Patent Application
20130068381
The invention relates to a system and method for manufacturing paper sleeves from sheet stock, and in particular, forming conical sleeves for bundling flowers.
Sleeves are used for protecting and presenting products in commerce, for example flowers or plants. Sleeves may be formed by wrapping a single sheet of material about a bundle of plants, or may be pre-formed by rolling single sheets, or by combining multiple sheets, for example by melting seams containing polymeric material.
In an embodiment of the disclosure, a sleeve is formed by applying a first predetermined pattern of adhesive onto a first elongate sheet using a application roller having an embossed resilient pattern corresponding to the first predetermined pattern, the embossed resilient pattern operative to transfer adhesive from an adhesive supply to the first elongate sheet as the application roller is rotated in spaced conformity relative to the first elongate sheet; adhering, using the predetermined pattern of adhesive, a second elongate sheet to the first elongate sheet, thereby forming a web including the predetermined pattern of adhesive disposed between the first sheet and the second sheet; and passing the web through a cutter operative to separate sections of the web comprising adhered first and second sheet sections bounded together along opposing peripheral edges by the adhesive.
In alternative embodiments, the predetermined pattern of adhesive is applied to the second elongate sheet; the predetermined pattern of adhesive forms at least one line extending at an angle transversely across the first elongate sheet relative to a longitudinal axis of the first elongate sheet; the predetermined pattern of adhesive forms two non-parallel lines extending at an angle transversely across the first elongate sheet relative to a longitudinal axis of the first elongate sheet; each of the two lines forms the same angle relative to a side edge of the first elongate sheet; the first elongate sheet comprises paper; the first and second elongate sheet comprise Kraft paper; the first and second elongate sheet comprise paper of between 10 and 100 gsm; the first and second elongate sheets comprise paper.
In other embodiments, the sleeve is entirely formed of materials which readily degrade in a natural environment; the sleeve is sized and dimensioned to contain cut plants having stems, the stems extendable through an open end of the sleeve; the adhesive is water-based or solvent free, and rapidly degrades in a natural environment; and adhesive is applied by being first transferred from a supply tray to an intermediate roller, and from the intermediate roller to the application roller, thereby applying a layer of adhesive having a predetermined thickness onto the embossed resilient pattern; the intermediate roller and or the application roller are heated to maintain the adhesive in a liquid state.
In yet other embodiments, forming a sleeve further comprises cutting the adhered first and second elongate sheets using one or more cutting blades moveable from a position above the adhered sheets to a position below the adhered sheets, thereby separating individual sleeves along the predetermined pattern of adhesive; the first and second adhered sheets are supported by a surface, the surface being provided with grooves into which the cutting blades may move after cutting the adhered sheets; the cutting blades may be moved manually or by a mechanical actuator; cutting is performed using a laser; and the cutting blades may be moved by a first mechanical actuator, and wherein the adhered sheets are positioned under the cutting blades by a second mechanical actuator, the first mechanical and second mechanical actuators coordinated in their respective moving and positioning.
In another embodiment of the disclosure, a sleeve is formed by applying a first predetermined pattern of adhesive onto a first elongate sheet using a rotating cylinder having an embossed resilient pattern corresponding to the first predetermined pattern, the embossed resilient pattern operative to transfer adhesive from an adhesive supply to the first elongate sheet as the rotating cylinder is rotated in spaced conformity relative to the first elongate sheet; adhering, using the predetermined pattern of adhesive, a second elongate sheet to the first elongate sheet, thereby forming a web including the predetermined pattern of adhesive disposed between the first sheet and the second sheet; and passing the web through a cutter operative to separate sections of the web comprising adhered first and second sheet sections bounded together along opposing peripheral edges by the adhesive, the cutter including one or more cutting blades moveable from a position above the web to a position below the web, thereby separating individual sleeves from the web.
In a further embodiment, a sleeve is formed by applying a first predetermined pattern of adhesive onto a first elongate sheet using a rotating cylinder having an embossed resilient pattern corresponding to the first predetermined pattern, the embossed resilient pattern operative to transfer adhesive from an adhesive supply to the first elongate sheet as the rotating cylinder is rotated in spaced conformity relative to the first elongate sheet; adhering, using the predetermined pattern of adhesive, a second elongate sheet to the first elongate sheet, thereby forming a web including the predetermined pattern of adhesive disposed between the first sheet and the second sheet; forming the web into a roll; and passing the web from the roll through a cutter using a first mechanical actuator, the cutter operative to separate sections of the web comprising adhered first and second sheet sections bounded together along opposing peripheral edges by the adhesive, the cutter including one or more cutting blades moveable from a position above the web to a position below the web, thereby separating individual sleeves from the web, the passing of the first mechanical actuator coordinated with the moving of the second mechanical actuator.
A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples and that the systems and methods described below can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present subject matter in virtually any appropriately detailed structure and function. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the concepts.
The terms “a” or “an”, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms “including” and “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as “connected,” although not necessarily directly, and not necessarily mechanically.
With reference to
Seams 106, 108 are formed by adhering mutually facing edge portions of sheets 102, 104. A width of seams 106, 108 is determined by a strength of an adhesive securing sheets 102, 104 together along a seam 106, 108, whereby a smaller or narrower seam 106, 108 may be formed as an adhesive strength of the bond between sheets 102, 104 becomes stronger.
Sheets 102, 104 may be formed of any material which may be mutually adhered, and is selected with consideration given to the material to be contained, the conditions of the containment, and the cost of the material. For containing living plants, for example flowers, it is advantageous if sheets 102, 104 are resistant to degradation due to moisture, and have sufficient strength to offer protection to delicate living structures. Sheets 102, 104 may be formed of opaque or transparent material, and may be decorated by printing, embossing, reliefs, or perforations, on one or both sides of a sheet. Example materials include polymeric materials, including but not limited to polypropylene, BOPP (Biaxially Oriented Polypropylene), polystyrene, nylon, mylar, tyvek, cellophane, fabric, woven material, fibrous material, webbed material, paper, cardboard, metalized material, foil, metallic foil, foam, open cell foam, closed cell foam, and multilayer materials comprising any combination of materials. One or both of sheets 102, 104 may be formed of a biodegradable material, for example a polylactide (PLA) material. Sheets 102, 104 may be printed with an arbitrary, repeating, or representational predetermined pattern, or any image or indicia.
Either or both of sheets 102, 104 may be composed of multiple layers of differing or like materials. Sheets 102, 104 define an inner surface 112 facing inner containment area 110, and an outer surface 114 facing away from inner containment area 110. Inner surface 112, for example, may be polymeric, or otherwise resistant to moisture and or tearing. Outer surface 114 may be, for example, cellulosic, selected to be comfortable to grasp or grip by a human hand. Outer surface 114 may further have greater or lesser moisture resistance, strength, elasticity, texture, or other properties than inner surface 112. Sheets 102, 104 may be shaped differently than each other. Sheets 102, 104 may advantageously be formed of a material that readily passes humidity from inner containment area 110 to an exterior of sleeve 100, particularly for living plants.
The disclosure is particularly advantageous for forming sleeves including paper material, which is positively adhered by adhesive, and cannot be joined by melting. Sheets 102, 104 are advantageously formed with a material which eliminates or reduces humidity to which plant, and particularly floral contents, may be exposed during packing, storage, transport, and distribution, and or enables dissipation of humidity that may be formed within sleeve 100, which has been introduced by the contained material, and particularly introduced by living material such as plants. Paper of between 30 and 60 gsm have been found advantageous in these regards, however thinner or thicker material, for example between 10 and 100 gsm, and other forms of paper, may advantageously be used, depending on the rigors of the application. More particularly, Kraft paper has been found advantageous, due to its physical properties, including breathability, strength, and reduced cost relative to other materials which may be available, including polymeric material. Materials for forming sheets 102, 104 are advantageously provided in rolls having a maximum weight of 100 kg each, so that they may be handled expeditiously within the production facility; however, much lighter or heavier rolls may be used, as is understood within the art.
Sheets 102, 104 may be composed of different materials, or materials having a different appearance. This may be advantageous, for example, where one sheet 102, 104 faces a potential consumer and the other sheet 102, 104 faces away from a potential consumer, for example in a retail display. One sheet 102, 104 may have a greater resistance to sunlight, chemicals, or moisture, for example, than the other sheet 102, 104, and sleeve 100 is so arranged when stored, transported, or displayed, to take advantage of the relative difference in properties of sheets 102, 104.
Referring now to
Any of rollers 204, 206, 208, or 214 may be temperature controlled, including being heated or cooled, to maintain a desired temperature of adhesive 116 and or sheet 102, 104. Sheet 102 or 104, after being printed with adhesive 116, may be cooled prior to rolling for storage, by passing sheet 102 or 104 over a cold plate, or passed in the path of forced air, or by using other known means. In an embodiment, a rolled sheet 102 or 104, having been printed with adhesive 116, is not used for a period of time, for example one to ten hours, and advantageously for a period of five hours, before being adhered to form a precursor to sleeve 100. A lining sheet or release layer, not shown, may be rolled together with sheet 102, 104, to prevent adhesive 116 from adhering to an adjacent rolled layer of sheet 102, 104. Rollers 204, 206, 208, or 214 may be made from any suitable material, including metal, natural material, polymeric material, or resilient material.
Referring now to
In
Cutting grooves 316 are advantageously provided within surface 314, to preserve and guide a cutting implement. Grooves 316 are oriented to have a matching configuration with respect to lengths of adhesive 116 within web 130. Accordingly, once web 130 and adhesive 116 is aligned over grooves 316, a cutting implement may be drawn through web 130 to separate individually adhered sleeves, as shown in
More particularly, sleeves 100 comprise successive sections of sheets 102, 104 bound along opposing peripheral side edges with a seam 106, 108 joined by adhesive 116. In one embodiment, sleeve 102, 104 edges perpendicular to the opposed peripheral side edges, forming top end 146 and bottom end 148 of sleeve 100, are not adhered, and may therefore be moved apart, expanding adhered sheet 102, 104 sections to form openings in top end 146 and bottom end 148, into inner containment area 110. For containing plants or flowers, one or more stems are inserted into sleeve 100 so that the stems may project through the open bottom end 148, and the flowering or enlarged end of the plant may reside within, and or project from open top end 146. In this manner, the plants may be assembled and maintained in a mutually conforming configuration, or bunched, and are thereby protected from environmental conditions and or mutual abrasion due to vibration.
In another embodiment, top end 146 or bottom end 148 may be provided with length of adhesive, wherein either top ends 146 or bottom ends 148 of sheets 102, 104 are adhered using the apparatus and methods described herein. As such, a fillable cone is formed. In yet another embodiment, top and bottom ends 146, 148 of sheets 102, 104 are adhered as described herein, however material to be contained is placed between sheets 102, 104, advantageously before sheets 102, 104 are adhered along all sides. Alternatively, material to be contained may be placed within a sealed sleeve 100 by leaving a gap or forming an opening in one or both of sheets 102, 104, for example by injection, and later optionally sealing the opening.
In one embodiment, shown in
Cutting blades 320 may be formed with any suitable material of sufficient strength and durability, for example, a metal, ceramic, or plastic material, including as examples stainless steel, carbon steel, laminate, and titanium. It should be understood that although two cutting blades 320 are shown in
Cutting blades 320 may be manually raised and lowered, for example through use of handle 322. In the embodiment shown in
It should be understood that other methods of cutting individual sleeves from web 130 may be used, including reciprocating blades, rotary blades, cutting drums, and other methods known in the art, or hereinafter developed.
Cutting device 300 may advantageously be provided on or incorporated within a supporting cart or table 318. Apparatus (not shown) operative to collate cut sleeves, as well as to bale or package cut sleeves, for example within corrugated cardboard boxes, may be provided at a location downstream from cutting grooves 316. Alternatively, cut sleeves may be collected and or packaged manually.
In an alternative embodiment of the disclosure, cutting device 300 may use laser light to cut web 130, the laser light substituting for blades 320. A digital cutting machine incorporating laser light cutting may advantageously be combined with other aspects of the disclosure, including for example roll feed from supply roll 118, advantageously coordinating laser cutting with any or all of motor 304, feed roller 302, computer 306, sensor 308, and feed guide 312.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention.
All references cited herein are expressly incorporated by reference in their entirety. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. There are many different features to the present invention and it is contemplated that these features may be used together or separately. Thus, the invention should not be limited to any particular combination of features or to a particular application of the invention. Further, it should be understood that variations and modifications within the spirit and scope of the invention might occur to those skilled in the art to which the invention pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present invention are to be included as further embodiments of the present invention.
