U.S. patent application number 12/820679 was filed with the patent office on 2010-10-14 for soap bar wrapper.
This patent application is currently assigned to Colgate-Palmolive Company. Invention is credited to Steve Johnson, Randy Kliment, Alan Nimmey, Todd VanGordon.
Application Number | 20100257821 12/820679 |
Document ID | / |
Family ID | 27404350 |
Filed Date | 2010-10-14 |
United States Patent
Application |
20100257821 |
Kind Code |
A1 |
Nimmey; Alan ; et
al. |
October 14, 2010 |
SOAP BAR WRAPPER
Abstract
A method of wrapping a generally rectangular soap bar. In one
aspect, the invention can be a method of wrapping a generally
rectangular soap bar having a shared-bottom surface comprising
wrapping a film laterally around said soap bar and overlapping the
edges of said film that extend longitudinally across a bottom
surface of said soap bar, placing said soap bar on a sealing plate
that has a shape that is complementary to the shape of the bottom
surface of said soap bar, folding the film at a longitudinal end of
said soap bar, and sealing said overlapping edges of film and the
folded film at the longitudinal end.
Inventors: |
Nimmey; Alan; (Cenon,
FR) ; VanGordon; Todd; (Basking Ridge, NJ) ;
Johnson; Steve; (Basking Ridge, NJ) ; Kliment;
Randy; (Milford, NJ) |
Correspondence
Address: |
COLGATE-PALMOLIVE COMPANY
909 RIVER ROAD
PISCATAWAY
NJ
08855
US
|
Assignee: |
Colgate-Palmolive Company
New York
NY
|
Family ID: |
27404350 |
Appl. No.: |
12/820679 |
Filed: |
June 22, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10479197 |
Jul 26, 2004 |
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PCT/US02/16914 |
May 30, 2002 |
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12820679 |
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60295380 |
Jun 1, 2001 |
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10479197 |
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60313119 |
Aug 17, 2001 |
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60295380 |
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60343379 |
Dec 21, 2001 |
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60313119 |
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Current U.S.
Class: |
53/461 |
Current CPC
Class: |
B65D 75/08 20130101;
B65D 65/10 20130101 |
Class at
Publication: |
53/461 |
International
Class: |
B65B 11/00 20060101
B65B011/00 |
Claims
1. A method of wrapping a generally rectangular soap bar having a
shared-bottom surface comprising wrapping a film laterally around
said soap bar and overlapping the edges of said film that extend
longitudinally across a bottom surface of said soap bar, placing
said soap bar on a sealing plate that has a shape that is
complementary to the shape of the bottom surface of said soap bar,
folding the film at a longitudinal end of said soap bar, and
sealing said overlapping edges of film and the folded film at the
longitudinal end.
2. A method as in claim 1 wherein the bottom surface of said soap
bar is concave in shape and said sealing plate is convex shape.
3. A method as in claim 2 wherein said film is folded at both
longitudinal ends of said soap bar.
4. A method as in claim 2 wherein the overlapping edges of film and
the folded film at the longitudinal end are sealed at about the
same time.
5. A method as in claim 2 wherein the overlapping edges of film and
the folded film at the longitudinal end are sealed
sequentially.
6. A method as in claim 2 wherein said film is a thermoplastic film
having a thickness of about 60 micron to about 180 micron and a
Taber stiffness of more than about 5.
7. A method as in claim 6 wherein said film is selected from the
group consisting of polyethylenes, polypropylenes, vinyl polymers,
acrylic polymers, styrenes and polyesters.
8. A method as in claim 7 wherein the film is biaxially oriented
polypropylene.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S.
patent application Ser. No. 10/479,197, filed Jul. 26, 2004, which
in turn is a national stage entry under 35 U.S.C. .sctn. 371 of
PCT/US02/16914, filed May 30, 2002, which in turn claims the
benefit of U.S. Provisional Application No. 60/343,379, filed Dec.
21, 2001, U.S. Provisional Application No. 60/313,119, filed Aug.
17, 2001, and U.S. Provisional Application No. 60/295,380, filed
Jun. 1, 2001, the entireties of which are hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] This invention relates to wrappers for shaped soap bars.
More particularly this invention relates to a method of wrapping a
shaped generally rectangular soap bar with a single plastic
wrapper.
BACKGROUND OF THE INVENTION
[0003] Soap bars are produced in various shapes. These range from
round, to square, to rectangular to elliptical and variations on
these shapes. Some soap bar shapes are easy to wrap while others
present a measure of difficulty. Square, rectangular and circular
shaped bars are relatively easy to package. They can be wrapped in
a single relatively thin plastic film folded at the ends and heat
sealed. These also can be packaged in a flow wrap. In this type of
wrapper the ends are fin sealed rather than being folded and
sealed. However elliptical shaped bars and generally rectangular
shapes having curved edges and curved primary surfaces present
packaging difficulties in other than flow wrap packaging. Examples
of generally rectangular soap bars are shown in U.S. Des. 345,817;
U.S. Des. 346,241; U.S. Des. 348,539 and U.S. Des. 348,541. These
design patents are incorporated herein by reference. These have a
rectangular-like shape having main top, bottom, side and end
surfaces that are curved. Further the transition of one surface to
another surface is curved. The soap bars are rectangular-like but
with non-planar top, bottom and front and rear connecting surfaces.
The end surfaces may have a flat area for sealing but otherwise
usually are curved. This includes ovoid shaped soap bars since they
also have an elongated type of structure. The transition from one
surface to another surface preferably also is curved. This curving
gives the soap bar a pleasing, aesthetic shape. Such soap bars are
described herein as generally rectangular shaped soap bars.
[0004] In order to wrap such bars so that they have a substantially
rectangular shape, a stiffener reinforcing element is
conventionally used to shape the package. The stiffener reinforcing
element is a piece of relatively stiff material such as paperboard,
paperboard coated with plastic or plastic that is wrapped laterally
around the soap bar with the ends of the soap bar being open. Then
the soap bar and the stiffener reinforcing element are surrounded
by a wrapper which is folded at its ends and the flaps of the folds
heat sealed, one to the other. There also is a longitudinal seal of
the film on the bottom surface of the package.
[0005] A problem in the use of a stiffener reinforcing element is
that it requires the handling and use of two films. The stiffener
reinforcing element film and the wrapper film. The packaging
process and cost can be reduced with the use of only one film, the
wrapper film. That is, the stiffener reinforcing element films is
deleted. It has been found that this can be done if a particular
wrapper film is used. This film will be sufficiently stiff to
provide a rectangular shape to the packaged soap bar, but yet be
able to be readily folded and sealed to produce the package.
BRIEF DESCRIPTION OF THE INVENTION
[0006] It has been found that a reinforcing element stiffener is
not required if a plastic wrapper of about 60 micron to about 180
micron is used, and preferably about 90 micron to about 150 micron.
This plastic can be of a monolayer or laminate multi-layer
construction. Such a plastic has a sufficient thickness to form and
maintain a generally rectangular shape, but yet a thickness where
the film can be folded to form the end side panels without the need
for optional fold enhancement techniques. Preferably it will be a
thermoplastic film to aid in the sealing of the film. In such a
wrapping of soap bars there also is a longitudinal lap seal on the
lower surface of the package with the end seals having folds and
the folds sealed. There usually are heat seals since thermoplastic
films are used. An adhesive can be used to form such heat seals in
conjunctions with the thermoplastic films.
[0007] The films of this invention have a Taber stiffness of more
than about 5 to form the package and are sufficiently flexible so
that end panels can be formed and sealed. Preferably the Taber
stiffness is about 8 to 20. A preferred film is biaxially oriented
polypropylene. This can be a monolayer or a multi-layer of two or
more layers. However any other sealable plastic films having
similar Taber stiffness can be used. These usually will have a
thickness in the 60 micron to 180 micron range. However, it is the
stiffness that primarily will control use. The films should have a
Taber stiffness of about 7 to 20 which is equivalent to that of
about 60 micron to about 180 micron biaxially oriented
polypropylene film.
[0008] In one optional embodiment the films are weakened by
thinning, perforating, or slitting at the point that a fold is to
be made in the film to make the end panels for the soap bar
package. This will aid in making folds at the proper fold lines and
will also provide a technique for making more consistent and crisp
folds.
[0009] In a further optional embodiment to aid in making the
longitudinal bottom seal a seal plate is used that is complementary
to the shape of the bottom surface of the soap bar. In a preferred
embodiment the bottom surface of the soap bar is concave and the
seal plate surface is convex. The concave curvature being such that
the convex surface of the seal plate contacts the concave curvature
of the soap bar surface. In this way a good longitudinal heat seal
can be made.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a top plan view of a sheet of film having fold
assisting perforations.
[0011] FIG. 2 is a top plan view of a sheet of film having fold
assisting slits.
[0012] FIG. 3 is a side elevational view of a seal plate having a
seal surface complimentary to the bottom surface of a soap bar.
[0013] FIG. 4 is a side elevational view if a soap bar on the
sealing plate of FIG. 3.
[0014] FIG. 5 is a side elevational view of a wrapped soap bar
being sealed on the seal plate of FIG. 3.
[0015] FIG. 6 is a view of a soap bar package with folded end
seals.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention although useful with many objects will
be described with regard to a soap package that does not require a
stiffener to wrap generally rectangular soap bars and will be set
out in more detail with reference to the preferred embodiments. A
generally rectangular soap bar is one described above that has an
elongated rectangular-like shape inclusive of an ovoid shape, with
main surfaces that are curved and preferably curved in the
transition from one main surface to another. Examples are shown in
the above U.S. Design Patents which have been incorporated herein
by reference. It is an aesthetically pleasing shaped soap bar and
one that is relatively easy to grip and to use. However, it is
difficult to package in other than a carton, flow wrap, or a two
component package that requires both a stiffener sheet laterally
around the soap bar and a wrapper film that fully encloses the soap
bar.
[0017] It has been found that a one piece package can be used to
package soap bars and other objects that are not generally
rectangular in shape. A single plastic film having a thickness of
60 micron to about 180 micron and preferably about 90 micron to
about 150 micron, and a Taber stiffness of more than about 5, and
preferably about 7 to about 20 can be used. This is an average
Taber Stiffness for both directions. This film is sufficiently
stiff to form a rectangular-like package for the soap bar or other
object. This film can be opaque, transparent or translucent. The
film also can be printed with a decoration or information about the
product.
[0018] FIG. 1 shows a soap bar that is packaged in a 104 micron
biaxially oriented polypropylene film. The soap bar is generally
rectangular, having curved surfaces where the top and bottom
surfaces intersect the longitudinal side surfaces and the lateral
end surfaces. The present film will provide a package with
essentially flat top and bottom surfaces. At the corners there may
be some chamfering of the film. However, this chamfering is in
itself decorative.
[0019] It also is a part of the present invention to form weakened
points or lines for the end folds of the soap wrapper to be formed.
In wrapping the soap bar a piece of film is cut and is wrapped
laterally around a soap bar. Where the longitudinal ends of the
film overlaps, a seal is provided on the bottom wall surface. The
ends are then folded inward to form end seals. This folding inward
consists of first folding inward the ends of the sidewalls and then
folding inward over the folded ends of the sidewalls the ends of
the top wall and bottom wall. This folding of the ends of the top
wall and the bottom wall can be in either order. However, it is
preferred to first fold the end of the bottom wall and then the end
of the top wall. After the folds have been made the overlapping
pieces are sealed, one to the other to form the side. This usually
will be through a heat sealing through the use of a thermoplastic
plastic material which may have a coating to assist in bonding.
[0020] When the film has a relatively high Taber stiffness and
consequently is relatively thick it is advantageous to weaken the
film where folds are to be made. FIG. 1 shows a plurality of
perforations 12 and 14 in film 10 where there is to be a fold to
form the end walls 13. The portion 11 will form the top surface,
bottom surface and the connecting sidewall surfaces. Perforations
16 and 18 are fold lines in the end walls to form the overlapping
seals as described above. FIG. 2 shows the use of slits to form the
weakened areas. The film 20 has slits 22 and 24 which are fold
points of the area 21 from the end wall areas 23. These
perforations or slits can be made mechanically or electronically
with the use of lasers. The area 21 will form the top surface,
bottom surface and the connecting sidewalls. The area 23 will form
the folded and sealed end walls. Slits 26 and 28 are weak
points/lines to also assist in making the folds to form the end
walls. This weakening assists the automatic packaging equipment to
make the folds at the right position. A further embodiment is that
in place of perforations and slits, the film can be weakened by
being thinned at these fold points or lines to about half its
thickness. This technique will preserve the barrier function of the
package's main body panels.
[0021] In addition to making seals in the end walls, there is the
need to make a longitudinal seal in the bottom of the package. In
this seal the film is overlapped and the overlapped portions heat
sealed together. This is conventionally accomplished by the wrapped
soap bar passing over a heated seal plate. This seal plate usually
is a flat plate. However, for soap bars with a shaped lower surface
it is preferred that the seal plate have a surface that is
complimentary to the shape of the bar lower surface.
[0022] FIG. 3 shows a seal plate 30 having a planar lower surface
32 and a convex upper surface 34. As is seen in FIG. 4 this convex
surface 34 is complementary to the concave lower surface 44 of soap
bar 40. FIG. 5 shows a packaged soap bar 40 on seal plate 30 with
the lower surface 48 of film 42 being sealed. The wrapped soap bar
moves over the seal plate surface 34 at a rate of about 60 to 600
soap bars a minute. Front side 45 of the soap wrapper 42 is shown
in this view. Also shown are the folds 46(a) and 47(a) on the left
side end of the soap bar package and 46(b) and 47(b) on the right
side end of the soap bar package. Further shown are the parts 56(a)
and 58(a) of the front side 45 that are first folded in with the
similar parts from the rear side surface to form part of the end
seal. This shows rear side end 56(b) that is folded in to form the
left side. The end seals can be made at about the time that the
bottom surface seal is being made, or can be made prior to or
subsequent to making the bottom surface seal. As described above
the film material to form the end walls is folded. The end film
material from the front and rear sidewalls is folded inwardly
first, and then the top surface and the bottom surface film
materials are folded in an overlapping arrangement and sealed. This
end seal configuration is further shown in FIG. 6.
[0023] The film material can be essentially any thermoplastic
having a thickness of about 60 microns to about 180 microns and
preferably about 90 microns to about 150 microns. The Taber
stiffness should be more than about 5, and preferably about 7 to
20. The useful plastics are polyethylenes, polypropylenes, vinyl
polymers such as polyvinyl chloride and polyvinyl acetate,
ethylene-propylene copolymers, acrylic polymers, styrenes and
polyesters such as polyethylene terephthalate. Functional
equivalents of these materials also can be used. A preferred
material is biaxially oriented polypropylene. These thermoplastics
can be transparent, translucent or opaque and can contain fillers
and blowing agents.
* * * * *