Patent Application
20240059042
The preferred embodiments of the present invention relate to the use of a tensioning device for applying resistance to the dispensing of slit sheet material thereby expanding the slit sheet material.
Further information relating to the paper which can be used in the present invention, slit patterns, and the expansion process is found in U.S. Pat. Nos. 5,538,778; 5,667,871; 5,688,578; and 5,782,735; 3,908,071; Ser. No. 14/901,977; WO1984002936A1; US20020060034; US 2007/0240841 A1; U.S. Pat. Nos. 3,104,197; 3,220,116; 3,266,972; 3,269,393; 3,908,071; 6,024,832; U.S. Pat. No. 6,458,447 B1; and U.S. Pat. No. 6,712,930 B2; the disclosures of which are incorporated by reference herein, as though recited in full.
This application incorporates by reference herein, as though recited in full, the disclosures of publication No. US 2018/0222665, and publication No. US 2018/0127197.
There have been a number of devices to dispense expanded slit sheet material that are motorized for powered dispensing and manual devices that must provide a tensioning method. For example, Geami WrapPak® ExBox is a self-contained, disposable, and recyclable combination of die cut Kraft paper and tissue interleaf that in combination is used to cushion and protect fragile items during shipment.
The preferred embodiments overcome problems in the above and/or other background art.
Another notable aspect according to some preferred embodiments of the present invention is to create a lightweight expanded slit sheet made from paper using a paper dispenser that provides for the expansion of a slit sheet of paper.
In accordance with one illustrative broad embodiment of the invention, a dispenser is provided for expanding slit paper in which a roll of slit sheet material can be installed without removing any parts during each roll change.
According to some illustrative embodiments, a device for dispensing expandable slit sheet paper is provided that includes: a roll of expandable slit sheet paper, an interior core member, wherein said roll of expandable slit sheet paper is wound on said interior core member, means for variably applying a frictional resistance to the rotation of said core member by varyingly applying pressure on an interior of said core member, such as, in some embodiments, with a rigid pressure member.
In some implementations, the device further includes reciprocating mechanism for reciprocating the rigid pressure member. In some examples, the reciprocating mechanism includes a rotatable cam. In some examples, the rigid pressure member includes a reciprocated shim. In some examples, the shim includes a curved outer surface that is movable towards and away from the inside surface of the core. In some examples, the shim has a radius of curvature similar to that of the core. In some examples, there is less than 3 shims. In some examples, there is one shim such that pressure is applied in a single region by a surface of the one shim.
In various embodiments, one or more of the various features described herein-below in relation to Embodiment 1 or in relation to other Embodiments can be employed within this embodiment.
According to some other illustrative embodiments, a device for dispensing expandable slit sheet paper is provided that includes: a roll of expandable slit sheet paper, an interior core member, wherein said roll of expandable slit sheet paper is wound on said interior core member, a core-attachment member configured to be fixed to the core for rotation with the core during use, means for variably applying a frictional resistance to the rotation of said core member by varyingly applying pressure directly or indirectly to the core-attachment member.
In some examples, the means for variably applying a frictional resistance to the rotation of said core member by varyingly applying pressure directly or indirectly to the core-attachment member applies pressure directly to the core-attachment member. In some examples, the core-attachment member is configured to be inserted at least partly within the interior of the core. In some examples, the core-attachment member is press-fit within the core. In some examples, the core-attachment member is secured to the core by one or more projectable member that extends outwardly to grip an interior of the core. In some examples, the means for variably applying a frictional resistance to the rotation of said core member by varyingly applying directly or indirectly to the core-attachment member includes variably applying pressure with a rigid pressure member. In some examples, the device further includes a reciprocating mechanism for reciprocating the rigid pressure member. In some examples, the reciprocating mechanism includes a rotatable cam. In some examples, the rigid pressure member includes a reciprocated shim. In some examples, the shim includes a curved outer surface that is movable towards and away from the inside surface of the core. In some examples, the shim has a radius of curvature similar to that of the core. In some examples, there are less than 3 shims. In some examples, there is one shim such that pressure is applied in a single region by a surface of the one shim.
In various embodiments, one or more of the various features described herein-below in relation to Embodiment 2 or 4 or in relation to other Embodiments can be employed within this embodiment.
According to some other illustrative embodiments, a device for dispensing expandable slit sheet paper is provided that includes: a roll of expandable slit sheet paper, an interior core member, wherein said roll of expandable slit sheet paper is wound on said interior core member, means for applying a frictional resistance to the rotation of said core member by applying pressure or resistance to at least one face surface of the expandable slit sheet paper.
In some examples, the device further includes at least one roll that is configured to be moved against a face surface of the expandable slit sheet paper. In some examples, the device further includes a pair of opposing rolls that are configured to apply resistant to the paper after exiting the roll. In some examples, the device further includes at least one roll that is adapted to be moved towards a face of the paper. In some examples, the device further includes at least one roll that is adapted to be moved towards a face of the paper after extending from the paper roll.
In various embodiments, one or more of the various features described herein-below in relation to Embodiment 3 or in relation to other Embodiments can be employed within this embodiment.
According to some other illustrative embodiments, a device for dispensing expandable slit sheet paper is provided that includes: a roll of expandable slit sheet paper, a frame configured to rotatably support the roll of expandable slit sheet paper; a plurality of rollers configured to receive an end of the expandable slit sheet paper; at least one of said plurality of rollers being configured to apply resistance to the expandable slit sheet paper, whereby when the expandable slit sheet paper is manually pulled from a distal end of the expandable slit sheet paper, said expandable slit sheet paper is expanded.
In some examples, the plurality of rollers includes a pair of rollers, said pair of rollers being arranged such that the expandable slit sheet paper is passed in between said pair of rollers. In some examples, at least one of said pair of rollers is movable with respect to said expandable slit sheet paper. In some examples, an upper one of said pair of rollers is movable with respect to said expandable slit sheet paper. In some examples, said expandable slit sheet paper is configured to follow an S-curve between said pair of rollers, with said expandable slit sheet paper extending in an arc around at least a portion of a periphery of at least one of said pair of rollers. In some examples, said expandable slit sheet paper is configured to extend underneath and past a bottom of a lower one of said pair of rollers, around a front side of said lower one of said pair of rollers, backwardly between said pair of rollers, and around and over the top of an upper one of said pair of rollers. In some examples, the distal end of the expandable slit sheet paper is configured to be manually grasped after passing around and over the top of the upper one of said pair of rollers. In some examples, said roll of expandable slit sheet paper is supported on a rod that extends through a center of said roll, and wherein said frame includes at least one lateral side member configured to support said rod. In some examples, said frame includes two lateral side members configured to removably support opposite ends of said rod. In some examples, said two lateral side members include receiving slots configured to removably support said rod. In some examples, said lateral side members are made of metal. In some examples, said lateral side members are made of steel. In some examples, said device is configured to convey at least one additional layer of sheet material. In some examples, said at least one additional layer of sheet material includes an interleaf layer. In some examples, said at least one additional layer of sheet material includes an additional expandable slit sheet paper layer. In some examples, said device further includes a mechanism for adjusting the resistance applied by said at least one of said plurality of rollers to said expandable slit sheet paper. In some examples, said mechanism for adjusting includes manually rotated member that increases or decreases resistance applied to the expandable slit sheet paper based on the rotational position of said manually rotated member. In some examples, said expandable slit sheet paper is made with an extensible paper. In some examples, said extensible paper has an extensibility in a machine direction of greater than 3%. In some examples, said extensible paper has an extensibility of between about 3-20% in a machine direction. In some examples, said extensible paper has an extensibility of between about 3-9% in a machine direction.
In various embodiments, one or more of the various features described herein-below in relation to Embodiment 3 or in relation to other Embodiments can be employed within this embodiment.
According to some illustrative embodiments, a device for dispensing expandable slit sheet paper is provided that includes: a roll of expandable slit sheet paper, an interior core member, wherein said roll of expandable slit sheet paper is wound on said interior core member, means for variably applying a frictional resistance by: a) varyingly applying resistance at at least one face surface of the expandable slit sheet paper; b) variably applying a frictional resistance to the rotation of said core member by varyingly applying pressure on an interior of said core member with a rigid pressure member; c) variably applying a frictional resistance to the rotation of said core member by varyingly applying pressure directly or indirectly to a core-attachment member; and/or d) otherwise variably applying a frictional resistance that resists rotation of the roll and/or movement of said expandable slit sheet paper; and wherein said means for variably applying a frictional resistance includes an automation mechanism for automated control of the frictional resistance.
In some examples, the automation mechanism includes a computer or controller. In some examples, the automation mechanism includes a mechanism for manually setting a desired resistance which is imparted via the automation mechanism. In some examples, the mechanism for manually setting includes a manual dial, a key pad or other input device.
In various embodiments, various features described herein related to Embodiment 5 can be employed within the context of any of the embodiments described herein.
The above and/or other aspects, features and/or advantages of various embodiments will be further appreciated in view of the following description in conjunction with the accompanying figures. Various embodiments can include and/or exclude different aspects, features and/or advantages where applicable. In addition, various embodiments can combine one or more aspect or feature of other embodiments where applicable. The descriptions of aspects, features and/or advantages of particular embodiments should not be construed as limiting other embodiments or the claims.
The preferred embodiments of the present invention are described by a way of example, and not limitation, in relation to the accompanying figures, in which:
While the present invention may be embodied in many different forms, the illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and that such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein.
Illustrative Expandable Slit Sheet Paper:
In the preferred embodiments, systems and methods of the preferred embodiments of the present invention can be employed for expanding an expandable slit sheet similar to that shown in
Extensible Paper Employed in Some Preferred Embodiments:
In some more preferred embodiments, the expandable slit sheet paper is made with an extensible paper. In some most preferred embodiments, extensible papers as set forth in the present inventor's U.S. Pat. No. 10,669,086 are employed, the entire disclosure of which is incorporated herein by reference.
According to some embodiments, the extensible paper is extensible in a machine direction in a range of at least 5%. According to some embodiments, the extensible paper is extensible in a cross direction in a range of at least 5%. According to some embodiments, the extensible paper is extensible in a machine direction in a range of at least 5% and in a cross direction in a range of at least 5%. According to some embodiments, the extensible paper is extensible in a machine direction in a range of at least 6% and in a cross direction in a range of at least 6%. According to some embodiments, the extensible paper is extensible in a machine direction in a range of at least 7% and in a cross direction in a range of at least 7%. According to some, most preferred, embodiments, the extensible paper is extensible in a machine direction in a range of at least 8% and in a cross direction in a range of at least 8%. According to some embodiments, the extensible paper is extensible in a machine direction in a range of between 5% to 15% and in a cross direction in a range of between 5% to 15%. According to some embodiments, the extensible paper is extensible in a machine direction in a range of between 7% to 15% and in a cross direction in a range of between 7% to 15%.
According to some illustrative embodiments, the plurality of slits each have a width of between 0.35 and 0.65 inches; according to some embodiments, the plurality of slits each have a width of between 0.45 and 0.55 inches. According to some embodiments, the plurality of slits each have a width of about 0.5 inches. According to some embodiments, the plurality of slits each have a width of less than 0.5 inches. According to some embodiments, the plurality of slits each have a width of less than 0.45 inches. According to some embodiments, the plurality of slits each have a width of less than 0.4 inches.
In some more preferred embodiments, extensible papers as set forth in the above-referenced U.S. Pat. No. 10,669,086 are employed. Towards that end, the following paragraphs (in quotations) under this section are quoted from the '086 patent set forth details of extensible papers according to some preferred embodiments that can be employed in preferred embodiments of the present invention.
“For the purposes of the present invention, the term ‘extensible’ as applied to paper sheets, means a paper sheet that is able to stretch in a longitudinal direction of the paper sheet upon applying a force in the longitudinal direction of the paper sheet. Illustrative extensible sheets are disclosed in U.S. Pat. No. 3,908,071, U.S. patent application Ser. No. 14/901,977 (U.S. Pat. No. 9,945,077), International Application No. WO 1984002936, U.S. Publication Nos. 2002/0060034, 2007/0240841 (U.S. Pat. No. 7,918,966), and U.S. Pat. Nos. 3,104,197, 3,220,116, 3,266,972, 3,269,393, 3,908,071, 6,024,832, 6,458,447, and 6,712,930, the entire disclosures of which are incorporated by reference herein, as though recited in full. It should be understood that the stretching of an extensible paper must be measured in an unslit sheet of paper. As disclosed in U.S. Pat. No. 3,266,972, the test and characterization procedures employed in measuring elongation (extensibility) properties can be in accordance with standard TAPPI test Elongation T457. In addition, as disclosed in U.S. Pat. No. 3,266,972, the expression ‘extensible papers’ means a paper having an increasable elongation in the machine direction as compared to standard, non-extensible Kraft paper.”
“In some preferred embodiments, extensible paper can be produced by varying the accumulation of paper fibers by essentially slowing the paper feeding process during the drying method to trap extra fibers that make the paper appear to have microscopically sized rows of paper that you would see if one were to pleat the paper. The difference is that extensible paper's microscopic rows are adhered to each other through the use of binders and other types of adhesives in conjunction with the drying process. Reference is made to patent U.S. Application No. 2007/0240841 (U.S. Pat. No. 7,918,966) where the purpose is to create a non-creped extensible paper that does not easily disconnect from itself. In addition, the surface of the extensible paper is still fairly flat.”
“In the preferred embodiments of the present invention, the extensible paper that is employed has low extensible properties as compared to other types of extensible papers. In this regard, an optimal extensible paper enables a smooth transition from an unexpanded to the expanded slit sheet by providing a small amount of stretching at the very start of expansion of the extensible slit sheet paper material.”
“In some exemplary constructions, during expansion of a slit sheet, the force required to initiate expansion is substantially higher than the force required to continue expansion. For example, once the paper initially starts to bend at the slits, the expansion continues more easily during continued bending at the slits. The force required to continue the expansion of the slit sheet during this continued bending is dramatically reduced beyond the above-noted initial expansion. In some preferred embodiments, the extensible slit sheet paper substantially reduces the force required to initiate expansion. On the other hand, in some preferred embodiments, during the above-noted continued expansion, the extensible paper does not substantially stretch simultaneously with the process of expanding the slit sheet paper; otherwise, the expanded sheet might not optimally be made into a cushioning wrap.”
“It should be noted that in this application, all theories related to functioning of the invention are provided to facilitate appreciation of concepts of the invention, rather than by way of limitation. Extensible paper, as designed, stretches as part of an increase in paper strength. In some embodiments, the functioning of the invention involves that the extensible slit sheet paper substantially utilizes the extensible property to ease the rotating the cells into the stretched shape and to resist tearing of the slit sheet during the expansion step. This means that at the initial point at which the cell rotates (i.e., initiating rotation between legs 38a and 38b on each side of the slit and land 20) the extensible slit sheet paper is substantially enhanced by the extensible paper's ability to stretch. In some embodiments, the functioning of the invention, thus, involves that extensible papers' properties are substantially utilized at this initial point and substantially finished as soon as the cell begins to rotate into its three-dimensional shape (i.e., after this initial point, the reliance on the extensible nature of the paper may be less substantial or even non-existent). After that initial point, the slit pattern properties, regardless of paper type, opens with greater ease to the point at which it forms a hexagon. Accordingly, in some embodiments, the extensible property substantially merely comes into play at the initial moment of expansion. In some other embodiments, while the extensible features of the paper comes into play most substantially at this initial point of rotation, the extensible features of the paper can have some affect during further expansion of the paper, whereby the initial point of expansion can be substantially facilitated due to extensibility and further expansion can also be, at least, somewhat facilitated due to extensibility.”
“In some of the preferred embodiments, preferable extensible papers that can be employed include extensible papers where the purpose of the extensible nature is to provide the type of stretching found for the use of multi-wall bags for heavy weight items like cement, or seed and the like. U.S. Patent Publication No. 2016/0355985 (U.S. application Ser. No. 14/901,997) and U.S. Pat. Nos. 3,104,197 and 3,266,972 teach the manufacture and properties of this form of extensible paper. Further teachings can be found in “Understanding sheet extensibility”, R. S. Seth, Pulp & Paper Canada T31, 106:2 (2005) III, pages 33-40 (T31-T38). The disclosures of the foregoing patents, patent publication, and printed publication are incorporated herein by reference, as though recited in full.”
“The prior expanded slit sheet art (See, e.g., U.S. Pat. Nos. 5,538,778, 5,667,871, 5,688,578, and 5,782,735) focused on paper strength to inhibit tearing during the expansion process and Kraft paper was satisfactory because the strength required coincided with the thickness required to make a satisfactory wrapping product. The increased strength of an expandable sheet does not contribute to or increase the value/performance of the expansion of the slit sheet material. It has now been found by the present inventor that an expandable slit sheet paper can be substantially improved by the use of an extensible sheet. In the preferred embodiments, this use of an extensible slit sheet paper advantageously provides a reduction in force required to open the slit sheet and therefore provides a faster and easier expanding process for the user of the expanded slit sheet. The unexpected benefit resulting from the reduction in force at the very start of the expansion of the slit sheet provides an unexpected improvement to the slit sheet packaging product and renders the employment of the extensible paper highly unique. Notably, the prior expanded slit sheet paper persisted in and was widely used in the marketplace for decades without the contemplation of the present invention or the potential advantages therefrom.”
“As set forth in this application, the present inventor has discovered that the force needed to expand an expandable slit sheet paper is far greater than the force required to expand an extensible slit sheet paper. By way of example, a 50 pound Kraft paper expandable slit sheet that is 15” wide prior to expansion requires approximately 4-6 pounds or 0.4 pounds per inch, whereas the force required to expand an extensible slit sheet of the same paper weight is 0.15-0.22 pounds per inch. This is a marked difference between the papers. Kraft paper has the strength to provide an acceptable expandable slit sheet. However, unexpectedly, the extensible slit sheet imparts an ease of expansion that greatly reduces the force required to expand the slit sheet, not based on the main purpose for extensible paper which is to increase its tensile strength but, rather, its capability to stretch. Since extensible paper is higher in cost and Kraft paper was strong enough, it was not previously known that extensible paper could be of benefit for making slit paper sheets of the types found in, e.g., U.S. Pat. Nos. 5,538,778, 5,667,871, 5,688,578, and 5,782,735, and U.S. Non-Provisional application Ser. No. 15/428,144. For example, it was not appreciated that an extensible slit sheet could have provided an equivalent strength to light weight, thin papers that previously had no applicability as a wrapping product. Light weight Kraft paper tears more easily than heavier weights of Kraft paper. It has now been found that the extensible paper enables the use of the lighter weight expanded slit-sheet papers that also advantageously provide gentler cushioning required by fragile items when a slit sheet is expanded, in contrast to the more rigid cushioning provided by heavier weight expanded slit-sheet papers.” “Reference is particularly made to the graph of Table 1 on page 5 of U.S. Patent Publication No. 2016/0355985 (now U.S. Pat. No. 9,945,077) as if recited in full, that describes paper strength based on certain manufacturing techniques. Within the graph is a column describing elongation at the point of paper break (or tearing of fibers) separated into two sub columns of the machine direction (MD) and cross direction (CD), also referred to as transverse direction. The elongation percentage of Table 1 ranges from 5.3% to 7.1% in the cross direction (CD) and 3.3% to 10.6% in the machine direction (MD).”
“Reference is also made to U.S. Pat. No. 3,266,972 within Table Ill of column 5 which references elongation in the percentage range from 3.7% to 4.6% in the CD or cross direction and 9.7% to 11.1% in the machine direction.”
“In both '985 and '972, the variations are based on the manufacturing process that places an emphasis on tensile strength and stretch in either the cross direction or machine direction accordingly.”
“The present inventor has discovered that for the purposes of expanding an extensible slit sheet paper for use as a packaging wrap and/or void fill, machine direction extensible ranges from 1%-9% provide an adequate extensibility, with 1% to 6% preferred, and 1% to 4% most highly preferred. The lower the extensibility coincides with lower costs of the paper per square foot. As indicated above, it should be understood that extensibility is measured on unslit paper.”
“In some alternative embodiments, machine direction extensibility ranges of the extendible slit sheet paper can have ranges of:
“For the purposes of expanding the slit sheet paper for use as a packaging wrap and/or void fill, it has been found that cross direction extensible ranges from 1%-5% provides an adequate extensibility with 1% to 4% preferred, and 1% to 3% most highly preferred.”
“In some alternative embodiments, cross direction extensibility ranges of the extendible slit sheet paper can have ranges of: a) from 1.5%-5%, or more preferably from 1.5% to 4%, or even more preferably from 1.5% to 3%; or b) from 2%-5%, or more preferably from 2% to 4%, or even more preferably from 2% to 3%.”
“In combination with the extensible paper, a smaller, lighter weight, and recyclable version of an expander can be employed (such as, e.g., made entirely or substantially entirely with recyclable cardboard in some illustrative embodiments). This expands the market to customers that use a very small amount of wrap as compared to the industrial market. It also provides for a less expensive expansion device to be employed for expanding the slit paper. Additionally, it enhances the ease of use by the packer by providing for less ripping during the wrapping process that occurs when the tension is not properly set. This occurs as the roll, during its continued use, becomes smaller and lighter in weight. As the roll of expanded slit sheet becomes lighter the tension required increases. Thus, there need for a varying tensioning method. With the use of the extensible paper, the tension required is significantly decreased and the strength of the paper is increased. Both benefit the person wrapping by making the tensioning required much less precise to the point at which, a single tension setting can be used with little or no adjustment. If the tension is set higher than necessary, the increase in strength from the extensible paper keeps the product from tearing and therefore makes it easier for the packer to use. Therefore, the packer can make fewer adjustments as the slit sheet roll becomes smaller and smaller.”
“The reduction in the force required to expand the slit paper enables a new product to be created using lighter weight papers. In the past, expanded slit sheet paper is primarily used as a wrapping product whereas its use as a void fill would be in limited circumstances due to void fill being typically the cheapest, that is, the lowest cost of all packaging products. The increased strength of the extensible sheet enables the use of a thinner and lighter weight slit sheet paper as a void fill product. If the expanded slit sheet is not being used as a wrap, then the thicker 0.005″, 50 pounds per 3,000 square feet paper and above is not required and a lighter weight 0.003-0.0045″ thick, 30-40 pounds per 3,000 square feet paper can be used as void fill. It can also be used to provide cushioning that other paper void fill products have not been able to provide. It has now been found that even though the extensible paper has a 10% higher price, the use of a thinner paper provides much more square footage per ton and more than compensates for the increased cost of the extensible paper as compared to Kraft paper.”
In a preferred embodiment, as shown in
In the preferred embodiments, the shim is a projection that is movably received within an opening in the sleeve and which contacts the rotating CAM block 105, and the shim 104 is configured to make sliding contact with a cam surface of the CAM block 105 while the CAM block 105 is rotated such as to impart a variable motion to the shim (e.g., being reciprocatable upwardly and downwardly). The shim is, thus, variably pressed against the interior of the core member and, thus, variably provides a rotational resistance to the drawing of paper from the roll of expandable slit sheet paper. The rotational resistance causes the slit paper to expand as it is drawn from the roll of slit sheet paper.
Thus, in the preferred embodiments, the shim 104 is a member that slides on the CAM block 105 during operation. The shim 104 can be made of a variety of materials. In some preferred embodiments, the shim is relatively rigid and has a smooth outer surface. In some examples, the shim can be a piece of wood, metal, ceramic, or plastic. In some illustrative and non-limiting embodiments, the shim has a thick middle region and tapers to a thin edge as shown. In some embodiments, the shim 104 has a curved contact surface that is configured to follow a curvature of the interior of the core. In some preferred embodiments, the shim 104 is driven between the CAM block 105 and the interior of the core upon which the paper roll is wound. In some implementations, the shim variably separates or spaces the sleeve 200 from the interior core member (not shown) when raised such as to press against the interior of the core while the surface of the shim 104 extends further above a perimeter surface of the sleeve.
In some preferred implementations, the shim 104 operates as a wedge which fits into the space between the cam block and the interior of the core member, and is pressed by the cam block against the interior of the core member. In some preferred embodiments, the shim 104 has a curved or an arcuate upper surface and a flat or planar surface, thus, providing a bow like configuration as illustrated in
In this second embodiment, a tensioning device is formed as best shown in
In the illustrated embodiment, the insert 500 includes a smooth radial section 502 with open area 503 (e.g., the area 503 can be a cup-shaped circular receiving opening). In addition, the insert 500 as includes a tapered or conical portion adjacent the smooth section 502, which has a radial diameter that decreases in a direction away from the open area 503. As shown the outer surface of the tapered or conical portion preferably include a roughed frictional surface, such as, e.g., a plurality of ridges and/or grooves extending in an axial direction (e.g., generally parallel to an axis of the core). As discussed below, the roughed frictional surface helps to create a firm engagement with the paper core when inserted into an open end of the paper core.
As shown in
In the perspective view of
Among other things, in some embodiments, this combination enables the roll of paper to be loaded without the need for removing the tensioning rod, thumbscrew, and spring. In particular, 2018/0222665 discloses at ¶ that: “FIG. 6 is the single expansion apparatus made up of two yokes 602 and preferably at least three cross members 601. Paper core 608 sits in the yoke 602 and holds the paper roll 603 that is wound around it. A threaded insert 607 receives thumb screw 604 first through the spring 605 and then through roll holder 606 and into the metal threaded insert 607 to enable the roll holder to apply downward pressure to the paper core 608.”
Additionally, the system shown in
As shown in the perspective view in
Additionally, another embodiment that is similar to that shown in
With reference to
The framework is made up of two side frames and steel slats that are bolted in place to connect the two side frames together.
Handling the paper roll is quite simple wherein the paper is supported by a paper tube and two plastic centering cores that arrive with each expanded slit sheet paper roll. A steel rod is placed through the paper roll. On the left end of the rod is a permanent fixture that centers the paper so that the paper is centered on the machine. The second removable rod slides into place to hold the paper from sliding rightward. The rod itself is self-positioning by using a slot that is machined into both side frames which mates with a reduced diameter slot on the rod itself. These two create a locking mechanism that does not allow lateral movement of the rod.
The paper is then feed through the pressure rollers and awaits the use of an operator's hands to pull the paper through. A simple method of loading the paper is to guide the paper between the rollers with one hand and then with the other roll the upper pressure roller towards the back of the machine. This will force the paper through the rollers.
The pressure roller system is made up of a number of parts to enable a constant and even pressure regardless of the size of the paper roll. As it unwinds the paper roll gets lighter but, this will not affect the ability of the expander to maintain consistent stretching Properties. The first two parts are the horizontally oriented and parallel aluminum rolls that are held in place by a rod, or journal, that are at each end of the rubber-aluminum roll. Each rod is then affixed to the side frame through a brass or plastic bushing to inhibit side to side movement with the use of set screws. Each aluminum roller has a rubber to enhance the gripping action required to feed the paper. At this point, the rollers are able to turn freely.
To create the friction portion of the manual expander, spring-type vertically oriented set screw presses on both sides of the roller down on the bushing of the top roller system. By applying more or less pressure the set screws create the perfect pressure that allows the paper to feed and stretch but, not rip.
The set screw has a small protrusion at the bottom end that is spring loaded so that the pressure increases as you screw in the set screw. The ball bearing presses on a rod that in turn applies pressure to the bushing. The set screw itself is screwed into a machined cup that is attached to the frame. This cup is for the extra width of this type of spring operated set screw and the associated threads that enable the buildup of the pressure as the set screws are turned clockwise. Preferably, both set screws place the same amount of pressure on both sides of the roller or the paper can tend to lead to the side that has the greater pressure.
To set the pressure rollers to the right pressure, the user would guide the paper through the rollers and attempt to stretch the paper. If the paper does not stretch then a clockwise turn of both setscrews will add pressure. If the paper tears then the setscrews should be turned counterclockwise.
In the embodiment shown in
In some preferred embodiments, a mechanism is provided to inhibit nesting between adjacent layers. For example, in some embodiments, the expandable slit sheet paper can be configured to present a unique expansion pattern; for example, providing a non-uniform or chaotic pattern as described below. As another example, an interleaf (e.g., another layer of non-expandable paper) can be provided to inhibit nesting.
With respect to embodiments that employ a non-uniform pattern, by way of example, such a non-uniform layer can help the sheet material to package an item correctly. In some embodiments, a non-uniform layer of material is one that the hexagonal cells open in a random fashion at least 50% of the time to provide the inability for the cells to nest as they are wound against successive expanded layers around an object being packaged.
The present inventor has found that the deliberate desire for a chaotic pattern of switchbacks of at least 50% of the total number of cells create a non-nesting effect between the adjacent layers that buildup around an item to be wrapped by the expanded slit sheet material. These random changes are created by switchbacks due to the use of thinner paper that is less effected by the wedge effect of the tooling used to cut the paper as described in the prior art so referenced within this filing.
With respect to embodiments that employ an interleaf material, the prior art teaching of Ser. No. 14/480,319 desires a uniformity of cells with the deliberate use of a double layer feeding system that requires each layer to face in opposition to the layer underneath. In this case the deliberate use of uniformity inhibits nesting of the product as prior art teaches to cure this through the use of an interleaf that separates the cells as shown in filing U.S. Pat. No. 5,688,578.
In testing an illustrative example of this new structure against the uniformly but opposing double layer expanded slit sheet system a 400 foot roll of single layer cells created a diameter of 25″ while 200′ of the double layer system produced 22″. Each roll had the exact amount of paper in length and weight. Two layers of double equals 400 feet of continuously feed single layer chaotic product. The rolls at the end of the testing had the same square footage of material used. They varied in paper weight since the paper with the majority of virgin paper was thinner and therefore weight less per square foot as the recycled paper. The virgin paper as per the TAPPI standard weighed 50 pounds per 3000 square feet of material while the recycled paper weighed 60 pounds per 3000 square feet of material prior to expansion.
In some embodiments, the present invention provides a random chaotic pattern that produces the same non-nesting effect as the double layer in a similar way but, with a chaotic looking patter as shown schematically in, for example,
In some embodiments, a double layer manual expander, as shown in
With reference to
Additionally, in some embodiments, the upper journal 109B can be vertically movable within the slot S.
With respect to
In some alternative embodiments, while the above examples of the third embodiment apply resistance by pressure to the paper of the paper roll (i.e., along the face surface of the paper, rather than the thin edge surface of the paper) after removal from the paper roll as shown in
Although a rubberized roll is described, it should be appreciated that other embodiments could include other roll materials, such as, e.g., plastics, metals, and/or other suitable materials. For example, in some embodiments, the rollers (e.g., rollers 1006 in
In some embodiments, the embodiments of
Towards this end, some embodiments of employing an S curve manner of dispensing are shown in, e.g.,
Looking from the perspective of angles formed by the axis of rollers 309 and 312, the intersection of the path of the slit paper with a line between the axis of each roller, and the tangent point at which the paper leaves a roller, is an acute angle. The relative positions of the two rollers and their proximity has a bearing on the acute angle that is formed. For example, the closer the proximity of the two rollers, the greater the acute angle.
Looking further to
With reference to
The contact region advantageously is greater than ¼ of the circumference (i.e., 90°), and preferably greater than ½ of the circumference (i.e., 180°), and, most preferably, up to about 250°, which produces contact of the paper with about 70% of the hook surface of the rollers.
Furthermore, contact of the slit sheet with the hooks of each roller is preferably advantageously in the range from 90° to less than 270°. More preferably, contact of the slit sheet with the hooks of each roller is in the range from 180° to 235° which produces contact of the paper in the range from about 50% to 65% of the hook surface of the rollers. As shown in in the embodiment of
In
As discussed above, although in some implementations of the embodiments shown in
In the embodiment shown in
In operation, as with the embodiment shown in
As shown in
A fifth embodiment of the invention is shown in
Additionally, in some embodiments, a computer controller can also be provided that automatically adjusts the applied tensioning to a desired range or within a desired limit.
In various embodiments, automated aspects of this fifth embodiment can be implemented within any other embodiment of the invention shown herein. In some embodiments, with respect to embodiments like that shown in
For the purposes of the present invention, the term “worm motor drive” as employed herein, refers to an electrical system by which a shaft will move upwards or downwards by electrical input.
For the purposes of the present invention, the term “control switch” refers to an electrical device than can adjust the worm gear motor to cycle up or down either by turning a knob or pressing an up or down button.
For the purposes of the present invention, the term “worm gear” refers to an electrical motor that can push a rod up and down. A motor of this type can be driven by air pressure and other designs that are found commonly within the art to move a shaft back and forth or up and down.
In the preferred implementations of this fifth embodiment, a time-saving solution for adjusting the position and, therefore, pressure exerted by a tensioning device is provided (such as, e.g., tension rod against a paper core around which the expanded slit sheet material is wound). According to some embodiments described herein, a tensioning device is adjusted by hand (for example, a thumbscrew is manually adjusted or turned by hand which in turn puts pressure on a spring). The spring in turn puts pressure on the tension rod and then finally onto the paper core.
This manual process is very easy and successful when the dispenser is on the packing table and within a short distance from the packer. According to this fifth embodiment, a power tension system is provided. For example, in some implementations, this new art can be employed to apply a powered tension system in the even that the unit is placed too far away for the packer (i.e., the individual operating the device) to easily operate the device by hand (e.g., to turn the thumbscrew by hand). In this case, the packer would have a controller that can control the tensioning via an automated system, such as, e.g., to either raise or lower a motor worm gear to add or subtract tension as needed.
The worm gear motor is the preferred device among a number of devices such as, a stepper motor, compressed air cylinder, jackscrew motor, etc., that could be used to apply pressure on the paper core (not numbered but shown in part in
While
Additionally, although
For the purposes of the present invention the term “paper roll” describes a slit sheet material wound around a core (such as, e.g., a paper core).
For the purposes of the present invention, the term “yoke” includes a structure contoured or shaped to support or carry a load.
For the purposes of the present invention, the term “rod” includes an elongated or straight element that is longer than it is wide and that is sufficiently rigid to support a roll of expandable slit paper. The term “rod” is inclusive of a slender bar, a pole, rod, shaft, strut, and a beam.
For the purposes of the present invention, the term “core support member” includes a structure that contacts an interior of a core member and bears the weight of a roll of paper that is wound around the core member by having the weight borne from the interior of a hollow core member.
For the purposes of the present invention, the term “paper core” includes a paper tube around which the expandable slit sheet paper is wound and “interior core member” includes that the core member has slit-expandable paper wound around the core member and is interior to the roll of paper.
For the purposes of the present invention, the term “curvature” includes an arcuate or essentially circular configuration that is shaped or curved like an arc or bow.
For the purposes of the present invention, the term “tensioning mechanism” includes a pressure assembly that applies pressure to variably increase or decrease friction and thereby variably resistance the unwinding the paper from the roll. The friction provides a rotational resistance that causes the slit paper to expand as it is drawn from the roll of slit sheet paper.
For the purposes of the present invention, the term “attached” means securely fixing one part to another as in the art of assembling wood, wood composites, metals, or plastics in order to create a bolted, screwed, secured, fastened, or sealed assembly and is inclusive of permanent assemblies and configurations that can be disassembled. Moreover, being “attached” does not require a direct connection between elements, but can include attachment via an intermediary member.
For the purposes of the present invention, the term “shim” includes, e.g., a thin, often tapered piece of material (such as wood, metal, or stone) used to fill in space between elements or components (such as, e.g., for support, leveling and/or adjustment of fit). In some examples, a shim can function as a wedge between two structures and can create a little extra height or a little extra space.
Within this application, the use of individual numerical values is stated as approximations as though the values were preceded by the word “about”, “substantially”, or “approximately.” Similarly, the numerical values in the various ranges specified in this application, unless expressly indicated otherwise, are stated as approximations as though the minimum and maximum values within the stated ranges were both preceded by the word “about”, “substantially”, or “approximately.” In this manner, variations above and below the stated ranges can be used to achieve substantially the same results as values within the ranges. As used herein, the terms “about”, “substantially”, and “approximately” when referring to a numerical value shall have their plain and ordinary meanings to a person of ordinary skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue. The amount of broadening from the strict numerical boundary depends upon many factors. For example, some of the factors which may be considered include the criticality of the element and/or the effect a given amount of variation will have on the performance of the claimed subject matter, as well as other considerations known to those of skill in the art. As used herein, the use of differing amounts of significant digits for different numerical values is not meant to limit how the use of the words “about”, “substantially”, or “approximately” will serve to broaden a particular numerical value or range. Thus, as a general matter, “about”, “substantially”, or “approximately” broaden the numerical value. Also, the disclosure of ranges is intended as a continuous range including every value between the minimum and maximum values plus the broadening of the range afforded by the use of the term “about”, “substantially”, or “approximately”. Thus, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. To the extent that determining a given amount of variation of some the factors such as the criticality of the slit patterns, paper width differential pre- and post-expansion, paper weights and type, as well as other considerations known to those of skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue will have on the performance of the claimed subject matter, is not considered to be within the ability of one of ordinary skill in the art, or is not explicitly stated in the claims, then the terms “about”, “substantially”, and “approximately” should be understood to mean the numerical value, plus or minus 15%.
All U.S. and foreign patents, patent applications, patent publications, and all other publications cited in this application are incorporated herein by reference in this application in their entireties as though recited herein in full.
The present application is a continuation of U.S. application Ser. No. 17/239,682, filed Apr. 25, 2021, which is 1) a non-provisional of U.S. Provisional Application No. 63/015,610, filed Apr. 26, 2020 and which is 2) a continuation-in-part of U.S. application Ser. No. 16/749,875, filed Jan. 22, 2020, which is a non-provisional of U.S. Provisional Application No. 62/795,310, the disclosures of which prior applications are all incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 63015610 | Apr 2020 | US | |
| 62795310 | Jan 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17239682 | Apr 2021 | US |
| Child | 18238527 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16749875 | Jan 2020 | US |
| Child | 17239682 | US |
