The present inventions are directed to a package assembly. In particular, the present inventions are directed to a package assembly that includes a stretchable resilient member connected to a frame member.
Protective packaging devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact with the inner walls of the box that might be caused by shocks imparted to the box during loading, transit, and/or unloading.
In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is suspended within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.
U.S. Pat. No. 6,675,973 discloses a number of inventions directed to suspension packaging assemblies which incorporate frame members and one or more retention members. For example, many of the embodiments of the U.S. Pat. No. 6,675,973 patent include the use of a retention member formed of a resilient material. Additionally, some of the retention members include pockets at opposite ends thereof.
In several of the embodiments disclosed in the U.S. Pat. No. 6,675,973 patent, free ends of the frame members are inserted into the pockets of the retention member. The free ends of the frame member are then bent, pivoted, or folded to generate the desired tension in the retention member. Because the retention member is made from a resilient material, the retention member can stretch and thus provide a mechanism for suspending an article to be packaged, for example, within a box.
An aspect of at least one of the embodiments disclosed herein includes the realization that packaging devices that are designed to retain items to be packaged using a thin stretchable film can be further improved by heat sealing the thin stretchable film to a frame member of the package device. As such, the resulting packaging devices with a thin resilient member attached thereto can be manufactured using high speed, automated manufacturing processes, thus increasing the total number of packaging devices prepared within a certain period of time. Moreover, use of heat sealing can further reduce the total size of the thin resilient member used by 20% to 30% depending on the method of attachment for the thin resilient member.
For example, in some embodiments, the resilient member can be heat sealed to a frame member with the resilient member disposed over a central portion of the frame member. The resilient member can be a thin resilient sheet and the frame member can be formed from corrugated material. The resilient member can be heat sealed to one or more rotatable portions of the frame member and sized such that, when the rotatable portions are rotated relative to the central portion, the resilient member can be stretched and thus aid in forming shock absorbing packaging for an article.
Heat sealing of the resilient member to the frame member can be achieved with a variety of different heat sealing techniques, for example, by heat sealing the resilient member directly to a surface of the frame member, by heat sealing the resilient member to a coating placed over a surface of the frame member, or a combination of both.
In some embodiments, in order to allow the resilient member to be stretched or tensioned, less than all of the resilient member is heat sealed to the frame member. In some embodiments, only about 10% or less of the resilient member is heat sealed. As should be understood, the frame member can have a variety of different shapes, wall portions, and apertures depending on the nature of the item to be packaged, the desired packaging method (e.g., suspension or retention), the container in which the frame member is placed, and a variety of other factors.
In some embodiments, the resilient member can be formed with two layers of different material, heat sealed to one another, and optionally, heat sealed to the frame member. In some cases, the two different materials can be different kinds of material, different thicknesses of the same material, different grades of translucency (e.g., one layer being opaque and one layer being transparent), different modules of elasticity or other different characteristics. When using heat sealing to attach the layers to one another, different materials having melt index values over a large range of such values can be used. For example, with regard to some materials, different layers made from different materials can be heat sealed together using high speed manufacturing equipment. Such high speed heat sealing is achieved more easily when the melt index of these materials falls approximately within the range of 7.0 to 10.0. However, other materials and other attachment techniques can also be used.
Thus, in accordance with an embodiment, a suspension packaging assembly can comprise at least one frame member having a central portion, a first end and a second end disposed opposite the first end relative to the central portion, a first foldable portion disposed at the first end and a second foldable portion disposed at the second end. Additionally, a resilient member can comprise a first layer having first and second longitudinal ends and first and second lateral edges and a second layer having first and second longitudinal ends and first and second lateral edges, the first layer being heat sealed to the second layer along the corresponding first and second lateral edges.
In accordance with another embodiment, a resilient member for providing damage protection for packaged goods can comprise a first layer having first and second longitudinal ends and first and second lateral edges. A second layer can include first and second longitudinal ends and first and second lateral edges, where the first layer is heat sealed to the second layer along the corresponding first and second lateral edges.
All of these embodiments are intended to be within the scope of at least one of the inventions disclosed herein. These and other embodiments of the inventions will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the inventions not being limited to any particular preferred embodiment disclosed.
These and other features of the inventions are described below with reference to the drawings of several embodiments of the present package assemblies and kits which are intended to illustrate, but not to limit, the inventions. The drawings contain the following figures:
An improved packaging assembly is disclosed herein. The packaging assembly includes an improved structure which provides new alternatives to known suspension packaging systems.
In the following detailed description, terms of orientation such as “top”, “bottom,” “upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,” “midpoint,” and “end” are used herein to simplify the description in the context of the illustrated embodiments. Because other orientations are possible, however, the present inventions should not be limited to the illustrated orientations.
Additionally, the terms “suspension” and “suspend” as used herein, are intended to refer to packaging configurations where an associated article is held in a position spaced from another member using a suspension technique, such as where an article is surrounded by stretchable films so as to be spaced away from rigid walls including walls of a container or box or walls of other rigid associated packaging members, devices, or mechanisms.
Further, the term “retention”, as used herein, is intended to refer to packaging configurations wherein an associated article is held in the position pressed against another member, such as a frame member, a rigid member, or other packaging member, device, or mechanism, using techniques such as those including a stretchable, thin film pressing the article against the other member. Some of the embodiments of Packaging assembly is disclosed herein include aspects of both retention configurations and suspension configurations. Such embodiments might include, for example, stretchable, thin film material used to present article against a component made from rigid material but configured to be flexible and providing shock absorption. Such embodiments can be considered as a retention device and as a suspension device. Further, such embodiments can also be referred to as an “retention-suspension hybrid packaging configuration”. Those skilled in the art will appreciate that other orientations of various components described herein are possible.
The packaging assemblies disclosed herein can include a frame member 100 (
The inventions and embodiments disclosed herein are described in the context of suspension packaging assemblies, retention packaging assemblies, and hybrid suspension-retention packaging assemblies because they have particular utility in those contexts. However, the inventions disclosed herein can be used in other contexts as well.
With reference to
In some embodiments, the foldable portions 112, 114 are configured to increase a tension in the resilient member 200 for holding one or more articles in a desired position relative to the central portion 110; an exemplary position being shown in
With reference to
The outer layers can be formed from fibrous materials such as paper-based and wood-based materials. This can include, for example, pulp, cardboard, cartonboard, paperboard, paper, chipboard and other such paper-based and wood-based materials known to those in the art. The outer layers can be formed from other materials such as plastics including high density polyethylene (HDPE), low density polyethylene (LDPE), polyvinyl chloride (PVC), nylon, composites such as fiberglass, metals, and any other such materials used by those in the art. The outer layers can be porous, including the fibrous materials and plastic materials described above, with the porosity chosen to enhance the heat seal between the frame member 100 and the resilient member 200. Heat sealing and the effect of porosity will be discussed in further detail below.
It should be appreciated that different materials can be used for different portions of the outer layers. For example, the top layer 120 and the bottom layer 122 can be formed from different materials. In some embodiments, particular portions of the top layer 120 and the bottom layer 122 can be formed from different materials. For example, the materials used for the foldable portions 112, 114 can be different from the materials used for the central member 100. By using different materials, it is possible to further enhance the performance of the frame member 100. For example, materials which are more suitable for heat sealing can be used along surfaces upon which a heat seal is to be formed whereas other types of materials can be used for the remaining surfaces.
The inner layer 124 can be formed from any of the materials as herein described as well as those used by those in the art. For example, the inner layer 124 can be formed from paper-based materials such as cardboard, paperboard, or paper. The chosen material for constructing the frame member 100 can be any substantially rigid, but foldable material. It will be appreciated that, although denominated as rigid or substantially rigid, the chosen material would preferably have an amount of flexibility in the cases of physical impact. The illustrated frame member 100 is a generally thin, planar member; however, the frame member 100 can have other configurations.
With continued reference to
These coatings can provide additional benefits when applied to the frame member 100. For example, coatings can include: ultraviolet (UV) coatings which assist with inhibiting deleterious effects of ultraviolet rays on the surface, aqueous coatings which can assist with inhibiting moisture from being absorbed into frame member 100, varnish coatings which can provide a sheen on the surface thus enhancing the appearance of the frame member 100, soft touch coatings which can provide a smooth or softer surface which can reduce the likelihood of damaging an article contacting the surface, and other types of coatings. Moreover, such coatings can also be beneficial in providing a surface to which a heat seal can be formed as will be described in further detail below. In this way, the coating layers can also be considered to work as a bonding layer. For example, such coatings can be formed from materials such as polyolefin, ethylene acrylic, polyurethane, low density polyethylene (LDPE), high density polyethylene (HDPE), and other types of polymers which can bond with the resilient member, such as resilient member 200. Other types of coatings include: polyamides, polyethylene terphthalates (PET), glycol-modified polyethylene terephthalate (PETG), polyvinylidene chlorides, polyvinyl chlorides, etc., and highly crystalline non-polar materials such as high-density polyethylene and polypropylene, ethylene-vinyl acetate (EVA), ethyl methyl acrylate (EMA), ionomers, acrylic polymers, acrylate copolymer, modifications of these compounds, and similar compounds. Such coatings can also include those produced by companies such as Endura Coatings, Michelman Inc., The Seydel Companies, Inc., Lubrizol Corporation, and other such companies.
As shown in
Such “localized application” of coating layers can be particularly advantageous in reducing the total amount of coating used for the frame member thus reducing material waste and reducing costs. For example, the coating layers can be placed along portions on which a heat seal will be formed. Such coating layers can also be placed proximate to portions on which a heat seal will be formed in order to account for slightly misplaced heat seals due to mechanical tolerances of the machinery used. In some embodiments, frame member 100 can be “flood coated” such that a coating layer is placed over a substantial portion, or the entirety of, the top layer 120, the bottom layer 122 or both. “Flood coating” can be preferable due to ease of application of the coating and/or if there is a benefit to adding the coating layer over the entire surface, such as the UV-coatings, aqueous coatings, varnish coatings, or soft-touch coatings as described above.
The central portion 110 can be sized and dimensioned so as to engage or provide support for one or more articles. Although the central portion 110 is described primarily as being disposed at the center of the frame member 100, the central portion 110 can be at other locations. Additionally, the central portion 110 can comprise a plurality of members, each configured to engage an article. For the sake of convenience, the central portion 110 is described as a generally planar centrally disposed member.
The size of the central portion 110, which defines a loading area, can be chosen arbitrarily or to accommodate, support, or engage an article of a particular size. The loading area size can be chosen based on the number and configuration of the articles on or proximate to the central portion 110. In some non-limiting exemplary embodiments, the central portion can be used to package one or more communication devices (e.g., portable phones, cellular phones, radios, headsets, microphones, etc.), electric devices and components, accessories (e.g., cellular phone covers), storage devices (e.g., disk drives), and the like. In certain embodiments, the central portion 110 is configured to package one more portable music players, such as IPODs® or MP3 players.
It is contemplated that the central portion 110 can be designed to package any number and type of articles. In the illustrated embodiment, the central portion 110 is somewhat square shaped and has a surface area (i.e., the loading area) of about 40-60 inches square. In some non-limiting embodiments, the central portion has a loading area more than about 40 inches square, 45 inches square, 50 inches square, 55 inches square, 60 inches square, and ranges encompassing such areas. However, these are merely exemplary embodiments, and the central portion 110 can have other dimensions for use in communication devices, packaging modems, hard drives, portable phones, or any other article that is to be packaged.
The illustrated central portion 110 has a generally flat upper surface that an article can rest against. Other non-limiting central portions can have mounting structures, apertures, recesses, partitions, separators, or other suitable structures for inhibiting movement of an article engaging the central portion or for providing additional shock protection. For example, the central portion 110 can have at least one holder that is sized and configured to receive an article.
Fold lines 116, 118 can be defined between the central portion 110 and the foldable portions 112, 114, respectively. The fold lines 116, 118 can be formed as perforations in the frame member 100, i.e., broken cut lines passing partially or completely through the material forming the frame member 100. In the alternative, or in addition, the fold lines 116, 118 can be crushed portions of the material forming the frame member 100. Of course, depending on the material used to construct the frame member 100, the fold lines 116, 118 can be formed as mechanical hinges, thinned portions, adhesive tape, or any other appropriate mechanical connection which would allow various portions of the foldable member to be folded or rotated with respect to each other. These concepts apply to all the fold lines 116, 118 described herein, although this description will not be repeated with respect to the other fold lines described below.
With such fold lines 116, 118, the foldable portions 112, 114 can be bent upwardly or downwardly relative to the central portion 110 as desired. With this flexibility, the foldable portions 112, 114 can be folded upwardly so as to create slack in the resilient member 200 to load an article to be packaged and folded downwardly to increase tension in the resilient member 200, described in greater detail below.
The illustrated configuration of the frame member 100 is merely one example of many different kinds and shapes of frame members that can be used. U.S. Pat. Nos. 6,675,973, 7,882,956, 7,296,681, 7,753,209, 8,028,838, 8,235,216, 8,627,958 and U.S. patent application Ser. Nos. 12/958,261 and 13/221,784, the contents of each of which is hereby incorporated by reference, all disclose various different kinds of frame members with various different combinations of additional folding portions which can be used as a substitute for the illustrated frame member 100. Certain of these embodiments are described in further detail below in connection with
With reference to
The resilient member 200 can be formed from a resilient body 202. For purposes of convenience for the following description, the body 202 is identified as having a midpoint M positioned in the vicinity of the middle of the resilient body 202. Resilient body 202 can also include ends 204, 206 disposed at opposite longitudinal and thereof.
The resilient member 200, in some embodiments, has a Length L1 that is sized depending in the devices with which the resilient member 200 is to cooperate, such as goods. Thus, the Length L1 can be sized such that when the resilient member 200 is in its final state, e.g., engaged with the foldable portions 112, 114, it generates the desired tension for the corresponding packaging application. Thus, the Length L1 will be smaller where a higher tension is desired and will be larger where a lower tension is desired. Additionally, the Length L1 might be different for different sized articles that are to be packaged. One of ordinary skill in the art can determine the Length L1 for the corresponding application. Additionally, one of ordinary skill in the art is fully aware of how to perform industry standard drop tests to confirm the appropriate dimensioning of the frame member 100 and the resilient member 200.
The resilient member 200 can be formed of any resilient material. In some embodiments, the resilient member 200 can be formed of a layer of polyethylene films, low density polyethylene (LDPE), polyurethane, TPU, or virtually any polymer, or plastic film. The density of the layers of film can be varied to provide the desired retention characteristics such as overall strength, resiliency, and vibrational response. Preferably the density of the material used to form the resilient member 200 is determined such that the resilient member 200 is substantially resilient when used to package a desired article. The layer used to form resilient member 200 can be monolayer or multilayer sheet depending on the application.
As illustrated in
As illustrated in
As illustrated in
With reference now to
As the foldable portions 112, 114 are further pivoted downwardly about the fold lines 116, 118, until they are doubled back adjacent to the lower surface of the central portion 110, the foldable portions 112, 114, continue to add additional tension into the resilient member 200. The frame member 100 and the resilient member 200 can be configured to form a spring when disposed in a box or container 310 in the arrangement shown in
Accordingly, when the frame member 100, resilient member 200, and the article 300 are arranged in the configuration shown in
Further, the container 310 can define a maximum inner height, for example, when the lid portion of the container 310 is closed. With the maximum inner height set to a dimension less than the maximum overall height of the article 300 and frame member 100, the foldable portions 112, 114 are maintained such that the angular position γ (
With reference now to
The source portion 420 of the system 400 can include one or more source rolls of raw material for making the resilient member 200. In the illustrated embodiment, the source portion 420 can comprise, in some embodiments, a roll 422 of raw material for forming the resilient member 200. As is well known in the art, the roll 422 is mounted so as to provide some resistance against turning, so as to thereby maintain an acceptable minimum tension.
As illustrated in
In the illustrated embodiment, the heat sealing portion 520 and the cutting portion 550 are integrated into single component referred to herein as the heat sealing device 552. However, other configurations can also be used. In the illustrated embodiment, the heat sealing device 552 is configured to form one or more heat seals between the strip 426 and the frame material 604, such as corrugated, fed towards the heat sealing portion 520 and cutting portion 550 via a feed device 602. It should be noted that any materials from which the frame member 100 can be made can be fed using the feed device 602. Moreover, it should be noted that the frame material 604 can either be unfinished frame material which has not yet been cut to size and/or include folds, partially unfinished frame material which has not yet been completely cut to size and/or include all folds, or finished frame material which has already been fully cut with all folds fully formed. In addition, the frame material 604 can have coating layers applied to surfaces of the frame material 604 for embodiments of a frame member, such as frame member 100, in which a coating layer can be used for heat sealing.
The heat sealing device 552 can also be configured to cut the strip 426. In embodiments where the frame material 604 is unfinished or partially unfinished, the heat sealing device 552 can be used to also cut the frame material 604 into a frame member, such as frame member 100. Individual heat-sealed packaging assemblies such as packaging assembly 140 can then be discharged from the device 552. The heat-sealed assemblies can then be placed in a container 650 where they can be temporarily stacked and stored.
With reference to
The cutting head 554 can include a cutting portion 560. In some embodiments, the cutting head can also include a first heat sealing portion (not shown) and a second heat sealing portion (not shown) proximate the cutting portion 560. As the strip 426 and frame material 604 move under the heat sealing head 553 and cutting head 554, the heads can move downwardly and press the cutting portion 560 down into the strip 426 and, in some embodiments the frame material 604, so as to simultaneously cut the strip 426 into a resilient member 200 and, in some embodiments, the frame material 604 into a frame member 100, as well as heat seal the strip 426 onto the frame material 604 along heat seals 302, 304. In embodiments with the cutting head 554 including a first heat sealing portion and a second heat sealing portion, this can also be used to potentially heat seal other portions of the strip 426 to the frame material 604.
It should be understood that, in some embodiments, the heat seals can be created along a lower surface of the frame material 604 such as is shown in
The heat sealing portion 552 can include a conveyor system to carry the strip 426 and the frame material 604 into the area beneath the heat sealing head 553 and cutting head 554 to be cut and heat sealed. The conveyor system can then carry the assembled frame member 100 and resilient member 200 away from the heat sealing head 553 and the cutting head 554. In some embodiments, a cooling device, such as a forced convection device can be located downstream of the heat sealing device 552 to expedite cooling of the heat seal. Of course, a forced convection device is entirely optional particularly in cases where the heat seal can be air cooled effectively.
In some embodiments, the assembled frame member 100 and resilient member 200 can then be stacked in a container 650 where they can be allowed to further cool. Due to the assembled frame member 100 and resilient member 200 being stacked such that the heat sealed resilient member 200 is placed between two frame members 100, the risk of two assemblies sticking together is reduced since a recently heat-sealed resilient member 200, after cooling slightly, will stick to a frame member 100 stacked on top of it. As should be understood by those of skill in the art, this risk can be further reduced by allowing the assemblies to cool before being stacked in container 650. Accordingly, in some embodiments, the conveyor can be extended further such that the assemblies are provided additional time to cool or by including a cooling device downstream of the heat sealing device 552. As such, the assemblies can be stacked in an automated manner, using well known high speed/high volume devices for aligning dropping items into a container. Thus, some embodiments can help reduce man power required for production and thus reduce production costs.
Optionally, the cutting portion 560 can be configured to only perforate or score the strip 426 and/or frame material 604 so that the resilient members 200 and/or frame members 100 are still attached but easily separable from each other.
As noted above, the strip 426 can be made from materials having different melt indexes. The melt index of a material refers to the temperature at which the material will begin to flow and thereby can form clean heat seals. Most materials have different melt index values. The melt index values of many soft polys vary from about 7.0 to 9.7. Thus, the strip 426 can be conveniently heat sealed to frame material 604 if the melt index is in the range of about 7.0 to about 10.0, they can be easily heat sealed together using the above-described apparatus 400 and provide clean heat seals.
Further, the strip 426 can have different moduli of elasticity. A more flexible material can be used or a relatively stiffer material can be used. For example, the strip 426 can be a polyurethane or a low density polyethylene. In this example, a six inch wide, 24 inch long strip of low density polyethylene will stretch only about six inches before failure while a six inch wide by 24 inch long strip of polyurethane will stretch 18 inches before failure. In some embodiments, the strip 426 can be formed from two types of materials with certain materials being used along portions which are heat sealed and other materials being used for other portions. In some embodiments, between about 0% to about 40%, between about 5% to about 30%, between about 10% to about 20%, about 15%, or any other value including those within these ranges of the resilient member 200 can be formed from a different material.
The thicknesses of the strip 426 can also be different along different portions. For example, depending on the application, strip 426 can be thicker along portions which are heat sealed as well as areas proximate the portions to be heat sealed whereas the strip 426 can be thinner along others portions. This can potentially enhance the strength of the bond of the resilient member 200 when it is attached to the frame member 100. In some embodiments, between about 0% to about 40%, between about 5% to about 30%, between about 10% to about 20%, about 15%, or any other value including those within these ranges of the resilient member 200 can have a greater thickness than the remaining portions. This can help save cost of materials because thinner materials are less expensive, less waste, etc.
With reference to
The resilient member 200b can be formed from a resilient body 202. For purposes of convenience for the following description, the body 202 is identified as having a midpoint M position in the vicinity of the middle of the resilient body 202. Resilient body 202 can also include end portions 204, 206 disposed at opposite longitudinal and thereof. In the illustrated embodiment, the resilient member 200b is formed from two pieces of resilient material connected together, and sized to cooperate with the foldable portions 112, 114 of the frame member 100. As illustrated in
One of ordinary skill in the art will appreciate that there are numerous methods for securing the two layers of material to each other. However, it has been found that heat sealing is particularly advantageous as it does not require expensive adhesives and the time consuming steps required for using such adhesives. However, such adhesives can be used if desired. Welding processes (e.g. induction welding), fusing techniques, and the like can also be used to form the heat sealing lines 210, 212 as well as any other heat sealing described herein.
The resilient member 200b, in some embodiments, has a Length L1 that is sized depending in the devices with which the resilient member 200b is to cooperate, such as goods. Similar to the resilient member 200 described in connection with
The resilient member 200b can be formed of any resilient material. In some embodiments, the resilient member 200b can be formed of two layers of polyethylene films, low density polyethylene (LDPE), polyurethane, TPU, or virtually any polymer, or plastic film. The density of the layers of film can be varied to provide the desired retention characteristics such as overall strength, resiliency, and vibrational response. Preferably the density of the material used to form the resilient member 200b is determined such that the resilient member 200b is substantially resilient when used to package a desired article. Each of the layers used to form resilient member 200b can be monolayer or multilayer sheet depending on the application.
As illustrated in
As illustrated in
Due to the dual layer design of retention member 200b, the article to be packaged 300 can be inserted between the resilient member 200b and the frame member 100 or between the upper and lower layers 230, 232 of the resilient member 200b. For example, in some embodiments, the resilient member 200b can include the opening device 208 which can be configured to allow the article 300 to be inserted into the space between the upper and lower layers 230, 232. In some embodiments, the opening device 208 can be in the form of perforations in the upper layer 230 configured to allow the upper layer 230 to be ruptured and opened thereby allowing the insertion of the article 300 into the space between the upper and lower layers 230, 232.
In other embodiments, the opening device 208 can be in the form of a zipper, a tongue-and-groove zip-type closure member, Velcro®, low strength adhesives, flaps, magnets, or any other type of closing device.
Optionally, the opening device 208 can be positioned on the lower layer 232 (illustrated in phantom line in
In some embodiments, opening devices 208 can be provided on both of the upper and lower layers 230, 232. As such, the resilient member 200b can be used in various ways, allowing the article to be inserted into the space between the layers 230, 232 through either of the opening devices 208 on either layer 230, 232.
With reference now to
As the foldable portions 112, 114 are further pivoted downwardly about the fold lines 116, 118, until they are doubled back adjacent to the lower surface of the central portion 110, the foldable portions 112, 114, continue to add additional tension into the resilient member 200b, and more particularly, the upper and lower layers 230, 232 of the resilient member 200b. The frame member 100 and the resilient member 200b can be configured to form a spring when disposed in a box or container 310 in the arrangement shown in
Accordingly, when the frame member 100, resilient member 200b, and the article 300 are arranged in the configuration shown in
Further, the container 310 can define a maximum inner height, for example, when the lid portion of the container 310 is closed. With the maximum inner height set to a dimension less than the maximum overall height of the article 300 and frame member 100, the foldable portions 112, 114 are maintained such that the angular position y (
With continued reference to
The source portion 420 of the system 400b can include one or more source rolls of raw material for making the resilient member 2b00. In the illustrated embodiment, the source portion 420 can comprise, in some embodiments, one or more rolls of raw material for forming the resilient member 200b. In the illustrated embodiment, a first roll 422 serves as a source of the upper layer of film for forming the upper layer 230 of the resilient member 200b and the second roll 424 serves as a source for the material performing the second lower layer 232 of the resilient member 200b. In the illustrated embodiment, the rolls 422, 424 are approximately the same width. However, it should be understood that rolls of different width can also be used.
Additionally, as described above, the material on the rolls 422, 424 can be different kinds of materials, different thicknesses and have different melting indexes. Additionally, as well known in the art, the rolls 422, 424 are mounted so as to provide some resistance against turning, so as to thereby maintain an acceptable minimum tension.
As illustrated in
The source 420 can also include one or more tensioning rollers 430 configured for maintaining tension in the strips 426, 428 as they are pulled through the system 400b. The tensioning of such layers of material is well known to those of ordinary skill in the art, and thus is not described in further detail.
Optionally, as noted above, the manufacturing apparatus 400 can include an opening portion 450 configured to provide the opening device 208 to the resilient member 200b. In the illustrated embodiment, the opening device portion 450 is configured to perforate the strip of material 426 so as to form an opening device 208 in the resilient member 200b. In some embodiments, the opening portion 450 can include a block member 452 and a cutting head 454. In such an arrangement, the cutting head 454 can include a cutting blade (not shown) configured to reciprocate in a direction perpendicular to the material 426 in a timed fashion so as to create perforations at desired locations.
For example, as shown in
Optionally, the system 400b can include a set of diverter rollers 455, configured to allow the lower strip 428 to bypass the opening portion 450. Thus, the opening portion can selectively provide opening devices 208 to only one or to both of the strips 426, 428.
In some embodiments, one of or both of the strip 426, 428 can include printed portions 429, such as advertising, trade names, trademarks, logos, coupons, or other indicia. Thus, the resulting resilient member 200b can include such printing on one or both of the layers 426, 428. In some embodiments, one or both of the layers 426, 428 can be pre-printed with the desired printed portions 429. For example, in some embodiments, the printed portions 429 can be applied to the layer 428 and the layer 426 can be translucent or transparent. Thus, during use, the printed portions 429 can be viewed through the upper layer 426 (layer 230 in
With continued reference to
Using such as registration device 460, the system 400b can be configured to create opening devices and heat seals in locations that are at predetermined spacings from the printed portions 429. For example, the opening devices 208 can be centered on the printed portions 429 and the cuts created by the cutting portion 550 can be disposed between the printed portions 429. Other spaced relationships can also be used.
With continued reference to
In the illustrated embodiment, the heat sealing portion 520 and the cutting portion 550 are integrated into single component referred to herein as the heat sealing device 552. However, other configurations can also be used. In the illustrated embodiment, the heat sealing device 552 is configured to form one or more heat seals between the layers of the strips 426, 428 and the frame material 604, such as corrugated, fed towards the heat sealing portion 520 and cutting portion 550 via a feed device 602.
The heat sealing device 552 can also cut the strips 426, 428, between the two parallel heat seals. In embodiments where the frame material 604 has not been fully cut, the heat sealing device 552 can be used to also cut the frame material 604 into frame member 100. Individual resilient member 200b and frame member 100 heat-sealed assemblies can then discharged from the device 552. The heat-sealed assemblies can then be placed in a container 650 (
With reference to
The heat sealing and cutting head 554 can include a cutting portion 560. In some embodiments, the cutting head can also include a first heat sealing portion 556 and a second heat sealing portion 558 adjacent proximate the cutting portion 560. As the strips 426, 428 and frame material 604 move under the heat sealing head 553 and cutting head 554, the heads can move downwardly and press the cutting portion 560 down into the strips 426, 428 and, in some embodiments, the frame material 604 so as to simultaneously cut those the strips 426, 428 into a resilient member 200b and, in some embodiments, the frame material 604 into a frame member 100, as well as heat seal the strips 426, 428 onto the frame material 604 along heat seals 302, 304 and together along heat seals 210, 212. In embodiments with the cutting head 554 including a first heat sealing portion 556 and a second heat sealing portion 558, these portions 556, 558 can be used to form heat seals such as heat seals 210, 212, heat seals the strips 426, 428 directly to the frame member 100, or a combination of both.
The heat sealing portion 552 can include a conveyor system to carry the strip 426, 428 and the frame material 604 into the area beneath the heat sealing head 553 and cutting head 554 to be cut and heat sealed. The conveyor system can then carry the assembled frame member 100 and resilient member 200b away from the heat sealing head 553 and the cutting head 554. In some embodiments, a cooling device, such as a forced convection device can be located downstream of the heat sealing device 552 to expedite cooling of the heat seal. Of course, a forced convection device is entirely optional particularly in cases where the heat seal can be air cooled effectively. The assembled frame members 100 can then be stacked in a container 650.
Optionally, the cutting portion 560 can be configured to only perforate or score the strips 426, 428 and/or frame material 604 so that the resilient members 200 and/or frame members 100 are still attached but easily separable from each other.
As noted above, the strips 426, 428 can be made from materials having different melt indexes. The melt index of a material refers to the temperature at which the material will begin to flow and thereby can form clean heat seals. Most materials have different melt index values. The melt index values of many soft polys vary from about 7.0 to 9.7. Thus, the layer strips 426, 428 can have different melt indexes and conveniently if those melt indexes are in the range of about 7.0 to about 10.0, they can be easily heat sealed together using the above-described system 400b and provide clean heat seals.
Further, the strips 426, 428 can have different moduli of elasticity. In some embodiments, for example, more flexible material can be used as the top layer 426 while a relatively stiffer layer can be used as the lower layer 428. For example, the upper layer, and some embodiments is a polyurethane while a low density polyethylene is used as the lower layer 428. Although these materials behave very differently with regard to failure, they can be easily heat sealed together using the system 400b described above and provide the desired shock absorption for packaging articles 300 described above. As described above, the one or more of the strips, such as strips 426, 428, can be formed from two types of materials with certain materials being used along portions which are heat sealed and other materials being used for other portions.
The thicknesses of the strips, such as strips 426, 428, can also be different compared to each other. In addition, the thickness of the strips can also be different along different portions as described above. Moreover, the widths of the strips 426, 428 can be slightly different. For example, the width of the strip 428 can be greater than the width of the strip 426. Thus, when heat sealed together, the ends of the lower layer 232 can extend beyond the ends of the upper layer 230. This can be particularly advantageous, for example, heat sealing the lower layer 232 to the frame material 604 is more effective. This can be the case, for example, if the strip 428 is a material which more suitable for heat sealing to the frame material 604 such as the raw frame material or a coating on the frame material 604. The strip 426 can then be heat sealed along portions of its periphery, such as described herein, to the strip 428 rather than the frame material 604. Of course, it should be understood that strip 426 can also be heat sealed to the frame material 604.
Further, because various different kinds of material can be heat sealed together as described above, the colors of the materials can also be different. For example, the strip 426 could be translucent or transparent and the strip 428 could be translucent or opaque. Thus, the strip 428 could include printed portions 429 that can be seen through the layer formed by the strip 426. The printed portions could be any form of advertising, including but without limitation, trademarks, trade names, service marks, logos, coupons, etc.
With reference now to
With reference first to
Generally, the amount of heat and pressure applied to the resilient member 200 can be chosen so as to be sufficient to cause the resilient member 200 to soften and/or partially melt so as to generate a connection to the top layer 120. The amount of heat applied can be controlled by selecting an appropriate temperature for the heat seal head 553 and controlling the amount of time this temperature is applied to the resilient member 200. The temperature can also be varied as a function of time and/or force applied. The amount of pressure can be controlled by controlling the amount of force applied to the heat seal head 553, such as via motors or other mechanisms. The pressure can also be varied as a function of time and/or the temperature applied.
In some embodiments, the temperature, pressure and times of application of each can be chosen such that the resilient member 200 can form a bond, upon cooling and solidifying, with a material to which it is placed adjacent during the heat sealing process. For example, in the illustrated embodiment, the temperature, pressure and times of application of each can be chosen such that the resilient member 200 forms a bond with an outer layer, such as the top layer 120. For example, in some embodiments, the upper layer 120 can be made from a fibrous material, such as those noted above commonly used for forming outer layers of materials known as “corrugated cardboard”. In such embodiments, the temperature, pressure and times of the heat sealing process can be chosen such that at least some of the resilient member 200 flows into close contact with the fibers forming the upper layer, thereby forming a connection that is enhanced with a mechanical engagement of the material of the resilient member 200 and the surfaces of the fibers contained in the upper layer 120. The more the resilient member 200 flows into and around the fibers, the stronger the connection between the fibers and the.
In some embodiments, the resilient member 200 can melt and flow through pores or openings of the outer layer and into cavities 125 of the inner layer 124. Such cavities 125 can be formed during the processes for manufacturing the upper layer 120 or at any time after manufacturing. For example, although not illustrated, a “pricking” device can be used to generate one or a plurality of cavities 125 with the upward openings at the first surface of the upper layer 120. Thus, when the resilient member 200 is heated during the heat sealing process, some of the resilient member 200 can flow more readily into the cavities 125, thereby enhancing a connection between the resilient member 200 and the upper layer 120. Further, in some examples, a heat sealing head can be modified to include a plurality of pins which simultaneously form a cavities 125 and heat the resilient member 200 sufficiently to cause the material forming the resilient member 200 to flow into the cavities 125. Other techniques can also be used.
With continued reference to
If too much temperature and/or pressure had been applied during the associated heat sealing process, too much of the resilient member 200 might flow into the upper layer 120, thereby leaving a thickness 311 that is insufficient to maintain a reliable connection between the free portion of the resilient member 200 and the upper layer 120, for example, allowing the resilient member 200 to tear in the vicinity of the transition portion 309 when subjected to a load during normal use. One of ordinary skill in the art, in light of the description set forth herein, can determine the appropriate amount of pressure and/or temperature to use in order to provide a transition portion 309 with sufficient strength.
Fibrous materials, such as cardboard, paperboard, paper, and the like can include pores or openings. Additionally, as discussed above, other types of porous materials can be used for the outer layer. Moreover, in some embodiments, to enhance the ability for the resilient member 200 to flow into cavities 125 of the inner layer 124, a separate device can be incorporated in the manufacturing system, such as systems 400, 400b, to create additional pores or openings at least along portions of the frame member 100 on which the resilient member is to be heat sealed. This device can include one or more pins, needles or other puncturing devices to create pores or openings. This device can also be part of the heat sealing head 553 or cutting head 554. The size of the pores or openings can be chosen to allow sufficient flow into the inner layer 124. In some embodiments, rather than creating pores or openings, a device can be used to create one or more slits at least along portions of the frame member 100 on which the resilient member is to be heat sealed. Creation of pores, openings, or slits can help improve the strength of the heat seal of the resilient member 200 to the frame member 100 and reduce the temperature, pressure and/or time of application of each to form the heat seal 302b.
With reference now to
For example, in embodiments where the resilient member 200 is formed from a polymer or plastic-based material and the coating 130 is also formed from a polymer or plastic-based material, the resilient member 200 and/or coating 130 can melt such that the resilient member 200 and coating 130 bond upon cooling and solidifying. Moreover, it should also be appreciated that some degree of flow of the resilient member 200 and/or coating 130 through the outer layer, such as top layer 120, can also occur. Reference should be made above to discussion above in connection with
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The following temperatures, pressures and times of applications can be used for heat sealing the resilient member 200 directly to the frame member 100:
The temperatures, pressures and times noted above provide acceptable results. Additionally, ranges of variations from the above, specifically listed temperatures, pressures and times also provide acceptable results. Magnitudes of such ranges of variations can be affected by various other parameters, such as environmental temperature, starting temperature of the materials, environmental humidity, variations in material compositions, impurities in the materials, impurities in the air, etc. In light of the ranges of variations that can provide acceptable results, as used herein for characterizing values of temperatures, pressures and times, the term “about” is intended to mean that a variation of about 10% of the stated number is included. For example, the statement “polyurethane heat sealed at a temperature of about 225° F., for about 15 seconds, at a pressure of about 0.5 lb. f/in” is intended to include at least “a temperature of 202.5-247.5° F., for 13.5-16.5 seconds, at a pressure of 0.49-0.51 lb. f/in”. Larger ranges of included values may also be included.
In some embodiments, the heat sealed areas of the resilient member 200 can account for between about 1% to 40% of the total area of the resilient member 200, between about 5% to about 30% of the total area of the resilient member 200, between about 10% to about 20% of the total area of the resilient member 200, about 10% of the total area of the resilient member 200, or any other value including those within these ranges. Moreover, in some embodiments, the area of the resilient member 200 between the heat sealed portions can account for between about 50% to about 99% of the total area of the resilient member 200, between about 65% to about 95% of the total area of the resilient member 200, between about 80% to about 90% of the total area of the resilient member 200, about 90% of the total area of the resilient member 200, or any other value including those within these ranges. In some embodiments, the heat sealed areas of the resilient member 200 can account for between about 1% to 40% of the total area of the frame member 100, between about 5% to about 30% of the total area of the frame member 100, between about 10% to about 20% of the total area of the frame member 100, about 10% of the total area of the frame member 100, or any other value including those within these ranges.
The manufacturing process as herein described can be modified to produce other articles, such as differently shaped frame members, to which a resilient member can be attached.
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Preferably, clearances 826, 828, 830, 832 are formed between the side panels 810, 812, 814, 816, and the rotatable portions 790, 792. The clearances 826, 828, 830, 832 provide gaps between the rotatable portions 790, 792 and the side panels 814, 816 such that when a user rotates the rotatable portions 790, 792 around the fold lines 794, 796, respectively, the rotatable portions 790, 792 rotate freely and thus, are not impeded by the side panels 810, 812, 814, 816.
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With reference to
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In the illustrated embodiment, as shown in
With reference to
Resilient members 200d, 200d′ have lengths L1A′, L1B′, respectively, which are configured such that the rotatable portions 968, 970, and 976, 978 can be moved between positions in which the resilient members 200d, 200d′ are slackened and positions in which the resilient members 200d, 200d′ are tightened. For example, although not illustrated, the rotatable portions 976, 978 shown in
It is apparent to one of ordinary skill in the art that the length L1B′ can be adjusted accordingly to generate the desired tension and in light of the overall strength of the frame member 956 and the strength of the resilient member 200d′.
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While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope defined by the claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.
This application is a continuation of application of U.S. patent application Ser. No. 15/706,594, filed Sep. 15, 2017, which is a continuation of U.S. patent application Ser. No. 14/222,410, filed Mar. 21, 2014. The disclosures of all of these prior applications are hereby incorporated by reference herein in their entirety and should be considered a part of this specification for all purposes. Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
Number | Date | Country | |
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Parent | 15706594 | Sep 2017 | US |
Child | 17448024 | US | |
Parent | 14222410 | Mar 2014 | US |
Child | 15706594 | US |