Package Assembly with Tear Away Film and Manufacturing System

Abstract

A package assembly includes a number of containers, a heat-shrink wrapping disposed around the containers and tear strip; the tear strip aids in opening the heat-shrink wrapping. The tear strip can be defined by perforations disposed through the heat-shrink wrapping and arranged in pathways. The perforations are cut in the heat-shrink wrapping with a packaging apparatus having a cutting member. The cutting member is used in combination with a die to leave a chad attached to heat-shrink wrapping. Thereafter, the heat-shrink wrapping is shrunk with a heating source in order to bundle containers together within the package assembly.

Description

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

In order to bundle containers together for shipment and storage, the containers are oftentimes bundled together in various ways. One way in which containers are bundled together is via the use of a heat-shrink wrapping, which is subsequently heated. In this way, the containers are containers are held in a stable configuration.

The heat-shrink wrapping has certain disadvantages, however. One such disadvantage is that the heat-shrink wrapping can be difficult to remove once transit of the containers is complete. Removal of the heat-shrink wrapping can require tugging and tearing of the heat-shrink wrapping, or cutting it with a knife, scissors, or other sharp utensil. For the end-user of the product, this can be an onerous task. Further, with the rise of safety concerns, some outlet stores have adopted “no-knife” policies. In these stores, the clerks, stockroom workers, and floor employees are not allowed to carry cutting devices, making removal of the heat-shrink wrapping even more cumbersome.

An additional drawback of heat-shrink wrapping is that it has a tendency to prevent cooling of the contents within the heat-shrink wrapping. In particular, heat from the packaging assembly can become trapped within the heat-shrink wrapping which, in some cases, can negatively impact the contents within the containers.

In light of the drawbacks associated with traditional heat-shrink wrapping and packaging methods and apparatuses, there is a need for a package assembly, method, and apparatus that reduces or eliminates the need for usage of specialty tools (e.g., knives, scissors, box cutters), facilitates cooling of the contents within the heat-shrink wrapping, and increases the rate of packaging.

Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below.

BRIEF SUMMARY OF THE INVENTION

In some embodiments, a package assembly comprises a plurality of containers wrapped in a heat-shrink wrapping. The heat-shrink wrapping defines a plurality of perforations disposed through the heat-shrink wrapping. The plurality of perforations are arranged in first and second pathways and the pathways define a tear strip therebetween.

In some embodiments, the first and second pathways are parallel to one another along at least portions thereof.

In some embodiments, the wrapping further defines at least one hole therethrough, the hole being larger than the perforations.

In some embodiments, the pathways intersect at least one hole.

In some embodiments, the tear strip is in the shape of an hour-glass.

In some embodiments, the pathways are parallel to a plane defined by the bottom of the containers.

In some embodiments, the tear strip is removable from the package assembly.

In some embodiments, the heat-shrink wrapping has a plurality of chads attached thereto.

In some embodiments, a method of making a package assembly comprises providing a plurality of containers and providing a heat-shrink wrapping. The method further comprises perforating the heat-shrink wrapping in first and second pathways and wrapping the plurality of containers with the heat-shrink wrapping. The method further comprises applying heat to the heat-shrink wrapping and shrinking the heat-shrink wrapping around the plurality of containers. Additionally, the first and second pathways define a tear strip therebetween.

In some embodiments, the method further comprises the step of cooling the package assembly.

In some embodiments, the step of perforating the heat-shrink wrapping comprises producing a chad which remains connected to the heat-shrink wrapping.

In some embodiments, the method further comprises the step of providing a heat-shrink wrapping dispenser.

In some embodiments, a packaging apparatus comprises a heat-shrink wrapping dispenser, a perforating assembly, and a heat source. The perforating assembly comprises a die member and a cutting member. The cutting member is configured to work in conjunction with the die member. The cutting member comprises a die-facing perimeter, the die-facing perimeter having a cutting portion and a non-cutting portion. The cutting portion extends around only a portion of the die-facing perimeter.

In some embodiments, the cutting member further comprises a bevel extending away from the die-facing perimeter.

In some embodiments, the cutting member further comprises a plurality of cutting teeth disposed along a portion of its die-facing perimeter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an embodiment of a package assembly.

FIGS. 2-4 show perspective views of the embodiment of the package assembly of FIG. 1 in various states.

FIGS. 5-12 show perspective views of embodiments of a package assembly in various arrangements.

FIG. 13 shows an embodiment of a die plate 122.

FIG. 14 shows a perspective view of an embodiment of a package assembly.

FIG. 15 shows a perspective view of an embodiment of a packaging apparatus.

FIG. 16 shows a perspective view of an embodiment of a perforating assembly.

FIG. 17 shows a perspective view of an embodiment of a cutting member.

FIG. 18 shows a method of making a package assembly.

DETAILED DESCRIPTION OF THE INVENTION

In order to reduce, or overcome, the problems associated with traditional packaging methods, apparatus, and assemblies, a new package assembly, method of producing the package assembly, and packaging apparatus are herein disclosed. Each is described, in turn, in the following description.

PACKAGE ASSEMBLY

With regard to FIG. 1, a package assembly 10 is shown. The package assembly includes a plurality of containers 12 and a film or heat-shrink wrapping 14. The containers 12 can be of any desirable shape or configuration, for example cylindrical, conical, frusto-conical, spherical, cuboid, pyramidal, and combinations thereof. Additional examples of suitable packaging configurations can be found in U.S. Pat. Nos. 7,604,114 to Gessler, 7,392,905 to Andersen, 7,370,761 to Andersen, 6,588,594 to Andersen, 5,887,717 to Anderson, and 7,467,504 to Mate, the contents of each of which are herein incorporated by reference in their entirety.

In addition to the foregoing, the heat-shrink wrapping 14 has therethrough a plurality of perforations 16. In some embodiments, the perforations are arranged in one or more pathways 18. As shown in FIG. 1, for example, the pathways 18 include a first pathway 18a and a second pathway 18b. Between the first and second pathways 18a, 18b is a tear strip 20. The tear strip 20 facilitates easy opening and removal of the heat-shrink wrapping 14. Further, in some embodiments, the package assembly 10 includes a base pad 22, on which the containers 12 reside. The base pad 22 provides additional support for the containers 12 during the packaging assembly and transport.

Turning to FIG. 2, the package assembly 10 shows the tear strip 20 as it is initially pulled away from the remaining heat-shrink wrapping 14. In some embodiments, the tear strip 20 will originate at a hole 24 (also referred to as a “bulls-eye”, which is a byproduct of known packaging techniques), for example at an end of the heat-shrink wrapping 14. It will be appreciated that, at least in some embodiments, the size of the hole 24 is much larger than the size of a perforation 16.

In FIG. 3, the tear strip 20 is further pulled away from the remaining heat-shrink wrapping 14. As illustrated, the tear strip 20 peels away from the remaining -shrink wrapping 14 along the pathways 18 formed by the perforations 16.

With regard to FIG. 4, the tear strip 20 is almost fully removed from the remaining heat-shrink wrapping 14. In some embodiments, the tear strip 20 is entirely removable from the package assembly 10, for example via perforations extending from hole 24 on one end of the package assembly 10 to a similar hole 24 on another end, or side, of the package assembly 10. In some embodiments, however, the tear strip 20 is peeled away from the remaining heat-shrink wrapping 14 but it is not entirely removable. In this way, the orientation of the perforations 16 does not permit complete removal of the tear strip 20.

With regard to FIG. 5, in some embodiments, the perforations 16 are spaced at least a distance Y away from the hole 24. This minimum spacing ensures that a tear does not unintentionally form between hole 24 and the first perforation 16a. It will be appreciated that the minimum spacing is a function of the material used for the heat-shrink wrapping 14, the heat used to shrink the heat-shrink wrapping 14, orientation of containers 12, and size and shape of the package assembly 10. Indeed, the spacing between the hole 24 and the first perforation 16a may vary, for example, such that the Y≦spacing≦X, where X is the maximum permissible spacing to facilitate tearing of the tear strip 20. For instances in which the spacing is greater than X, it becomes too difficult to start a tear along the tear strip 20.

With regard to FIG. 6, in some embodiments, the pathways 18 are oriented such that the tear strip 20 is wider at its ends than middle. In FIG. 6, for example, the tear strip 20 has an hour glass configuration. Such a configuration can be desirable, for example, in order to provide easy access to the containers 12.

With regard to FIGS. 7 and 8, in some embodiments, the pathways 18 are oriented on one or more sides of the package assembly 10. In FIG. 7, for example, pathways 18 are disposed on all sides of the package assembly 10. In FIG. 8, for example, pathways 18 are disposed on only some of the sides of the package assembly 10. In the embodiments shown in FIGS. 7 and 8, the pathways 18 are parallel to one another and parallel to a plane defined by the bottom of the containers 12. Other configurations are also permissible.

With regard to FIG. 9, the pathways 18 can also be oriented in a transverse direction. In this way, hole 24, which remains after of the shrink process, is located on a side not associated with the tear strip 20. Instead, an opening 26 is used at an end 28 of the tear strip 20 to facilitate removal of the tear strip 20, as desired.

Turning to FIG. 10, in some embodiments, a tear strip 20 is disposed on both the top 30 and bottom 32 of the package assembly 10. The tear strips 20 can be symmetric or asymmetric. Further, the orientation and/or configuration of the pathways 18 along the top 30 can be the same or different than the pathways 18 along the bottom 32.

With regard to FIG. 11, in some embodiments, the pathways 18 extend along only a portion of the top 30 (or any other surface) of the package assembly 10. In this way, the tear strip 20 may not be entirely removable from the package assembly 10. By maintaining the connection between the tear strip 20 and package assembly 10, it will be appreciated that the user will not have to discard two or more separate wrapper components. Instead, the wrapper will remain in a single piece, with the contents of the package assembly 10 accessible.

With regard to FIG. 12, in some embodiments, the pathways 18 are different from one another such that the first pathway 18a is shorter than the second pathway 18b.

With regard to FIG. 14, in some embodiments, the package assembly 10 comprises 12 containers. Although shown with 12 containers, it will be appreciated that any suitable number of containers 12 can be used, for example 4, 6, 8, 9, 10, 12, 20, 25, 100. Further, the containers 12 can be stacked in multiple rows. Additionally, the package assembly 10 can have any suitable number of pathways 18 and any suitable number of tear strips 20.

In at least one embodiment, the heat-shrink wrapping 14 is provided with only a single pathway 18 of perforations 16. By applying force along this single pathway 18 (such as with a user's finger, etc.) the heat-shrink wrapping 14 can be split or otherwise opened along the pathway 18.

PACKAGING APPARATUS

Turning to FIG. 15, an embodiment of the packaging apparatus 100 is shown therein. In some embodiments, the packaging apparatus 100 comprises a heat-shrink wrapping dispenser 102. The packaging apparatus 100 further comprises a perforating assembly 106, a heating source 108, a first conveyor 110 and a second conveyor 112.

In some embodiments, the heat-shrink wrapping dispenser 102 comprises at least one roll of heat-shrink wrapping 14 which feeds out of the heat-shrink wrapping dispenser 102.

As shown in greater detail in FIG. 16, the perforating assembly 106 comprises a die member 114 and a cutting member 116. The die member 114 works in conjunction with the cutting member 116 to make the perforations 16 in the heat-shrink wrapping 14. As will be appreciated, the cutting member(s) 116 move in and out of the die member(s) 114 to perforate the heat-shrink wrapping 14. Further, the die member 114 has a support 115 which is disposed on a backside of the heat-shrink wrapping 14 to provide support as the perforations are cut 16.

With regard to FIG. 17, a cutting member 116 or punch is shown in greater detail. In some embodiments, the cutting member 116 has a plurality of cutting teeth 118 along a portion of its die-facing perimeter 113. In some embodiments, the cutting teeth 118 do not extend around the entirety of the die-facing perimeter 113, however. Instead, the cutting member 116 has a cutting portion 124 and a non-cutting portion 126 to facilitate creation of non-severed or hanging chads 120. In some embodiments, the non-cutting portion 126 comprises a bevel 117 that extends away from the die-facing perimeter 113. In this way, the cutting member 116 perforates the heat-shrink wrapping 14 without severing the chad 120 (FIG. 15) from the heat-shrink wrapping 14. The chad 120 thereby remains attached to the heat-shrink wrapping 14. Maintaining attachment of the chad 120 to the heat-shrink wrapping 14 is beneficial, in some embodiments, in order to reduce or eliminate the production of waste material, which can clutter the assembly process. Consequently, there are no chads 120 to pick up or dispose of. This, in turn, reduces cost and machine down-time.

In some embodiments, the cutting member 116 produces perforations 16 having c-shape or v-shape perimeters, such that the open part of the “c” or “v” remains attached to the heat-shrink wrapping 14.

With further regard to the cutting member 116, the skilled artisan will appreciate that it can take on any desirable cross-section, for example circular, triangular, square, rectangular, elliptical, rhomboid, or any other suitable shape or polygon. Examples of some suitable cross sections are shown via die plate 122 in FIG. 13. The die plate 122 can be used in conjunction with the die member 114 such that the shape of the perforations 16 can be changed, as desired.

Returning to FIG. 15, in some embodiments, the perforating assembly 106 perforates the heat-shrink wrapping 14 while the heat-shrink wrapping 14 is statically positioned. The heat-shrink wrapping 14 is therefore indexed or otherwise stopped to permit the cutting member 116 or punch to be actuated, thereby penetrating the heat-shrink wrapping 14.

In some embodiments, the perforating assembly 106 is adjustable to permit an operator to easily adjust the pitch of the perforations 16 and the depth of cutting member 116 travel, for example to regulate the amount of material holding the chad 120 to the heat-shrink wrapping 14. In some embodiments, an actuator is used to relocate one or more groups of cutting members 116 or punches and die members 114 to adjust the pattern of the perforations. Further, it will be appreciated that the actuator(s) and die members 114 can be employed in any configuration or along any axis in order to adjust the pattern and orientation of the perforations 16. And, the packaging apparatus 100 can be used, for example, in conjunction with the “Packaging System for Split Package Assembly,” disclosed in U.S. Pat. No. 7,467,504, the contents of which are herein incorporated by reference.

METHOD OF MAKING PACKAGE ASSEMBLY

As illustrated via FIG. 18, a method of making the package assembly 200 is described. In some embodiments, the method includes the steps of providing the containers 202. In some embodiments, the packaging apparatus 100 (FIG. 15) can be added to an existing assembly line, for example, where the containers were previously assembled onto a base pad 22 or the like. The method of making the package assembly 200 further comprises the steps of providing a heat-shrink wrapping 204 and perforating the heat-shrink wrapping 206. After the heat-shrink wrapping 14 has been perforated, it is applied to the containers via step 208. Thereafter, heat is applied to the heat-shrink wrapping 14 at step 210 to shrink the heat-shrink wrapping 14.

As will be appreciated, upon application of heat to the heat-shrink wrapping 14, the size of the perforations 16 is reduced. Further, the chads 120 (FIG. 15) shrink in size and do not appear unsightly, upon completion of the package assembly, or interfere with any additional packaging processes.

In order to facilitate homogeneity, reduce viscosity, or to destroy pathogens, mixing machines commonly heat packaged product to temperatures ranging from fifty to ninety degrees Celsius. In the production of perishable goods, and more specifically, perishable goods which can be spoiled by transient periods at moderate temperatures, rapid cooling of the final package becomes of critical importance. Moreover, minimizing package cooling time allows the producer to cycle through product more quickly, reducing work-in-process and space requirements, thus increasing profitability.

It has been determined that strategically located apertures, when used in conjunction with adequate airflow, can reduce cooling cycles by more than twenty-five percent. Cooling speed, or time rate of thermal dissipation, is increased because the apertures simultaneously increase the exposed heat-dissipating surface area, and reduce the air temperature in the vicinity of the heat-dissipating surfaces. Moreover, by locating the apertures where tension is low in the wrapping, package integrity can be preserved.

Consequently, the embodiments disclosed in the immediate disclosure have advantages over previously known package assemblies, methods, and packaging apparatus.

Additionally, it will be appreciated that embodiments having perforations on opposite sides of the packaging apparatus 10 (e.g., FIGS. 7 and 10), more than one perforating assembly 106 can be used.

The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this field of art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to.” Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.

Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.

This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.

Claims

1. A package assembly comprising: a plurality of containers wrapped in a heat-shrink wrapping, the heat-shrink wrapping defining a hole and a plurality of perforations disposed therethrough, the hole and each of the perforations having an opening size, the opening size of the hole being greater than any of the perforations, the plurality of perforations arranged in first and second pathways, the plurality of perforations arranged in each pathway being spaced apart from one another at a first distance, the pathways defining a tear strip therebetween and extending from the hole, each pathway being spaced apart from the hole at a second distance, wherein the second distance is greater than the first distance.

2. The package assembly of claim 1, wherein the first and second pathways are parallel to one another along at least portions thereof.

3. (canceled)

4. (canceled)

5. The package assembly of claim 1, wherein the tear strip is in the shape of an hour-glass.

6. The package assembly of claim 1, wherein the pathways are parallel to a plane defined by the bottom of the containers.

7. The package assembly of claim 1, wherein the tear strip is removable from the package assembly.

8. The package assembly of claim 1, wherein the heat-shrink wrapping has a plurality of chads attached thereto.

9. The method of making a package assembly comprising: providing a plurality of containers;providing a heat-shrink wrapping, the heat-shrink wrapping defining at least one hole extending therethrough, the hole having a hole opening size;perforating the heat-shrink wrapping to created a plurality of perforations arranged in first and second pathways, and wherein each of the perforations has a a perforation size, the perforation size being smaller than the hole opening size;wrapping the plurality of containers with the heat-shrink wrapping;applying heat to the heat-shrink wrapping; andshrinking the heat-shrink wrapping around the plurality of containers, wherein the first and second pathways define a tear strip therebetween, and extending from the hole.

10. The method of claim 9, further comprising cooling the package assembly.

11. The method of claim 9, wherein the step of perforating the heat-shrink wrapping comprises producing a chad which remains connected to the heat-shrink wrapping.

12. The method of claim 9, further comprising providing a heat-shrink wrapping dispenser.