Packaging for golf balls

Abstract

A package and related technique is disclosed for wrapping and enclosing a collection of golf ball sleeves that avoids the use of costly retaining boxes or cartons. The package comprises an opaque, partially opaque, or partially transparent multi-layer overwrap. The resulting package inhibits light transmission, exhibits high strength and is economical.

Description

FIELD OF THE INVENTION

[0002] The present invention relates to novel materials, configurations, and methods for the packaging of golf balls, and particularly for the packaging of multiple sleeves of golf balls. The invention is more specifically directed to the use of overwraps, such as multi-layer overwraps, for packaging various arrangements and configurations of golf ball sleeves. The present invention eliminates the need for prior art boxes and cartons that are otherwise required for retaining multiple sleeves of golf balls. The present invention also relates to methods for economically and securely packaging multiple sleeves of golf balls and the resulting packaged products produced thereby.

BACKGROUND OF THE INVENTION

[0003] Golf balls are typically packaged in small, generally rectangular cardboard boxes referred to in the industry as “sleeves.” These boxes may or may not have a window, which allows for one or more of the balls to be viewed. Sleeves are customarily sized to accommodate three golf balls per sleeve, however sleeves are known that accommodate greater (i.e., four or more) or lesser (i.e., two or less) numbers of balls.

[0004] The balls are generally arranged within the sleeve such that they are aligned with one another along the length or longitudinal axis of the sleeve. Examples of such golf ball sleeves are described and shown in U.S. Pat. Nos. 5,044,548 to Olsen et al. as item 4 and 6,290,062 to Ohno et al. as item 11.

[0005] Alternative configurations are also available for arranging balls within a sleeve. Examples of such alternative configurations include arranging the balls in triangular configurations, in round packages, in tubes, and other novelty configurations.

[0006] Golf balls are usually sold in larger, generally rectangular cardboard retaining boxes that hold and retain multiple sleeves. Although the number of sleeves grouped within a box may vary, it is typical for groups of 4-6 sleeves to be arranged and sold together. The sleeves are generally arranged side-by-side within the box such that the widths of each sleeve are aligned with one another along the length or longitudinal axis of the retaining box. This results in a retaining box having, for example, a 1×4, 1×5, 1×6, etc. sleeve arrangements. An example of such a retaining box is illustrated in the '062 patent as item 1 and in the '548 patent as items 2 and 3. However, retaining boxes of alternative sleeve arrangements, such as a 2×2 sleeve arrangement, are also available.

[0007] Generally, all of the balls within a particular sleeve are labeled with the same number (i.e., 0, 1, 2, 3, 4, etc.) or indicia (i.e., hearts, diamonds, spades, clubs, etc.). In turn, the balls of the various sleeves contained within a retaining box generally have differing numbers or indicia. This allows for golfers utilizing the same brand or type of ball to distinguish their balls from one another during play.

[0008] Most of the boxes for retaining sleeves of golf balls have a top with four downwardly extending sides, sometimes referred to as a lid, and a bottom with four upwardly extending sides. The top and bottom components are sized such that the top is slightly larger than the bottom, and such that the top closely fits over and about the bottom when the box is closed.

[0009] Furthermore, it is customary for at least the top or lid of the retaining box to contain decorative artwork, printing and/or labeling. Sometimes, one or more sides of the top also contain such printing. And, it is also known to provide decorative printing, logos, or product information on the bottom component of the box. Although aesthetically pleasing, such printing increases the cost of packaging and further adds to the overall manufacturing time of the final packaged product.

[0010] Prior to shipping and distributing retaining boxes containing multiple sleeves for retail sale, the boxes are often further wrapped in a thin protective plastic layer. Typically, these thin layers are in the form of conventional shrink-wrapping. This is a technique of packaging with plastic film in which strains in the plastic are released by raising the temperature of the film, causing it to shrink-fit over the object being packaged. Although not significantly increasing the overall strength and rigidity of the package, the protective layer assists in decreasing the ingress of moisture, dust, etc. into the package, and it also reduces theft of sleeves or individual golf balls from the package. Such protective layers further add to the overall cost and manufacturing time for the final packaged product.

[0011] In view of the desire to reduce packaging costs and time to complete the final packaged product, it would be desirable to eliminate one or more of these packaging components. It would also be desirable to eliminate one or more of these packaging components in order to reduce the overall process time for packaging the final multi-sleeve package.

[0012] Additionally, elimination of the retaining boxes would also result in a smaller and lighter packaged product. This will reduce storage space, reduce transportation costs, increase the amount of multi-sleeve packages available for limited in-store shelf space, etc.

[0013] As previously noted, it is known to pack multiple cartons or containers within a layer of shrink wrapping. However, such wrapping, which deforms and generally contracts upon application of heat, is not typically amenable to receiving printing and other markings. Moreover, shrink-wrapping materials generally exhibit relatively low blocking or masking characteristics. Consequently, they are not all that useful in minimizing viewing of a package's internal contents, etc. Furthermore, such wrapping is, in many instances, not strong enough to retain its contents without the use of a stronger, more rigid retaining box. Additionally, such wrapping is considered by some consumers to be aesthetically unattractive.

[0014] It is also known to package cartons or containers within a layer of other material besides shrink-wrap. Examples of this practice include gift wrapping as described in U.S. Pat. Nos. 3,311,289 to French, and 5,337,943 to Hendren. However, as far as is known, previous practices involving the wrapping of cartons were merely for either covering the carton to mask its contents, or merely for decorative purposes.

[0015] Accordingly, there is a need for an improved packaging for golf balls, one which serves to promote the aesthetics and attractiveness of the final wrapped package, and furthermore, one which also serves to sufficiently increase the resulting strength and rigidity of the wrapped package such that various packaging components, otherwise necessary, can be eliminated. It would be particularly desirable to provide such a package and a method for producing such a package, that are both adapted for the golf ball field.

SUMMARY OF THE INVENTION

[0016] In one aspect, the present invention provides a package for economically and securely retaining multiple sleeves of golf balls. The package comprises a collection of golf ball sleeves, which is directly enclosed by an opaque, partially opaque, transparent, or partially transparent overwrap, preferably a multi-layer sheet. The sheet is substantially resistant to shrinkage. The resulting package is non-rigid but sufficiently strong such that an intermediate retaining box for holding the collection of sleeves is not required. The invention results in a uniform, symmetrical, semi-flexible package, which is conducive to packaging in larger transportation packages or for stacking or display.

[0017] In another aspect, the present invention provides a package that is particularly adapted for distribution and retail display of a plurality of golf ball sleeves. The package comprises a collection of golf ball sleeves and a sheet of opaque, partially opaque, transparent, or partially transparent multi-layer film disposed about and enclosing the collection of sleeves. The multi-layer film includes an inner layer adjacent to the sleeves that is formed from a polymer and a thin metallic foil overlay. The multi-layer film also includes an outer layer formed from a polymer. The interior surface of the outer layer also contains decorative artwork, printing, painting and/or labeling indicia. This results in the metallic foil and printing indicia being sandwiched between two polymer layers.

[0018] In yet another aspect, the present invention provides a multi-sleeve golf ball pack having a generally rectangular shape and comprising a plurality of sleeves and an opaque, or partially opaque, multi-layer sheet enclosing the sleeves. The multi-layer sheet includes an inner layer immediately adjacent to the sleeves and formed from a polyolefin material and a thin metallic foil overlay, and an outer layer comprising a second polyolefin material. Printing indicia reversibly applied may also be present on the interior surface of the outer polyolefin material next to the thin metallic overlay of the inner layer. The multi-layer sheet is resistant to shrinkage, exhibiting a shrinkage rate of about 2% or less.

[0019] In a further aspect, the present invention provides a method for packaging a plurality of golf ball sleeves. The method comprises providing an opaque, partially opaque, transparent, or partially transparent multi-layer film having an inner layer of a polyolefin and a metal foil, and an outer layer of a polyolefin. The outer polyolefin contains on its interior surface, reversibly printed display or print indicia. The method also includes a step of enclosing the sleeves with the multi-layer film such that the metal foil of the inner layer of the multi-layer film contacts the deposited print indicia. The enclosing operation is performed by securing together two opposite edges of the film by cold seal, hot seal, etc.

[0020] In an additional aspect, there is provided a new and improved package for shipping, storing, and/or displaying golf ball sleeves. Preferably, the packaging material is relatively non-rigid and opaque to avoid, or minimize, light transmittal. More preferably, the sleeves are packaged in arrangements of 1×2, 1×3, 1×4, 1×5, and 1×6. Other arrangements are also possible such as 2×2, 3×3, etc. The package provides protection during shipment and storage, and also provides a surface for the aesthetically pleasing presentation of advertising, graphic or display information and the like. Moreover, the resulting package has the rigidity necessary for subsequent shipping and handling without the necessity of utilizing boxes or cartons that are otherwise required for retaining multiple sleeves of golf balls.

[0021] These and other objects and features of the present invention will be apparent from the following description of the drawings and the detailed description of the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The invention may take form in various components and arrangements of components and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.

[0023] FIG. 1 is a perspective view illustrating a preferred three-sleeve pack (i.e., 1×3) embodiment in accordance with the present invention;

[0024] FIG. 2 is a perspective view of a preferred four-sleeve pack (i.e., 1×4) embodiment in accordance with the present invention;

[0025] FIG. 3 is a perspective view of a preferred five-sleeve pack (i.e., 1×5) embodiment in accordance with the present invention;

[0026] FIG. 4 is a perspective view of a preferred six-sleeve pack (i.e., 1×6) embodiment in accordance with the present invention;

[0027] FIGS. 5-9 are perspective views illustrating a first end of a preferred multi-sleeve pack embodiment undergoing various stages of wrapping in accordance with a preferred technique of the present invention;

[0028] FIG. 10 is a perspective view of a preferred multi-sleeve pack embodiment illustrating in greater detail the multi-layers of the preferred embodiment overwrap and exemplary printing and marking configurations deposited upon the overwrap;

[0029] FIG. 11 is a perspective view illustrating an end and a bottom surface of a preferred multi-sleeve pack embodiment in accordance with the present invention;

[0030] FIG. 12 is a perspective view of another preferred multi-sleeve pack embodiment in accordance with the present invention;

[0031] FIG. 13 is a perspective view of yet another preferred multi-sleeve pack embodiment in accordance with the present invention; and

[0032] FIGS. 14A, B, and C are perspective views of three, four, and six pack embodiments of the invention respectively showing the interior sleeves and balls in phantom.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] The present invention provides a unique and novel packaging configuration for multiple sleeves of golf balls. The present invention encompasses multi-sleeve packs such as a three-sleeve pack, a four-sleeve pack, a five-sleeve pack, and a six-sleeve pack. These preferred embodiments are illustrated in FIGS. 14, respectively. The present invention further encompasses packages containing more than six sleeves such as eight, nine, or more sleeves. The present invention also includes packages containing two sleeves.

[0034] FIG. 1 is a perspective view illustrating a preferred three-sleeve pack embodiment in accordance with the present invention. The three-sleeve pack 100 comprises overwrap 102 which surrounds and encloses three sleeves, sleeve 104a, sleeve 104b, and sleeve 104c. It will be appreciated that each of the sleeves contains one or more golf balls 101. As an example, FIG. 1 illustrates sleeve 104c containing three golf balls 101. The three-sleeve pack 100 includes a first end 106, a second opposite end 108, and a top 112, and a bottom 110 extending therebetween. Also extending between the first and second ends 106 and 108, respectively, are a first longitudinal side 114 and a second opposite longitudinal side 116. The first longitudinal side 114 and the second longitudinal side 116 also extend between the top 112 and the bottom 110. Defined along each end of the preferred embodiment pack 100 are an upper flap 118 of folded overwrap and a lower flap 120 of folded overwrap. As explained in greater detail herein, a seam 122 extends along a portion of the first end 106, along the entire length of the bottom 110, and along a portion of the second end 108. Preferably, the seam 122 is relatively transparent.

[0035] FIG. 2 is a perspective view illustrating a preferred four-sleeve pack embodiment in accordance with the present invention. The four-sleeve pack 200 comprises overwrap 202 which surrounds and encloses four sleeves, sleeve 204a, sleeve 204b, sleeve 204c, and sleeve 204d. The four-sleeve pack 200 includes a first end 206, a second opposite end 208, and a top 212, and a bottom 210 extending therebetween. Also extending between the first and second ends 206 and 208, respectively, are a first longitudinal side 214 and a second opposite longitudinal side 216. The first longitudinal side 214 and the second longitudinal side 216 also extend between the top and bottom 212 and 210, respectively. Defined along each end of the preferred embodiment pack 200 are an upper flap 218 of folded overwrap and a lower flap 220 of folded overwrap. As explained in greater detail herein, a seam 222, preferably relatively transparent, extends along a portion of the first end 206, along the entire length of the bottom 210, and along a portion of the second end 208. This is described in greater detail herein.

[0036] FIG. 3 is a perspective view illustrating a preferred five-sleeve pack embodiment in accordance with the present invention. The five-sleeve pack 300 comprises overwrap 302 which surrounds and encloses five sleeves, sleeve 304a, sleeve 304b, sleeve 304c, sleeve 304d, and sleeve 304e. The five-sleeve pack 300 includes a first end 306, a second opposite end 308, and a top 312, and a bottom 310 extending therebetween. Also extending between the first and second ends 306 and 308, respectively, are a first longitudinal side 314 and a second opposite longitudinal side 316. The first longitudinal side 314 and the second longitudinal side 316 also extend between the top and bottom 312 and 310, respectively. Defined along each end of the preferred embodiment pack 300 are an upper flap 318 of folded overwrap and a lower flap 320 of folded overwrap. As referenced below, a seam 322 extends along a portion of the first end 306, along the entire length of the bottom 310, and along a portion of the second end 308.

[0037] FIG. 4 is a perspective view illustrating a preferred six-sleeve pack embodiment in accordance with the present invention. The six-sleeve pack 400 comprises overwrap 402 which surrounds and encloses six sleeves, sleeve 404a, sleeve 404b, sleeve 404c, sleeve 404d, sleeve 404e, and sleeve 404f. The six-sleeve pack 400 includes a first end 406, a second opposite end 408, and a top 412, and a bottom 410 extending therebetween. Also extending between the first and second ends 406 and 408, respectively, are a first longitudinal side 414 and a second opposite longitudinal side 416. The first longitudinal side 414 and the second longitudinal side 416 also extend between the top and bottom 412 and 410, respectively. Defined along each end of the preferred embodiment pack 400 are an upper flap 418 of folded overwrap and a lower flap 420 of folded overwrap. A seam 422 extends along a portion of the first end 406, along the entire length of the bottom 410, and along a portion of the second end 408. This is again described in greater detail herein.

[0038] FIGS. 5-9 illustrate a first end of a multi-sleeve pack, which is undergoing packaging by use of the overwrap in accordance with the present invention. These figures also illustrate a preferred technique for enclosing a collection of sleeves with overwrap in accordance with the present invention. Specifically, FIG. 5 illustrates an end 506 of a preferred embodiment multi-sleeve pack 500. The multi-sleeve pack 500 includes a plurality of sleeves, such as sleeves 504a, 504b, etc. which are arranged in a side-by-side configuration. Other configurations are also possible for arranging the sleeves and are encompassed by the present invention.

[0039] An effective amount of overwrap 502 is placed over the collection of sleeves. The overwrap is arranged such that it is fitted over the collection of sleeves, around their exposed ends, and joined along the opposite side of the sleeves. As previously described herein, the resulting pack 500 includes a top and bottom 512 and 510, respectively, that extend between a first and a second longitudinal side 514 and 516, respectively. The overwrap 502 is in a sheet or layer form and is defined by two opposing edges referred to herein as a first longitudinal overwrap edge 530 and a second opposite longitudinal overwrap edge 532. The overwrap is oriented relative to the collection of sleeves such that these edges 530, 532 extend along the length of the collection of sleeves. Restated, the overwrap is oriented relative to the collection of sleeves such that the edges 530, 532 extend in a direction that is perpendicular to the longitudinal dimension of each of the sleeves (for sleeves containing at least two balls). The term “longitudinal dimension” as used herein refers to the length as measured along the longitudinal sides of the multi-sleeve packs described herein.

[0040] As described in greater detail herein, the edges 530 and 532 are joined together to form a seam. That seam extends along the bottom of the resulting multi-sleeve pack and further extends along portions of the first and second ends. It is most preferred to locate the seam of the multi-sleeve packs described herein along the bottom or underside of the package. And, it is most preferred to orient the seam so that it is parallel to the longitudinal dimension of the resulting multi-sleeve pack. However, other variations and configurations for the seam are encompassed by the present invention. For example, it is contemplated to define the seam directly along one of the longitudinal sides of the pack.

[0041] As further illustrated in FIG. 5, it is preferred that the overwrap 502 extend beyond each of the ends of the collection of sleeves, such as the end 506. The amount of overwrap 502 that extends beyond an end is herein designated as distance E and is generally at least about one-half the height of the multi-sleeve pack 500, as measured along either of the sides 514 and 516, or the end 506. As shown in FIG. 5, this height dimension would extend vertically along side 514 for instance.

[0042] FIG. 6 illustrates the preferred embodiment multi-sleeve pack 500 in which the overwrap 502 has been joined along the previously noted edges 530 and 532 to thereby form a seam 522. At this stage, the overwrap 502 extends over the top and bottom of the collection of sleeves and thereby forms the top and bottom 512 and 510, respectively, of the pack 500 and also extends about the first and second longitudinal sides 514 and 516, respectively. However, each end of the pack 500 is open and one side of each of the two outermost sleeves is exposed. One such exposed end is first end 506.

[0043] FIG. 7 illustrates a preferred folding configuration for enclosing each of the ends of the multi-sleeve pack 500. In this configuration, the portion of overwrap 502 which extends beyond the first end 506 and located adjacent the first and second longitudinal sides 514 and 516 is pushed inward toward the center of the multi-sleeve pack 500 against the first end 506. This is depicted by arrow A. Each of the folded regions of overwrap is then further contacted along the side of the exposed sleeve such as at end 506. This defines an upper flap 518 and a lower flap 520.

[0044] FIG. 8 illustrates the next step of the preferred embodiment folding technique in which the lower flap 520 is folded upward until it contacts the exposed side of the sleeve along first end 506.

[0045] FIG. 9 illustrates the next step in which the upper flap 518 is folded downward and over at least a portion of the lower flap 520. Preferably, adhesive is not used to seal the end of the multi-sleeve pack 500. Instead, localized heat is preferably used to partially melt and bond the various flaps and folded edges to themselves and thereby effectively seal the end of the resulting package.

[0046] FIG. 10 illustrates an end 606, which is open and unsealed, of another preferred embodiment multi-sleeve pack 600. FIG. 10 also illustrates, in an exploded view fashion, a plurality of layers constituting the overwrap 602. The pack 600 includes an effective amount of overwrap 602 that encloses and seals a plurality of sleeves as described herein. FIG. 10 further illustrates the multi-sleeve pack 600 prior to the overwrap being entirely sealed around the plurality of sleeves. Accordingly, the overwrap defines a first longitudinal overwrap edge 630 and a second longitudinal overwrap edge 632. Edges 630 and 632 are joined together to thereby form a seal as described herein. Other variations of the packaging operation are also possible. Most preferably, the seam is aligned with the longitudinal axis of the package. Moreover, in order to preserve the preferred style of graphics, the seam is preferably on the bottom and the other seals are on the ends. However, the seam can also exist on one of the longitudinal sides.

[0047] FIG. 10 additionally illustrates that the overwrap 602 preferably includes a plurality of layers. In a most preferred aspect, the overwrap 602 includes an inner layer of material 650 and an outer layer of material 652. This is described in greater detail herein. Deposited upon the inner surface area of outer layer 652 of the overwrap 602, are various printing and marking designations. These are illustrated in FIG. 10 as 654a, 654b, and 654c. These regions may be colored (i.e., four-color, etc.) and are reverse-printed upon the inner surface area of the outer layer of the overwrap as desired. Although optional, the inner layer 650 preferably includes a metallic foil or liner. This is also described in greater detail herein.

[0048] As previously noted, in closing or sealing each of the exposed ends of the multi-sleeve packs described herein, it is preferred that adhesive not be used. Instead, application to a localized heat source is preferably employed to close off or seal each end of the resulting package. However, the present invention includes the use of an adhesive at one or both ends to seal the resulting package. Depending upon the adhesive selected, various degrees of sealing and permeability may be obtained.

[0049] Preferably, the overwrap is an opaque, or partially opaque, transparent, or partially transparent multi-layer flexible wrapping material. The multi-layer material includes an outer layer of polymeric or plastic material that, upon the overwrap being wrapped about a collection of sleeves, constitutes the outermost layer of the overwrap. The polymeric or plastic material is preferably a polyolefin such as polypropylene, but it may comprise other materials including, but not limited to, acrylonitrile-butadiene-styrenes, acrylics, cellophane, cellulosics, fluoropolymers, ionomers, polyamides, polycarbonates, polyesters, polyimides, polyethylenes, polystyrenes, vinyls, and polyurethanes. On the inner surface of the outer layer, print indicia, such as designs, drawings, graphics, type, etc., may be deposited in reverse format. The preferred thickness of the first outer layer is from about 0.01 mm to about 0.25 mm. The preferred gauges of the first, or outer layer are from about 50 to about 200; more preferably 80 to 160; and most preferably about 120 gauge.

[0050] The multi-layer material further includes an inner layer of a polymeric or plastic material. The inner layer also includes a thin layer of metal or foil. The thin layer of metal or foil is desirable in order to block out, or mask, visibility of underlying material, to add strength, etc. The inner layer is oriented such that the metal or foil layer is directed outwardly and most preferably contacting the print indicia of the outer layer. The inner layer is preferably a polyolefin and most preferably polypropylene in combination with a thin metal film. As a result of the inclusion of the thin metal film, the material shrinks only a minimal amount (i.e. about 2%). A preferred thickness for the second layer is from about 0.01 mm to about 0.25 mm. The preferred gauge of the second, or inner layer, is from about 60 to about 100; more preferably 70 to 90; and most preferably about 80 gauge.

[0051] An example of a commercially available material suitable for use as the outer layer of the overwrap as described herein, is available from AET Films, of New Castle, Delaware, under the designation PST-2 Transparent OPP film. PST-2 is a transparent, coextruded, biaxially oriented polypropylene (OPP) film. It has a sealant layer on one side and a treated bonding/print layer on the other side. The non-sealable side is surface treated for adhesions of inks, etc., to provide high-quality graphics. The PST-2 multi-layer film is available in a wide range of thicknesses, such as from 60 gauge to 140 gauge. Properties of this preferred material are set forth below:

[0052] Physical Properties of PST-2 Film

	Machine Direction	Transverse Direction
Physical Properties
Tensile strength, psi	21,000	40,000
Tensile modulus, psi	300,000	550,000
Elongation, %	170	60
Shrinkage at 248° F., %(1)	<10	<10
Optical Properties
Haze, %(2) 2.2
45° Gloss(3) 87
Surface Properties
COF
Sealant to Sealant (kinetic)
0.26
Barrier Properties
Gauge	WVTR(4)
60	0.54
70	0.49
80	0.40
100	0.34
120	0.27
Seal Properties
Seal strength at 240° F. (g/in.)
230
20 psi, 1/2 second
(1)AET Method
(2)ASTM D-1003
(3)ASTM D-2457
(4)g/100 in2/24 hr at 100° F., 90% RH

[0053] Another preferred commercially available material for forming the outer layer of the overwrap is SPW-L (Bicor®), available from Exxon Mobil Chemical Company (Films Business) of Macedon, N.Y. Bicor SPW-L is a one-side treated, one side sealable, coextruded OPP film. The treated surface side provides for enhanced ink adhesion. It is available in the following gauges:

	Gauge
Product	(mil)	Gauge (micron)	Yield (in2/lb)	Yield (m2/kg)
70 SPW-L	.70	18	44,000	62.5
90 SPW-L	.90	23	34,000	48.3
120 SPW-L	1.20	30	25,400	36.1

[0054] These OPP films have the following properties:

PROPERTY	UNITS	TEST PROC. #	70 SPW-L	90 SPW-L	120 SPW-L
Average Values of Critical Properties
Yield	in2/lb	520	44,000	34,000	25,400
	m2/kg	520	62.5	48.3	36.1
Unit Weight	lb/ream	520	9.8	12.7	17.0
	g/m2	520	16.0	20.7	27.7
Haze	%	444	2.0	2.0	2.0
COF untr/untr		430	.25	.25	.25
Descriptive Properties
Gauge	mil	nominal	.70	.90	1.20
	micron	nominal	18	23	30
Tensile Strength
MD	lb/in2	506	20,000	20,000	20,000
	N/mm2	506	140	140	140
TD	lb/in2	506	36,000	36,000	36,000
	N/mm2	506	250	250	250
Dimensional Stability
@ 275° F. (135° C.)
MD	% change	438	−4.5	−4.5	−4.5
TD	% change	438	−5.0	−5.0	−5.0
Gloss (45°)		442	88	88	88
WVTR @ 100° F. (38° C.),	g/100 in2/24 hr	518	.47	.36	.26
90% RH	g/m2/24 hr	518	7.3	5.6	4.0
Crimp Seal MST
to achieve a 200 g/in seal	° F.	490	225	225	225
to achieve a 200 g/2.5 cm seal	° C.	490	107	107	107

[0055] An alternative, and currently somewhat less preferred OPP film for use as the outer layer in the overwrap of the present invention is AmTopp-VA produced by AmTopp® Division of Interplast Group, Ltd. of Livingston, N.J. The AmTopp-VA film is a co-extruded, two side sealable, one side treated for ink adhesion, biaxially oriented film. It is available in the following gauges:

	VA18	VA20	VA22	VA25	VA30	VA35
Thickness (mils)	0.7	0.8	0.9	1.0	1.2	1.4
Yield (sq in/lb)	44,000	38,700	34,300	31,000	25,700	22,000
WVTR* (g/100 in2/24 hrs)	0.52	0.48	0.45	0.41	0.38	0.28
OTR** (cc/100 in 2/24 hrs)	140	013	120	110	95	80
*ASTM F1249 (100 deg F., 100% RH)
**ASTM D3985 (72 deg F., 0% RH)

[0056] Additionally, AmTopp-VA has the following basic physical properties:

Physical Properties	Test Method	Unit	Typical Value
Haze	ASTM D1003-	%	2-3
Gloss (45°)	61	G.U.	85
Tensile Strength	ASTM D2457-77	PSI	MD 17,000
			TD 30,000
Secant Modulus	ASTM D882	PSI	MD 250,000
			TD 450,000
Elongation	ASTM D882	%	MD 190
			TD 70
Coefficient of Friction (untreated)	ASTM D1894		Kinetic 0.25
			Static 0.40
Shrinkage	5 min., 266° F. (air oven)	%	MD < 5
			TD < 3
Heat Seal Range	1/2 sec., 30 PSI	Deg. F.	Untreated 200-300
			Treated 250-300

[0057] An example of a commercially available material suitable for use as the inner layer of the overwrap of the present invention is MT Metallized OPP Film from AET Films. MT is a metallized, biaxially oriented polypropylene (OPP) film. It is sealable on one side and metallized on the other side. The multi-layer film is available in a range of thicknesses, such as from about 60 gauge to about 80 gauge. Properties of this preferred multi-layer film are set forth below:

[0058] Physical Properties of MT Film

	Machine
Physical Properties	Direction	Transverse Direction
Tensile strength, psi	18,700	36,000
Tensile modulus, psi	204,000	325,000
Elongation, %	210	75
Barrier Properties (MT)
Gauge	WVTR(1)	O2TR(2)
70 gauge OPP/60 MT	0.012	6.0
Lamination
70 gauge OPP/70 MT	0.01	6.0
Lamination
70 gauge OPP/80 MT	0.01	6.0
Lamination
Seal Properties
Seal Strength at 240° F. g/in., Film	250
20 psi, 1/2 second
Hot tack(3)
g/in., at 255° F.	200
(1)g/100 in2/24 hr at 100° F. 90% RH
(2)cc/100 in2/24 hr at 73° F., 0% RH
(3)AET Method

[0059] A further preferred commercially available material for forming the inner layer of the overwrap is Exxon Mobile's Mellallyte™ MET. It is a moderate barrier, metallized OPP film available in 70 gauge film as shown below:

Product	Gauge (mil)	Gauge (micron)	Yield (in2/lb)	Yield (m2/kg)
70 MET	70	18	44,000	62.5

[0060] 70 MET possesses the following characteristics:

Property	Units	Test Proc. #	70 MET
Average Values of Critical Properties
Yield	in2/lb	520	44,000
	m2/kg	520	62.5
Unit Weight	lb/ream	520	9.8
	g/m2	520	16.0
WVTR, flat sheeta @ 100° F. (38° C.), 90% RH	g/100 in2/24 hr	518	.02
	g/m2/24 hr	518	.31
Descriptive Properties
Gauge	mil	nominal	.70
	micron	nominal	18
Tensile Strength
MD	lb/in2	510	22,000
	N/mm2	510	150
TD	lb/in2	510	34,000
	N/mm2	510	235
Dimensional Stability
@ 275° F. (135° C.)
MD	% change	438	−4.5
TD	% change	438	−2.5
Light Transmission	%	456	0.4
Optical Density		474	2.4
Crimp Seal Strengthb
@ 205° F., 20 psi, 3/4 sec	g/in	490	400
@ 96°, 1.4 bars, .75 s	g/2.5 cm	490	400
Crimp Seal MSTb
to achieve a 200 g/in seal	° F.	490	185
to achieve a 200 g/2.5 cm seal	° C.	490	85

[0061] Moreover, an alternative, and currently somewhat less preferred metallized OPP film for use as the inner layer in the overwrap is DF-MGxx, available from DOR Film of Carmiel, Israel. DF-MGxx exhibits the following properties:

PROPERTIES	UNIT	TYPICAL VALUES	TEST METHODS
Name		MG15	MG18	MG20	MG25	MG30	MG35	MG40	MG50
Thickness	μm	15	18	20	25	30	35	40	50
Yield	m2/kg	72.5	60.2	54.6	43.7	36.5	31.3	27.4	22
Tensile Strength
MD	N/mm2	170	165	165	165	165	165	165	165	ASTM D 882
TD		310	300	300	300	300	290	290	290	DIN 53455
Elongation at Break
MD	%	160	170	175	175	175	185	185	185	ASTM D 882
TD		60	60	65	65	65	60	60	60	882DIN 53455
Coefficient of Friction	—	0.55	0.55	0.55	0.55	0.5	0.5	0.5	0.5	ASTM D 1894
Film/Film
(Treated to Untreated)
WVTR	Gr/m2/24 hr	0.8	0.8	0.8	0.8	0.8	0.8	0.8	0.8	ASTM E 96
										38° C., 90% RH.
Oxygen Permeability	Cm3/m2/24 hr (1 at)	150	150	150	150	150	150	150	150	ASTM D 1434
										25° C., 0% R.H.H.
Optical Density	O.D.	2.2	2.2	2.2	2.2	2.2	2.2	2.2	2.2	MACBETH FD
										932
Heat Seal Range	° C.	110° C.-150 C.	DOR FILM'S
			STNDARDS
Seal Strength	N/15 mm	2.2	2.4	2.5	2.5	4.0	4.7	5.5	6.5	DOR FILM'S
										STANDARDS

[0062] Most preferably, the multi-layer overwrap packaging material comprises an outer layer of 120 gauge oriented polypropylene (OPP) that contains print indicia on its interior surface. The inner layer of the overwrap of most packaging consists of 70-80 gauge striped metallized OPP. The metal side of the inner layer faces the printed side of the outer layer, and the two are laminated together. As a result, both the metal and the printing are protected by OPP because they are sandwiched between layers. This material shrinks only about 2% because of the foil layer. Optimally included in exterior surfaces of the outer and inner layers are one or more sealant laminates or layers.

[0063] The multi-layer film may comprise layers in addition to the inner and outer layers described herein. The present invention encompasses the use of multi-layer films having three, four, or greater numbers of layers. A variety of layers may be utilized depending upon the desired application and anticipated environmental conditions to which the final multi-sleeve package will be exposed.

[0064] It is also contemplated that a wide array of materials may be used in the multi-layer sheets, such as for example acrylonitrile-butadiene-styrenes, acrylics, cellophane, cellulosics, fluoropolymers, ionomers, polyamides, polycarbonates, polyesters, polyimides, polyethylenes, polypropylenes, polystyrenes, vinyls, polyurethanes, and certain engineered specialty plastics. An informative discussion of the design characteristics, physical properties, and processing factors for film and sheeting materials is provided in Kirk-Othmer, Encyclopedia of Chemical Technology, fourth edition, Volume 10, pages 761-787, herein incorporated by reference.

[0065] Alternatively, and less preferably, single layer sheets can also be utilized in the present invention. Although a single layer may not be as opaque, it is less expensive and fairly functional. Generally, such single layer sheets are used to package sleeves of less-expensive golf balls, such as X-outs. Examples of such single layer sheets include, but are not limited to, Bicor™, OPPalyte™ and Metallyte™ families of films available from Exxon Mobile, and BNL, BX® 323, BXT® and CHZ films available from AET. The single layer sheets are printable (treated on one or both sides) and sealable, preferably two side heat sealable, and would function in a manner similar to the multi-layer sheets previously described.

[0066] FIG. 11 illustrates a sealed end of another preferred embodiment multi-sleeve pack 700. FIG. 11 also illustrates the bottom of the multi-sleeve pack 700. The pack 700 includes an overwrap 702, which encloses a plurality of golf ball sleeves. The pack 700 includes a first end 706, a bottom 710, and opposite first and second longitudinal sides 714 and 716 as described herein. The first end 706 of the multi-sleeve pack 700 includes an upper flap 718 and a lower flap 720. It will be noted that the seam 722 that extends along the bottom 710 of the multi-sleeve pack 700 also extends along a portion of the first end 706. Specifically, the seam 722 extends only within the lower flap 720 and not within the upper flap 718. The resulting package may be airtight, waterproof, and/or impermeable to other environmental factors or agents as desired.

[0067] FIG. 12 illustrates another preferred multi-sleeve pack embodiment 800 in accordance with the present invention. In this embodiment, the overwrap 802 is formed from materials that are transparent or non-opaque. In this embodiment, the preferred pack 800 comprises a plurality of golf ball sleeves 804a, 804b, etc. that are enclosed within the overwrap 802. Pack 800 further features a seam 822 extending along its underside and preferably partially along both of its ends as previously described herein. The pack 800 additionally features a layer of coloring or other agent to provide an opaque region 850. Preferably, the opaque region 850 extends over the entirety of the overwrap 802, except for a transparent window region 852. As a result of the transparency of window region 852, one or more sleeves 804, e.g. 804a and 804b, are visible. In the event that the overwrap 802 comprises a metal foil layer (which is generally opaque), it is preferred that the metal foil layer not extend within the region of the window 852.

[0068] FIG. 12 further illustrates another significant feature of the present invention, the provision of a perforated or otherwise weakened tear line 860 and a pull tab 862 in the overwrap 802. Preferably, the tear line 860 is defined in the overwrap 802 such that upon packaging the desired golf sleeves in the overwrap 802, the tear line is defined near one of the ends of the resulting package, such as shown in FIG. 12. Most preferably, the tear line 860 extends about the entire perimeter of the pack 800 and is oriented generally perpendicular to the portion of the seam 822 that extends along the bottom of the pack 800. As will be appreciated, by providing tear line 860 and pull tab 862 in the overwrap, the pack 800 may be readily opened by merely pulling the tab 862. Variations as to the orientation and placement of the tear line 860, pull tab 862, and window region 852 are contemplated and encompassed by the present invention.

[0069] FIG. 13 illustrates another preferred multi-sleeve pack 900 in accordance with the present invention. The pack 900 parallels the previously described pack 800. The pack 900 comprises an overwrap 902, a seam 922, a tear line 960, and a pull tab 962. The pack 900 further includes a plurality of opaque regions, preferably of different colors, that define a transparent window. Specifically, different colored regions 950a, 950b, 950c, and 950d are provided that define a transparent window 952. As will be understood, the various colored regions may also define various letters, words, trademarks, and identifying markings.

[0070] Details of forming and design of tear lines and pull tabs are provided in the prior art. See for example, U.S. Pat. Nos. 4,947,994 to Newsome; 5,921,464 to Seki; and 6,006,907 to Sato et al; all of which are herein incorporated by reference.

[0071] It is also envisioned to provide a resealable feature for any of the multi-sleeve packs described herein. Specifically, it is contemplated to provide such a resealable feature along one of the ends of a multi-sleeve pack. Details as to the design and construction of a resealable closure are provided in U.S. Pat. Nos. 5,944,425 to Formann; 5,983,594 to Formann; 6,076,969 to Jaisle et al.; and 6,318,894 to Derenthal; all of which are hereby incorporated by reference.

[0072] Several commercially available machines have been identified which, if appropriately configured by one skilled in the packaging art, can wrap multiple sleeves as described herein. The preferred machine is a “FA-ST” Series High Speed Wrapping Machine, available from Package Machinery Company of West Springfield, Mass. Particularly preferred wrapping machines include those referred to as “FA-ST” having model numbers FA-ST, FA-ST2, and FA-ST4. Additional systems contemplated include PRB Penta Overwrapping machine, available from Penta Packaging Systems of Fairfield, N.J.; a Marden Edwards Wrapper from Marden Edwards Ltd. of the United Kingdom; and a wrapping system from Klockner of Germany and Sollas Packaging Machinery of the Netherlands.

[0073] Preferably, the FA-ST wrapping machine has certain preferred features. The following features are preferred for the wrapping machine, however, it will be understood that the present invention includes the use of wrapping machines having none, some, or all of these features. Specifically, the preferred embodiment wrapping machine that is utilized in the present invention has an electronically driven dual servo film and knife assembly. In addition, the machine has a high speed color registration mark sensor and a film static eliminator bar. Additionally, it is preferred that the elevator and folder and pusher assemblies are all servo driven and, most preferably with adjustable speed settings. Furthermore, the preferred embodiment machine includes an adjustable tack bar assembly and a quick-change folding line with conventional bottom plate and adjustable side folders. Furthermore, the present invention includes machines having adjustable side heaters and anti-friction coated film path components. Furthermore, it is preferred that jam sensors be provided along the product path and include a film run-out sensor. Such machines also preferably contain a fault indicator stack light assembly and a central lubrication block. All conventional safety components and safety interlocks are preferably provided on the machine. A self-sharpening rotary knife is utilized by the machine for cutting operations. It is also preferred that the machine be automated with varying levels of operation. Conventional automation controls are typically interfaced with the machine such as those provided by Allen-Bradley under the designation Control Logix PLC and Ultra Series components. It is further contemplated that various operator control panels and touch screen color operator terminals may be provided.

[0074] A preferred speed range for a preferred embodiment machine utilized in conjunction with the present invention is generally from about 30 packages to about 150 packages per minute. Generally, such machines may wrap packages having a minimum size of about 2″×1 ⅛″×⅜″ to a maximum size of about 11 ½″×5 ⅝″×3″. Film cutoff lengths generally range from a minimum of about 4¼″ to a maximum of about 16″. And, such machines generally accommodate film roll widths of from a minimum of about 3 ¼″ to a maximum of about 17 ¼″.

[0075] In operation, sleeves filled with golf balls are brought (i.e. by conveyor, etc.) to the packaging machine. A pusher loads the sleeves (2, 3, 4, 5, etc.) into the wrapper. Film is fed from another side, and a desired length is cut for wrapping. The film is wrapped around the sleeves, the bottom is heat sealed, and then the ends pass by Teflon® coated, heated bars and they are also heat sealed. The wrapped package then is packed with others into a shipping box or whatever shipping container is appropriate.

[0076] It will be appreciated that any of the features in any of the embodiments described herein may be utilized or provided in combination with any of the other features of other embodiments described herein. That is, the present invention includes multi-sleeve packs having additional combinations of features that are not expressly disclosed herein.

[0077] Use of the present invention multi-sleeve packs and related packaging techniques results in significant cost savings and reductions in packaging time. As previously explained, use of the present invention eliminates the need for providing relatively expensive retaining boxes for golf ball sleeves, packing the sleeves within those retaining boxes, closing the boxes or otherwise preparing them for shipment, and further wrapping or packaging the retaining boxes.

[0078] The present invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

1. A package for economically and securely retaining multiple sleeves of golf balls, said package comprising: a plurality of golf ball sleeves; and an opaque, multi-layer sheet containing a masking layer and exhibiting a shrink rate of about 2% or less is disposed about and enclosing said plurality of golf ball sleeves; wherein said package is free from a retaining box otherwise used to contain said plurality of golf ball sleeves.

2. The package of claim 1 wherein said plurality of golf ball sleeves constitutes three, four, five or six sleeves.

3. The package of claim 1 wherein said multi-layer sheet includes a first layer of a polyolefin material and a second layer of a polyolefin material.

4. The package of claim 3 wherein said polyolefin material of at least one of said first layer and said second layer is selected from the group consisting of acrylonitrile-butadiene-styrenes, acrylics, cellophane, cellulosics, fluoropolymers, ionomers, polyamides, polycarbonates, polyesters, polyimides, polyethylenes, polypropylenes, polystyrenes, vinyls, polyurethanes and combinations thereof.

5. The package of claim 4 wherein said polyolefin material of at least one of said first layer and said second layer is polypropylene.

6. The package of claim 3 wherein said first layer also includes a treated layer for ink adhesion.

7. The package of claim 3 wherein said second layer also includes a thin metal film.

8. The package of claim 6 wherein said first layer also includes a print indicia on one surface.

9. The package of claim 8 wherein said multi-layer film is oriented such that said metallic foil overlay is immediately adjacent to the print indicia.

10. A package adapted for distribution and retail display of a plurality of golf ball sleeves, said package comprising: a plurality of golf ball sleeves, each said golf ball sleeve containing at least one golf ball; and a sheet of multi-layer film disposed about and enclosing said plurality of golf ball sleeves, said multi-layer film including (i) an inner layer disposed immediately adjacent to said plurality of golf balls, said inner layer comprising a polyolefin material and a metallic foil overlay, and (ii) an outer layer constituting the exterior of said package and comprising a polyolefin material containing print indicia on its inner surface.

11. The package of claim 10 wherein said multi-layer film is oriented such that said metallic foil overlay is immediately adjacent to the print indicia.

12. The package of claim 10 wherein said polyolefin material of said inner layer and said outer layer of said multi-layer film is selected from the group consisting of acrylonitrile-butadiene-styrenes, acrylics, cellophane, cellulosics, fluoropolymers, ionomers, polyamides, polycarbonates, polyesters, polyimides, polyethylenes, polypropylenes, polystyrenes, vinyls, polyurethanes and combinations thereof.

13. The package of claim 12 wherein said polyolefin material of at least one of said inner layer and said outer layer of said multi-layer film is polypropylene.

14. The package of claim 10 wherein said package is rectangular in shape and defines a top, a bottom, a first end extending between said top and bottom, and a second end opposite from said first end, said sheet of multi-layer film further including a seam extending along said bottom of said package.

15. The package of claim 14 wherein said seam further extends along at least a portion of said first end and at least a portion of said second end of said package.

16. The package of claim 15 wherein said seam is parallel to the longitudinal dimension of said package.

17. The package of claim 10 wherein said sheet of multi-layer film further includes a tear line and a pull tab for facilitating removal of said sheet from said plurality of golf ball sleeves.

18. The package of claim 10 wherein said inner layer of said multi-layer film has a thickness of from about 0.01 mm to about 0.25 mm.

19. The package of claim 10 wherein said outer layer of said multi-layer film has a thickness of from about 0.01 mm to about 0.25 mm.

20. A multi-sleeve golf ball pack having a generally rectangular shape and defining a top, an oppositely directed bottom, a first end disposed between said top and bottom, a second end opposite from said first end and disposed between said top and bottom, a first longitudinal side disposed between said top and bottom and further disposed between said first and second ends, and a second longitudinal side opposite from said first longitudinal side and disposed between said top and bottom and further disposed between said first and second ends, said multi-sleeve golf ball pack comprising: a plurality of sleeves, each sleeve containing at least one golf ball; and a multi-layer sheet disposed about and enclosing said plurality of sleeves, said multi-layer sheet including (i) an inner layer disposed immediately adjacent to said plurality of sleeves and comprising a first polyolefin material and metallic foil overlay, and (ii) an outer layer comprising a second polyolefin material containing print indicia on its interior surface.

21. The multi-sleeve golf ball pack of claim 20 wherein said multi-layer sheet defines a first opaque region and a second transparent region.

22. The multi-sleeve pack of claim 21 wherein said inner layer of said multi-layer sheet further comprises a metal foil in said first opaque region.

23. A method for packaging a plurality of golf ball sleeves, said method comprising the steps of: providing a plurality of golf ball sleeves; providing a sheet of a multi-layer film of a size sufficient to enclose said plurality of sleeves, said multi-layer film having a first edge and a second edge opposite from said first edge, and further having a third edge extending between said first and said second edges, and a fourth edge, opposite from said third edge and also extending between said first and said second edges, said multi-layer film further having an inner layer including a polyolefin and a metal foil overlay and an outer layer including a polyolefin; contacting at least a portion of said plurality of golf ball sleeves with said inner layer of said multi-layer film; and enclosing said plurality of golf ball sleeves with said multi-layer film by at least securing together said first and said second edges of said multi-layer film.

24. The method of claim 23 wherein said step of enclosing said plurality of golf ball sleeves by securing together said first and said second edges of said multi-layer film results in an upper folded flap and a lower folded flap formed at each end of the resulting package, said method further comprising: contacting said lower folded flap with at least a portion of said plurality of golf ball sleeves; and positioning said upper folded flap over at least a portion of said lower folded flap.

25. The method of claim 24 further comprising: heating said upper folded flap and said lower folded flap such that said flaps adhere to one another.

26. The method of claim 24 further comprising: applying an effective amount of adhesive upon at least a portion of said upper folded flap and said lower folded flap to thereby secure said upper and lower folded flaps to one another.