Patent Application
20160176606
The scope of the invention is packaging to protect objects or appliances, especially voluminous electrical household appliances such as refrigerators, washing machines, dishwashers, ovens or similar, comprising at least one protective cover composed of at least two layered films or sheets, each film with at least one layer of plastic. The two stacked layers of film are joined by transverse and longitudinal joint lines, these joint lines preferably made using heat sealing, creating pads of different sizes which are filled with fluid to protect the aforesaid objects or appliances from rubbing, bumping and/or vibrations during storage and/or transport until they are put into service at the final user's address.
The procedure for manufacturing this packaging to protect objects is also part of the scope of this invention.
Packaging for objects comprises a variety of covers or elements, commonly but not exclusively, two covers, one upper and one lower, or two sides, one left and one right, or one back and one front, or a base upon which the object is positioned and a lid which is positioned on top of the object, four edge protectors which at least partially cover the four edges of the object, from the base to the lid, and panels halfway up the sides of the object, used to spread the load produced by the forks on the lift trucks. Similarly, packaging can include four edge protectors that extend past its top and bottom so as to make the base and lid or just one of them unnecessary, as described, for example, in the Spanish utility model published under number ES 1069687 U.
Packaging can also be utilized to protect one of the faces of the object during transport, as described, for example, in patent ES 2382853 A1.
In any case, packaging with any number of covers, and with one arrangement or another, is usually complemented by a plastic shrink wrap or stretch wrap, or a cardboard box, to prevent movement of the packaging parts or elements and of course, the packaged and protected object.
Normally, although not exclusively, the covers that constitute conventional packaging are usually made from cardboard and/or cut or molded EPS (expanded polystyrene).
This type of packaging is sufficient to protect all types of objects and appliances at a reasonable cost. However, manufacturing them requires a large amount of energy in the form of steam and compressed air. Once the product has been obtained by transforming the raw material, and due to the low densities obtained, transporting this product is costly due to the ratio of transport cost per kilogram of product transported. In some cases, this characteristic leads the packaging manufacturing company to build transformation facilities close to its customers, with the investment costs this involves. This type of product also requires molds to be built, which are generally made from metal, to make it possible to obtain the shapes to fit the object to be packaged. Another characteristic feature of this packaging, particularly those made from EPS, is that even though they are fully recyclable materials, collecting and transporting discarded packaging requires significant investments due, again, to its low density and the ratio of transport cost per kilogram of material transported.
Also used in packaging is plastic bubble wrapping or bubble packaging. This is characterized by having closed bubbles, i.e. separate bubbles, of equal size and uniform distribution throughout the surface of the plastic sheet supporting them, so giving protection to the object partially or completely enveloped by the bubbled plastic, protecting its surface and cushioning impacts and/or vibrations. However, this type of packaging does not intentionally adapt the size, shape and position of the bubbles to the object surface details or to its shape or outline. Also, in the case of using a cardboard box, for example, to complete the packaging, this can leave gaps between the packaged object and the box containing it.
In other cases, bubbled plastic, in which the bubbles have become larger pads, is used to fill spaces between the object and the box, generally made from cardboard, enclosing the object-bubbled plastic combination. In this regard, the patents U.S. Pat. No. 7,254,932 and U.S. Pat. No. 8,366,594 describe packaging of this type which is conceived to fill the gap between the object or set of objects placed in a cardboard box. However, this type of protection generally has all or a large proportion of the pads connected together, and if one of them breaks, all the rest connected to it will lose the air contained in them, rendering the packaging useless. Another possibility is that they have one-way air valves to make each pad independent, and if any break, the rest will retain the air inside them and the protection capability of the packaging will not be lost entirely. However, these items make the packaging more expensive.
None of these types of packaging are usually made in situ, i.e. alongside the object or appliance production line, nor are they made when needed, i.e. they are manufactured somewhere other than where they are used and before they need to be used, hence after being manufactured they need to be stored and transported to the object or appliance producer's factory.
The purpose of the invention is to provide packaging for objects or appliances which is minimally as protective against rubbing, bumping and/or vibrations as current packaging made from plastics and/or cardboard, and is made to achieve economic savings in manufacturing and distribution, as well as achieving greater ease of recycling. The economic savings is mainly due to the packaging detailed in the invention using less raw material, a fraction of the energy used in manufacturing current packaging, and a much more favorable ratio of transport cost per kilogram of material transported, due to the fact that the density of the transported material is several times higher than that of current packaging made from cardboard and/or EPS. At the same time, the greater ease of recycling comes from the use of less raw material, and that the packaging fluid can be extracted easily by breaking or cutting the pads, hence the discarded packaging will occupy less space and have a higher density than current packaging, improving the transport cost per transported kilogram of material to be recycled.
The first objective of the invention is achieved by making packaging available to protect objects or appliances, especially voluminous electrical household appliances such as refrigerators, washing machines, dishwashers, ovens or similar, characterized in that it comprises at least one protective cover composed of at least two layered films or sheets, each film with at least one layer of plastic, the two stacked layers of film are joined by transverse and longitudinal joint lines, where these joint lines form pads filled with fluid, and this protective cover has at least one layer of pads, with fold zones, gap zones and with the possibility of having closure zones, such that this protective cover specifically fits the surface and outline of the object to be protected during storage and transport, from manufacture until it is put into service at the final user's address.
That is to say, the packaging can be made up of one or several protective covers, obtained from a film or sheet which is preferably multilayer and has at least one plastic layer. As such, the film or sheet is preferably a multilayer plastic material, but these can be layers of different materials, such as paper, cardboard or metal, or a combination of different materials in one film.
To be able to adapt the protective cover to the surface and the shape of the object it protects, both the transverse and longitudinal joint lines can have constant or varying spacing to form pads of the same or different dimensions.
That is to say, each fluid-filled pad in the protective cover is appropriately configured in dimensions, shape and position for the protective cover to fit the details of the object's external surface, and its shape or general outline, to protect it during storage and transport.
The protective cover is the result of folding the packaging sheet, which is an intermediate product in the process to obtain the packaging detailed in the invention, in a process described later. The concept of the packaging sheet will now be explained to facilitate understanding of the characteristics of the protective cover which is the subject of the invention. The packaging sheet comprises the same characteristics as the protective cover, except that it is flat and therefore does not have the characteristics of a three-dimensional element, that is, for example, that it is formed of a single layer of pads and not several layers of pads, from which the protective cover can be configured. The packaging sheet, like the protective cover derived from it, comprises fold zones as well as the pads, which correspond to areas in which the pads are of a size and position so as to allow the sheet to be folded in these zones to fit the general shape of the object it is desired to pack and protect in the end, such that the fold zones facilitate the folding of the packaging sheet, leading to different types of protective covers, such as bases or lids, edge protectors, corner protectors, panels, etc.
The packaging sheet with the pads and the fold zones also includes gap zones, as areas where the pads are of the appropriate size and position to adapt the protective cover to the surface details of certain areas of the object to be packaged, such as recesses, projections, etc.
In a preferred configuration, the pads form a closed, fluid-filled cavity in each case. That is to say, the pads are not connected together, thus preventing the fluid from one pad to flow to another. In another configuration, one part of the pads can be connected together; in this case the cavity will be open. This connection is made using channels of appropriate dimensions, allowing fluid to flow from one pad to another at a controlled rate to increase control over the protection of the object to be packaged. Both configurations can coexist in the same protective cover.
Clearly, the pads and their configuration (shape, size and position) will have the function of cushioning the packaged object from the blows and/or vibrations it could receive during transport, storage or handling.
The protection against impacts or vibrations is provided by the plastic's capacity to deform without breaking, up to a certain limit, thus absorbing the energy from that impact or vibration. The connected pads provide additional protection by allowing the fluid to move in a given direction at a controlled rate in the event of an impact or vibration. When the fluid flows through a narrow passage, the rate of deformation of certain pads can be controlled, thus making it possible to improve packaging design.
After folding, the packaging sheet, which is a flat element of a certain thickness, adopts a shape in three dimensions, so leading to the protective cover. This has an internal surface that can adapt to the external surface details of the object and enclose it entirely or partially, and in a preferred configuration, a basically flat external surface which fits the internal surface of the final wrap, commonly a sheet of shrink wrap or stretch wrap plastic or a cardboard box, and in another configuration, the external surface of the protective cover adopts a shape which is basically not flat, for decorative and/or structural reasons.
Logically, the packaging with its protected object can be housed in a cardboard box or wrapped in a sheet of shrink wrap or stretch wrap plastic.
Similarly, another objective of the invention is the method or procedure for transforming the film to obtain the fluid-filled pads. The procedure comprises three stages; Stage 1: Shaping of the transverse joints; Stage 2: Shaping of the longitudinal joints and simultaneous fluid filling, shaping of the gap and closure zones; and Stage 3: Folding the packaging sheet and obtaining the protective cover. These three stages make it possible, starting from at least two reels of film, to obtain a protective cover in three dimensions with its shape and surfaces adapted to the object that needs to be protected, and to be manufactured where and when this protective cover is needed. Thanks to this manufacturing method, with joint modules that enable joints to be made with the necessary quality and characteristics, the packaging can be manufactured in the same facilities where the object is manufactured, not in separate facilities, and the packaging does not require transportation. It is also manufactured when it is used, not before, and it therefore does not require storage after being inflated, with the volume this occupies. Example. In the current technique, the packaging is preformed uninflated, delivered in rolls or boxes as preformed sheet and needs to be inflated one by one, which is why all the pads or chambers are connected. With the method proposed in this invention, the protective cover is made alongside the production line for the objects or appliances when said object or appliance is finished and ready to be packaged.
As regards the procedure for manufacturing the packaging described, this is based on stacking at least two films of the appropriate width and thickness, and composed of at least one layer of plastic. It consists of joining the films by means of transverse joint lines forming transverse channels between each two consecutive transverse joint lines. These transverse channels are open on at least one of their ends to give a preformed sheet characterized, logically, by having transverse channels open on at least one of their ends; the subsequent joining by means of longitudinal joint lines to form pads, fold zones, gap zones and closure zones, filling these pads with a fluid in the longitudinal joint execution phase, to create the packaging sheet; when folding the packaging sheet at the fold zones, this packaging sheet can be closed onto itself using the closure zones, creating the protective cover which is the objective of the invention.
The terms “preformed sheet” and “packaging sheet” are understood to mean two intermediate states or semi-finished products between the initial film and the protective cover which is the objective of the invention.
In an initial shaping stage, the initial films are moved in a longitudinal direction, that is to say in the direction of the longest dimension of the films, at a controlled speed, in which the appropriately spaced transverse joints are made in the films to form the aforementioned transverse channels that can be of different widths in the same preformed sheet. These joints can be made by welding or by using adhesive. In the case of welding, any system or method known for welding plastics can be used, such as using heat or radiofrequency vibration for example, and in an ideal process, the shaping system can be based on the use of at least one roller of the appropriate length and sufficient diameter to obtain a number of welds per minute as determined in the packaging design, in accordance with production needs for the protective cover. The cylinder shall have, welding bands on its external surface in the shape and thickness required for the design of the protective cover to be obtained. The welding bands on the cylinder can be movable so that they can project out from the external surface of the cylinder, or be flush with it or concealed in it, thus making it possible to vary the number of joint lines per linear meter of preformed sheet, and avoid the need to manufacture a different cylinder for each number of joint lines per linear meter of preformed sheet needed. This system makes it possible to make uniformly spaced or non-uniformly spaced joint lines to adapt the size of the pads to the outline of the object to be protected. In another configuration, the joint between the films to obtain the packaging sheet can be made using adhesive, with the adhesive being deposited on one of the plastic films by spraying, then stacking the second film on the first, already impregnated with adhesive, and joining the two films using pressure rollers. The two films will join at the lines printed on the first film.
The intermediate material called “preformed sheet” is obtained in this way. Forming the joint lines in separate stages makes it possible to prepare and store reels of preformed sheet, if necessary, before it is required, thus enabling the rate of packaging production to be matched to the production rate of the objects.
The size, thickness and shape of the joint lines is determined by the type of film, the size of the transverse channel formed by two contiguous joint lines, the fluid they are to contain and the shape of the packaging sheet that is desired.
As regards the dimensions, position and separation between the transverse channels, this is determined depending on the dimension and shape of the object to be packaged, and the relative position of the channel with respect to the surface shapes of the packaged object. For example, if there is a hollow in the surface of the object to be packaged, the position of the transverse channel or channels in that zone will be defined so as to enable pads to be created to fill said hollow. Another example is if the packaging sheet needs to cover a curved surface, such as an edge of the object to be packaged, in the transverse direction of the packaging sheet. In this first stage, transverse channels will be positioned to allow such a rotation or folding of the packaging sheet.
The transverse channels will in any case form an angle of between 90° and 0° with the longest dimension direction of the sheet, or if the sheet dimensions are equal, with either of the main sheet directions.
The second stage in the packaging sheet manufacturing procedure is performed by making longitudinal joints on the preformed sheet obtained in the previous stage, by means of a system of joint modules arranged in a group, and comprising joint wheels and evacuation wheels, as well as the appropriate mechanisms to allow the separate vertical movement of each wheel as well as the appropriate means for producing joints by welding the films, via a thermal or vibration method or by any other system known for joining plastic.
Each joint module can form welds independently of the rest of the modules, thus producing pads of different sizes in the same packaging sheet, creating fold zones, gap zones and closure zones on the packaging sheet.
The longitudinal joints are made at the same time that fluid is introduced into the transverse channels from at least one of their sides, giving rise to fluid-filled pads, such that the transverse channels are in this case inflated by introducing a fluid through the open side or sides of the transverse channels. The channels are subdivided into parts, which are not necessarily equal, to form fluid-filled pads of an appropriate size and position to fit the outline and surface of the object area to be covered.
The fluid can be a gas or mixture of gases, a liquid or foam.
Specifically, each joint module is positioned independent to the rest of the modules and in an appropriate place with respect to the preformed sheet from the previous shaping stage to make longitudinal joint lines, such that these modules are positioned in a group to join the center of the sheet first and extend the joints towards the sides of the preformed sheet. This arrangement from the center to the outside is what enables the joint to be made between the two films at the same time that the fluid is introduced.
Each joint module of those participating in the longitudinal joint stage for the preformed sheet which will constitute the packaging sheet contains one or more evacuation wheels, the function of which is to prevent fluid from entering the pads, leaving them totally or partially empty of fluid. These evacuation wheels can be configured to join, for example by welding, or only bring together the two plastic layers or films forming the preformed sheet.
Different zones on the packaging sheet are shaped in this stage, each with a different function.
Specifically, the fold zones leave spaces without pads, or with pads of the appropriate size and position, to facilitate folding of the packaging sheet to adopt the shape of the outline of the object to be packaged. The gap zones are for the packaging sheet to take the shape of the surface of the object to be packaged, that is to say to fill hollows in the object surface or leave spaces for projecting zones of the object surface, enabling it, once packaged, to take on a principally parallelepiped or cylindrical shape to facilitate covering either in a cardboard box or in a plastic shape. Similarly, the closure zones are specific packaging sheet development zones, allowing the closure of the packaging sheet onto itself to obtain a compact, easy to handle packaging piece. These closure zones are necessary if the protective cover is composed of more than one layer of pads; the closure zones are not needed with a single layer of pads.
In the longitudinal joint stage, what previously were open transverse channels become closed pads, but always with the option of connecting them together, containing a fluid inside, or fold or gap zones.
The longitudinal joint lines form an angle of between 0° and 90° in the direction of the longest dimension of the sheet, or if the sheet dimensions are equal, with the direction taken in the first shaping stage.
After the previous stages, that is to say the creation of the transverse and longitudinal joints, the obtained packaging sheet is folded in a third stage, not shown in any figures. The folding is done in a specific order to obtain the appropriate shape of the outline of the packaging piece, whether in the form of a panel, edge protection, lid, etc., of the thickness required for the packaging piece, and with the position required for the fold and gap zones of said packaging piece, in the appropriate place depending on the surface of the object to be packaged, to protect it from impacts and vibrations.
To complement the description to be given next, and in order to improve understanding of the characteristics of the invention, a set of illustrative (though non-limiting) drawings representing an example creation of the invention, accompany this descriptive record and form an integral part of it. The figures, the description and the claims contain numerous characteristics in combination. The person skilled in the art will consider the advantageous characteristics individually as well, and combine them in other reasonable combinations.
Shown in these are the following:
Shown in
In further detail, this
Shown in
Shown in
As can be seen in the figures referred to above and, more specifically in
Similarly established in said packaging sheet (22) are fold zones (35), where the pads or bags (32) are of lesser amplitude to allow precise folding of the packaging sheet (22) in these zones (35).
Also shaped are gap zones (36) to fit projecting parts (38) or recessed parts of the object to be protected (21), finally with closure zones (37) of the packaging sheet (22), enabling the closure of said sheet (22) onto itself to give the packaging cover (20) rigidity.
The fluid (33) needed to fill the pads or bags (32) is introduced at the same time that the longitudinal joints (31) are made in the transformation zone of the second stage (26), as shown in
Clearly, the shapes and sizes of the pads (32) can be of a larger or smaller size, always appropriate to the protective cover (20) to be obtained and more specifically to the type of object to be protected (21).
As regards the procedure for obtaining the protective cover (20) which is the subject of the invention,
As already stated, the joining of the transverse lines (30) can be made by welding or using adhesive. When the joining is performed by welding as shown in
It has been previously stated that the transverse joint or joints (30) can also be made using adhesive with the device and mechanisms or means appropriate for the purpose.
In a second shaping phase shown in
Each joint module (44) is positioned independently from the rest of the modules (44) and in an appropriate place with respect to the preformed sheet (24) obtained in the previous shaping stage, with these modules (44) positioned in a group. As can be seen in
According to the characteristic of the protective cover (20) that is desired, fold zones (35) can be arranged in the packaging sheet (22) in both the transverse and longitudinal directions.
Once the packaging sheet (22) has been obtained, as represented in
| Number | Date | Country | Kind |
|---|---|---|---|
| P201330988 | Jul 2013 | ES | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/ES2014/070537 | 7/1/2014 | WO | 00 |
