U.S. patent application number 10/717462 was filed with the patent office on 2005-05-26 for packaging apparatus and method.
Invention is credited to Foster, Dale L., Osborne, Joseph Spencer III, Vershum, Raymond G..
Application Number | 20050109655 10/717462 |
Document ID | / |
Family ID | 34750855 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050109655 |
Kind Code |
A1 |
Vershum, Raymond G. ; et
al. |
May 26, 2005 |
Packaging apparatus and method
Abstract
A covering 10 for protecting an item that is placed within the
covering 10 is provided. The covering 10 includes a substantially
continuous tubing 11 having an inner surface 22, an outer surface
20, and a first opening 32 providing access to a cavity 34 of the
continuous tubing 11. The continuous tubing 11 is adapted to have
items to be protected inserted into cavity 34 of the tubing 11
through the first opening 32. A method for creating the protective
covering 10 is also provided. In one preferred embodiment of the
invention the method includes sealing an automobile bumper in the
tubing 11 for protection of the bumper during material handling
thereof.
Inventors: |
Vershum, Raymond G.;
(Youngstown, OH) ; Foster, Dale L.; (Boardman,
OH) ; Osborne, Joseph Spencer III; (Bardstown,
KY) |
Correspondence
Address: |
PAUL J. NYKAZA, ESQ.
Wallenstein Wagner & Rockey, Ltd.
53rd Floor
311 South Wacker
Chicago
IL
60606-6630
US
|
Family ID: |
34750855 |
Appl. No.: |
10/717462 |
Filed: |
November 21, 2003 |
Current U.S.
Class: |
206/521 ;
206/484 |
Current CPC
Class: |
B65D 85/68 20130101;
B65D 75/06 20130101 |
Class at
Publication: |
206/521 ;
206/484 |
International
Class: |
B65D 085/30 |
Claims
We claim:
1. A protective wrap for an item, comprising: an overwrap material
having a first edge and a second edge, the first and second edges
being joined substantially adjacent the edges to form a
substantially continuous tubing having a cavity, the tubing having
a first opening providing access to the cavity of the tubing, and
the substantially continuous tubing being adapted to have the item
to be wrapped inserted into cavity of the tubing through the first
opening.
2. The protective wrap of claim 1, wherein the first and second
edges of the overwrap material are secured to one another with a
stitching extending longitudinally about the tubing.
3. The protective wrap of claim 1, wherein the overwrap material
comprises a laminate composition of a first layer adhered to a
second layer.
4. The protective wrap of claim 3, wherein the first layer and the
second layer are adhered together with heat.
5. The protective wrap of claim 3, wherein the first layer is a
high density material having properties to substantially resist
tearing or puncturing of the tubing.
6. The protective wrap of claim 5, wherein the first layer is a
high density polyethylene material.
7. The protective wrap of claim 3, wherein the second layer is a
low density material having cushioning properties.
8. The protective wrap of claim 7, wherein the second layer is a
low density polyethylene foam material.
9. The protective wrap of claim 1, wherein the item to be wrapped
in the protective wrap is an automotive product.
10. The protective wrap of claim 9, wherein the automotive product
is a automobile bumper.
11. The protective wrap of claim 1, wherein a portion of the
substantially continuous tubing opposing the first opening is
maintained in a roll prior to having the item inserted into the
cavity of the tubing through the first opening.
12. The protective wrap of claim 11, wherein the roll has no
core.
13. The protective wrap of claim 2, wherein the first and second
edges are connected in an overlapping configuration.
14. The protective wrap of claim 2, wherein the first and second
edges are connected in a fin seal configuration.
15. The protective wrap of claim 1, wherein the substantially
continuous tubing has a length, wherein the length of the
substantially continuous tubing is greater than a length of the
product adapted to be inserted into the tubing, and wherein the
substantially continuous tubing is adapted to be cut into a
discrete section to contain the product.
16. A covering for protecting an item that is placed within the
covering, comprising: a substantially continuous tubing having an
inner surface, an outer surface, and a first opening providing
access to a cavity of the continuous tubing, the continuous tubing
being adapted to have the item to be protected inserted into cavity
of the tubing through the first opening, wherein the inner surface
of the tubing has cushioning properties to cushion items that are
located in the cavity of the tubing, and wherein the outer surface
of the tubing has properties to substantially resist tearing or
puncturing of the tubing during normal use.
17. The covering of claim 16, wherein the substantially continuous
tubing is adapted to be sheared into intervals of tubing, and
wherein a length of the intervals of the tubing is less than the
length of the substantially continuous tubing.
18. The covering of claim 16, wherein the tubing is made of a first
layer of material laminated to a second layer of material, the
outer surface comprising the first layer of material and the inner
surface comprising the second layer of material.
19. The covering of claim 16, wherein the inner surface is made of
a low density polyethylene, and wherein the outer surface is made
of a high density polyethylene.
20. The covering of claim 16, wherein the substantially continuous
tubing is made of a sheet of material having a first edge and a
second edge, the sheet of material being joined longitudinally
adjacent the first and second edges to form the substantially
continuous tubing.
21. The covering of claim 20, wherein the sheet of material is
joined adjacent the first and second edges with a stitching
extending longitudinally about the sheet of material.
22. A covering for protecting items that are placed within the
covering, comprising: a substantially continuous tubing having a
first opening providing access to a cavity of the tubing for
insertion of items to be protected while in the tubing, the tubing
being made of a laminate composition of a first layer adhered to a
second layer.
23. The covering of claim 20, wherein the first layer is made of a
high density polyethylene, and wherein the second layer is made of
a low density polyethylene.
24. A covering for protecting an automobile bumper to be located
within the covering, comprising: a laminate tubing having an inner
surface having cushioning properties, an outer surface having
protective properties to substantially resist tearing or puncturing
of the tubing during normal use, the tubing having an opening
providing access to a cavity into which the automobile bumper is
inserted, wherein the tubing having a length which is longer than a
length of the inserted automobile bumper, and wherein first and
second ends of the tubing are sealed to enclose the automobile
bumper in the cavity of the tubing.
25. A method of manufacturing a protective container, comprising
the steps of: providing a sheet material having a protective first
surface and an opposing cushioning second surface, the sheet
material also having a first edge and an opposing second edge; and,
forming a substantially continuous tubing having a cavity by
joining a portion of the sheet material adjacent the first edge to
a portion of the sheet material adjacent the second edge, wherein
the second surface of the sheet material forms a wall of the
cavity.
26. The method of manufacturing the protective container of claim
25, wherein the sheet material is a substantially continuous sheet
material, and wherein the tubing manufactured from the sheet
material is a substantially continuous tubing.
27. The method of manufacturing the protective container of claim
25, wherein the step of joining the first and second edges
comprises stitching the first and second edges together about a
longitudinal axis of the tubing.
28. The method of manufacturing the protective container of claim
25, further comprising the steps of: providing a first material
having protective properties; providing a second material having
cushioning properties; laminating the first and second materials
together to form a laminate composition, wherein the sheet material
is formed of the laminate composition.
29. The method of manufacturing the protective container of claim
28, wherein the first material is a high density polyethylene.
30. The method of manufacturing the protective container of claim
28, wherein the second material is a low density polyethylene.
31. The method of manufacturing the protective container of claim
25 wherein 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, and further comprising the step of
cutting the substantially continuous tubing transverse to the seam
to create separate pieces of the tubing.
32. A method of manufacturing a protective container, comprising
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
laminate material having a first edge, and a second edge; folding
the laminate material such that the first edge and the second edge
are substantially adjacent one another; 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.
33. The method of claim 32, wherein the first layer of material is
a high density polyethylene.
34. The method of claim 32, wherein the second layer of material is
a low density polyethylene.
35. The method of claim 32, wherein the step of securing a portion
of the laminate material adjacent the first edge to a portion of
the laminate material adjacent the second edge comprises adhering a
portion adjacent the first edge to a portion adjacent the second
edge.
36. The method of claim 32, wherein the step of securing a portion
of the laminate material adjacent the first edge to a portion of
the laminate material adjacent the second edge comprises stitching
a portion adjacent the first edge to a portion adjacent the second
edge.
37. An apparatus for converting a substantially continuous tubing
of protective material into a protective container for items
inserted in the tubing, the apparatus comprising: a cutter having a
cutting surface, the cutter engaging a rail and traversing about
the rail, wherein the cutting surface of the cutter is adapted to
shear the tubing during traversing of the cutter about the
rail.
38. The apparatus of claim 37, wherein the rail has a first area
and a second area, the cutter traversing the rail from the first
area through the second area, and wherein the cutter is adapted to
engage the tubing in the second area.
39. The apparatus of claim 37, further comprising an engaging
mechanism secured to the cutter, the engaging mechanism having a
first mating member and the rail having a second mating member, the
first mating member slidingly mating with the second mating
member.
40. The apparatus of claim 37, further comprising a stand
supporting the rail.
41. The apparatus of claim 40, wherein the stand is adjacent a
surface for supporting the tubing, and wherein a first area of the
rail extends distal the surface of the stand.
42. The apparatus of claim 37, further comprising a guard that
extends over the cutting surface of the cutter to protect the
cutting surface during periods of non-use.
43. A system for creating a protective covering from a
substantially continuous tubing, comprising: a length of protective
wrap, the protective wrap comprising a tubing having an outer
surface and an inner surface, the inner surface defining a cavity;
and, a cutter having a cutter surface, wherein the cutter engages
the tubing at intervals to shear the tubing into discrete sections,
the discrete sections of tubing being adapted to accept an item
within the cavity thereof.
44. The system of claim 43, wherein a length of the sections of the
sheared tubing is variable.
45. The system of claim 43, wherein a length of the sections of the
sheared tubing is substantially uniform.
46. The system of claim 43, wherein the tubing is made of a
laminate composition having a first layer adhered to a second layer
adhered.
47. The system of claim 43 further comprising an unwind apparatus,
wherein the tubing is positioned into a roll prior to being sheared
into sections, and wherein the unwind apparatus retains the roll of
tubing, the unwind apparatus having rollers for allowing the roll
of tubing to be unrolled prior to being sheared by the cutter.
48. The system of claim 47, wherein the unwind apparatus has a
plurality of first rollers and a plurality of second rollers, and
wherein the first rollers are offset from the plurality of second
rollers to allow for varying diameter rolls of tubing.
49. The system of claim 43, further comprising a cutting rail, the
cutter engaging the cutting rail and traversing about the rail,
wherein the cutting surface of the cutter is adapted to shear the
tubing during traversing of the cutter about the rail.
50. The system of claim 49, wherein the cutting rail has a first
area and a second area, the cutter traversing the rail from the
first area through the second area, and wherein the cutter is
adapted to engage the tubing in the second area.
51. The system of claim 49, further comprising an engaging
mechanism secured to the cutter, the engaging mechanism having a
first mating member and the rail having a second mating member, the
first mating member slidingly mating with the second mating
member.
52. The system of claim 49, further comprising a surface for
supporting the tubing during shearing thereof, the surface being
located adjacent the cutting rail.
53. A system for overwrapping a product for protecting the product
in the overwrap, comprising: a tubing having an inner 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, wherein the inner surface of the tubing defines a
cavity extending inwardly from the first opening, the cavity being
accessible from the first end and the second end of the tubing;
and, means for closing the first and second ends of the tubing to
secure product stored within the cavity of the tubing.
54. The system of claim 53, wherein the means for closing the first
and second ends of the tubing comprises respectively sealing the
first and second ends.
55. The system of claim 53, wherein the means for closing the first
and second ends of the tubing comprises taping the first end of the
tubing, and taping the second end of the tubing.
56. The system of claim 55, wherein the first end of the tubing is
folded against the outer surface of the tubing and taped in place,
and wherein the second end of the tubing is folded against the
outer surface of the tubing and taped in place.
57. A system for protecting a product during any step of material
handling, comprising: a supply of substantially continuous tubing,
the tubing having a leading edge; an unwind supporting the supply
of substantially continuous tubing; and, a cutter having a cutter
surface, the cutter selectively engaging 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 being adapted to accept items within the cavity.
58. The system of claim 57, wherein the tubing is made of a
laminate composition having a first layer adhered to a second layer
adhered.
59. The system of claim 57, wherein the unwind 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.
60. The system of claim 59, wherein the unwind has first rollers
offset from second rollers to allow for varying diameter rolls of
tubing.
61. The system of claim 57, further comprising a cutting rail, the
cutter engaging the cutting rail and traversing about the rail,
wherein the cutting surface of the cutter is adapted to shear the
tubing during traversing of the cutter about the rail.
62. The system of claim 57, further comprising a surface for
supporting the substantially continuous tubing during shearing
thereof, the surface being located adjacent the cutter.
63. A system for protecting a packaged automobile bumper during any
step of material handling, comprising: a supply of substantially
continuous tubing, the tubing being formed of a two-layer
construction wherein the first layer is a high density material and
the second layer is a low density material, the tubing having an
opening at a leading edge thereof, the opening providing access to
a cavity of the tubing; an unwind supporting the supply of
substantially continuous tubing; a cutter having a cutter surface,
the cutter selectively engaging 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 being
adapted to accept automobile bumpers within the cavity, wherein the
unwind 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; a cutting rail, the cutter engaging the cutting rail and
traversing about the rail, wherein the cutting surface of the
cutter is adapted to shear the tubing transverse to a longitudinal
axis of the tubing during traversing of the cutter about the rail;
and, a surface for supporting the substantially continuous tubing
during shearing thereof, the surface being located adjacent the
cutter, the surface further supporting the automobile bumper during
insertion of the bumper into the cavity of the tubing.
64. A system for protecting a product during any step of material
handling, comprising: a supply of sheet material having a first
surface, a second surface opposing the first surface, a first edge,
and a second edge opposing the first edge; a converter having a
former for folding a portion of the supply of sheet material
between the first edge and the second edge, wherein a first portion
of the second surface of the sheet material is adjacent a second
portion of the second surface of the sheet material after the
portion of the sheet material is folded; a joiner downstream of the
converter, the joiner joining the sheet material substantially
adjacent the first and second edges of the sheet material, wherein
the sheet material having its edges joined forms the tubing; a
cutter downstream of the joiner, the cutter having a cutter
surface, wherein the cutter selectively engages the tubing to shear
the tubing into intervals of tubing having a length, the intervals
of tubing being adapted to accept items within the cavity.
65. The system of claim 64, wherein the sheet material comprises a
first layer of material having protective properties, and a second
layer of material having cushioning properties, wherein the first
layer of material is laminated to the second layer of material.
66. A method of overwrapping products to protect the products,
comprising the steps of: 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.
67. The method of claim 66 wherein the tubing has a length, wherein
the product to be inserted into the tubing has a length, and
wherein the length of the tubing is greater than the length of the
product, and wherein the step of sealing the first and second ends
of the tubing comprises folding the tubing adjacent the first end
of the tubing and taping the first end of the tubing to the outer
surface of the tubing, and folding the tubing adjacent the second
end of the tubing and taping the second end of the tubing to the
outer surface of the tubing.
68. The method of claim 66, wherein the tubing comprises a laminate
structure having a outer protective layer and an inner cushioning
layer.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to the field of
packaging, and more specifically to an apparatus and method for
packaging items for protection during shipment.
BACKGROUND OF THE INVENTION
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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 to refer to all of the processes and
factors relevant to ensuring the safety of an item or items during
the "material handling" process. 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.
[0006] Another common method of protecting consumer products is to
make a molded expanded polystyrene (EPS) barrier that encloses all
or part of the item 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 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.
[0007] 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 and often does not
accomplish the desired result because of inherent deficiencies.
[0008] 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 performance and cost deficiencies. Accordingly, a simple and
inexpensive apparatus and method for packaging a variety of
products is desired.
SUMMARY OF THE INVENTION
[0009] 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 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.
[0010] 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.
[0011] 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 first 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 in
place, and the second end of the tubing is folded against the outer
surface of the tubing and taped in place.
[0012] 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.
[0013] 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.
[0014] 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 cutting
surface of the cutter is adapted to shear the tubing during
traversing of the cutter about the rail.
[0015] 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 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.
[0016] 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 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.
[0017] 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.
[0018] 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 laminate 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.
[0019] 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.
[0020] 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 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.
[0021] 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 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 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.
[0022] According to another aspect of the present invention, a
method of manufacturing 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.
[0023] 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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 laminate material
having a first edge, and a second edge, folding the laminate
material such that the first edge and the second edge are
substantially 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.
[0028] 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 having a 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.
[0029] 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.
[0030] 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.
[0031] According to another aspect of the present invention, the
system has a surface for supporting the substantially continuous
tubing during shearing thereof. In a preferred embodiment, the
surface is located adjacent the cutter.
[0032] According to another 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, 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.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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
[0037] To understand the present invention, it will now be
described by way of example, with reference to the accompanying
drawings in which:
[0038] FIG. 1 is a perspective view of a roll of protective tubing
of the present invention;
[0039] FIG. 2 is an expanded side view of one embodiment of the
material comprising the protective tubing of FIG. 1;
[0040] FIGS. 3A and 3B are elevation views of various seams of the
protective tubing of FIG. 1;
[0041] FIGS. 3C and 3D are elevation views of various stitches of
the seam of the protective tubing of FIG. 1;
[0042] FIG. 4 is a schematic view of the method of the present
invention;
[0043] FIG. 5 is a perspective view of an unwind assembly of the
assembly station of FIG. 4;
[0044] FIG. 5a is a schematic top view of the unwind assembly of
FIG. 5;
[0045] FIG. 5b is a schematic top view of the unwind assembly of
FIG. 5;
[0046] FIG. 6 is a perspective view of a cutter assembly of the
assembly station of FIG. 4;
[0047] FIG. 7 is an end view of the cutter assembly of FIG. 6;
[0048] FIG. 8 is a perspective view of a product being inserted
into the protective tubing of the present invention;
[0049] FIG. 9 is a perspective view of a product in an unsealed
protective tubing of the present invention; and,
[0050] FIG. 10 is a perspective view of a product overwrapped with
the protective tubing of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0051] 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.
[0052] 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
of this 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 11. Products are overwrapped
by being inserted into the protective tubing 11 at the assembly
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.
[0053] The protective covering 10 will be described first in this
disclosure, followed by a description of a system and method for
overwrapping products utilizing the aspects of the present
invention.
[0054] Protective Overwrapping Material
[0055] 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.
[0056] 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 10 assists in providing puncture resistance and surface
protection for the product contained in the tubing 11. 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.
[0057] Additionally, in a preferred embodiment, the second layer 18
is made of a material that has cushioning properties. In one
embodiment, the second layer 18 of material is also a 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 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 11, however polyethylenic resins are
preferred.
[0058] The polyethylenic resins used in the present invention can
be those obtained by polymerizing ethylene, or polymerizing
ethylene with other aliphatic monoolefins, such as, propylene,
1-butene, 1-pentene, 3-methyl-1-butene, 4-methyl-1-pentene,
4-methyl-1-hexene, or 5-methyl-1-hexene alone or mixtures thereof,
or with various other polymerizable compounds.
[0059] Additionally, polyethylenic resins useful in the invention
include homopolymers of ethylene and copolymers of ethylene and
other ethylenically-unsaturated monomers having 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.
[0060] 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 50 mole 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.
[0061] Examples of monomers which are copolymerizable with ethylene
are vinyl acetate, 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, polyisoprene,
polychloroprene, chlorinated polyethylene, polyvinyl chloride,
styrene/butadiene copolymer, vinyl acetate/ethylene copolymer,
acrylonitrile/butadiene copolymer and vinyl chloride/vinyl acetate
copolymer.
[0062] 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. 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 agent(s) 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 agent(s) is mixed with the melted
polyethylenic plastic and nucleating 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 agent(s) 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.
[0063] 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 180-300.degree. F., and the pressure
utilized to perform the lamination process ranges from 30 to 80
p.s.i. The lamination process creates a laminated sheet material
14.
[0064] Tubing
[0065] The protective overwrapping 10 and protective tubing 11 of
the present invention may comprise a single material, a composite
material, a blend, a laminate material, or any 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 FIG. 2. To create a protective tubing 11, the material 14
is converted from a sheet material into a tubing.
[0066] 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 14. 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 14 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 11. 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 tubing 11 of the present
invention.
[0067] 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.
[0068] 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 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.
[0069] 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. 3B, the first and second
edges 24, 26 may be connected in an overlapping configuration.
Excess material extending past the connected area may be trimmed
from the tubing 11.
[0070] After the sheet material 14 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 (not 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.
[0071] 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 11, 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 11
has protective properties to substantially resist puncturing and
tearing of the tubing 11 during normal use thereof. As shown in
FIG. 8, the substantially continuous tubing 11 is adapted to have
items to be protected inserted into the cavity 34 of the tubing 11
through the first opening 32.
[0072] System for Overwrapping Products
[0073] 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 all of the processes for creating the
substantially continuous tubing 11, 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 for 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 11, and a means for
creating the seam 29, such as a sewing apparatus.
[0074] Once the tubing 11 has been created, it is typically rolled
into a substantially continuous roll 30 as shown in FIG. 1. 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 54, 58. As best shown in FIGS. 5a and 5b, the unwind
assembly 36 also has two first shafts 56, each which hold a
plurality of rollers 54 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.
[0075] 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. 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.
[0076] In a preferred embodiment, as shown in FIGS. 6 and 7, the
cutting assembly 38 also 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 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 the tubing 11 for shearing the
tubing 11 into discrete sections.
[0077] 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 rail 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.
[0078] 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.
[0079] 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 more of the
following: a portion of the extended tubing 11, 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.
[0080] Method of Overwrapping Products
[0081] 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 ordinary skill in
the art would readily understand, varying steps in the system 15
may occur in 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 11 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 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 11 as shown in FIG. 9. The tubing 11 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 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.
[0082] 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.
[0083] 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.
[0084] 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.
[0085] 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.
* * * * *