Patent Application
20230159253
The present invention relates to packing products and, more particularly, to sustainable, re-usable, and efficient packing products for protecting packaged items.
A significant number of items are shipped throughout the world every day. The growth of on-line purchasing has increased shipping tremendously. However, merchandise damaged during transit creates lost revenue for the vendor, the shipper, and frustration for the recipient. It is thus beneficial to the shipper, the merchant, and the recipient that the shipped items arrive undamaged. Items are shipped to a consumer via box, envelope, or other style of container. To try and ensure items do not get damaged during transit, dunnage or packing material is typically used to bundle the item(s) for shipping.
Heretofore, various types of low density packing materials have been used. Plastic “peanuts”, plastic balls, plastic bubble-wrap, plastic air-filled “pillows,” form-fitting foam, straw and straw-like material have been or are being used as packing material. Most if not all of these packing materials have drawbacks. Plastic and similar materials are bad for the environment because they are generally not biodegradable and toxic to wildlife. The use of many, small pieces of low density packing material (e.g. Styrofoam balls, or peanuts), while efficient to surround and retain packed items, creates unpacking problems. Air-filled pillows do not effectively bundle items, allowing for gaps within the packaging. Such prior art packing material creates other problems as well.
In view of the above, it is evident that paper packing material would be preferred over other types of packing material since paper is biodegradable, recyclable, sustainable, and low density. However, lengths of crumpled or twisted paper, clumps of paper, or shredded paper is not practical for wrapping items, or for large-scale packaging.
Several patents and/or patent publications provide various ways of converting paper into a low density packing or cushioning product since paper converted into a low density packing or cushioning product is generally practical for packing. For example, U.S. Pat. No. 6,626,813 discloses a cushioning conversion system and method for making a coil of cushioning product from a sheet of paper.
In view of the above, it would therefore be desirable to have a paper-based packing product that alleviates the shortcomings of the prior art. It would be further desirable to have a paper-based packing product formed to provide adequate volume filler as a package/packaging without being a solid mass. It would be still further desirable to have a paper-based packing product formed to provide structural integrity with a lesser amount of material than a solid mass. It would be moreover desirable that the paper-based packing product clump or bunch together to create a packing mass about an item or items for packing. It would be further desirous to have a paper-based packing product formed by a single or double curl or spiral of cohesive paper wherein the cohesive portion of the paper is on the outside of the curl/spiral (i.e., faces radially outward). It would therefore be even further desirous to have a paper-based packing product of individual curls/spirals that forms a generally cohesive mass about an item or items for packing. The present invention addresses the above issues.
A paper-based packing product, use, machine and method of manufacture is provided that affords protection of packed/packaged items.
In one form, the packing product is fashioned as a curl or spiral (collectively, curl) from a dimension controlled, spiraled/wound strip of cohesive paper having a cohesive side and a non-cohesive side and formed with a leading end that is bent upon itself such that a cohesive side of the leading end contacts the cohesive side of the dimension controlled strip of cohesive paper, and a trailing end opposite the leading end that is bent upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the dimensioned strip of cohesive paper, wherein the dimensioned strip of cohesive paper is spiraled or wound into a curl or spiral with the cohesive side of the dimensioned strip of cohesive paper on the outside of the curl/spiral.
A plurality of the present curls provides a generally cohesive mass or clump around an item or items in packing due to the curls loosely adhering to one another. The curls may also loosely adhere to the item or items. A method of packing an item or items includes placing a plurality of the present packing curls into a package with the item or items. The method may include providing a plurality of curls dimensioned and sized according to the item or items being packed. Smaller items may use smaller curls while large items may use larger curls, or vice versa. A mix of curl sizes may be used.
A curl may be formed from roll of cohesive paper that is dimensioned into a strip of cohesive paper having a width that is preferably, but not necessarily, one quarter inch (¼″) to three quarters inch (¾″), with one half inch (½″) being most preferable, and preferably, but not necessarily, two inches (2″) to six inches (6″) long. Other sizes are contemplated and may depend on the size of the item or items being packed. The cohesive paper has a weight that is preferably, but not necessarily, from the teens to the fifties. The width or vertical side of a curl provides blocking/stack strength for the packaged item, while the size of the curl (length or horizontal side) provides cushioning for the packaged item. When a plurality of curls are clumped together in random directions, a protectant mass is formed around an item or items by interaction of the cohesive nature of the cohesive paper of each curl with respect to other curls. A mass of curls can assume any size and shape, especially around a packaged item, such as in a corrugated box.
The curls can be used for single or multiple, light or heavy items. The curls may also be used in conjunction with an item or items wrapped in cohesive paper. With the cohesive side of the paper placed on the outside of the item or items, the curls surround the item or items to stabilize as well as protect the item(s). Such packing also keeps the item(s) free from abrasion. Other types of cohesive wrapping such as, but not limited to, foam may be used in place of cohesive paper wrapping.
The curl producing machine may be sized according to application need. For instance, a small desktop curl producing machine may be used for packing small boxes, while a larger, free-standing curl producing machine may be used for packing larger boxes. Curl producing machines may be fashioned for low volume curl production or high volume curl production.
A method and machine of producing a curl includes providing a roll of a cohesive paper sheet having a cohesive side and a non-cohesive side, cutting the cohesive paper sheet into a dimensioned strip, creating a folded leading end on the dimensioned strip that is bent upon itself such that a cohesive side of the leading end adheres to the cohesive side of the dimensioned strip of cohesive paper, creating a trailing end on the dimensioned strip opposite the leading end that is bent upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the dimensioned strip of cohesive paper, and winding/spiraling and cutting the dimensioned and end folded strip of cohesive paper into a curl or spiral with the cohesive side of the dimensioned and end folded strip of cohesive paper on the outside. Cutting of the strips may occur before winding, after winding, or in conjunction with winding.
A method of and machine for packing or cushioning one or more items includes providing a plurality of the present curls or spirals around or about the one or more items, with or without the item(s) first being swathed in a cohesive wrapper. The plurality of curls are preferably, but not necessarily, dimensioned and sized according to the item or items being packed. Smaller items may use smaller curls while large items may use larger curls, or vice versa. A mix of curl sizes may be used. The present machines for producing the curls are adjustable to provide different lengths of curls, width, etc. for different packing needs.
Different cohesive papers may be used for the curls. The cohesive paper may be have a color, be different weights, or have texturing.
In another form, the packing product is fashioned as a double curl, either a “B” or modified “B” (collectively, “B”), from a dimension controlled strip of paper. The strip of paper may be cohesive paper having a cohesive side and a non-cohesive side, a coated paper, or the like. The “B” is formed by a first curl wound or spiraled about a first end of the dimensioned controlled strip of paper, and a second curl wound or spiraled about a second end of the dimensioned controlled strip of paper. A small portion of the dimension controlled strip of paper connects the first and second curls. The first and second curls are wound or spiraled in opposite directions. If cohesive paper is used, the first and second curls are formed such that the cohesive side is/faces radially outward (outside) and the non-cohesive side is/faces radially inward (inside).
A plurality of “B”s provide a generally unified mass or clump around an item or items within (packed) in a receptacle (for example, but not limited to, and interchangeably herewith, a package, container, box, envelope, case, carton, basket, chest, drawer, packet, canister, can, or the like). In the case of the use of cohesive paper to form the “B”s, a plurality of cohesive “B”s provide a unified cohesive mass or clump around an item or items in a receptacle due to the cohesive “B”s loosely adhering to one another. The cohesive “B”s of the unified cohesive clump may also loosely adhere to the item or items, as well as the interior of the receptacle. A mass or clump may be compressed to reduce its volume and/or provide tighter packing. Mass or clump reduction may also be used to create or provide blocking or bracing of items within a receptacle. “B”s are moldable and fit the form of the item(s) being packed/packaged.
A method of packing an item or items using the present invention includes placing a plurality of the present “B”s in a receptacle (e.g. a packing container) along with the item or items. The “B”s may be cohesive “B”s or not (collectively “B”s unless indicated specifically as being cohesive or non-cohesive). The method may include providing a plurality of “B”s dimensioned and sized according to the item or items being packed, size of the receptacle, weight of the item or items being packed, or other parameter/consideration. Smaller and/or lighter items may use smaller “B”s while larger and/or heavier items may use larger “B”s, or vice versa. A mix of different sized “B”s may be used. Other considerations, characteristics, and/or factors may determine dimensions or influence specifics of the “B”s. “B”s may be used for large, medium, or small items/receptacles, as well as light, medium, or heavy items/receptacles.
In one form, a “B” is formed from a roll or other source of paper (cohesive, non-cohesive, or a cohesive/non-cohesive blend, coated or the like) that is dimensioned controlled into a strip of paper having a width that is preferably, but not necessarily, one quarter inch (¼″) to three quarters inch (¾″), with one half inch (½″) being most preferable, and preferably, but not necessarily, two inches (2″) to twelve inches (12″) long. Other sizes are contemplated and may depend on factors and/or characteristics of the item or items being packed. The paper preferably, but not necessarily, has a weight from the teens to the fifties. The width or vertical side of a “B” provides blocking/stack strength for the packaged item(s), while the radial size or diameter of the first and second curls of the “B” provides cushioning as well as other benefits for the packaged item. When a plurality of “B”s are clumped together in random directions, a protectant mass is formed around an item or items by interaction of the shape of the curls of each “B” and, when cohesive paper forms the “B”s, “B”s naturally additionally adhere to one or another due to the cohesive side of each “B” faces outward. A mass of “B”s can assume any size and shape, especially around a packaged item, such as in a corrugated box. The mass also forming well inside the corrugated box. The “B”s surrounding the item or items stabilize as well as protect the item(s). Such packing also keeps the item(s) free from abrasion.
“B”s can be used to pack single or multiple items, light or heavy items, and within any receptacle, closed or open. “B”s may also be used in conjunction with an item or items that are wrapped in various materials such as, but not limited to, bubble wrap, tissue paper, butcher’s paper, newspaper, cohesive paper, construction paper, coated paper, cotton paper, and plant paper. Other types of wrapping such as, but not limited to, foam may be used in place of paper wrapping.
The “B” producing machine may be sized according to application need. For instance, a small desktop “B” producing machine may be used for packing small boxes, while a larger, free-standing “B” producing machine may be used for packing larger boxes. “B” producing machines may be fashioned for low volume “B” production or high volume “B” production.
A method of and machine for producing the present “B”s includes providing a roll of paper (i.e. a roll of a continuous sheet of paper), forming a first curl of a first diameter at the leading end of the roll of paper, cutting the roll of paper into a strip of paper having the first curl to provide the strip of paper with a trailing end distal the first curl, then forming a second curl of a second diameter at the trailing end of the strip of paper. If cohesive paper (e.g. paper with a cohesive on one face or side thereof) is used, the first and second curls are formed with the cohesive side facing radially outward.
In one exemplary form, a machine/method for producing the present “B”s uses a roll of paper to continuously create “B”s, preferably, but not necessarily, automatically, with pre-set dimension control of the produced “B”s. The present “B” producing machine is preferably, but not necessarily, processor controlled (e.g. computer) that at least provides control of the various components of the machine. The processor may also allow custom or on-the-fly creation of “B”s by dimension control including, but not limited to, the spiral length (amount) of each curl, the width of the strip of paper and each curl, the tightness of each curl (spiral), the length of connection between the first and second curls, and the like.
In the exemplary form of the machine/method for producing the present “B”s, the sheet paper is fed through a first slot of a first slotted spindle or rod then a second slot of a second slotted spindle or rod, rotating the second slotted spindle in a first rotational direction to wind the leading end of the roll of sheet paper into a first curl, cutting the roll of sheet paper at a location before the second slotted spindle to create a strip of paper with a trailing end distal the first curl, rotating the first slotted spindle in a second rotational direction that is opposite the first rotational direction to wind the trailing end of the strip of sheet paper into a second curl, and ejecting the produced “B” from the first and second slotted spindles/machine. Variations are contemplated. Other steps not specifically mentioned in this paragraph may intervene per the present principles and specification. The roll of sheet paper may be further dimensionally controlled by cutting the roll of sheet paper into one or more widths. Other dimensions may be changed.
A method of and machine for packing or cushioning one or more items within a packing container or receptacle includes providing a machine to produce a plurality of the present “B”s, then placing them around or about the one or more items, with or without the item(s) first being wrapped. The plurality of “B”s are preferably, but not necessarily, dimensioned and sized according to the item or items being packed and/or receptacle particulars. Smaller items may use smaller “B”s while large items may use larger “B”s, or vice versa. A mix of various sized “B”s may be used. The present machines for producing the “B”s are adjustable to provide different lengths of “B”s, width, etc. for different packing needs.
Different papers may be used for the “B”s. The paper may be have a color, pattern, be different weights, have texturing or the like.
The present packing product is advantageous by providing efficient packing and/or cushioning of an item or items in a receptacle without necessarily filling the entire cavity of the receptacle. For instance, the present packing product does not need to fill the interior corners of a receptacle as it clumps around the item(s) in the receptacle. This cuts down on the amount of necessary packing product.
Further, the present packing product is lightweight. Moreover, the volume of the present packing product is not solid. It encompasses air between its curls.
The present “B”s provide a simple solution for multiple packing/packaging needs such as general void fill, protective void fill, general cushioning, light duty cushioning, heavy duty cushioning, blocking and bracing, decoratively, and containment. The present “B”s are also sustainable, reusable and/or recyclable by the consumer and in the supply chain, reusable by the same business, and end user reusable.
The present “B”s are easy and simple to use, provide for faster packing/packaging (which is a reduction in labor), allows the use of less material to pack/package items over conventional/prior art packing product. Use of the present “B”s can replace plastic and foam packing, result in reduction of packed/packaged item damage, and provide a positive customer experience.
Items as delicate or fragile as glass ornaments of any shape up to items of any practical weight and shape can be packed using the present “B”s, particularly when the “B”s have been custom produced regarding their curl size (number of turns).
Further aspects of the present invention will become apparent from consideration of the drawings and the following description of forms of the present invention. A person skilled in the art will realize that other forms of the invention are possible and that the details of the invention can be modified in a number of respects without departing from the inventive concept. The following drawings and description are to be regarded as illustrative in nature and not restrictive.
The present invention and its features will be better understood by reference to the accompanying illustrations/drawings, wherein:
For the purposes of promoting an understanding of the principles of this invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring to
Cohesive paper (a continuous cohesive paper sheet), collectively cohesive paper P, from the cohesive paper roll 14 is received by/into a paper feed/feeder/feed mechanism (collectively, feed) 18 which directs the cohesive paper P into the housing 12 and to a paper guide 19. The paper guide 19 includes first and second feed rollers R1, R2 disposed opposite one another such that the cohesive paper P is properly received and aligned for curling and cutting. The first and second rollers R1, R2 lead the cohesive paper P over a third roller R3 such that the cohesive paper P is received onto a shaft 20. A rotation mechanism 21, here shown as a first motive roller 22 and a second motive roller 23 connected by a belt or belt drive 25, rotates the shaft 20 and cohesive paper to provide wound cohesive paper 24 about the shaft 20.
The wound cohesive paper 24 travels about the shaft 20 where it encounters a cutter 26, here shown as two cutting blades C1 and C2, that cuts the wound cohesive paper 24 into cohesive paper packing curls (curls) 30, one of which is shown in
While the machine 10 cuts the wound cohesive paper 24 into curls 30 after winding on the shaft 24, it should be appreciated that a machine may produce the present curls by first cutting the cohesive paper into the desired size (width and length) of strips before curling. Moreover, the roll of cohesive paper may already have a width of one quarter inch (¼″) to three quarters inch (¾″), which is then cut to a length of two inches (2″) to six inches (6″) long for curling.
Variations in the curl producing machine 10 are contemplated such as, but not limited to, placement and numbers of cohesive paper guide/feed rollers, the manner of rotating the curling shaft, the manner of feeding the cohesive paper into the curling and cutting mechanisms, and the like. Other variations are contemplated, the end result of which is to make/produce curls 30.
Referring now to
The individual length-cut sheets are conveyed to a folder or folding section 120 via drive rollers (D.R.). The folding section 120 is designed to create a folded leading end or edge 202 and a folded trailing end or edge 204 opposite to the folded leading end 202 to each individual length-cut sheet of cohesive paper 200 (see, e.g.,
In
In
Referring to
The packing product production machine 413 is configured to hold a roll of cohesive (non-cohesive, coated, or otherwise) paper 415 for making the present packing material. The roll of paper 415 is held on a rotatable shaft 416 and rotationally supported by a first retention spindle 417 on a first side of the roll of paper 415, and a second retention spindle 441 on a second side of the roll of paper 415, the nomenclature first and second being arbitrary. The first and second retention spindles 417, 441 hold the roll of paper 415 onto the shaft 415 such that the roll of paper 415 can rotate with the shaft 416. The roll of paper 415 has a continuous sheet of paper 420 that is fed into the various components/mechanisms of the packing material production machine 413 that will cut and dimension the sheet of paper 420 into a strip 400, form one or more “B”s from the strip 400, and eject the one or more formed “B”s from the packing product forming machine 413, as described in more detail below.
The sheet of paper 420 is fed into a packing product forming portion or section 448. The sheet of paper 420 extends under a guide roller 422, under a rotating cutting roller 425, then over the cutter 426. As explained above, the cutter 426 dimensions the sheet of paper 420 into strips 400 of paper of widths according to the cutter 426. The cutting roller 425 is rotated by a cutting roller motor 427 that is supported on a frame portion 428 that is attached to a brace 423 that extends from the upturned portion 429. The cutting roller motor 427 is coupled to the cutting roller 425 for rotating the cutting roller 425 and feeding the sheet of paper 420 over the cutter 420 in order to cut the sheet of paper 420 into the strips of paper 400. The leading end 407 of the width-dimensioned strip(s) of paper 400 is then fed into and through a first curling rod or spindle 450, then further fed into and through a second curling rod or spindle 451, the nomenclature first and second being arbitrary. The first curling rod 450 is coupled to a first curling rod motor 431 that is supported on a first frame portion 431 that extends from the mounting plate 434 for rotating the first curling rod 450, while the second curling rod 451 is coupled to a second curling rod motor 433 that is supported on a second frame portion 432 that extends from the mounting plate 434 for rotating the second curling rod 450, the nomenclature first and second being arbitrary. The first curling rod motor 431 provides rotational positioning of the first curling rod 450. Additionally, the first curling rod motor 431 is controllable to rotate the first curling rod 450 a given number of revolutions in order to curl the trailing end 408 of the width-dimensioned strip(s) of paper 400 as described herein. The given number of revolutions may be controlled to provide the second curl 405 of the “B” 404 with the given number of spirals as desired for a particular packing application or otherwise, and/or a particular diameter. The diameter may depend on the tightness of the spiral and the length of the second curl 405. The second curling rod motor 433 provides rotational positioning of the second curling rod 451. Additionally, the second curling rod motor 433 is controllable to rotate the second curling rod 451 a given number of revolutions in order to curl the leading end 407 of the width-dimensioned strip(s) of paper 400 as described herein. The given number of revolutions may be controlled to provide the first curl 406 of the “B” 404 with the given number of spirals as desired for a particular packing application or otherwise and/or a particular diameter. The diameter may depend on the tightness of the spiral and the length of the first curl 406. The given number of spirals of the first curl 406 and the given number of spirals of the second curl 405 may be the same or different, again depending on the particular packing application or otherwise. As represented in
As shown in
The packing product production machine 413 further has a sheet cutting motor 442 that is in communication with the processor 460 and labeled M5 in
As best seen in
As depicted in
The cutter 426 of the packing product production machine 413 may be replaceable in order to create “B”s of various widths. For example, one cutter may provide for a given number of “B”s of the same width. Another cutter may provide for a given number of “B”s of different widths. Rather than switching out cutters, the cutter 426 may allow for automatic change of its cutting blades to set a width or widths of formed “B”s. The interface would thus allow for the user to select the cutting width(s).
It should be appreciated that other manners of producing packing product, “B”s, or modified “B”s, in accordance with the present principles may be used, and are contemplated.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only preferred embodiments have been shown and described, and that all changes and modifications that come within the spirit of the invention are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention.
This U.S. non-provisional patent application is a continuation-in-part of U.S. Non-Provisional Pat. Application Serial No. 17/573,058 filed Jan. 11, 2022 titled Packing Material, Use, and Methods of Manufacture, which claims the benefit of and/or priority under 35 U.S.C. §119(e) to U.S. Provisional Pat. Application Serial No. 63/135,820 filed Jan. 11, 2021 titled Packing Material and Method of Manufacture, the entire contents of each of which is specifically incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63135820 | Jan 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17573058 | Jan 2022 | US |
| Child | 18094241 | US |
