Roll package with die-cut edge protection

Abstract

A roll package with die-cut edge protection having a Kraft paper layer surrounding the outer roll surface. A header is positioned adjacent the roll end and the Kraft paper layer has a die-cut edge folded radially inwardly adjacent the header without crimping. An outer plastic wrap layer is positioned adjacent the Kraft paper layer and the die-cut edge.

Description

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a package which includes edge protection.

[0003] Packages for rolls are well known in the art. U.S. Pat. Nos. 5,850,918 and 5,890,591 disclose roll packages. These patents disclose packages which utilize axial wraps and radial wraps. For the purposes of this patent application, a radial wrap is a film layer which is wrapped in a direction perpendicular or generally perpendicular to the core or the longitudinal centerline of the roll being wrapped. In some embodiments, the radial wrap is in a direction generally perpendicular to the longitudinal centerline, but not directly perpendicular. A spiral wrap is an example of this type of a radial wrap.

[0004] The prior art patents also disclose the use of a header or disc positioned adjacent the ends of a roll. Often the header is manufactured from protective cardboard materials.

SUMMARY OF THE INVENTION

[0005] The present invention is directed to a package having die-cut edge protection for use with a variety of rolls. The package includes a header positioned adjacent at least one of the roll ends. A Kraft paper layer surrounds the outer cylindrical surface of the roll adjacent the roll end. An important feature of the present invention is a die-cut edge on the Kraft paper layer which extends radially inwardly adjacent the header without crimping. An outer plastic wrap layer is positioned over the Kraft paper layer and over the die-cut edge.

[0006] In other embodiments, the package also includes a flexible, solid edge band positioned adjacent the Kraft paper layer at the edge of the roll.

[0007] Other objects and advantages of the present invention will become apparent to those skilled in the art upon review of the following description of the preferred embodiments and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of a roll package with die-cut edge protection according to the present invention;

[0009] FIG. 2 is a fragmentary enlarged, cross-sectional view taken along the line 2-2 of FIG. 1;

[0010] FIG. 3 is a perspective view, showing another embodiment of a roll package, according to the present invention, having a flexible edge band in addition to the die-cut edge protection;

[0011] FIG. 4 is a fragmentary enlarged cross-sectional view taken along the line 4-4 of FIG. 3;

[0012] FIG. 5 is a perspective view, similar to FIG. 3, having a flexible edge band at both ends of the package;

[0013] FIG. 6 is a fragmentary, enlarged cross-sectional view taken along the line 6-6 of FIG. 5;

[0014] FIG. 7 is a perspective view, similar to FIG. 1 showing another embodiment of a roll package, according to the present invention and having a continuous Kraft paper layer surrounding the outer cylindrical surface of the roll throughout the length of the roll; and

[0015] FIG. 8 is a perspective view of another embodiment of a roll package according to the present invention, having multiple Kraft paper layers surrounding the outer cylindrical roll surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] The preferred embodiments and the best mode of the present invention will now be described in detail with reference being made to the accompanying drawings.

[0017] Referring to FIG. 1, a package according to the present invention is generally indicated by the reference number 10. The package 10 is used to cover or enclose a roll 11. In most situations, the roll 11 is a cylindrical paper roll. However, the roll 11 can be a variety of roll products including, for examples, paper rolls, metal rolls, plastic rolls, fibrous material rolls or rolls of non-woven materials. The roll 11 can also comprise cable-like products, for examples, fiber optic cables, cooper wires, aluminum wires and similarly wound products.

[0018] The roll 11 is a cylindrical roll having an outer cylindrical surface 12 and opposed roll ends 13.

[0019] The package 10 includes a header 15 which is normally constructed of a cardboard or expanded plastic material. Headers are well known in the art. The header 15 is positioned adjacent the roll end 13. A Kraft paper layer 17 is position over the outer cylindrical surface 12 of the roll 11. The Kraft paper layer may be constructed of various types of Kraft paper. A preferred Kraft paper is a plain, 40 lb. Kraft wrapper stock. An important feature of the present invention is that the Kraft paper layer includes a die-cut edge 18 comprised of a plurality of die-cut tabs 19 which extend radially inwardly and are positioned directly adjacent the header 15. This eliminates crimp damage or edge damage, which was sometimes found in prior art Kraft paper wraps. The roll package 10 also includes an outer plastic wrap layer 20 positioned over the Kraft paper layer 17 and the die-cut edge 18. The outer plastic wrap 20 may consist of multiple wraps of a plastic, normally a polyethylene material. The outer plastic wrap layer 20 is recyclable and helps prevent moisture damage.

[0020] Referring to FIGS. 3 and 4, another embodiment of a package with die-cut edge protection, according to the present invention, is generally indicated by the reference number 25. The package 25 is similar to the package 10 illustrated in FIGS. 1 and 2 with the exception that a flexible edge band 26 is mounted adjacent the header 15a. The flexible edge band 26 includes a cylindrical wall 27 and an integral end wall 28. The flexible plastic edge band 26 is normally constructed of a polyolefin material such as a polyethylene. The flexible edge band material may have a thickness ranging between 5 mil to about 100 mil. The flexible edge band 26 may be positioned over the Kraft paper layer 17a and over the outer plastic wrap layer 20a. In the alternative, the outer plastic wrap layer 20a is positioned over the flexible edge band 26.

[0021] Another roll package with die-cut edge protection, according to the present invention, is generally indicted in FIGS. 5 and 6 by the reference number 30. The roll package 30 is similar to the roll package 25 illustrated in FIGS. 3 and 4 with the exception that a flexible edge band 26b is mounted adjacent each end of the roll package 30. The outer plastic wrap layer 20b is spirally wrapped over the outer cylindrical surface 12b of the roll 11b. The Kraft paper layer 17b includes die-cut edges 18a, having die-cut tabs 19 which are folded inwardly adjacent the headers 15b. This allows the overlapped die-cut tabs 19 to neatly extend inwardly adjacent the headers 15b thereby minimizing or eliminating crimp damage. Preferably, the headers 15b are made of recycled board having an exterior layer of polyethylene for moisture protection. The outer wrap layer 20b of the roll package 30 provides further moisture resistance.

[0022] Referring to FIG. 7, still another embodiment of a roll package with die-cut edge protection, according to the present invention, is generally indicated by the reference number 35. The roll package 35 is similar in construction to the roll package 10, illustrated in FIGS. 1 and 2. However, the roll package 35 includes a Kraft paper layer 17c which extends throughout the entire length of the roll package 35. Rather than having multiple adjacent layers, the Kraft paper layer 17c is wrapped over the outer cylindrical surface 12c of the roll package 10c throughout its length. Again, the roll package 35 includes die-cut edges 18c adjacent the headers 15c.

[0023] An outer plastic wrap layer 20c is positioned over the Kraft paper layer 17c throughout its length and also over the die-cut edges 18c, as indicated in FIG. 7.

[0024] A still further embodiment of a roll package with die-cut edge protection is indicated by the reference number 40 in FIG. 8. The roll package 40 is similar to the roll package 35 illustrated in FIG. 7 with the exception that the Kraft paper layer 41 comprises three separate layer portions 42, 43 and 44. The Kraft paper layer portions 42, 43 and 44 are positioned over the outer cylindrical roll surface 12e of the roll 11e. The Kraft paper layer portions 42 and 44 include die-cut edges 18e which are folded over the headers 15e in the normal manner. Similarly, an outer plastic wrap layer 20e extends over both the portions 42-44 of the Kraft paper layer 41 and over the opposed die-cut edges 18e.

[0025] Numerous modifications may be made to the preferred embodiments of the roll package described above without departing from the scope of the present invention or from the following claims.

Claims

1. A package for a roll, the roll having an outer cylindrical roll surface and opposed roll ends, said package including a header positioned adjacent a roll end, a Kraft paper layer surrounding the outer cylindrical roll surface adjacent the roll end, said Kraft paper layer including a die-cut edge extending radially inwardly at said roll end and an outer plastic wrap layer positioned adjacent said Kraft paper layer and said die-cut edge.

2. A package for a roll according to claim 1, wherein a die-cut edge is positioned over a header at each end of the roll.

3. A package for a roll according to claim 1, including a flexible edge band positioned adjacent the intersection of the outer cylindrical roll surface and the roll edge.

4. A package for a roll according to claim 3, including a flexible edge band positioned adjacent each end of the roll.

5. A package for a roll, according to claim 1, wherein said outer plastic wrap layer is radially wrapped over the outer cylindrical roll surface and over said Kraft paper layer.

6. A package for a roll, according to claim 1, wherein said Kraft paper layer is continuous and extends throughout the length of the roll.

7. A package for a roll, according to claim 1, wherein said Kraft paper layer is composed of multiple portions positioned along the cylindrical outer surface of the roll.

8. A package, according to claim 5, wherein said die-cut edge comprises a plurality of die-cut tabs folded inwardly adjacent said header.