U.S. patent application number 11/934657 was filed with the patent office on 2008-05-08 for fiberfill packaging method and apparatus.
This patent application is currently assigned to L&P PROPERTY MANAGEMENT COMPANY. Invention is credited to Robert D. Heilman, Jeffrey R. Kumm, Linda Pumphrey.
Application Number | 20080104932 11/934657 |
Document ID | / |
Family ID | 39358507 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080104932 |
Kind Code |
A1 |
Heilman; Robert D. ; et
al. |
May 8, 2008 |
FIBERFILL PACKAGING METHOD AND APPARATUS
Abstract
A method for packaging a product comprises compressing a product
in a first direction and a second direction, and transferring the
product into a package having an opening, wherein the product is
oriented in the package such that neither the first direction nor
the second direction are aligned with the opening is disclosed. A
packaging apparatus comprises a first plate oriented in a first
direction, a second plate oriented in a second direction that
intersects the first direction, a third plate oriented in a third
direction that intersects the second direction but does not
intersect the first direction, and a chute aligned with the third
direction.
Inventors: |
Heilman; Robert D.;
(Buffalo, NY) ; Pumphrey; Linda; (Fairfield,
OH) ; Kumm; Jeffrey R.; (Amherst, NY) |
Correspondence
Address: |
CONLEY ROSE, P.C.
5601 GRANITE PARKWAY, SUITE 750
PLANO
TX
75024
US
|
Assignee: |
L&P PROPERTY MANAGEMENT
COMPANY
South Gate
CA
|
Family ID: |
39358507 |
Appl. No.: |
11/934657 |
Filed: |
November 2, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60864353 |
Nov 3, 2006 |
|
|
|
Current U.S.
Class: |
53/439 ; 428/222;
53/469; 53/529 |
Current CPC
Class: |
B65B 1/24 20130101; Y10T
428/249922 20150401; B65B 63/02 20130101 |
Class at
Publication: |
53/439 ; 428/222;
53/469; 53/529 |
International
Class: |
B65B 1/24 20060101
B65B001/24; B65B 63/02 20060101 B65B063/02 |
Claims
1. A method for packaging a product, comprising: compressing a
product in a first direction and a second direction; and
transferring the product into a package having an opening; wherein
the product is oriented in the package such that neither the first
direction nor the second direction are aligned with the
opening.
2. The method of claim 1 wherein the first direction is
substantially perpendicular to the second direction.
3. The method of claim 1: wherein the product is transferred into
the package in a third direction; and wherein the product is not
substantially compressed in the third direction.
4. The method of claim 3 wherein the third direction is
substantially perpendicular to the first direction and the second
direction.
5. The method of claim 1 wherein the package comprises a plurality
of side surfaces, and the product expands until the product is
constrained by the side surfaces of the package.
6. The method of claim 5 wherein the product only expands in the
first direction and the second direction.
7. The method of claim 1 further comprising sealing the
package.
8. The method of claim 1 wherein the product is fiberfill.
9. An apparatus comprising: a first plate oriented in a first
direction; a second plate oriented in a second direction that
intersects the first direction; a third plate oriented in a third
direction that intersects the second direction but does not
intersect the first direction; and a chute aligned with the third
direction.
10. The apparatus of claim 9 further comprising: a loading area
configured to receive a product, the loading area intersecting the
first direction.
11. The apparatus of claim 9 wherein the first direction, the
second direction, and the third direction are substantially
perpendicular to one another.
12. The apparatus of claim 9: wherein the first plate has a first
range of motion extending between a first uncompressed position and
a first compressed position; wherein the second plate has a second
range of motion extending between a second uncompressed position
and a second compressed position; and wherein upon placing the
first plate in the first compressed position, at least a portion of
the second plate is flush with at least a portion of the first
plate for at least part of the second range of motion.
13. The apparatus of claim 9: wherein the second plate has a second
range of motion extending between a second uncompressed position
and a second compressed position; wherein the third plate has a
third range of motion extending between a retained position and a
transferred position; and wherein upon placing the second plate in
the second compressed position, at least a portion of the third
plate is flush with at least a portion of the second plate for at
least part of the third range of motion.
14. The apparatus of claim 9 wherein the third plate transfers a
product through the chute without substantially compressing the
product in the third direction.
15. A packaged product comprising: a package having a plurality of
sides and an opening; and a product disposed within the package,
the product having a compressed direction and an uncompressed
direction; wherein the compressed direction is aligned with at
least one of the sides and the uncompressed direction is aligned
with the opening.
16. The packaged product of claim 15 wherein the product is
fiberfill.
17. The packaged product of claim 15 wherein upon removal of a
first portion of the product from the package through the opening,
a second portion of the product remains within the package.
18. The packaged product of claim 15 wherein the opening further
comprises a closure that is selectively opened and closed.
19. The apparatus of claim 18 wherein the product remains in the
package when the closure is opened.
20. The apparatus of claim 18 wherein the package is substantially
free of any void space when the closure is closed.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to and the benefit
under 35 U.S.C. .sctn.119(e) of U.S. Provisional Application Ser.
No. 60/864,353 filed Nov. 3, 2006 and entitled "Fiberfill Packaging
Method and Apparatus," hereby incorporated herein for all
purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND
[0004] Fiberfill is a product comprising a plurality of loose
fibers that are not woven, knitted, or otherwise bonded together.
Generally, fiberfill is used as cushioning or stuffing material for
pillows, mattress toppers, quilts, toys, and other stuffed items.
Fiberfill has a resilient nature such that it returns to its
original shape when compressed or otherwise distorted. Fiberfill is
typically lofty in nature in that it has a relatively low mass per
unit volume. The lofty nature of fiberfill leads to high
transportation and storage costs because these costs are generally
based on the volume, not the weight, of the fiberfill.
Consequently, a need exists for a method to package fiberfill and
other products so as to reduce their volume and thus their
transportation and storage costs.
SUMMARY
[0005] In one aspect, the disclosure describes a method for
packaging a product, comprising compressing a product in a first
direction and a second direction, and transferring the product into
a package having an opening, wherein the product is oriented in the
package such that neither the first direction nor the second
direction are aligned with the opening.
[0006] In a second aspect, the disclosure describes an apparatus
comprising a first plate oriented in a first direction, a second
plate oriented in a second direction that intersects the first
direction, a third plate oriented in a third direction that
intersects the second direction but does not intersect the first
direction, and a chute aligned with the third direction.
[0007] In a third aspect, the disclosure describes an apparatus
comprising a package having a plurality of sides and an opening,
and a product located within the package, the product having a
compressed direction and an uncompressed direction, wherein the
compressed direction is aligned with at least one of the sides and
the uncompressed direction is aligned with the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present disclosure,
and for further details and advantages thereof, reference is now
made to the following Detailed Description taken in conjunction
with the accompanying drawings, in which:
[0009] FIG. 1 is a flow chart of one embodiment of a packaging
method;
[0010] FIG. 2 is a perspective view of one embodiment of a
packaging apparatus;
[0011] FIG. 3 is a top plan view of the packaging apparatus of FIG.
2;
[0012] FIG. 4 is a front elevation view of the packaging apparatus
of FIG. 2;
[0013] FIG. 5 is a side elevation view of the packaging apparatus
of FIG. 2;
[0014] FIG. 6 is a side view of a loading area of the packaging
apparatus of FIG. 2, the loading area comprising a lid shown in an
open position;
[0015] FIG. 7 is a side view of the loading area of FIG. 6
depicting the lid in a closed position;
[0016] FIG. 8 is a cross-sectional side view of the packaging
apparatus of FIG. 2 taken along section line 8-8 of FIG. 3;
[0017] FIG. 9 is a cross-sectional side view of the packaging
apparatus of FIG. 2 taken along section line 9-9 of FIG. 4;
[0018] FIG. 10 is a perspective view of a package positioned
adjacent a discharge chute of a packaging apparatus and receiving a
compressed product therein;
[0019] FIG. 11 is a top view of one embodiment of a packaged
product; and
[0020] FIG. 12 is a side view of the packaged product of FIG.
11.
DETAILED DESCRIPTION
[0021] Described herein is a product packaging method and apparatus
suitable for implementing the product packaging method. The method
comprises compressing a product in at least one direction to reduce
the void space therein without compressing the product in at least
another direction. The product is then transferred into a package
such that the compressed surfaces of the produce are aligned with
the sides of the package and an uncompressed surface of the product
is aligned with an opening in the package. The resulting packaged
product has a substantially reduced volume as compared to an
uncompressed product.
[0022] In one embodiment, the product that is compressed by the
method and apparatus described herein is fiberfill, which may be
used as a stuffing and/or cushioning material. Fiberfill comprises
a plurality of loose fibers that are not woven, knitted, or
otherwise bonded together. Fiberfill may comprise natural fibers,
such as cotton, wool, or silk, or synthetic fibers, such as
polyester, polypropylene, or rayon. Persons of ordinary skill in
the art are aware of many other fiber types and blends that are
suitable for use as fiberfill. The fiberfill has a resilient nature
such that it returns to its original shape when compressed or
otherwise distorted. Fiberfill is generally lofty in nature in that
it has a relatively low mass per unit volume. The lofty nature of
fiberfill leads to high transportation and storage costs because
these costs are generally based on the volume, not the weight, of
the fiberfill. Thus, significant cost savings and/or convenience
can be achieved by compressing the fiberfill so that the fiberfill
consumes less space when it is shipped and stored.
[0023] FIG. 1 illustrates a flowchart of one embodiment of a
packaging method 100. Briefly, the packaging method 100 comprises
receiving an uncompressed product at 102, compressing the product
in a first direction at 104, compressing the product in a second
direction at 106, and transferring the product into the package at
108. If desired, the packaging method 100 may also include sealing
the package at 110. Each of the blocks in the packaging method 100
is described in detail below.
[0024] In an embodiment, the packaging method 100 comprises
receiving the uncompressed product at 102. Generally, a packaging
apparatus, such as the packaging apparatus described herein, will
be configured with a loading area or other device that positions
the product in the packaging apparatus such that the product may be
subsequently compressed in the first direction per 104. An operator
may manually load the product into the packaging apparatus, or a
machine may automatically load the product into the packaging
apparatus. If desired, the packaging apparatus may be part of a
larger process such that the packaging apparatus receives the
product immediately after the product leaves a manufacturing
process.
[0025] In an embodiment, the packaging method 100 comprises
compressing the product in a first direction at 104. The first
direction may be part of a Cartesian coordinate system containing
three perpendicular coordinate directions. For example, the first
direction could be substantially horizontal with respect to a
reference plane. Alternatively, the first direction may be a
direction that is not perpendicular to the second direction and/or
the third direction, but instead exists at an angle, such as about
75, about 60, about 45, about 30, or about 15 degrees, with respect
to one or both of the second and third directions. Further, the
first direction could be part of any other coordinate system known
to persons of ordinary skill in the art.
[0026] In an embodiment, the packaging method 100 comprises
compressing the product in a second direction at 106. The second
direction may also be part of the Cartesian coordinate system, and
may be perpendicular to the first direction. For example, if the
first direction is substantially horizontal, then the second
direction may be substantially vertical. Alternatively, the second
direction may be a direction that is not perpendicular to the first
direction and/or the third direction, but instead exists at an
angle, such as about 75, about 60, about 45, about 30, or about 15
degrees, with respect to one or both of the first and third
directions. Further, the second direction could be part of any
other coordinate system known to persons of ordinary skill in the
art.
[0027] The extent of compression in the first direction and the
second direction can be varied to achieve a desired size and shape
of compressed product. Specifically, if a smaller product is
desired, the compression in the first direction and/or the second
direction may be increased such that the void space within the
product is reduced. For example, the product can be compressed in
the first direction and the second direction until at least about
80, at least about 90, or at least about 99 percent of the void
space in the product is removed. In addition, the compression in
the first direction and the second direction can be varied to
achieve the desired shape of the compressed product. For example,
if the compression in the first direction and the second direction
remove 99 percent of the void space within the product, a
rectangular product may be obtained by compressing the product in
the first direction to remove 60 percent of the void space, and
then compressing the product in the second direction to remove the
remaining 33 percent of the void space. Such a compression scheme
would produce a product that is wider in the second direction than
in the first direction. In other embodiments, the compression in
the first direction may be less than, greater than, or
substantially equal to the compression in the second direction,
resulting in various sizes and shapes of compressed products.
[0028] In an embodiment, the packaging method 100 comprises
transferring the product into the package at 108. The product may
be transferred into the package in a third direction by a variety
of different methods, such as by pushing, pulling, or otherwise
transferring the product into the package. The third direction may
also be part of the Cartesian coordinate system, and may be
substantially perpendicular to the first direction and/or the
second direction. For example, if the first direction is
substantially horizontal from left to right and the second
direction is substantially vertical, then the third direction could
be substantially horizontal from front to back. Alternatively, the
third direction may be a direction that is not perpendicular to the
first direction and/or the second direction, but instead exists at
an angle, such as about 75, about 60, about 45, about 30, or about
15 degrees, with respect to one or both of the first and second
directions. Further, the third direction could be part of any other
coordinate system known to persons of ordinary skill in the art. In
addition, it is not required that the first, second, and third
directions meet at a common point. Instead, one or more of the
first, second, and third directions may be offset from one another,
as is illustrated in the packaging apparatus described herein.
[0029] The packaging method 100 may optionally comprise sealing the
package at 110. In an embodiment, the package is a bag-shaped
container with an open end. The open end can be closed and/or
sealed to retain the compressed product within the package and/or
protect the product. The package may be closed and/or sealed with
any type of closure device, including a drawstring, a ZIPLOC.RTM.
type closure, tape, zip-tie, heat-sealed, or other closure means.
In addition, if an airtight closure is used, a vacuum source can be
applied to the inside of the package, the outside of the package
can be compressed, or other means may be used to remove any excess
air from within the package such that the product is further
compressed and the volume of the package is further reduced.
[0030] FIGS. 2-9 illustrate various views of one representative
packaging apparatus 200 suitable for compressing a product in
accordance with the method 100 of FIG. 1. The packaging apparatus
200 comprises a loading area 202, a first compression assembly 220,
a second compression assembly 230, a third compression assembly
240, and a discharge chute 210. In an embodiment, the first
compression assembly 220 is oriented in the first direction, which
in the embodiment illustrated herein is substantially horizontal
with respect to the floor upon which the packaging apparatus
stands, and extending from left to right. In an embodiment, the
second compression assembly 230 is oriented in the second
direction, which in the embodiment illustrated herein is vertical
and substantially perpendicular to the first direction. In an
embodiment, the third compression assembly 240 is oriented in the
third direction, which in the embodiment illustrated herein is
substantially horizontal and extending from the back of the
apparatus 200 to the front of the apparatus 200 and is
substantially perpendicular to the first and second directions.
Although the first, second, and third directions are substantially
perpendicular to each other, the first, second, and third
directions do not intersect at a common point, as shown in FIGS. 8
and 9.
[0031] As best depicted in FIGS. 3, 4 and 8, in an embodiment, the
loading area 202 is a compartment configured to receive the product
that will be compressed by the packaging apparatus 200.
Specifically, the loading area 202 aligns the uncompressed product
with the first direction as described below. As depicted
specifically in FIGS. 6 and 7, the loading area 202 contains a lid
203 that may be opened as shown in FIG. 6 and closed as shown in
FIG. 7 so that the operator can insert a predetermined amount of
the product, such as three pounds of fiberfill, for example, into
the packaging apparatus 200. If desired, the loading area 202 may
be configured with a latch, lock, or similar means to allow the lid
203 to be secured in the closed position.
[0032] FIG. 8 depicts the first compression assembly 220 oriented
in the first direction. The first compression assembly 220
comprises a first cylinder 228, a first piston 222, a first plate
224, and a first housing 226. The first plate 224 may be circular,
elliptical, square, rectangular, or any other shape and is
generally shaped and sized to conform to the shape of the inside of
the first housing 226. The first compression assembly 220 may be
operated by pneumatic, hydraulic, electrical, mechanical, or some
other actuation means to move the first piston 222 and first plate
224 relative to the first cylinder 228 and first housing 226.
Specifically, the first piston 222 and first plate 224 are
extendable between a first uncompressed position, as shown in solid
lines in FIG. 8, and a first compressed position, as shown in
phantom lines in FIG. 8. The movement of the first plate 224 from
the first uncompressed position to the first compressed position
causes the product to be compressed in the first direction without
being substantially compressed in either the second or third
directions. As described below, the second compression assembly 230
is typically oriented in a second uncompressed position and the
third compression assembly is typically in the retained position
when the first plate 224 is moved from the first uncompressed
position to the first compressed position.
[0033] FIGS. 8 and 9 depict the second compression assembly 230
oriented in the second direction in the second uncompressed
position and the second compressed position, respectively. The
second compression assembly 230 comprises a second cylinder 238, a
second piston 232, a second plate 234, and a second housing 236.
The second plate 234 may be circular, elliptical, square,
rectangular, or any other shape and is generally shaped and sized
to conform to the shape of the inside of the second housing 236.
The second compression assembly 230 is operated by pneumatic,
hydraulic, electrical, mechanical, or some other actuation means to
move the second piston 232 and the second plate 234 relative to the
second cylinder 238 and the second housing 236. Specifically, the
second piston 232 and the second plate 234 are extendable between a
second uncompressed position, as shown in solid lines in FIG. 8,
and a second compressed position, as shown in phantom lines in FIG.
8 and in solid lines in FIG. 9. The movement of the second plate
234 from the second uncompressed position to the second compressed
position causes the product to be compressed in the second
direction without being substantially compressed in the first or
third directions. The first compression assembly 220 is typically
oriented in the first compressed position and the third compression
assembly is typically oriented in the retained position when the
second plate 234 is moved from the second uncompressed position to
the second compressed position. In addition, at least part of the
side of the second plate 234 may move flush across at least part of
the face of the first plate 224 such that the second plate 234
scrapes any excess portion of the product, such as loose fibers,
from at least part of the face of the first plate 224. Moreover,
once the second plate 234 is in the second compressed position, the
first plate 224 may be moved back to the first uncompressed
position as shown in FIG. 8 without uncompressing the product.
[0034] FIG. 9 shows the detail of the third compression assembly
240 oriented in the third direction. The third compression assembly
240 comprises a third cylinder 248, a third piston 242, a third
plate 244, and a third housing 246. The third plate 244 may be
circular, elliptical, square, rectangular, or any other shape and
is generally shaped and sized to conform to the shape of the inside
of the third housing 246. The third compression assembly 240 is
operated by pneumatic, hydraulic, electrical, mechanical, or some
other actuation means to move the third piston 242 and the third
plate 244 relative to the third cylinder 248 and the third housing
246. Specifically, the third piston 242 and the third plate 244 are
extendable between the retained position, as shown in solid lines
in FIG. 9, and a transferred position, as shown in phantom lines in
FIG. 9. The movement of the third plate 244 from the retained
position to the transferred position causes the product to be
transferred out of the open-ended discharge chute 210 in the third
direction without being substantially compressed in any direction.
The second compression assembly 230 is typically oriented in the
second compressed position when the third plate 244 is moved from
the retained position to the transferred position. In addition, at
least part of the side of the third plate 244 may move flush across
at least part of the face of the second plate 234 such that the
third plate 244 scrapes any excess portion of the product, such as
loose fibers, from at least part of the face of the second plate
234.
[0035] FIG. 10 illustrates one embodiment of a package 250
positioned adjacent the discharge chute 210 and receiving the
compressed product 252. In an embodiment, the package 250 may
comprise an open end 254, a closed end 258, and a plurality of side
surfaces 260 joined to the closed end 258. The closed end 258 may
be configured with a handle 256 to facilitate handling of the
package 250. The open end 254 is configured to receive the
compressed product 252 and may be sized and shaped to conform to
the size of the discharge chute 210. Specifically, the open end 254
may be fitted over the chute 210 prior to moving the third plate
244 from the retained position to the transferred position. As the
third plate 244 moves to the transferred position, the compressed
product 252 is pushed out of the chute 210 and into the package 250
through the open end 254. When the compressed product 252 enters
the package 250, the product 252 expands in the first direction and
the second direction until restrained by the sides 260 of the
package 250, but does not substantially expand in the third
direction because the product 252 has not been compressed in the
third direction. The open end 254 may then be closed and/or sealed
and the product may be shipped or stored as desired.
[0036] FIGS. 11 and 12 illustrate the force of the product 252
against the package 250. As shown by the arrows in FIGS. 11 and 12,
the product 252 is constrained by the package sides 260 in the
first direction and the second direction, but not the third
direction. Specifically, the open end 254 does not have to be
closed or sealed to retain the product 252 within the package 250.
Such a configuration substantially reduces the stress placed on any
closure used on the open end 254.
[0037] There are several advantages to a product 252 that is
packaged using the disclosed packaging method 100 and apparatus
200. First, the product 252 is compressed such that it has a
substantially reduced void space. The substantially reduced void
space reduces the overall volume of the package 250, which reduces
the shipping and storage costs for the product 252. Second, a
product 252 packaged using the disclosed packaging method 100 will
remain in the package 250 after the open end 254 of the package 250
has been opened. Specifically, because the product 252 is oriented
such that the third direction is aligned with the open end 254 and
the product 252 is compressed in the first direction and the second
direction but not the third direction, the product 252 will not
substantially expand when the open end 254 of the package 250 is
open. Such a feature also allows the package 250 to be repeatedly
opened and closed without the product 252 escaping the package 250.
Finally, a product 252 packaged using the disclosed packaging
method 100 allows a consumer to remove a portion of the product 252
from the package 250 without substantially uncompressing the
remaining portion of the product 252. More specifically, the
consumer can remove a portion of the product 252 from the package
250, and then reseal the package 250 without the remaining portion
of the product 252 losing any substantial compression. Without
being limited by theory, it is envisioned that such a feature is
made possible in part by the fact that the product 252 exerts force
on the sides 260 of the package 250 and not the open end 254 or the
closed end 258.
[0038] While several embodiments have been disclosed and described
herein, it should be understood that the disclosed systems and
methods may be embodied in many other specific forms without
departing from the spirit or scope of the present disclosure. The
present examples are to be considered as illustrative and not
restrictive, and the intention is not to be limited to the details
given herein. For example, the various elements or components may
be combined or integrated in another system or certain features may
be omitted, or not implemented.
[0039] In addition, techniques, systems, subsystems, and methods
described and illustrated in the various embodiments as discrete or
separate may be combined or integrated with other systems, modules,
techniques, or methods without departing from the scope of the
present disclosure. Other items shown or discussed as directly
coupled or communicating with each other may be coupled through
some interface or device, such that the items may no longer be
considered directly coupled to each other but may still be
indirectly coupled and in communication, whether electrically,
mechanically, or otherwise with one another. Other examples of
changes, substitutions, and alterations are ascertainable by one
skilled in the art and could be made without departing from the
spirit and scope disclosed herein.
* * * * *