Note: Descriptions are shown in the official language in which they were submitted.
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PACKAGING APPARATUS AND 19~IETHOD
DESCRIPTION
Technical Field
The present invention relates generally to the field of packaging, and more
specifically to an apparatus and method foi packaging items for protection
during shipment.
Background of the Invention
Consumers demand that products they purchase be free of surface marks or any
other
physical damage. Often, damage to products occurs during shipping. Regardless
of the type
of shipment (i.e., water, air, road or rail), products may be subjected to
physical impact,
dropping, crushing, tearing, breaking, rough handling, puncturing or collision
at any time.
There are a variety of methods and. devices which are commonly used for
insulating and
protecting products and components from physical damage during handling,
shipping,
transportation, etc.
Included in those devices which are utilized to isolate and protect products
from
damage are insulating materials and insulating devices. Examples of insulating
devices
include special containers, such as boxes, envelopes and other shipping
containers. Such
devices may be filled with various padding or other filler materials that are
useful as impact
insulation and shock absorption. For instance, materials such as corrugated
cardboard,,used
alone or in conjunction with plastic "bubble wrap", foam beads, foam "peanuts"
or the like,
generally represent the state-of the-art in protecting fragile objects during
shipping.
Examples of insulating materials include various packaging components. Such
materials are selected and designed for the purpose of providing specific
packaging
properties or a range or properties. Examples of packaging materials include
paper,
corrugated paper, fiber board, polyurethane foam and boards, expanded
polystyrene,
polyethylene foam, polypropylene foam, and the like. Further, engineered
packaging
components may be utilized.
Examples of engineered packaging components include plastic bags, corrugated
cartons, wood or paper pallets, corrugated slip sheets, expanded polystyrene
corners,
polyurethane foam inserts and other plastics, just to name a few. For purposes
of this
disclosure, the terms "packaging," "protection," "insulating" and "cushioning"
are intended
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2
to refer to all of the processes and factors relevant to ensuring the safety
of an item or items
during the "material handling" proeess_ Additionally, for purposes of this
disclosure, the
term "material handling" is intended to refer to all of the processes and
factors relevant to
the staging, organizing, storing, locating, loading, moving, shipping,
unloading, wrapping,
tracking, protecting and generally the overall safety and preservation of the
products.
Another common method of protecting consumer products is to make a molded
expanded polystyrene (EPS) barrier that encloses all or part of the i em to be
protected. The
EPS along with the product are then usually placed in a corrugated box or
container which is
sealed for shipment. One significant downside to EPS packaging is the extreme
cost
o associated with the molds to create the EPS insulation. In order to
precisely shape the
molded EPS for the particular product, tooling must be specifically designed.
While very
expensive, this tooling has a somewhat limited production life. Different
tooling and
molded packaging part design is needed for each and every different item to be
shipped if a
close conforming fit between the part and the EPS barrier is desired. Further,
the machinery
for molding EPS is very expensive and thus is a major factor in the cost of
such protective
packaging.
Further, requirements for determining the means for packaging a product
includes
the cost and time to complete the process. Often, products are merely over-
wrapped in a
polymer-based protective sheet wrapping material. This over-wrapping may be
secured
around the product with tape or other strapping material. Such a process,
however, results in
excess waste of the over-wrapping product and strapping material, thereby
increasing cost.
Furthermore, such a process is slow arid often does not accomplish the desired
result because
of inherent deficiencies.
As illustrated above, a multitude of various packaging materials and devices
exist
today. Most of these materials and devices, however, are not readily adaptable
to varying
sizes and shapes of product. Additionally many of these materials and devices
have
perforW ance and cost deficiencies. Accordingly, a simple and inexpensive
apparatus and
method for packaging a variety of products is desired.
Summary of the Invention
The present invention provides a protective covering for products. According
to one
aspect of the present invention, the protective covering is tubing. The tubing
has an inner
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3
surface, an outer surface, a first end having a first opening adjacent the
first end, a second
end having a second opening adjacent the second end, and a length extending
approximately
from the first end to the second end. The inner surface of the tubing defines
a cavity
extending inwardly from the first opening. The cavity is accessible from the
first end and
the second end of the tubing for inserting product into the cavity. Further,
means are
provided for closing the first and second ends of the tubing to secure product
stored within
the cavity of the tubing.
According to another aspect of the present invention, the product stored
within the
cavity of the tubing relates to automotive products. In one preferred
embodiment,
automobile bumpers are wrapped in the protective-tubing covering.
According to another aspect of the present invention, the means for closing
the first
and second ends of the tubing comprises respectively sealing the first and
second ends.
Additionally, the means for closing. the first and second ends of the tubing
may comprise
taping the f rst end of the tubing, and taping the second end of the tubing.
In one
embodiment, the first end of the tubing is folded against the outer surface of
the tubing and
taped implace, and the second end of the tubing is folded against the outer
surface of the
tubing and taped in place.
According to another aspect of the present invention, the protective covering
is a
substantially continuous tubing. The substantially continuous tubing has a
length, and
comprises a tubing having an outer surface and an inner surface. The inner
surface of the
tubing defines a cavity.
According to another aspect of the present invention, the substantially
continuous
tubing is cut at intervals into discrete sections having a length. The
discrete sections of
tubing are adapted to accept product or items to be protected within the
cavity of the tubing.
The length of the discrete sections of the sheared tubing may be variable or
substantially
uniform.
According to another aspect of the present invention, a cutter having a
cutting
surface, engages the substantially continuous tubing and is utilized to cut
the substantially
continuous tubing into the discrete sections. In one embodiment, the cutter
engages a rail
and traverses about the rail. The cutaing surface of the cutter is adapted to
shear the tubing
during traversing of the cutter about the rail.
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4
According to another aspect of the present invention, the protective covering
comprises an overwrap material. The overwrap material has a first edge and a
second edge.
The first and second edges are joined substantially adjacent the edges to form
a substantially
continuous tubing having a cavity. The substantially continuous tubing has a
first opening
s which provides access to the cavity of the tubing, and the substantially
continuous tubing is
adapted to have the items to be wrapped inserted into cavity of the tubing
through the first
opening.
According to another aspect of the present invention, the first and second
edges of
the overwrap material are secured to one another longitudinally about the
tubing. In one
o embodiment the first and second edges are secured with a stitching.
According to another
aspect, the first and second edges are connected in an overlapping
configuration. In another
embodiment, the first and second edges are connected in a fin seal
configuration.
According to another aspect of the present invention, the portion of the
substantially
continuous tubing opposing the first opening is maintained in a roll prior to
having the items
inserted into the cavity of the tubing through the first opening. In a
preferred embodiment,
the roll of the substantially continuous tubing has no core.
According to another aspect of the present invention, the protective covering
is made
of a laminate material comprising a plurality of layers. In one embodiment,
the laminafe
material comprises two layers, a first layer and a second layer, adhered
together. In a
preferred embodiment, the layers of the laminate material are adhered
together, preferably
with the use of heat.
According to another aspect of the present invention, the first layer and the
second
layer of the laminate composition are made of materials having different
properties. In one
embodiment, the first layer of the laminate composition is made of a first
material having
protective properties, while the second layer of the laminate composition is
made of a
second material having cushioning properties.
According to another aspect of the present invention, the first layer of the
laminate
composition is a high density material having properties to substantially
resist tearing or
puncturing of the tubing. And, the second layer of the laminate composition is
a low density
material having cushioning properties. In a preferred embodiment, the first
layer of the
laminate composition is made of a high density polyethylene, and the second
layer of the
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laminate composition is made of a low density polyethylene. In a most
preferred
embodiment, the low density polyethylene is a low density polyethylene foam
material.
According to another aspect of the present invention, a covering for
protecting items
that are placed within the covering is made of a substantially continuous
tubing having an
5 inner surface, an outer surface, and a first opening providing access to a
cavity of the
continuous tubing. The continuous tubing is adapted to have the items to be
protected
inserted into cavity of the tubing through the first opening. Further, the
inner surface of the
tubing has cushioning properties to cushion items that are located in the
cavity of the tubing,
and the outer surface of the tubing has properties to substantially resist
tearing or puncturing
0 of the tubing during normal use. The substantially continuous tubing is
adapted to be
sheared into intervals of tubing. Typically, the length of the intervals of
the tubing is less
than the. length of the substantially continuous tubing. Additionally, the
length of the
intervals of the tubing is typically greater than the length of the product
placed within the
tubing.
5 According to another aspect of the present invention, a method of
manufactuning the
protective container is provided: In one method a sheet material having a
protective first
surface and an opposing cushioning second surface is provided. The sheet
material also has
a first edge and an opposing second edge. A substantially continuous tubing
having a cavity
is formed by joining a portion of the sheet material adjacent the first edge
to a portion of the
sheet material adjacent the second edge. The second surface of the sheet
material forms a
wall of the cavity.
According to another aspect of the present invention, the sheet material is a
substantially continuous sheet material, and the tubing manufactured from the
sheet material
is a substantially continuous tubing.
According to another aspect of the present invention, the step of joining the
first and
second edges comprises stitching the first and second edges together about a
longitudinal
axis of the tubing.
According to another aspect of the present invention, the method of creating
the
sheet material comprises providing a first material having protective
properties, providing a
second material having cushioning properties, and laminating the first and
second materials
together to form a laminate composition.
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6
According to another aspect of the present invention, the step of joining a
portion of
the sheet material adjacent the first edge to a portion of the sheet material
adjacent the
second edge creates a seam. The method further comprises the step of cutting
the
substantially continuous tubing transverse to the seam to create separate
pieces of the tubing.
According to another aspect of the present invention, the method of
manufacturing a
protective container comprises the steps of providing a first layer of
material, providing a
second layer of material, adhering the first layer of material to the second
layer of material to
create a laminate material, the lanunate material having a first edge, and a
second edge,
folding the laminate material such that the first edge and the second edge are
substantially
o adjacent one another, and securing a portion of the laminate material
adjacent the first edge
to a portion of the laminate material adjacent the second edge to create a
protective tubing.
According to another aspect of the present invention, a system is provided for
protecting a product during any step'of material handling. The-system
comprises a supply of
substantially continuous tubing, the tubing having a leading edge, an unwind
supporting the
supply of substantially continuous tubing, and a cutter havinga cutter
surface. The cutter
selectively engages the substantially continuous tubing at a position distal
the leading edge
to shear the tubing into intervals of tubing having a length. The intervals of
tubing are
adapted to accept items within the cavity.
According to another aspect of the present invention, the unwind of the system
has
rollers for allowing a portion of the supply of substantially continuous
tubing distal the
leading edge of the supply of substantially continuous tubing to be positioned
at the cutter.
In one embodiment, the unwind has first rollers offset from second rollers to
allow for
varying diameter rolls of tubing.
According to another aspect of the present invention, the system has a cutting
rail.
The cutter engaging the cutting rail and traverses about the rail. During
traversing:of the
cutter about the rail, the cutting surface of the cutter is adapted to shear
the tubing.
According to another aspect of the present invention, the system has a surface
iFor
supporting the substantially continuous tubing during shearing thereof: In a
preferred
embodiment, the surface is located adjacent the cutter.
According to anothei aspect of the present invention, a system for protecting
a
product during any step of material handling is provided. The system comprises
a supply of
sheet material, having a first surface, a second surface opposing the first
surface, a first edge,
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7
and a second edge opposing the first edge, a converter, a joiner downstream of
the converter,
and a cutter downstream of the joiner. The converter has a former for folding
a portion of
the supply of sheet material between the first edge and the second edge. After
a portion of
the sheet material is folded, a first portion of the second surface of the
sheet material is
adjacent a second portion of the second surface of the sheet material. The
joiner joins the
sheet material substantially adjacent the first and second edges of the sheet
material to form
the tubing. The cutter has a cutter surface that selectively engages the
tubing to shear the
tubing into intervals of tubing having a length. The intervals of tubing are
adapted to accept
items within the cavity:
According to another aspect of the present invention, a method of overwrapping
products to protect the products is provided. The method comprises providing a
length of
tubing, the tubing having an inner surface and an outer surface, the inner
surface defining a
cavity, the tubing further having a first end and a second end, inserting the
product into the
cavity of the tubing, and sealing the first and.second ends of the tubing,
respectively, to
secure the product within the cavity of the tubing.
According to another aspect of the present invention, the tubing utilized to
overwrap
products has a length, and the product to be inserted into the tubing has a
length. The length
of the tubing is greater than the length of the product.
According to yet another aspect of the present invention, the process utilized
to seal
the first end of the tubing is to fold the tubing adjacent, the first end and
then to tape the first
end to the outer surface of the tubing adjacent the first end. Similarly, the
process utilized to
seal the second end of the tubing is to fold the tubing adjacent the second
end and then to
tape the second end to the outer surface of the tubing adjacent the second
end.
Other features and advantages of the invention will be apparent from the
following
specification taken in conjunction with the following drawings.
Brief Description of the Drawings
To understand the present invention, it will now be described by way of
example,
with reference to the accompanying drawings in which:
FIG: 1 is a perspective view of a roll of protective tubing of the present
invention;
FIG. 2 is an expanded side view of one embodiment of the material comprising
the
protective tubing of FIG. l;
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8
FIGS. 3A and 3B are elevation views of various seams of the protective tubing
of
FIG. 1;
FIGS. 3C and 3D are elevation views of various stitches of the seam of the
protective
tubing of FIG. l;
FIG. 4 is a schematic view of the method of the present invention;
FIG. 5 is a perspective view of an unwind assembly of the assembly station of
FIG. 4;
FIG. Sa is a schematic top view of the unwind assembly of FIG. 5;
FIG. Sb is a schematic top view of the unwind assembly of FIG. 5;
o FIG. 6 is a perspective view of a cutter assembly of the assembly station of
FIG. 4;
FIG. 7 is an end view of the cutter assembly of FIG. 6;
FIG. 8 is a perspective view of.a product being inserted into the protective
tubing of
the present invention;
FIG. 9 is a perspective view of a product in an unsealed protective tubing of
the
present invention; and,
FIG. 10 is a perspective view of a product overwrapped with the protective
tubing of
the present invention.
Detailed Description of the Preferred Embodiment
While this invention is susceptible of embodiments in many different forms,
there is
shown in the drawings and will herein be described in detail preferred
embodiments of the
invention with the understanding that the present disclosure is to be
considered as an
exemplification of the principles of the invention and is not intended to
limit the broad
aspect of the invention to the embodiments illustrated.
Referring now in detail to the FIGS., and initially to FIG. 1, there is shown
a
covering 10 utilized as a protective overwrapping 10 for products during
various steps in the
material handling process of the products. As explained above, for purposes
ofthis
disclosure, the term "material handling" is intended to refer to any or all of
the processes and
factors relevant to the staging, organizing, storing, locating, loading,
moving, shipping,
unloading, wrapping, tracking, protecting and generally the overall safety and
preservation
of the products. In a preferred embodiment, the protective covering 10 is a
tubing 1 i.
Products are overwrapped by being inserted into the protective tubing 11 at
the assemtrly
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9
station 12 as shown in FIGS. 4, 8 and 9, and as described in detail herein. In
one preferred
embodiment, automobile components are wrapped in the protective covering 10.
Specifically, automobile bumpers are wrapped in the protective tubing 11 of
the present
invention. As is understood by one of ordinary skill in the art, however,
other products may
be wrapped utilizing the protective covering 10 and system disclosed herein
without
departing from the spirit and scope of the present invention.
The protective covering 10 will be described first in this disclosure,
followed by a
description of a systeri~ and method for overwrapping products utilizing the
aspects of the
present invention.
0
Protective Overwrapping Material
In part, the protective overwrapping 10 comprises a material 14 that is
utilized to
attempt to protect the product contained in the protective overwrapping from
any physical
damage that may occur during material handling of the product. In a preferred
embodiment
of the material 14 which makes up the tubing 11 shown in FIGS. 1 and 2, the
material 14
comprises a laminate composition of a first layer 16 of material adhered to a
second layer 18
of material. When the tubing 11 is assembled from the sheet of material 14 (as
shown in
FIG. 1), the first layer 16 serves as the outside surface 20 of the tubing 11,
and the second
layer 18 serves as the inside surface 22 of the tubing 11.
In a preferred embodiment, the first layer 16 is made of a material that has
protective
properties. In one embodiment, the first layer 16 of material is a
polyethylene. The
polyethylene, for example, can be high density polyethylene or low density
polyethylene,
but the preferred polyethylene for the first layer 16 is a high density
polyethylene. Utilizing
a high density polyethylene material as the outer surface 20 of the protective
covering IO
assists in providing puncture resistance and surface protection for the
product contained in
the tubing i 1. In a most preferred embodiment, the first layer 16 of material
is a woven high
density polyethylene. Additional materials include co-extruded films comprised
of varying
combinations of linear low density polyethylene, high density polyethylene,
low density
polyethylene, monolayer high density polyethylene and monolayer low density
polyethylene.
Additionally, in a preferred embodiment, the second layer 18 is made of a
material
that has cushioning properties. In one embodiment, the second Iayer 18 of
material is also a
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5210 P 006 PATENT
polyethylene. Again, the polyethylene, for example, can be high density
polyethylene or
low density polyethylene, however the preferred polyethylene for the second
layer 18 is a
low density polyethylene. Most preferably, the low density polyethylene for
the second
layer 18 is made of a low density polyethylene foam to provide cushioning and
surface
s protection for the product contained in the tubing 11. It is understood by
those of ordinary
skill in the art the other polymeric material or polymeric resin may be
utilized for the
material 14 of the tubing I 1, however polyethylenic resins are preferred.
The polyethylenic resins used in the present invention can be those obtained
by
polymerizing ethylene, or polymerizing ethylene with other aliphatic
monoolefins, such as,
to propylene, 1-butene, 1-pentene, 3- methyl- 1-butene, 4-methyl-1-pentene, 4-
methyl-1-
hexene, or 5-methyl-1- hexene alone ar mixtures thereof, or with various other
polyrnerizable compounds.
Additionally, polyethylenic resins useful in the invention include
homopolymers of
ethylene and copolymers of ethylene and other ethylenically-unsaturated
monomers having
5 from 3 to about 8 carbon atoms, such as, propylene, butenes, pentenes,
hexenes and the like.
These comononers preferably have from 3 to about 6 carbon atoms, and, most
preferably,
have 3 or 4 carbon atoms. The copolymers can include other monomers compatible
with ethylene.
The term "polyethylenic resin (or material)", as used herein, is meant to
include not
only homopolymers of ethylene, but also ethylene copolymers composed both of
at least SO
:o ri~ole percent (preferably at least 70 mole percent) of an ethylene unit
and a minor proportion
of a monomer copolymerizable with ethylene, and blends of at least 50 percent
by weight
(preferably at least 60 percent by weight) of the ethylene homopolymer or
copolymer with
another compatible polymer.
Examples of monomers which are copolymerizable with ethylene are vinyl
acetate,
:5 vinyl chloride, propylene, butene, hexene, acrylic acid and its esters, and
methacrylic acid
and its esters. The ethylene homopolymer or copolymer can be blended with any
polymer
compatible with it. Examples of such compatible polymers include
polypropylene,
polybutadiene, poIyisoprene, polychloroprene, chlorinated polyethylene,
polyvinyl chloride,
styrenelbutadiene copolymer, vinyl acetate/ethylene copolymer,
acrylonitrile/butadiene
o copolymer and vinyl chloride/vinyl acetate copolymer.
The polyethylene foam material can be formed by means of a conventional
polyethylene foam sheet extrusion process or any other suitable foam sheet-
forming process.
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il
In a typical polyethylene foam sheet extrusion process, pellets of the
thermoplastic
polyethylene resin are blended with a solid phase nucleating agent and, then,
are melted in a
heated extruder where the plastic and nucleating agent combination is held at
both a high
temperature and a high pressure. The blowing agent(s), which generally
liquefies within the
extruder, and which will vaporize at die melt temperatures and atmospheric
pressure, is
added to the pressurized melted material. Within the molten extrudate, the
blowing agents)
tends to act as a plasticizer to reduce the viscosity of the extrudate, and,
thus, it lowers the
level of temperature necessary to maintain the hot melt condition of the
mixture of
thermoplastic polyethylene material and nucleating agent. The blowing agents)
is mixed
with the melted polyethylenic plastic and nucleati~ig agent, and the
combination is,
subsequently, cooled to an extrusion temperature suitable for foaming. To
prevent the
collapse of the resulting foam structure over time, a permeation modifier
agent is often also
added to the melt composition in the extruder (or as. otherwise conventional
or suitable). The
cooled combination is pushed through a die by the pressure gradient, and, when
released to
atmospheric pressure, the liquefied physical blowing agents) vaporizes and
expands to form
bubbles of gas at the nucleating sites established by the uniformly dispersed
nucleating agent
particles. The process can be usually operated on a continuous basis using a
conventional
extruder system.
The first and second layers 16, 18 of material are adhered together by any
suitable
means. Preferably the low density polyethylene and the high density
polyethylene sheets are
extruded in sheet form and laminated together thereafter extruding. Such
lamination of the
layers may take place immediately thereafter, or after any amount of time. The
two layers
16, 18 of material can be laminated together by the use of heat, adhesive
and/or any other
acceptable means. In a preferred embodiment, the first and second layers 16,
18 of
polyethylene are laminated together utilizing heat and pressure. Typically,
the temperatures
utilized to perform the lamination process range from I80-300° F_, and
the pressure utilized
to perform the lamination process ranges from 30 0 80 p.s.i. The lamination
process creates
a laminated sheet material 14.
Tubine
The protective overwrapping IO and protective tubing 11 of the present
invention
may comprise a single material, a composite material, a blend, a laminate
material, or any
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12
other combination of materials. In the preferred embodiment of the present
invention the
protective tubing 11 comprises the laminate material 14 (a first layer 16 of
material
laminated to a second layer 18 of material) shown in FTG. 2. To create a
protective tubing
11, the material 14 is converted from a sheet material into a tubing.
Initially, the material 14 in sheet form has a first edge 24 and an opposing
second
edge 26. In a preferred embodiment, the material 14 is provided as a
substantially
continuous sheet of material I4. As the sheet material traverses through a
converter 26,
illustrated schematically in FIG. 4, the sheet material is manipulated in a
manner commonly
known in the art such that a portion of the material 14 adjacent the first
edge 24 is positioned
to be substantially adjacent a portion of the material I4 adjacent the second
edge 26. Once a
portion of the first and second edges 24, 26 are substantially adjacent one
another, these
areas are secured to one another as shown in FIGS. 3A through 3D to create the
protective
tubing I I. Typically, the sheet of material 14 is joined longitudinally to
form the
substantially continuous tubing 11. It is understood that the reference to
securing or
connecting the edges 24, 26 refers to securing any portion of the material 14,
from the edges
24, 26 through to, and including the mid-Line area of the material 14, to
create the tubAng 11
of the present invention.
In one method of manufacturing the tubing 11 of the present invention, the
tubing is
manufactured as a substantially continuous tubing 11. As such, the material 14
utilized for
conversion into the substantially continuous tubing 11 is typically a
substantially continuous
sheet material 14. For purposes of this disclosure, "substantially continuous"
means that the
substantially continuous material, or substantially continuous tubing,
respectively, has a
length such that it may be separated into at least two sections for use as a
protective
covering. In a preferred embodiment, the substantially continuous tubing 11
has a length
such that the substantially continuous tubing 11 may be separated into a
plurality of sections
for use as a plurality of individual protective coverings.
In a preferred embodiment, the material 14 is joined at a seam 29 to form the
tubing
11 with an in-Line process. Such process may include joining a portion of the
material 14
adjacent the first edge 24 of the material 14 to a portion of the material 14
adjacent the
second edge 26 of the material 14 by adhering or securing the portion adjacent
the first edge
24 to the portion adjacent the second edge 26 to form a seam 29. As is
understood by one of
ordinary skill in the art, adhering a portion adjacent the first edge 24 of
material 14 to a~
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13
portion adjacent the second edge 26 of the material 14 to form the seam 29 may
be
accomplished via any suitable electrical, mechanical or chemical means,
including, but not
limited to heat, pressure, adhesive, staples, stitching, zippers, buttons,
etc. In a most
preferred embodiment, stitches 28 extending longitudinally about an axis of
the joined sheet
of material 14 are utilized to form the seam 29 of the tubing 11. In one
embodiment, as
shown in FIG. 3D, a surge stitch 31 is utilized to form the longitudinal seam
29. In another
embodiment, as shown in FIG. 3C, a double stitch 35 is utilized to form the
longitudinal
seam 29. It has been found that both the surge stitching 31 and a double
stitch 35 is
acceptable because they are easy and inexpensive to manufacture, and they
provide
acceptable strength for the seam 29.
Additionally, the configuration of the seam 29 of the sheet material in
forming the
tubing 11 may be variable. As shown in FIG. 3A, the first and second edges 24,
26 may be
connected in a fin seal configuration. And, as shown in FIG. 38, the first and
second edges
24, 26 may be connected in an pverlapping configuration. Excess material
extending past
the connected area may be trimmed from the tubing I 1.
After the sheet material I4 is converted into the tubing 11, the tubing 11 is
typically
wound into rolls 30 as shown in FIG. 1. The rolls 30 may be wound around a
core knot
shown) or they may be coreless. A coreless roll provides certain advantages
over a roll
having a core in that the user does not have to have special machinery to hold
the core, there
is less waste because there is no core, the weight of the roll is less, and
the roll may be
substantially flattened for shipping and storage.
As shown in FIGS. 3A-3B and 8-9, the substantially continuous tubing 11 has an
outer surface 20, an inner surface 22, and a first opening 32 adjacent the
first end 33 of the
tubing 11 providing access to a cavity 34 of the continuous tubing 11. The
material of the
inner surface 22 of the tubing 11 has cushioning properties to cushion product
within the
tubing 1 l, and to assist in keeping the surface of the product within the
tubing 11 damage
free, while the material of the outer surface 20 of the tubing I1 has
protective properties to
substantially resist puncturing and tearing of the tubing 1 I during normal
use thereof. As
shown in FIG. 8, the substantially continuous tubing I 1 is adapted to have
items to be
protected inserted into the cavity 34 of the tubing I 1 through the first
opening 32.
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5210 P 006 PATENT
14
System for Overwrapping Products
As shown in FIG. 4, a system 15 for creating a protective tubing 11 for
products
generally comprises an unwind assembly 36, a cutting assembly 38 and an
assembly area 40.
Additionally, the system 15 may include some or ail of the processes for
creating the
substantially continuous tubing 1 l, such as an, extruder 42 for manufacturing
the sheet
material 14, a laminator 44 for Laminating multiple layers of material 16, 18
into a composite
material 14, a converter 46 far converting the sheet material 14 into a tubing
11 having a
seam 29, and an winder 48 for winding the tubing 11 into a roll 30. The
converter 46
typically includes a forming plow to convert the sheet material 14 into the
tubing l I, and a
means for creating the seam 29, such as a sewing apparatus.
Once the tubing 11 has been created, it is typically rolled into a
substantially
continuous roll 30 as shown in FIG. I. It is understood that the substantially
continuous roll
30 may be relocated to another location for use in the system and method of
overwrapping
products as described herein. In one embodiment, the roll 30 is transferred to
the unwind
assembly 36. A preferred embodiment of an unwind assembly 36 for a coreless
roll 30 is
shown in FIG. 5. The unwind assembly 36 has a frame 50 and a plurality of
rollers S4, 58.
As best shown in FIGS. Sa and Sb, the unwind assembly 36 also has two first
shafts 56, each
which hold a plurality of rollers S4 thereon, and a second shaft 60 which also
holds a
plurality of rollers 58. The first shafts 56 are offset from the second shaft
60 to support or
retain the roll 30 and allow the substantially continuous roll 30 of tubing to
be unrolled even
as the diameter of the roll 30 decreases through use. Typically, the unwind
assembly 36 is
located upstream of the cutting assembly 38. In another embodiment, the tubing
11 may be
transferred directly from the convertor 46 to the cutter assembly 38 and
assembly area 40.
The cutting assembly 38, shown in FIGS. 6 and 7, comprises a cutter 62 having
a
cutting surface 64. In a preferred embodiment, the cutting surface 64
comprises a blade
which can shear or cut through the tubing 11. The cutter 62 may also have a
guard 66 to
shield access to the cutting surface 64 when the cutter 62 is not in use, a
handle 68 to allow
the user to manipulate the cutter 62, and a positioning member 70 to assist in
positioning the
tubing 11 such that it can be engaged by the cutting surface 64. In a
preferred embodiment,
the cutting surface 64 is positioned at an angle to the direction of movement
of the cutter 62,
and at an angle to the positioning member 70 of the cutter. While this
specific cutting
assembly 38 is disclosed, any cutter, including but not limited to scissors,
knives, blades, etc.
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5210 P 006 PATENT
may be utilized to shear the tubing into discrete sections. In the preferred
embodiment
disclosed, the cutter 62 generally cuts the tubing 11 transversely to the
longitudinal axis of
the tubing 11.
In a preferred embodiment, as shown in FIGS. 6 and 7, the cutting assembly 38
also
5 includes a cutting rail 72. While not necessary, the cutting rail 72 assists
in support the
cutting assembly 38, and it also assists in creating accurate cuts with the
cutter. The cutter
62 engages the cutting rail 72 and traverses about the cutting rail 72. The
cutting rail 72
operates as a track to maintain the cutter 62 in a cutting position during
engagement of the
tubing 11 by the cutter 62 when the cutter traverses about the cutting rail
72. The cutting
IO rail 72 further has a first area 74 and a second area 76. The first area 74
operates as a
staging area to maintain the cutter 62 away from the tubing 11 as the roll 30
of tubing 11 is
unrolled, or during any period of non-use. The second area 76 comprises the
cutting area.
During use, the cutter 62 traverses about the rail 72 from the first area 74
through the second
area 76. When in the second area 76 the cutting surface 64 of the cutter 62
typically engages
i5 the tubing l l for shearing the tubing 11 into discrete sections.
In a preferred embodiment, an engagement mechanism 78 is connected to the
cutter
62. As shown in FIG. 7, the engagement mechanism 78 has a first mating member
80, and
the cutting rail 72 has a second mating member 82. The first mating member 80
of the
engagement mechanism 78 slidingly mates with the second mating member 82 of
the cutting
rail 72 to allow the cutter 62 to slide and traverse about the cutting rail
72. Specifically, the
second mating member 82 of the cutting rail 72 comprises opposing flanges 84
of the nail 72,
and the first mating member 80 of the engagement mechanism 78 comprises
opposing
shoulders 86 of the engagement mechanism 78. The flanges 84 of the rail 72
operate to
prevent upward movement of the shoulders 86 of the engagement mechanism 78,
but allow
shoulders 86 to slide about the inner track 88 of the rail 72.
The cutting rail 72 may have its own framework 90 to independently support the
,
cutting rail 72, or the cutting rail 72 may be attached to an assembly table
92 as shown in
FIGS. 6 and 7. Additionally, the cutting rail 72 has a removable stop 93 at
the end of the
first area 74. The stop 93 retains the cutter 62 within the track 88 of the
rail 72. The stop 93
may be removed from the rail 72 to remove the cutter 62 from the rail 72.
In a preferred embodiment, a table or assembly surface 92, as shown in FIGS. 6-
9,
may be provided in the assembly area 40. The assembly table 92 assists in
supporting one or
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5210 P 006 PATENT
I6
more of the following: a portion of the extended tubing I l, the cutting rail
72, and the
product to be inserted into the tubing 11: As shown in FIG. 9, the first area
74 of the cutting
rail 72 extends distal the assembly surface 92.
Method of Overwrapping Products
After the tubing 11 has been manufactured, the method of overwrapping products
may be accomplished in a variety of manners. One method comprises placing the
substantially continuous roll 30 of tubing 11 on the unwind assembly 36. As
one of ardinary
skill in the art would readily understand, varying steps in the system 15 may
occur in
o varying locations. In a process where the assembly is conducted with a
downstream flow
from the right to the left, it is preferred that the roll 30 be placed on the
unwind assembly 36
such that the leading edge or first end 33 adjacent the first opening 32 of
the tubing 1:l is
removed tangentially from the top of the roll 30 in a clockwise manner. The
leading edge 33
of the roll 30 of tubing 11 is pulled past the cutting assembly 38 and onto
the cutting table
92, such that a length of the tubing 11 is removed from the roll 30. However,
the remaining
portion of the substantially continuous tubing 11 opposing the first opening
32, and not
being used for the current product covering, is maintained with the roll 30.
The product is
then inserted into the cavity 34 of the tubing 11 through the first opening 32
as shown in
FIG. 8. Typically, a length of tubing proximal the first opening 32 of the
tubing is provided
o between the end of the product in the cavity 34 and the first opening 32.
This length of
tubing 11 is provided to allow for sealing of the first opening 32. Once the
product is
inserted in the cavity 34, the tubing 11 can be sheared into a discrete
section or integral 94 of
the substantially continuous tubing 1 I as shown in FIG. 9. The tubing I 1 is
sheared by
cutting the substantially continuous tubing 11 transverse to the seam 29 to
create the
separate section 94 of tubing. The separate section 94 of the tubing has a
length which is
less than the length of the substantially continuous tubing 11. When the
tubing 11 is sheared
into the separate tubing section 94, a second end 96 having a second opening
98 is
developed. Typically, a similar length of tubing proximal the second end 98 of
the tubing is
provided between the opposing end of the product in the cavity 34 and the
second end 98 of
o the tubing. This length of tubing 11 is provided to allow for sealing of the
second opening
98. The tubing may be cut into sections having variable or substantially
uniform length.
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'5210 P 006 PATENT
17
Another method of overwrapping products, as shown in FIG. 9, comprises
initially
cutting the substantially continuous tubing 11 into a plurality of discrete
sections 94 before
product is positioned within the cavities 34 of the tubing sections 94. As
such, each discrete
section 94 of tubing will have a first end 33 having a first opening 32, a
second end 96
having a second opening 98, and a length extending approximately from the
first end 33 to
the second end. The cavity 34 of the tubing sections 94 is accessible from
both the first end
33 and the second end 96 of the sections 94. Typically, the length of the
tubing sections 94
is greater than the length of the product.
After the substantially continuous tubing 11 has been sheared into a discrete
section
94 of tubing, and once the product is appropriately fitted within the cavity
34 of the tubing
94, the ends 33, 96 of the tubing 94 can be sealed or closed to secure the
product with the
protective overwrapping as shown in FIG. 10. One means for closing the first
and second
ends 33, 96 of the tubing comprises respectively sealing the first and second
ends 33, 96:
Another means for closing the first and second ends 33, 96 of the tubing
comprises taping
the first end 33 of the tubing, and taping the second end 96 of the tubing to
close the
openings 32, 98. This may be accomplished by folding a portion of the tubing
94 adjacent
the first end 33 against the outer surface 20 of the tubing and taping the
first end 33 to the
outer surface 20 of the tubing. Similarly, a portion of the tubing 94 adjacent
the second end
96 of the tubing may be folded against the outer surface 20 of the tubing and
taped to the
outer surface 20 of the tubing.
Accordingly, the protective tubing 11 and system 15 of the present invention
provide
a simple and inexpensive system for over-wrapping product to protects the
products during-
the various stages of material handling. Specifically, the present invention
provides a
product and system which minimizes waste, minimizes assembly time, has a low
capital
cost, and provides superior performance. As such, the present invention
overcomes the
deficiencies in overwrapping seen in the prior art.
While the specific embodiments have been illustrated and described, numerous
modifications come to mind without significantly departing from the spirit of
the invention,
and the scope of protection is only limited by the scope of the accompanying
Claims.
