Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: VOID FILL PRODUCT AND METHOD AND APPARATUS FOR
MAKING THE SAME
FIELD OF THE INVENTION
The present invention relates to a void fill material or the
like and to the method and apparatus for making the same.
More particularly, this invention relates to apparatus and
methods for mechanically folding and embossing shredded
strips of sheet material into expanding void fill material.
BACKGROUND OF THE INVENTION
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 there between. 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
lightweight of the styrofoam peanuts also allows them to be
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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 non biodegradable
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
ingest them. Styrofoam peanuts are not digestible and cause
a major source of tracheal blockage in children.
Other packaging filler materials, such a shredded paper,
have also been used. Shredded paper, however, usually lays
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. Pat. 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 creping, crinkling or folding is disclosed
in U.S. Pat. Nos. 1,680,203 and 3,501,565. However, U.S.
Pat. No. 3,501,565 simply includes preliminary steps prior
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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. Pat. 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. Pat. 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
funneling of sheet paper or material into a compact
elongated form. U.S. Pat. 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. Pat.
Nos. 4,085,662; 4,650,456; and 4,699,609 disclose additional
devices for the folding and collapsing of elongated sheet
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. Pat. 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. Pat. 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.
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U.S. Pat. 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.
SUMMARY OF THE INVENTION
It is the general object of the present invention to provide
apparatus and methods for mechanically folding large
quantities of die cut strips of sheet material into
continuous exact lengths of folded or embossed, tightly
packed void fill material. The tightly packed void fill
material contains no airspaces creating a compact package,
reducing the cost related to shipping volumes, packaging
costs and saving on transportation costs.
Such apparatus being: unique in design, compact and simple
to operate.
Another object is to produce large quantities of
mechanically folded die cut strips of sheet material into
continuous exact lengths of folded or embossed, tightly
packed void fill material from biodegradable pulp materials
such as from paper, cardboard, foamed starch 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.
The present invention achieves these general and specific
objects and presents new apparatus and methods for producing
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a new type of expanding void fill 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 mechanically folded
material that is cut and slit to length, packed back to back
to form a tightly packed puck of void fill packaging
material comprising folded and embossed, interlocking strips
of sheet material which may:
(a) be used as padding to cushion and prevent heavier
objects from gravitating toward the bottom and/or sides of a
container, such padding requiring a lesser amount of raw
material to form a greater amount of interlocking bulk
packaging material than was previously available;
(b) be produced in smaller package that is easily shippable
and expands to five times its volume when released from its
package.
(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, starch 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.
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Large quantities of mechanically folded die cut void fill
material that is folded or embossed may be used for
decorative effects at parties or to fill the voids in gift
baskets or gift boxes.
The use of the tightly packed void fill puck of the present
invention enables an operator to use an exact amount of
desired packaging material, and thereby reduce waste.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the
drawings, wherein:
FIG. 1 is a simplified, partial, schematic, side view of an
embodiment of apparatus for making the void fill product of
the present invention wherein the material is cut to length
first, then slit width wise before being mechanically rolled
up and compressed end to end and tightly packed into a
cylindrical package ( puck).
FIG. 2 is a top plan view of the apparatus of FIG. 1.
FIG. 3 is a simplified, partial, schematic, side view of
another embodiment of apparatus for making the void fill
product of the present invention wherein the material is cut
to length first, then slit width wise before being
mechanically folded and compressed end to end and tightly
packed into a cylindrical package ( puck).
FIG. 4 is a top plan view of the apparatus of FIG. 2
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FIG. 5 is an enlarged, partial, schematic, side view of the
folding mechanism used to fold and compress the void fill.
FIG. 6 is all the possible shapes that the void fill can be
packed into.
FIG. 7 is another embodiment of a void fill product of the
present invention.
FIG. 8 is another embodiment of a void fill product of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and particularly to FIGS. 1 and 2,
a paper web consisting of one or more sheets of paper 1 is
pulled into one embodiment of apparatus according to the
present invention by a pair of pull rollers 2 and then fed
into rotary cutting rollers 3 that cut the paper web 1
horizontally to the desired length of the void fill product
to be formed. The cut paper web is then fed into push
rollers 4 that feed the cut paper web to pull rollers 5. The
pull rollers 5 feed the cut paper web to rotary slitting die
6 that slit the cut paper web longitudinally into strips.
After slitting, the slit and cut to length paper web is then
fed to the push rollers 7 that feed a helical bossing set 8
through the paper guide 13 stabilizing the sheet before
embossing 8. The embossed strips of paper then travel to the
winder 9 where the void fill is tightly wound. As shown in
Fig. 2 when the winding cycle is completed the apparatus
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stops briefly allowing the coil plunger 10 to push the
tightly compacted void fill in the packing coil 11 into the
packing sleeve 12 where a poly bag awaits the void fill.
In Fig. 3 and 4 a paper web 1 is pulled into another
embodiment of apparatus according to the present invention
by pull rollers 2 and then fed into the rotary cutting
rollers 3 wherein the paper web 1 is cut horizontally to
length. The cut paper web is then fed into the push rollers
4 that then feed the cut paper web to the pull rollers 5.
Pull rollers 5 feed the cut paper web to rotary slitting die
6 that slit the cut paper web longitudinally into strips.
After slitting, the slit and cut to length paper web is then
fed to push rollers 7 that feed folding gear set 14,15
through the paper guide 13 stabilizing the sheet before
folding. The folded strips of paper then travel to the
packing coil 9 where the void fill is tightly packed in the
packing coil 9 compressing and removing any air spaces. When
the compression cycle is completed the apparatus stops
briefly allowing the coil plunger to 10 push the tightly
compacted void fill in the packing coil 11 into the packing
sleeve 12 where a poly bag awaits the void fill.
Fig. 5 shows the process of how the mechanical folding and
compression is achieved by the apparatus of Fig 3 and 4. The
paper web 1 is guided through the paper guide 13 and fed to
both the top 14 and bottom 15 folding gear set. The cut to
length paper web 1 is fed to the front 17 of the nip of gear
set 14,15 where the folding starts. The individual sheets
of die cut paper travel through the nip 18 of gear set 14,15
and is folded. The compression of the void fill product
starts on leaving the end 19 of the nip of the gear set
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14,15. The void fill product is fed into the first stage 20
of compression as the void fill starts to travel down the
packing coil intake throat 23. The throat 23 is located and
installed tight up against the leavening side 21 and 22 of
gear set 14,15 to ensure a good capture and containment of
the void fill.
FIG. 6 indicates the different types of packaging
configurations that can be used for the compressed void fill
product of the present invention. The most likely used would
be 24, 25, 26, 27, 28, and 31.
Rather than producing individual strips of material from the
paper web, the present invention can be used to make
alternative shapes. One such alternative design is shown in
Fig. 7. In this embodiment the individual lengths of void
fill product 70 comprise a strip 71 having two parallel and
aligned rows of slits 72, 73 and then punched to form the
diamond shaped product shape illustrated. The individual
lengths of void fill product 70 are compressed and formed
into tightly compacted void fill product as shown in Figs 1-
4.
Another alternative design is shown in Fig. 8. In this
embodiment the individual lengths of void fill product 80
comprise a strip 81 having two parallel and aligned rows of
slits 82, 83 and then punched to form the double diamond
shaped product shape illustrated. The individual lengths of
void fill product 80 are compressed and formed into tightly
compacted void fill product as shown in Figs 1-4.
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The mechanically folding and compressing apparatus, and
method for use thereof, as described herein may be used to
mechanically fold and compress die cut strips of sheet
material into exact lengths of, tightly wound and packed
void fill packaging and/or decorative material. The
mechanically folded and compressed strips may serve as a
padding and/or void fill material having exact lengths. The
mechanically folded and compressed strips may be produced in
a variety of colors or combination of colors and may have
printing appearing thereon. The mechanically folded and
compressed strips are preferably made of recyclable,
biodegradable material, and may also be made of an edible
material or of a material which is approved by the U.S.
Federal Food and Drug Administration for use with edible
products. The present invention provides a product that is
not only a superior void fill but a product that
dramatically reduces the cost of shipping, in store shelf
space as well as provide the customer the flexibility to buy
one-pound pucks of void fill that explode to 5 times volume
when released from its packaging. The void fill product of
the present invention is not only environmentally friendly
but helps reduce emissions generated by trucking.
It is to be understood by one of ordinary skill in the art
that the present discussion is a description of exemplary
embodiments only, and is not intended to limit the broader
aspects of the present invention.
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Although various preferred embodiments of the present
invention have been described herein in detail, it will be
appreciated by those skilled in the art, that variations may
be made thereto without departing from the spirit of the
invention or the scope of the appended claims.
