Patent Application
20130270128
Imaging systems use print media for receiving ink droplets or toner particles to create a printed image. The print media includes stacks of sheet substrate or continuous print web media that are cut, packaged and distributed for use according to specific standards. The packaging used to transport large quantities of cut-sheet print media for printing can generate a great amount of packaging material waste. During shipping, the packaging secures the print media from being damaged, and further enables handling and loading upon arrival at a destination.
Sheet substrates, such as white sheets of paper, composite materials, or film substrates, are commonly cut in A/A4-sized photocopy or other custom formats, and then, transported in boxes, in which each box contains five to ten paper bundles or reams. The reams are further wrapped in individual paper wrappings and/or films, which are known as ream wraps. Each ream package can contain, for example, 500 A/A4-sized sheets or other custom sized sheets. However, one of the difficulties with ream packaging is the relatively large amounts of paper, composite, film, or media used to transport sheet substrate to desktop printers, faxes and photocopiers. In addition, access to the ream packages is not very efficient when multiple ream packages are being removed and being disposed of.
One or more implementations of the present disclosure are described with reference to the attached drawings, wherein like reference numerals are used to refer to like elements throughout. Packaging helps to keep stacks integral and aid in separating a convenient amount of imaging media. For example, moisture, dust, vibration, or shock could be detrimental to the stacks of imaging media, and impede subsequent use of the material for a customer.
Imaging media, such as sheets of paper, composite or translucent film, for example, allow for transferring ink jet droplets or toner particles to create, copy, or recreate a multitude of various images (e.g., textual images, graphic images, captured images such as photo images, symbols, etc.). The volume of imaging media used throughout the world is large enough that some international standard bodies have created recommendations for units to be used in packaging for shipment and transportation of the imaging media. For example, one ream is considered equal to 20 quires, which, in turn, is equal to 500 sheets of paper. Because of certain standards, recommendations, as well as the hazards mentioned, the dimensions of stacks of imaging media have influenced the design of the cartons carrying the stacks. The master cartons, for example, can tightly package the stacks of imaging media. Each stack can include multiple sheets of paper (e.g., 500 sheets or some other number of sheets). For users that only load a few stacks at a time into printer systems or printer trays, the tight packaging is not as burdensome to entities that can load larger amounts and the amount of ream wrap material left over from each stack is not as large. Therefore, an efficient packaging assembly is desirable that enables ease in accessing the stacks of imaging media or imaging material, while also reducing waste generated from transporting the imaging media from origination to a consumption and use destination point.
Aspects of examples for some embodiments discussed below relate to packaging assemblies, master cartons and manufacturing packaging assemblies. For example, a packaging assembly includes a master carton that secures stacks of imaging media, such as sheet substrate, composite, translucent substrate, and/or other similar imaging material that allows for printing on the surfaces. A separation access band provides a single layer of a pre-printed easy separation and access band (e.g., a separation access band) that separates the stacks of imaging media from one another and further offers protection from hazards (e.g., vibration, disorientation, etc.) during transport and storage at a destination.
Referring now to
The computing and control device 102 can include additional features and/or functionality. For example, device 102 can also include additional storage 110 (e.g., removable and/or non-removable) including, but not limited to, magnetic storage, optical storage, and the like. Computer readable instructions to implement manufacture of packaging assemblies including a master carton and separation access band for stacks of imaging media can be stored in storage 110. Storage 110 can also store other computer readable instructions to implement an operating system, an application program, and the like. Computer readable instructions can be loaded in memory 106 for execution by processing unit 104, for example.
The term “computer readable media” as used herein includes non-transitory computer readable storage media and communication media. Computer readable storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions or other data. Memory 106 and storage 110 are examples of computer readable storage media. Computer readable storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disks (DVDs) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium, which can be used to store the desired information and can be accessed by the computing and control device 102. Any such computer readable storage media can be part of computing and control device 102.
Device 102 can also include communication component(s) 116 that allows computing and control device 102 to communicate with other devices, such as a ream packaging assembly device or a sheeter device 120 for manufacturing a package assembly 130 with a PLC or assembly language. Communication component(s) 116 can include, but is not limited to, a modem, a Network Interface Card (NIC), an integrated network interface, a radio frequency transmitter/receiver, an infrared port, a USB connection, or other interfaces for connecting computing and control device 102 to other computing devices and controllers. Communication component(s) 116 can include a wired connection or a wireless connection. Communication component (s) 116 can transmit and/or receive communication data and media.
Computing and control device 102 can include input device(s) 112 such as keyboard, mouse, pen, voice input device, touch input device, infrared cameras, video input devices, and/or any other input device. Output device(s) 114 such as one or more displays, speakers, printers, and/or any other output device can also be included with computing and control device 102.
Storage devices utilized to store computer readable instructions can be distributed across a network. For example, the packaging assembly device 120 accessible via a network, a wired connection, or a wireless connection can store computer readable instructions to implement manufacture of a package assembly 130. The assembly device 120 can access computing and control device 102 and download a part or all of the computer readable instructions for execution of methods, which are discussed in further detail infra.
In one example of an embodiment, the ream packaging assembly device 120 is coupled to an assembly out-feed 122 that carries a discharge ream stream 124 from the sheeter device 120 having multiple stacks of imaging media, such with stacks of sheets of substrate. A diverter actuator 128 diverts each stack, such as a diverted stack 126 downstream until the diverted stack 126 reaches a separator 132. The separator 132 separates even and odd stacks of imaging media into two different directions, such as with an arm or a platen (not shown). For example, a first stack of imaging media 134 is separated into an even direction and a second stack of imaging media is separated into an odd direction. An odd stack of imaging media 142 is then translated into the packaging assembly 130 by the odd actuator 138, while an even stack of imaging media 144 is translated into the packaging assembly 130.
The packaging assembly 130 represents the final product of the system 100 where stacks of imaging material produced by the sheeter device 120 are positioned alongside (e.g., above and below) one another to form a plurality of stacks (e.g., five stacks, ten stacks, etc.). The plurality of stack of imaging material are secured with a separation access band (not shown), which is further discussed below. After the stacking process is complete, a packaging controller 150 controls the erection of a master carton (e.g., a corrugated cardboard or other rigid barrier material) around the plurality of stacks to generate a final product or master packaging assembly that is ready for shipping and/or distribution, after palletization.
Imaging media can include printable sheet substrates of paper and/or film for receiving images generated by the transfer of toner, ink or other image forming substance. The stacks 206 of the plurality of stacks 208 include imaging media. The master carton 202 comprises various rigid surfaces forming a container structure that supports the plurality of stacks 208 of imaging media. For example, the master carton 202 includes a first rigid compound surface 214 and a second rigid surface 216.
Although the master carton 202 is illustrated as a cube or box shape as an example, other geometries are also envisioned that are not exactly a cube or box, such as rectangular and other shapes that can retain the plurality of stacks 208. The first rigid surface 214 and the second rigid surface are substantially opposite to one another. For example, in a closed state where the master carton 202 is not opened on any side the first rigid surface 214 faces substantially opposite to the second rigid surface. The first rigid surface 214 and the second rigid surface 216 are rigid enough to structurally support the plurality of stacks 208 within the master carton 202.
Rigid is a relative term as used herein that can include semi-rigidness (i.e., not devoid of flexibility), and is meant to define a stiff surface, a stiff plane and/or a stiff area of the master carton 202, in which can or cannot be devoid of all flexibility. For example, the first rigid surface 214, the second rigid surface 216 and/or the master carton 202 can be rigid to provide structure with materials such as paper, cardboard, corrugated cardboard or other materials having polymers, in which each can be rigid by being completely rigid or semi-rigid with flexibility enough to not break under a pressure or a weight. The master carton 202 further includes a first side wall 218 on the right side and a second side wall 220 on the left side, which can also be rigid to structurally support the master carton 202.
The packaging assembly 130 further includes the separation access band 204 that separates the stacks 206 from one another. For example, the stacks 206 are divided by the separation access band 204 so that the stacks 206 can comprise a predetermined number of sheet substrates as imaging material (e.g., 500 sheets, 480 sheets or some other required number of sheets), in which the stacks are at least partially distinguished from one another by the separation access band 204. In one example, the separation access band 204 secures the different stacks to separate and secure the stacks together. The separation access band 204 can span at least the width of each stack and/or be a band of material that is smaller than the width of each stack of imaging material. The separation access band further comprises a pre-printed band that provides easy access to each stack of imaging media in the plurality of stacks 208.
The separation access band 204 at least partially extends transversely across a top and bottom surface of at least one stack of the plurality of stacks 208. For example, the separation access band 204 can form a pocket 222 for respective stacks of imaging material. The pocket 222 can extend over the entire top and bottom surface of at least one stack or partially extend over the top and bottom surfaces of at least one stack 206 of the plurality of stacks 208.
In one example of an embodiment, the pockets 222 of the separation access band 204 are formed with folds, such as a fold 224. The folds 224 can be formed at various angles, which can be uniform throughout the folds 224 of the separation access band 204, can be a diversity of different angles throughout the band 204, or have no sharp angles (e.g., without crease or fold) to form the pockets with a continuous smooth layer. For example, although each fold 224 of the separation access band 204 is illustrated at a perpendicular or ninety-degree angle, other angles are also envisioned that can form the pockets 222, in which each pocket of the separation access band 204 securely retains each stack 206 within the master carton 202.
Referring now to
In one example, the separation access band 204 wraps around the top and bottom surfaces of the stacks 206 of imaging media in a zigzag pattern 308. For example, the separation access band 204 at least partially ribbons across a top surface 306 and a bottom surface 304 of each stack 206. The separation access band 204 thus secures each stack of image media from vibration and shock during loading, delivery and storage before being used for printing. In addition, the separation access band 204 reduces the amount of material (e.g., paper) used for securing the plurality of stacks 208 in the master carton 202 because ream wrap is no longer needed. In addition, the packaging assembly 130 manufacturing processes inherently increase the process throughput, in speed since excess packaging is substantially eliminated. Although five stacks 206 of imaging media are illustrated, more or less stacks of imaging media can be within the master carton 202 and wrapped with the separation access band 204.
In another example of an embodiment, the separation access band 204 has a first end 310 and a second end 312. The second end 312 attaches at the bottom of the master carton at the second rigid surface 216. The separation access band 204 also attaches at the top surface of the master carton with the first end 310 at the flap 302. For example, the first end 310 and the second end 312 are attached by an adhesive material, such as a mechanical or chemical adhesive (e.g., glue, tape, etc.), at an endpoint or at an end portion, in which the first end 310 and the second end 312 respectively comprise a lifting mechanism for the stacks.
In one embodiment, the first end 310 of the separation access band 204 is removable so that at delivery destination or at a time of use the first end 310 can be pulled off to expose a top stack 314 of imaging media. For example,
Additionally, in another embodiment, for example, the first end 316 is attached to the flap 302 so that a top portion 316 of the separation access band 204 is at least partially lifted up. The lifted up top portion 316 thus is not substantially parallel to the plurality of stacks 208, which enables a user to grab hold of the separation access band 204 to separate the first end 310 from the flap 302. The flap 302 includes a rotational hinge portion 318 that allows the flap to open and close by rotationally hinging around the side wall 218, for example.
Instead of using ream package wrap to secure the stacks of imaging media, the separation access band secures, separates and divides the stacks 206 from one another. Consequently, the use of packaging material is reduced, and the time for packaging and shipping stacks of imaging media is shortened. Furthermore, the separation access band 204 allows the user to lift the stack 206 for convenient access.
At least one stack of the plurality of stacks 208 is positioned in a first direction 502 and at least one other stack in a second direction 504, such as with packaging assembly device. For example, a bottom stack 506 is positioned in the first direction 502 over the separation access band 204. The bottom stack 506 is then decremented in height, such as with a lowering table (not shown). A second stack 508 is positioned in the second direction 504 that is approximately opposite with respect to the first direction 502. A third stack 510 is then moved in the first direction 502, a fourth stack is moved in the second direction 504 and a fifth stack 514 is moved in the first direction 502. With each positioning of the stacks located above the bottom stack 506, the separation access band 204 is moved across the top of the lower stack and traverses the bottom of the stack being positioned. For example, the second stack 508 is used to move the separation access band 204 across a top surface 520 while the second stack 508 is being positioned from the second direction 504. Additionally, as the second stack 508 is positioned, the separation access band 204 is traversed across the top surface 520 and a bottom surface 522 of the second stack 508. The process continues similarly until the third stack 510, the fourth stack 512 and the fifth stack 514 are in position and the separation access band 204 is configured in a zigzag pattern that secures the stacks from vibration damage or disorientation.
As stated above, embodiments of the present disclosure are not limited to five stacks of imaging material and other numbers of a plurality of stack of imaging material or imaging media are also envisioned (e.g., more than five or less than five in number).
In another example of embodiments disclosed, the separation access band 204 is approximately symmetrical on a bottom half 516 and a top half 518. For example, the separation access band 204 has the first end 310 and the second end 312 that respectively attach proximate to the same side wall of the master carton. Therefore, for each package assembly 130 that is manufactured some package assemblies can have both ends of the separation access band 204 proximate to the one side while other packaging assemblies can have both ends of the separation access band 204 attached proximately to another side.
The separation access band 204 includes a first fold 524 that is proximately located to the first end 310 and a second fold 526 that is proximate to the second end 312. The first fold 524 and the second fold 526 in another example are located on a same side (e.g., the first wall 218 of the master carton 202 of
While the methods described within this disclosure are illustrated in and described herein as a series of acts or events, it will be appreciated that the illustrated ordering of such acts or events are not to be interpreted in a limiting sense. For example, some acts can occur in different orders and/or concurrently with other acts or events apart from those illustrated and/or described herein.
An example methodology 600 for implementing a method for manufacturing a packaging assembly is illustrated in
At 604, an additional stack of imaging media is positioned above the stack of imaging media. At 606, the separation access band is traversed across a top surface and a bottom surface of the stack of imaging media and the additional stack of imaging media respectively. For example, while the additional stack is positioned on top of or above the stack underneath, the additional stack is rigid enough to also concurrently traverse the separation access band 204 over the top surface of the first stack and the bottom surface of the additional or second stack of imaging material. Therefore, the separation access band zigzags around the bottoms and tops of each stack of imaging material to secure the stacks in place and protect from shock and vibration within a master carton.
If the answer to the decision at 708 is positive (e.g., yes), then a master carton is erected around the plurality of stacks of imaging media. The master carton includes a top rigid surface and a bottom rigid surface, in which the first stack is placed on top with the separation access band. At 712, a first end of the separation access band is attached to the top rigid surface. Further, a second end of the separation access band can be attached to a bottom rigid surface of the master carton.
In one example of an embodiment, a plurality of folds are formed along the separation access band to further form pockets that separate and secure the plurality of stacks of imaging media from one another. In another embodiment, positioning the stack of imaging media comprises positioning the stack of imaging media in a first direction, and positioning the additional stack of imaging media comprises positioning the additional stack of imaging media in a second direction that substantially opposes the first direction. For example, each stack of imaging material is positioned in a different direction than the stack beneath so that the stacks are used to move the separation access band in a zigzag fashion that ribbons across the surfaces of each stack and secures the plurality of stacks of imaging medium tightly.
In another embodiment, a first end of the separation access band is attached to a flap of the top rigid surface that provides access to the master carton. The top surface of the master carton can have one or more flaps, which form a top closure or top opening to the master carton. In one example, a fold is generated at the first end attached to the flap that enables the separation access band that traverses a top surface of the plurality of stacks to partially lift in response to the flap being opened. A person is thus able to pull the top portion of the separation access band or peal it off the flap to reveal the top stack of imaging media.
Many variations and modifications can be made to the above-described examples. All such modifications and variations are intended to be included herein within the scope of the disclosure and protected by the following claims. It will be noted that the singular forms “a,” “an,” and “the” include plural references unless the context clearly indicates otherwise.
