U.S. patent application number 13/944614 was filed with the patent office on 2014-02-20 for packaging structure.
The applicant listed for this patent is Illinois Tool Works Inc.. Invention is credited to Lloyd W. Lenig, John A. Rometty.
Application Number | 20140050897 13/944614 |
Document ID | / |
Family ID | 50100233 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140050897 |
Kind Code |
A1 |
Rometty; John A. ; et
al. |
February 20, 2014 |
PACKAGING STRUCTURE
Abstract
A rigid, shaped board structure is formed from a sheet of
material having a length and width. The sheet has a first side and
a second side. The sheet of material is folded in an accordion fold
defining a plurality of flutes. The flutes have first and second
legs opposing one another, defined by parallel material fold lines
such that a width of the first legs is about equal to a width of
the second legs. An adhesive is applied on at least one of each
opposing first and second legs. The sheet of material with the
adhesive thereon is compressed to fold along the fold lines to form
a flat compressed board. The flat compressed board is folded along
at least one board fold line parallel to the material fold lines to
form the rigid, shaped board structure.
Inventors: |
Rometty; John A.;
(Barrington, IL) ; Lenig; Lloyd W.; (Plymouth,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Illinois Tool Works Inc. |
Glenview |
IL |
US |
|
|
Family ID: |
50100233 |
Appl. No.: |
13/944614 |
Filed: |
July 17, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61683631 |
Aug 15, 2012 |
|
|
|
Current U.S.
Class: |
428/174 ;
493/333 |
Current CPC
Class: |
B65D 5/5033 20130101;
Y10T 428/24628 20150115; B65D 81/054 20130101 |
Class at
Publication: |
428/174 ;
493/333 |
International
Class: |
B65D 81/05 20060101
B65D081/05 |
Claims
1. A rigid, shaped board structure, comprising: a sheet of material
having a length and width, the sheet of material having a first
side and a second side, the sheet of material being folded along
its length in an accordion fold defining a plurality of flutes, the
flutes having first and second legs opposing one another, defined
by parallel material fold lines such that a width of the first legs
is about equal to a width of the second legs; an adhesive on at
least one of each opposing first and second legs, wherein the sheet
of material with the adhesive thereon is compressed to fold along
the fold lines to form a flat compressed board, and wherein the
flat compressed board is folded along at least one board fold line
parallel to the material fold lines to form the rigid, shaped board
structure.
2. The board structure of claim 1, wherein the sheet of material is
a fibrous material.
3. The board structure of claim 2, wherein the fibrous material is
paper.
4. The board structure of claim 1 wherein the board fold line is at
an angle of 90.degree..
5. The board structure of claim 1 further including multiple board
fold lines.
6. The board structure of claim 1 wherein the rigid shaped board
defines first and second edges, the edges having a wrapping
thereover.
7. The board structure of claim 1 further comprising a wrapping
surrounding the board.
8. The board structure of claim 1 wherein the rigid, shaped board
structure is formed from multiple sheets of material, at least two
of the sheets of material being folded in an accordion fold.
9. A method for making a rigid board structure, the method
comprising: folding a sheet of material in an accordion fold to
define a plurality of flutes, the flutes having first and second
legs opposing one another forming parallel material fold lines such
that a width of the first legs is about equal to a width of the
second legs; applying an adhesive to at least one of opposing first
and second legs; compressing the sheet of material with the
adhesive thereon to fold along the material fold lines to form a
flat compressed board; and folding the flat compressed board along
at least one board fold line, the board fold line being parallel to
the material fold lines to form the rigid shaped board
structure.
10. The method of claim 9 wherein in the material is a fibrous
material.
11. The method of claim 10 wherein the fibrous material is
paper.
12. The method of claim 9 wherein the board fold line is at an
angle of 90.degree..
13. The method of claim 9 wherein the board is folded at multiple
board fold lines parallel to the material fold lines to form the
rigid shaped board structure.
14. The method of claim 9 wherein the rigid, shaped board structure
defines first and second edges, the edges having a wrapping
thereover.
15. The method of claim 9 wherein the folded, compressed board is
wrapped in material.
16. The method of claim 9, wherein the folding a sheet of material
is a first sheet of material and further including folding a second
sheet of material along material fold lines.
Description
BACKGROUND
[0001] Rigid packaging material made for corner protection, edge
protection, stacking strength, and the like, such as
Angleboard.RTM. and G-Board, commercially available from Illinois
Tool Works, Inc., are all made using a similar basic technique,
which includes cutting paper to a specific size and gluing together
layer upon layer of the paper to create the structure. The
thickness of the structure can be altered by varying the amount of
layered paper and the amount of adhesive used.
[0002] These layers of paper can be made up of a composition of
many different types of paper including, but not limited to, clay
coated recycled board, uncoated recycled board, creme face, gypsum,
felt paper, news back board, medium, and liner board. After the
materials are laminated together, the product is formed to a
desired shape, such as a 90 degree angle board.
[0003] Laminated, shaped packaging has been used for packaging
loads which require edge protection, load unitization, load
stability, beam strength, and stacking strength. These materials
eliminate the need for corrugated cartons and dramatically reduce
the amount of material needed to ship and store loads.
[0004] While laminated, shaped packaging has been used with a great
deal of success for packaging items, its strength is often limited
by differences in composition as well as the potential for
delamination of the individual layers from the structure.
Individual plies of paper have a tendency to pull away and
delaminate, reducing the strength of the board structure.
[0005] G-board has a similar structure in that it is made in the
traditional method of layering and laminating individual sheets of
paper, to shape, for example, a 90 degree angle, and then folding
the ends back over to meet in the middle. In this manner, the edges
of the structure are covered. Again, the two issues here are that
its strength is dependent on the type of paper that is used, and
the apex of the angle has only half the paper that the outer
portions or edges have.
[0006] To increase the strength of these structures, manufacturers
have experimented with varying the type and percentage of each
paper used in a given structure's composition. Similarly, attempts
have been made to increase the strength of the product by varying
the type of adhesive used, novel wrapping techniques, new types of
paper, using plastics, and the like. These derivations have met
with limited success of repeatable strength and performance. Often,
the apex of the board remains intact and is the last area to be
compromised before failure.
[0007] Accordingly, there is a need for a shaped packaging
structure that does not delaminate when a load is applied to the
structure. More desirably, such a structure can be readily
manufactured from known materials, but requires less material than
traditional structures and/or displays greater strength and
integrity than comparable structures per unit weight.
SUMMARY
[0008] An embodiment of a rigid, shaped board structure is formed
from a sheet of material having a length and width. The sheet has a
first side and a second side. The sheet of material is folded in an
accordion fold that defines a plurality of flutes. The flutes have
first and second legs opposing one another. The legs are defined by
parallel material fold lines such that the width of the first legs
is about equal to the width of the second legs.
[0009] An adhesive is on at least one of each opposing first and
second leg. The sheet of material, with the adhesive thereon, is
compressed to fold along the fold lines and forms a flat compressed
board. The flat compressed board is folded along at least one board
fold line that is parallel to the material fold lines to form the
rigid, shaped board structure.
[0010] In an embodiment the sheet of material is made of a fibrous
material, such as paper. The shaped board can be folded along the
fold line at a 90.degree. angle.
[0011] In embodiments, the board can include multiple board fold
lines. The board, which has first and second edges, can have a
wrapping thereover. The wrapping can also surround the board as a
whole.
[0012] In an embodiment, the shaped board structure is formed from
multiple sheets of material, with at least two of the sheets being
folded in an accordion fold.
[0013] The board structure can be made by folding a sheet of
material in an accordion fold to define a plurality of flutes. The
flutes have first and second legs opposing one another that form
parallel material fold lines such that a width of the first legs is
about equal to a width of the second legs.
[0014] An adhesive can be applied to at least one of opposing first
and second legs. The sheet of material with the adhesive thereon is
compressed so that the material folds along the fold lines to form
a flat compressed board. The flat compressed board is then folded
along at least one board fold line, where the board fold line can
be parallel to the material fold lines to form the rigid shaped
board structure.
[0015] In an embodiment the sheet board material is made of a
fibrous material, such as paper. The shaped board can be folded
along the fold line at a 90.degree. angle.
[0016] In an embodiment the board can include multiple board fold
lines. A wrapping can be applied over the first and second edges.
The wrapping can also be applied to surround the board as a
whole.
[0017] In an embodiment, a method for making a packaging structure
includes folding at least one sheet and further includes folding a
second sheet of material along the material fold lines. In an
embodiment, the board is folded at multiple board fold lines
parallel to the material fold lines to form the rigid shaped board
structure. In an embodiment, the method includes wrapping the
folded, compressed board in a material. The method can include
folding multiple sheets of material along material fold lines to
form the board.
[0018] These and other features and advantages of the present
disclosure will be apparent from the following detailed
description, in conjunction with the appended claims.
DESCRIPTION OF THE DRAWINGS
[0019] The benefits and advantages of the present disclosure will
become more readily apparent to those of ordinary skill in the
relevant art after reviewing the following detailed description and
accompanying drawings, wherein:
[0020] FIG. 1 is a perspective view of an embodiment of a packaging
structure formed from a single sheet of material;
[0021] FIG. 2 is a perspective view of the material of the
packaging structure folded in an accordion fold, prior to
compression;
[0022] FIG. 3 is a perspective view of the compressed material,
formed as a flat board, prior to forming to its final shape;
[0023] FIG. 4 is an end of a compressed and partially folded
board;
[0024] FIG. 5 is an end view of the folded material, prior to
compression;
[0025] FIG. 6 is and end view of the board as it is folded to its
final shape; and
[0026] FIG. 7 is a perspective view of an embodiment of the board
positioned on a load.
DETAILED DESCRIPTION
[0027] While the present device is susceptible of embodiment in
various forms, there is shown in the drawings and will hereinafter
be described various embodiments with the understanding that the
present disclosure is to be considered an exemplification of the
device and method is not intended to be limited to the specific
embodiments disclosed.
[0028] Referring now to the figures and in particular to FIGS. 1-7,
a packaging board 10 for use with bent and angled shaped corners
and objects, includes a first side 12 with a first surface 14 and a
second side 16 with a second surface 18. The board 10 has a
longitudinal axis 20 extending from a first end 22 to a second end
24.
[0029] The board 10 is formed from a sheet of material M that is
folded along a series of fold lines 26a, 26b placed at equal
distances between the edges of the board 10. The plurality of
longitudinally positioned fold lines 26a, 26b are parallel to the
board's longitudinal axis 20.
[0030] The material M is folded along the fold lines 26a, 26b to
create a series of V shaped flutes 28. The flutes 28 define peaks
30 and valleys 32, respectively on opposite sides with the peak 30
the first side 12 being the valley 32 on the second side 16, and
vice versa. The flutes 28 extend in opposite directions from one
another. For purposes of the present disclosure, the term end
refers to the terminal ends of the board 10 or material M that
forms the board 10, for example, as indicated at 22 and 24 in FIG.
1, and the term edge refers to the edges or extreme outer bounds of
the board 10 or material M as indicated at 42a and 42b in FIGS.
1-3, the edges 42a, 42b being transverse to the ends 22, 24.
[0031] As shown in FIGS. 2-4, in a partially folded state in which
the material is compressed, the flute 28 has a first flute leg 34
and second flute leg 36, that meet at a fold line, for example,
26b. As seen in FIG. 5, the first flute leg 34 has a first length
L.sub.1 and the second flute leg 36 has a second length L.sub.2. In
an embodiment, the first flute leg length L.sub.1 and second flute
leg length L.sub.2 can be substantially equal to each other.
[0032] As shown in FIG. 2, adhesive A is placed along the first
flute leg 34, the second flute leg 36, or both flute legs 34, 36 of
the fluted portions 28. The board 10 is then compressed to form a
flat laminated structure as seen in FIG. 3, having folded edges
42a, 42b along the edge of the board 10.
[0033] After the flat board is formed, the flat board is folded to
a desired final shape. For example, for an angle board, the board
10 is folded about 90.degree. along the longitudinal axis 20
approximately equidistance from the alternating lateral fold lines
26a, 26b along the board 10. As the board 10 is folded along the
longitudinal axis, two board legs 44a, 44b are formed. The board
legs 44a, 44b extend outwardly from an apex 46 and, in an
embodiment, can be substantially equal in length and density. The
board 10 can be folded in a variety of different configurations,
such as Angleboard.RTM., U-board.RTM. (U-shaped cross-section with
upstanding legs extending from a base wall), G-board, or the like.
A wrap 48, as illustrated in FIG. 6 can be placed over individual
edges, or the entire structure. It will be appreciated that the
board legs 44a, 44b of the board 10 are rigid along their lengths,
as well as rigid relative to the apex of the board 46. That is, the
legs 44a, 44b cannot be folded inward, toward one another--that is,
the apex 46 is fixed or rigid.
[0034] As shown in FIG. 7, the board is used, for example, in
protecting the corners 50 of a load 52, extending partially over
the side surfaces 54 of the load 52. The board 10 can extend from a
top surface 56 of the load 52 to a bottom surface (not shown) with
the edges 44a, 44b forming columns 58.
[0035] The advantages of the present board structure will be
appreciated by those with skill in the art. The present layered
structure created from one or a minimal number of sheets uses less
material than traditional boards, but retains the same or displays
greater strength. It will be appreciated that the present board 10
is referred to as being formed from a single sheet of material M
that is accordion folded to form a flat board laminated structure
that is then folded to a desired final configuration (e.g.,
90.degree. angled board). It will be understood that multiple
sheets can be used, so long as the sheets are accordion folded to
form the longitudinal fold lines, e.g. 26a and 26b. For example, it
may be that a single sheet of material may not have sufficient
overall width such that when folded, it creates the desired
thickness t.sub.10 (FIG. 4). In such an instance, two or more
sheets of material may be needed to obtain the desired
configuration, size, and thickness of the final board 10.
[0036] In column strength testing, the average strength of
traditional Angleboard.RTM. was measured at 946 pounds. A similar
sized present board structure exhibited column strength of 1,380
pounds, an increase of about 145%. In similar testing, a present
board having 65% of the mass of a similarly sized traditional board
retained 93% of the strength.
[0037] The shape and strength of the present board allows it to
replace existing product with a board that contains less material,
yet provides the same strength as the product it replaces. The
increased column strength of the present board dues to the presence
of the fold lines 26a and 26b lends itself to be used as a
replacement in stacking applications, where the board is expected
to reinforce a stack of product and support the additional weight
when pallets are stacked on top of each other. The present board
can also be used to replace the cross members in appliance
packaging to prevent clamp trucks from damaging the load during
handling. The present board can be used in any application that
currently uses protection on corners or edges. The present board
has a greater strength per board weight than traditional boards,
and/or while reducing the amount of material needed, subsequently
decreasing the cost of manufacture.
[0038] All patents referred to herein, are incorporated herein by
reference, whether or not specifically done so within the text of
this disclosure. In the present disclosure, the words "a" or "an"
are to be taken to include both the singular and the plural.
Conversely, any reference to plural items shall, where appropriate,
include the singular.
[0039] From the foregoing it will be observed that numerous
modifications and variations can be effectuated without departing
from the true spirit and scope of the novel concepts of the present
disclosure. It is to be understood that no limitation with respect
to the specific embodiments illustrated is intended or should be
inferred. The disclosure is intended to cover by the appended
claims all such modifications as fall within the scope of the
claims.
* * * * *