparatus is very durable in design, is
easily constructed, is inexpensive and economical to
manufacture, and is extremely simple to use.
It should be noted that two paper products of the
invention were tested to determine the overall quality of the
packing product to compare the characteristics to that of
styrofoam peanuts. One of the paper products included
1/8 inch (.32 cm) wide strips of 22 pound, Kraft paper and
another 1/8 inch (.32 cm) wide product was formed on one-sided
272147
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corrugated cardboard paper of the type described hereinabove.
In standard drop tests, the packing product formed on the one-
sided corrugated material was equal to the stryrofoam peanuts.
However, since only one layer of the Kraft paper was used in
S the formation of the lighter packing product, the drop tests
were not as successful for this product as the Styrofoam
peanuts. This thin, light paper would not normally be
expected to have sufficient rigidity for a drop test when
compared to the styrofoam peanuts.
Nevertheless, based on the results of the tests, the
packing material sample displayed some very desirable
qualities for its intended use. In a comparison with the
standard Styrofoam packing material, the paper-derived samples
showed considerable comparable performance in the drop tests,
and superior qualities in expansion, settling and moisture
resistance. From the tests, it should be clear that with a
proper selection of material, the preferred packing product
could clearly perform as well as the standard Styrofoam
packing material, in most cases, and considerably better, in
other cases, without having the attendant disadvantages of the
styrofoam packing material.
