U.S. patent application number 10/996798 was filed with the patent office on 2006-01-05 for apparatus and method for packaging sheet material.
Invention is credited to Janica S. Behnke, Timothy P. Hartjes, Eric L. Stevens.
Application Number | 20060000190 10/996798 |
Document ID | / |
Family ID | 34619643 |
Filed Date | 2006-01-05 |
United States Patent
Application |
20060000190 |
Kind Code |
A1 |
Behnke; Janica S. ; et
al. |
January 5, 2006 |
Apparatus and method for packaging sheet material
Abstract
An apparatus and method for packaging sheet material. The
apparatus comprises a housing, a first forming guide, and a banding
unit. The housing defines a cylindrical cavity which is open at
both ends and includes a longitudinal opening which intersects the
cylindrical cavity. The first forming guide is affixed to the
housing adjacent the longitudinal opening and extends into the
cylindrical cavity. The banding unit is disposed adjacent the
downstream end of the cylindrical cavity. The method comprises
imparting a U-shaped form upon a stack of sheet material by
insertion of the stack into the upstream end of a cylindrical
cavity. The U-shaped stack of sheet material is then moved toward
and out of the downstream end of the cylindrical cavity. Finally,
the U-shaped stack is banded as the stack emerges from the
cylindrical cavity.
Inventors: |
Behnke; Janica S.;
(Appleton, WI) ; Stevens; Eric L.; (Middleville,
MI) ; Hartjes; Timothy P.; (Kimberly, WI) |
Correspondence
Address: |
FULBRIGHT AND JAWORSKI LLP
555 S. FLOWER STREET, 41ST FLOOR
LOS ANGELES
CA
90071
US
|
Family ID: |
34619643 |
Appl. No.: |
10/996798 |
Filed: |
November 23, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60524773 |
Nov 24, 2003 |
|
|
|
Current U.S.
Class: |
53/399 ; 53/117;
53/133.3; 53/412; 53/429; 53/442; 53/557; 53/582 |
Current CPC
Class: |
B65B 27/08 20130101;
B65B 13/186 20130101 |
Class at
Publication: |
053/399 ;
053/442; 053/557; 053/429; 053/582; 053/117; 053/412;
053/133.3 |
International
Class: |
B65B 63/04 20060101
B65B063/04; B65B 53/02 20060101 B65B053/02; B65B 13/02 20060101
B65B013/02 |
Claims
1. An apparatus for packaging sheet material comprising: a housing
defining a cylindrical cavity open at both ends and including a
longitudinal opening in a wall of the housing, the longitudinal
opening intersecting the cylindrical cavity; a first forming guide
affixed to the housing adjacent to the longitudinal opening and
extending into the cylindrical cavity; and a banding unit disposed
adjacent a downstream end of the cylindrical cavity.
2. The apparatus of claim 1 further comprising a second forming
guide having a radially defined end affixed to the housing at an
upstream end of the cylindrical cavity.
3. The apparatus of claim 1, wherein the first forming guide
extends longitudinally beyond an upstream end of the cylindrical
cavity.
4. The apparatus of claim 1, wherein the first forming guide
includes parallel walls, each being disposed on opposite sides of
the longitudinal opening.
5. The apparatus of claim 1 further comprising a shrink-wrap unit
disposed downstream of the banding unit.
6. The apparatus of claim 5 further comprising a perforation unit
disposed downstream of the shrink-wrap unit.
7. An apparatus for packaging sheet material comprising: a housing
defining a cylindrical cavity open at both ends and including a
longitudinal opening in a wall of the housing, the longitudinal
opening intersecting the cylindrical cavity; a first forming guide
affixed to the housing and extending into the cylindrical cavity,
the first forming guide including parallel walls, each being
disposed on opposite sides of the longitudinal opening; and a
second forming guide having a radially defined end affixed to the
housing at an upstream end of the cylindrical cavity; and a banding
unit disposed adjacent a downstream end of the cylindrical
cavity.
8. The apparatus of claim 7, wherein the first forming guide
extends longitudinally beyond an upstream end of the cylindrical
cavity.
9. The apparatus of claim 7 further comprising a shrink-wrap unit
disposed downstream of the banding unit.
10. The apparatus of claim 9 further comprising a perforation unit
disposed downstream of the shrink-wrap unit.
11. An apparatus for packaging sheet material comprising: a housing
defining a cylindrical cavity open at both ends and including a
longitudinal opening in a wall of the housing, the longitudinal
opening intersecting the cylindrical cavity; a first forming guide
affixed to the housing, extending longitudinally beyond an upstream
end of the cylindrical cavity, and extending radially into the
cylindrical cavity, the first forming guide including parallel
walls, each being disposed on opposite sides of the longitudinal
opening; and a second forming guide having a radially defined end
affixed to the housing at an upstream end of the cylindrical
cavity; a banding unit disposed adjacent a downstream end of the
cylindrical cavity; a shrink-wrap unit disposed downstream of the
banding unit; and a perforation unit disposed downstream of the
shrink-wrap unit.
12. An apparatus for packaging sheet material comprising: a housing
defining a cylindrical cavity open at both ends; means for causing
a stack of sheet material to take on a U-shaped form, wherein the
cylindrical cavity is adapted to allow passage of the U-shaped form
of the stack of sheet material therethrough; means for inserting a
support into the stack of sheet material as the U-shaped stack of
sheet material passes through the cylindrical cavity; and a banding
unit disposed adjacent a downstream end of the cylindrical
cavity.
13. A method of packaging sheet material comprising: imparting a
U-shaped form upon a stack of sheet material by insertion of the
stack into an upstream end of a cylindrical cavity, a diameter of
the cylindrical cavity being less than a width of the stack; moving
the U-shaped stack toward and out of a downstream end of the
cylindrical cavity; and banding the U-shaped stack as the stack
emerges from the downstream end of the cylindrical cavity.
14. The method of claim 13 further comprising placing a
heat-shrinkable wrap about the banded stack; and heating the
heat-shrinkable wrap.
15. The method of claim 14 further comprising perforating the
heat-shrinkable wrap.
16. The method of claim 13, wherein imparting the U-shaped form
upon the stack includes imparting the U-shaped form using a first
forming guide extending into the cylindrical cavity from a wall
defining the cylindrical cavity.
17. The method of claim 13, wherein imparting the U-shaped form
upon the stack includes guiding the stack into the cylindrical
cavity with a second forming guide having a radially defined end
affixed to an upstream wall defining the cylindrical cavity.
18. The method of claim 13, wherein moving the U-shaped stack
toward and out of the downstream end of the cylindrical cavity
comprises: inserting a support through an opening in a wall
defining the cylindrical cavity and into the U-shaped stack; and
moving the support and the U-shaped stack toward and out of the
downstream end of the cylindrical cavity.
19. A method of packaging sheet material comprising: imparting a
U-shaped form upon a stack of sheet material by insertion of the
stack into an upstream end of a cylindrical cavity, a diameter of
the cylindrical cavity being less than a width of the stack,
wherein a first forming guide extends into the cylindrical cavity
from a wall defining the cylindrical cavity and a second forming
guide is affixed to an upstream end of the wall defining the
cylindrical cavity; moving the U-shaped stack toward and out of a
downstream end of the cylindrical cavity; and banding the stack as
the stack emerges from the downstream end of the cylindrical
cavity.
20. The method of claim 19 further comprising placing a
heat-shrinkable wrap about the banded stack after; and heating the
heat-shrinkable wrap.
21. The method of claim 20 further comprising perforating the
heat-shrinkable wrap.
22. The method of claim 19, wherein moving the U-shaped stack
toward and out of the downstream end of the cylindrical cavity
comprises: inserting a support through an opening in a wall
defining the cylindrical cavity and into the U-shaped stack; and
moving the support and the U-shaped stack toward and out of the
downstream end of the cylindrical cavity.
23. A method of packaging sheet material comprising: imparting a
U-shaped form upon a stack of sheet material by insertion of the
stack into an upstream end of a cylindrical cavity, a diameter of
the cylindrical cavity being less than a width of the stack,
wherein a first forming guide extends radially into the cylindrical
cavity from a wall defining the cylindrical cavity and a second
forming guide is affixed to an upstream end of the wall defining
the cylindrical cavity; inserting a support through an opening in
the wall defining the cylindrical cavity and into the U-shaped
stack; and moving the support and the U-shaped stack toward and out
of the downstream end of the cylindrical cavity; and banding the
stack as the stack emerges from the downstream end of the
cylindrical cavity; placing a heat-shrinkable wrap about the banded
stack; and heating the heat-shrinkable wrap.
24. The method of claim 23 further comprising perforating the
heat-shrinkable wrap.
Description
PRIORITY
[0001] Priority is claimed to U.S. Provisional Patent Application
No. 60/524,773, filed Nov. 21, 2003, and to U.S. patent application
Ser. No. 10/772,967, filed Feb. 5, 2004, which claims priority to
U.S. Provisional Patent Application No. 60/446,293, filed Feb. 10,
2003. The disclosure of each of the aforementioned documents is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The field of the present invention is sheet material
packaging equipment and methods. 2. Background
[0004] Dispensers for sheet material are well known to the art and
come in different forms for dispensing a wide variety of sheet
materials. In some cases, the packaging in which the sheet material
is initially placed by the manufacturer also serves as the
dispenser. In other instances, the sheet material is packaged to
facilitate placement of the package in the dispenser and to
facilitate dispensation therefrom.
[0005] One common aspect of many of these dispensing methods is
that the sheet material is placed into a U-shaped form before being
inserted into the packaging. Different methods of forming the sheet
material into the U-shaped form are disclosed in U.S. Pat. No.
6,732,492 to Osborne et al. and U.S. Pat. No. 6,202,392 to
Greenwell et al. Other methods, such as the one disclosed in U.S.
Pat. No. 3,919,827 to Larson et al., which discloses an apparatus
for folding a stack of bags into a "W" shape prior to packaging,
are adaptable to place sheet material into a U-shaped form. The
solutions provided in the aforementioned patents, however, may not
be well suited for all types of stacked materials or for all
packaging needs.
SUMMARY OF THE INVENTION
[0006] The present invention is directed towards an apparatus and
method for packaging sheet material. Referring to the apparatus, a
housing defines a cylindrical cavity which is open at both ends. A
wall of the housing includes a longitudinal opening which
intersects the cylindrical cavity. A first forming guide is affixed
to the housing adjacent to the longitudinal opening and extends
into the cylindrical cavity. A banding unit is disposed adjacent
the downstream end of the cylindrical cavity. The first forming
guide may extend longitudinally beyond the upstream end of the
cylindrical cavity and may include parallel walls, each wall being
disposed on an opposite side of the longitudinal opening. Optional
features include a second forming guide which has a radially
defined end affixed to the housing at the upstream end of the
cylindrical cavity, a shrink-wrap unit disposed downstream of the
banding unit, and a perforation unit disposed downstream of the
shrink-wrap unit.
[0007] Turning to the method, a U-shaped form is imparted upon a
stack of sheet material by insertion of the stack into a
cylindrical cavity which has a diameter that is less than the width
of the stack. The U-shaped stack is moved toward and out of the
downstream end of the cylindrical cavity. The U-shaped stack is
then banded as it emerges from the cylindrical cavity. When in the
cylindrical cavity, a support may be inserted into the U-shaped
stack, with the support and the U-shaped stack being moved together
toward and out of the cylindrical cavity. After banding,
heat-shrinkable wrap may be placed on the banded stack, which may
also be perforated following application of heat.
[0008] Accordingly, the present invention provides an improved
apparatus and method for packaging sheet material. Other advantages
of the invention will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings, wherein like reference numerals refer to
similar components:
[0010] FIG. 1 is a perspective view of a package of sheet
material;
[0011] FIG. 2 is a perspective view of a package of sheet material
within a dispenser;
[0012] FIG. 3 is a schematic view of an apparatus for use in
packaging sheet material;
[0013] FIG. 4 is a perspective view of a forming unit for use in
packaging sheet material;
[0014] FIG. 5 is a cross-sectional along the line 5-5 of FIG.
4;
[0015] FIG. 6 is a cross-sectional along the line 6-6 of FIG.
4;
[0016] FIG. 7 is a perspective view of the upstream end of the
forming unit of FIG. 4;
[0017] FIG. 8 is a cross-sectional view of the forming unit of FIG.
4 with a stack of sheet material passing therethrough; and
[0018] FIG. 9 is a is a perspective view of the downstream end of
the forming unit of FIG. 4 with a stack of sheet material emerging
therefrom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Turning in detail to the drawings, FIG. 1 illustrates a
cartridge 11 of sheet material which is a product which may be
generated using the following apparatus and method. The cartridge
includes a U-shaped stack of sheet material 13, a supporting insert
15, a heat-shrunken wrap 17, and a band 19. The heat-shrunken wrap
17 and the band 19 both include perforations 21, 23, respectively,
to enable easy access to the sheet material 13 when the cartridge
11 is placed in the dispenser 25 shown in FIG. 2. The bottom of
supporting insert 15 extends below the ends of the U-shaped stack
of sheet material 13 by a small distance 27 to provide stability to
the cartridge 11 within the dispenser 25. The longitudinal ends of
the supporting insert 15 also extend beyond the longitudinal ends
of the U-shaped stack of sheet material 13 by a small distance 29
to provide further stability to the cartridge 12 within the
dispenser 25. The overall size of the support may vary as desired
or as needed to suit a particular dispenser.
[0020] FIG. 3 schematically illustrates a packaging apparatus 31 in
which product flows in the direction indicated, with the forming
unit being at the upstream end of the apparatus. A flat stack of
sheet material (not shown), preferably interfolded, initially
passes into the forming unit 33. The forming unit 33 imparts a
U-shaped form upon the stack of sheet material and allows the
support to be inserted into the U-shaped stack. The banding unit 35
is disposed downstream of the forming unit 33 and places a band
around the U-shaped stack of sheet material, preferably as the
U-shaped stack emerges from the forming unit 33. The band is
preferably perforated prior to being placed around the stack and is
preferably constructed from a thin sheet of paperboard material,
although other suitable materials may also be used. A shrink wrap
unit 37 is disposed downstream of the banding unit 35. This shrink
wrap unit 37 places a heat shrinkable wrap about the banded stack
of sheet material and heats the heat shrinkable wrap so that the
shrink wrap snuggly fits about the form of the U-shaped stack of
sheet material. Lastly, the newly packaged sheet material passes to
the perforation unit 39, where the perforations are made in the
shrink-wrap as shown in FIG. 1.
[0021] The banding unit 35, the shrink wrap unit 37, and the
perforation unit 39 are each of a type that are commonly used
throughout the packaging industry and are thus known to those
skilled in the packaging arts. As such, the details relating to
these downstream units are not discussed further herein.
[0022] A forming unit 33 is illustrated in FIGS. 4-6. Referring to
FIG. 4, the forming unit 33 has three primary parts: the housing
41, the first forming guide 43, and the second forming guide 45.
The housing includes a cylindrical tube 47, the interior of which
forms the cylindrical cavity 49, and two annular rings 51, 53
affixed to the cylindrical tube 47, one at the upstream end near
the second forming guide 45 and the second at the downstream end.
The cylindrical cavity 49 has a diameter less than the width of the
stack of sheet material that is to be packaged. The annular rings
51, 53 facilitate introduction of the forming unit 33 into a
production line with other equipment, such as the banding unit,
shrink wrap unit, and perforation unit. Specifically, the annular
rings 51, 53 provide a convenient surface with which to
mechanically attach the forming unit to other equipment.
[0023] As can be seen in FIGS. 5-6, an opening extends
longitudinally in the wall of the cylindrical tube 47, spanning
from the upstream end to the downstream end. A set of flanges 57a,
57b are attached to the cylindrical tube 47 at the downstream end
thereof, one on either side of the longitudinal opening. The
flanges 57a, 57b are secured together to help maintain the shape of
the cylindrical tube 47. A second set of flanges is similarly
attached to the upstream end of the cylindrical tube 47 (FIG. 6
shows one flange 59a of this second set). Two longitudinal flanges
61, 63 are also affixed to the exterior of the cylindrical tube 47,
one on either side of the longitudinal opening. These longitudinal
flanges 61, 63 are angled slightly away from the longitudinal
opening to help guide the support into and through the longitudinal
opening as discussed below.
[0024] The configuration of the first forming guide 43 is best seen
in FIGS. 5 and 6. Referring to FIG. 5, which shows the
cross-sectional view of the forming unit 33, the first forming
guide 43 is constructed of parallel walls 65, 67, each affixed to
the cylindrical tube 47 on opposite sides of the longitudinal
opening. The combination of the gap in the cylindrical tube 47 and
the parallel walls 65, 67 of the first forming guide 43 allow
insertion of the support into the formed stack of sheet material as
the stack passes through the forming unit 33. As can be seen in
FIG. 6, the two parallel walls of the first forming guide merge to
form an integral extension 69 which protrudes beyond the upstream
end of the cylindrical tube 47. The lower portion 71 of this
extension 69 is tapered to facilitate the passage of a stack of
sheet material.
[0025] FIGS. 4 and 6 best illustrate the second forming guide 45.
The second forming guide 45 includes a radially defined end 73
which is affixed to the upstream end of the housing 41. The inner
radius of the radially defined end 73 is approximately equal to the
inner radius of the cylindrical tube to allow a stack of sheet
material to easily transition from the second forming guide 45 into
the cylindrical tube 47. The opposite end 75 of the second forming
guide 45 is linearly defined, having an approximately rectangular
shape with three physical sides. The side walls of the second
forming guide 45 at the rectangular end 75 are set apart at least
as wide as the stack of sheet material. The rectangular end 75 of
the second forming guide 45 enables a flat stack of sheet material
to be conveyed from standard packaging equipment directly onto the
second forming guide 45 without significant, if any, modification
to the standard equipment. Between the two opposing ends of the
second forming guide 45, the walls of the second forming guide
smoothly transform from the rectangular shape at the rectangular
end 75 to the circular shape at radially defined end 73.
[0026] With the forming guides configured thusly, when a flat stack
of sheet material passes into the rectangular end of the second
forming guide and is pushed towards the radially defined end, the
outer edges of the flat stack curl about either side of the
extension of the first forming guide. The two forming guides thus
guide the stack of sheet material into the U-shaped form that
allows the stack to pass into the cylindrical cavity and is desired
for the final product.
[0027] Referring to FIGS. 7-9, the process of passing a stack of
sheet material through the forming unit is illustrated. In FIG. 7,
a stack of sheet material 81 is shown entering the second forming
guide 45. The stack 81 is moving toward the radially defined end 73
of the second forming guide 45. At this point, the flat stack of
sheet material 81 is beginning to take on the U-shaped form that is
desired for the final product. In particular, both sides 83, 85 of
the stack 81 are being curled upward by the second forming guide 45
to form the legs of the U-shaped form, while as the stack 81 moves
forward, the middle portion 87 of the stack 81 will be held down by
the lower edge of the first forming guide 43. FIG. 8 shows the
stack of sheet materials 81 within the cylindrical cavity 49. The
support 89 for the final packaged product is being inserted through
the longitudinal opening in the cylindrical tube 47. The parallel
walls 62, 65 of the first forming guide allow the support to be
inserted into the center of the U-shaped form of the stack of sheet
material 81. Once the support 89 is inserted into the stack of
sheet material 81, the stack 81 and support 89 are pushed or guided
out of the downstream end of the cylindrical cavity. FIG. 9 shows
the stack 81 emerging from the forming unit 33 after it has already
had a band 91 placed about it by the banding unit. At this point,
the stack is ready to be passed to the shrink-wrap unit and then to
the perforation unit, thereby forming the cartridge 11 shown in
FIG. 1.
[0028] Thus, an apparatus and a method for packaging sheet material
are disclosed. While embodiments of this invention have been shown
and described, it will be apparent to those skilled in the art that
many more modifications are possible without departing from the
inventive concepts herein. The invention, therefore, is not to be
restricted except in the spirit of the following claims.
* * * * *