Patent Application
20200277099
Protective packaging can be used to pack a range of products including hardware products, such as printers, in order to prevent damage to the products in the event of an external impact or vibration force, For example, protective packaging prevents damage to a product if it is accidentally dropped during transportation, or a vibration from transportation is transferred to the outside of the packaging, Packaging cushions can be provided around a product to absorb any impact forces exerted onto the product.
Various features of certain examples will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example only, a number of features, and wherein:
In the following description, for purposes of explanation, numerous specific details of certain examples are set forth. Reference in the specification to “an example” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least that one example, but not necessarily in other examples.
Packaging cushions can be provided as protective packaging inside of a corrugated box for example, and may include soft materials and ribs. Cushions can be made from moulded pulp, corrugated paper, polystyrene (known as Styrofoam, EPS) or expanded polyethylene (EPE) or other material.
Reinforced protection can be provided at the corners of packaging, for example by gluing, to improve protection. Shock absorbers may be adjustable, via slits in EPS, to better shape the protective packaging to a product. For example, cushioning boards made of paperboard can be connected to a packaging box with hinges to protect items such as glass bottles, where the cushioning boards are wrapped around the bottles. Other paper-based shock absorbers may be cut to shape to fit onto packaging, such as a cardboard box, by gluing to form the protective packaging.
The disclosure relates to paper-based protective packaging. Protective packaging may include paper-based moulded structures or cushions for protecting hardware products that are packed inside the packaging. The moulded structures may resemble cushioning ribs that are manufactured using paper-plate technology. The moulded structures may protect a product along a flat region of the product or an edge or corner of the product.
In an example, the moulded structure is moulded in an I-shaped form, such as that shown in
Each recessed region may define a hollow shell such that the moulded structure can be nested within a further moulded structure.
In an example, the moulded structures are mass produced and are provided into pre-defined cavities (by hand or dispensers) along a conveyor-like production line. A half-box may then be applied on top of the arranged moulded structures as a flat sheet, The flat sheet is pressed onto adhesive on the attachment surfaces of the moulded structures, For example, hot-melt glue or starch-based glue can be applied on the attachment surfaces or rib-flanges. The flat sheet of the box and the moulded structures are pressed together. A box can then be formed by folding the flat sheet into a half-box or an end-cap.
A method for moulding a moulded structure comprising a layer(s) or sheet(s) of paper for protective packaging according to an example will now be described.
In an example, a pre-defined moulding template may be provided that is product or packaging specific. The moulded structure is applied to packaging to form protective packaging for protecting a product during transportation.
A plurality of moulded structures may each be manufactured in a respective pre-defined moulding template on a production line. The method may further comprise the step of inserting a plurality of moulded structures into respective pre-positioned depressions in an assembly tray of a conveyer system or rotary table system. The moulded structures may be of the same type or can be a combination of different types or sizes. The moulded structures may be inserted manually by operators or automatically by robotic arms or dispensers. The method may further comprise the step of arranging a flat sheet of corrugated cardboard over the moulded structures. The flat sheet may be pressed onto adhesive and subsequently onto the attachment surfaces of the moulded structures. The method may further comprise the step of folding the flat sheet to form a half-box having the moulded structures attached thereto. The step of applying may comprise one or more of: gluing; stapling; and interconnecting.
In the example of
In an example, the moulded structure comprises an attachment surface 740. The attachment surface may be formed at or around a periphery of the first section and second section. The attachment surface or flange may be provided as a flat surface or flange that is suitable for attaching the moulded structure onto a package, for example using adhesive. The attachment surface may extend beyond an intersection with the shell forming the first and second sections such that the attachment surface protrudes beyond the shells, This provides a larger area for applying the moulded structure onto packaging to provide a more reliable attachment. This also allows for the application of more pressure during the gluing process without deforming the ribs.
In the example of
The intermediate section allows the first section to be arranged at an angle to the second section. The moulded structure may be substantially L-shaped. For example, the angle between the first and second sections may be around 90 degrees. The first and second sections may extend in two directions 750, 760 that are angled to one another. The moulded structure can be attached to a corner of packaging. As such, the moulded structure is suitable for absorbing an impact force at a corner of protective packaging, An impact of a product drop will have the energy being absorbed by the deformation of the papers in the recessed regions. The moulded structure may act like a cushion under an external force to cause one or more the sections to cave into the recessed region such that the impact force is absorbed.
The structure is moulded using paper-plate manufacturing technology in which a layer(s) or sheet(s) of paper is used. The paper-plate manufacturing process involves a moulding process utilizing pressure and heat using sheets of paper (as opposed to pulp). Paper thicknesses can range from 50 gsm to 1000 gsm. The tool for the moulding has to consider a maximum depth, angles of the sides and surfaces of the moulded structure and the flow of paper from a flat sheet to a moulded shape. The moulding template may be provided to conform to a packaging onto which the moulded structures are attached to form the protective packaging.
The moulded structure shown in
In an example a moulded structure or cushioning rib has six faces, twelve edges and eight corners. The moulded structure protects a product from external shock and vibration.
The protective packaging may comprise moulded structures that form paper-based ribs in either a fixed shape or an adjustable shape or a hinged shape. The adjustable moulded structure may be selected or modified to conform to a package or product shape. The moulded structures may be generally L-shaped and may comprise at least one hinge such that the angle of the L-shaped rib is adjustable. The moulded structures have recessed regions. As such, the moulded structures or ribs are formed of a shell of a layer or layers of paper.
The first section and/or the second section of the moulded structure may be provided to any desired length to suit the product to be protected. For example, the first section may be of the same or a different length to that of the second section. In an example, the first section may extend along one side of the product and the second section may extend further than the first section along another side of the product. In this way, differently shaped products (for example square or rectangular) can be sufficiently protected using the moulded
The moulded structure may be provided as a fixed unit having a shape formed directly from its moulding template. Alternatively, the moulded structure may be provided as an adjustable unit, such that the positions of the first and second sections relative to each other can be adjusted.
Whilst the shapes of the moulded structures can be designed to be product specific, the moulded structures may also be provided in different designs having different widths, lengths and depths in different paper thicknesses and paper types. This would allow a packaging designer to select for each surface or edge of their product, the moulded structure which is most applicable and provides the best fit to the product or the best protection. In an example, the moulded structures are provided as a mix of “standard” shapes which can be purchased on the open marked like a commodity, where they may have a product specific design, A packaging design can optimize the combination of different moulded structures by having many “standard” shaped moulded structures and a small number of product-specific designs requiring special mould-tooling. This would reduce the fixed one-time costs related to launching a new packaging design, Once the designer has selected the optimum moulded structure for and dimensions of the boxing for their product, the protective packaging can be optimised based on drop testing by changing some parameters, for example by applying different paper thicknesses or paper types, to find which is most suitable for the product in question. The moulded structures may be delivered, with different sizes or properties, as nested moulded structures. This would reduce the space for transporting the moulded structures and reduce transportation costs.
The moulded structures can be attached to paper-based packaging or a corrugated box to form the protective packaging.
The packaging to which the moulded structures are attached may be a half-opened corrugated box used to represent one of two end-caps for protecting a printer. The product can be provided with a left and right paper-based cushion to protect it during transportation or storage. In an example, the cushions can be attached to the packaging by gluing, stapling, or interlocking.
The moulded structures may alternatively, or additionally, be attached to an inner surface of the packaging such that they are arranged adjacent the product to be protected.
The packaging may comprise an end-cap suitable for protecting a printing product.
The moulded structures may be provided to conform to the shape of a product to be protected, for example as shown in
In an example, the first and second sections are adjusted via a hinged region. In an example, a moulded structure may comprise more than one hinge.
A shown in
Each recessed region may define a hollow shell such that the moulded structure can be nested within a further moulded structure.
The present disclosure provides environmental advantages with reduced manufacturing costs. The recessed regions of the moulded structures provide for a lighter shock absorber with lower material costs. Foam and EPS based packaging has already been banned by some environmental programs of selective countries, e.g. California, Italy, which push against the use of plastic-based packaging. Plastics packaging is being replaced by the use of moulded pulp but moulded pulp is a costly alternative to EPS because the pulp process starts with paper fibres in large amounts of water, where the water is sucked or pressed out and the remaining fibres use a significant amount of hot air drying. The pulping process is time-consuming and costly and further compounded by locations in areas with high relative humidity which do not support the drying process. The manufacturing techniques used for providing the moulded structures described herein allow for a reduction in energy used during manufacture, thus enabling a lower price per unit.
The present disclosure allows paper-based cushions to be manufactured or provided at a lower production cost. The cost of production is reduced because less energy is used during the manufacturing since the step of drying pulp, as used with existing methods, is removed. Much less heat energy is used using the paper-plate manufacturing technology. There is provided a faster moulding cycle with moulding times of around one second being achieved per mould (as opposed to one minute as with existing pulping techniques).
The present disclosure provides protective packaging that is more environmentally friendly and easier to recycle, Instead of using moulded pulp which has high energy consumption and manufacturing costs, paper-based plate technology is used to manufacture the moulded structures for protective packaging, where the moulded structures can be shaped to conform to product packaging.
The paper-based moulded structures described herein can possess similar material characteristics as the packaging to which they are attached. As such, the similar material used for both the inner and outer protection makes recycling easier and simpler because the moulded structures can be recycled with the outer packaging or corrugated boxing in the same paper recycling stream. The moulded structures according to the present disclosure therefore have a higher environmental perception than existing packaging.
While the method, apparatus and related aspects have been described with reference to certain examples, various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the present disclosure. In particular, a feature or block from one example may be combined with or substituted by a feature/block of another example.
The word “comprising” does not exclude the presence of elements other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims.
The features of any dependent claim may be combined with the features of any of the independent claims or other dependent claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2017/062386 | 11/17/2017 | WO | 00 |
