Patent Grant
11401125
The present invention generally relates to material roll dispensing assemblies, methods of manufacturing same and methods of use; and more particularly to dispensing assemblies that position dispensing materials for easy grasping, including dispensing materials such as aluminum foil, wax paper, parchment paper, wrapping paper and the like that are rolled and/or spooled onto a tube or core.
Barrier wrappings, packaging wrap that is spooled onto a tube or core, typically composed of cardboard or other fiber materials, have a plethora of applications, including food coverings and other wrapping materials which cover, wrap, contain, store or preserve goods. These wrapping materials include, for non-limiting example, aluminum foil, wax paper, freezer paper, parchment paper, deli wrap, paperboard (cardboard) produced from chemical pulp produced in the Kraft process (Kraft paper), as well as other similar materials in both gauge and weight, which are spooled onto a tube or core in a similar manner. Such wrapping materials are arranged on the tube or core and as the user utilizes the wrapping material, the material is unrolled or unspooled and cut along a metal cutter strip. When the section is removed or cut from the wrapping material spool the remaining wrapping material edge drops down to the bottom of the box containing the wrapping material spool. As a result, the wrapping material becomes crinkled and disheveled, and the user must struggle to find and grab the material edge with his/her fingers. Often, the user's fingers or hands inadvertently contact the metal cutter strip, which causes scratching, abrasions and/or cuts on the fingers or hands. This problem is especially prevalent with aluminum foils and some papers where instances of both paper cuts to fingers, from the sharp edge of a foil or paper sheet as well as abrasions to the back of the hand from the metal cutter, frequently occur. Heretofore disclosed and/or utilized tensioner and/or barrier wrapper devices fail to provide a cost-effective solution to this everyday problem experienced by consumers.
Examples of various tensioner and/or barrier wrapper devices are set forth summarily below:
U.S. Pat. No. 2,276,590 to Petskeyes et al. discloses a paper holding and tensioning means generally constructed having a holding bail which cooperates with an article elevator to hold one end of a piece of wrapping paper while the elevator is reciprocated in wrapping operation. The holding means is arranged and constructed to release and reengage the wrapping paper at the completion of the reciprocation or elevating cycle of the elevator. Paper on an article is tensioned while being wrapped or substantially wrapped as a result of the reciprocating movement of the elevator.
U.S. Pat. No. 2,326,220 to Henning et al. discloses a tensioning apparatus for maintaining the desired tension in an element being applied to a second element. In accordance with one embodiment of the invention, an apparatus is provided for maintaining constant tension in a web being wound from a pad or roll mounted concentrically of a constantly advancing cable onto said cable. The constant tension is effected by utilizing the speed-torque characteristic of an induction type torque motor to apply, through a planetary differential mechanism, a torque tending to rotate a spider on which the feed pad or roll is mounted in a direction opposite to the direction in which the motor which supplies power to advance the cable also tends to drive the pad through the differential mechanism.
U.S. Pat. No. 4,231,560 to Stohlquist discloses a tension controlled apparatus for feeding web material from a supply source to processing equipment of the type that exerts a pulling force on the web. The apparatus includes a drive wheel and a driven wheel mounted for rotation about an axis parallel to the drive wheel and for shifting movement toward and away from the drive wheel. A web feed roller is connected coaxially to the driven wheel for rotation thereby. Means are provided for guiding the web material to cause it to wrap partway around the web feed roller as it passes from the supply source to the processing equipment. The web material exits from the web feed roller in an exiting direction having a substantial component in a direction to shift the driven wheel into driving engagement with the drive wheel in response to tension applied by the processing machine on the web of material exiting from the feed roller.
U.S. Pat. No. 3,870,212 to Polk discloses a dispenser-holder of simple construction for foils which come packaged in a box of substantially square cross-section. The dispenser-holder is adapted to receive and hold the box. The holder has a rigid ledge with a cutting edge so that the foil may be unrolled from the box and cut to the desired size with one hand. After cutting, a protruding edge of the foil remains on the roll, and extends over the rigid ledge so that the next sheet is readily obtained therefrom.
U.S. Pat. No. 6,716,317 to Gafner et al. discloses a tension decurler for web material. The material is decurled by controlling web tension as well as the angle of wrap on a decurler roll and a cooperating pivot roll, all without affecting web tension in the downstream web converting process. An upstream brake roll and a downstream pull roll control web tension within the decurler apparatus and independent decurler rolls are provided for removing up-curl and down-curl.
U.S. Pat. No. 8,733,218 to Hansen et al. discloses an apparatus for dispensing sheet material from a sheet material dispenser. Dispenser embodiments include drive and tension rollers supported within a housing forming a nip therebetween. Pulling of sheet material through the nip and against the drive roller rotates the drive roller. Dispenser embodiments may include a cutting mechanism powered by drive roller rotation with an improved carrier-supported blade permitting highly-efficient dispenser operation. Dispenser embodiments may include a sheet material tail length adjuster which permits the attendant to shorten or lengthen the tail length extending away from the dispenser. Dispenser embodiments may further include a sheet material conservation feature which imposes a delay between dispense cycles, encouraging use of a single sheet of material and discouraging sheet material waste.
U.S. Pat. No. 9,284,085 to Pace discloses a device for holding and handling a roll of wrapping material. The device has a tube handle, a tube extension adjustably connected to the tube handle, a top-end cap on the tube handle, a bottom end cap on the tube extension, and a tensioning means, wherein the bottom end cap releasably holds the roll of wrapping material on the tube extension against the tensioning means. The tensioning means is adjustable while the device is in use, applying wrapping material to an item to be wrapped.
U.S. Patent Application No. 2008/0127791 to Benedetti et al. discloses a film dispenser comprising a housing adapted to receive and hold a roll of film. The dispenser has a dispensing opening through which a layer of the film may pass. In addition, the dispenser is provided with a movable cutting unit having a blade mounted therein. The dispenser further comprises a cutting channel-shaped and positioned to receive the blade. It is preferred that the dispenser has means to maintain tension in the film as it is cut.
U.S. Patent Application No. 2011/0147254 to Pierron discloses a foil packaging for soft food masses. A container film shape is formed into the shape of an open container and a lidding film is sealed onto the container film closing the container with a lid. The container film and lidding film are multi-layered. One of the layers is an aluminum foil, which is optionally pre-lacquered and if desired printed on and lacquer-coated on one side. The aluminum foil of the container film and the lidding film is coated with a polymer, and a hot-sealing lacquer is provided on the polymer layer of the container film. The polymer, optionally coated with hot-sealing lacquer, may be situated on the sealing side of the aluminum foil of the lidding film, and a corrosion protection layer, if desired in the form of a polymer, is provided on the other side of the aluminum foil. Alternatively, the aluminum foil of the lidding film may be coated on the sealing side with hot-sealing lacquer and the polymer layer, optionally coated with hot-sealing lacquer, is situated on the other side of the aluminum foil.
Foreign Patent Application No. WO/2003/099693 to Benedetti et al. discloses a film dispenser (10) comprising a housing (12) adapted to receive and hold a roll of film (14) and having a dispensing opening (50) through which a layer of the film may pass. The dispenser is provided with a movable cutting unit having a blade (30) mounted therein. The dispenser (10) further comprises a cutting channel (26) shaped and positioned to receive said blade (30). It is preferred that the dispenser (10) have means to maintain tension in the film as it is cut.
Foreign Patent Application No. EP0358477 to Asbury et al. discloses a tape dispenser including an automatic tension control mechanism and provision for auto-splicing the tail portion of one tape to the leading portion of another. The tensioning mechanism includes a brake band that extends at least partially about a tape spindle and is tensioned in response to the position of a spring-biased tensioning roller over which the tape is routed.
Internet Publication “Aluminum Foil Dispenser” found at http://www.organizeit.com/aluminum-foil-dispenser.asp discloses an aluminum foil dispenser having a magnetic lid and slide cutter that allows the user to cut a desired portion of aluminum foil. The dispenser can be refilled with store-bought rolls of aluminum foil or wax paper for reuse. Perforated end tabs or end locks located on end walls of dispenser boxes have been provided in the art to hold rolls within the box, such as those sold by Reynolds wrap. These end locks provide perforated tabs that are generally pressed from the exterior of the box, and face within the interior to hold a dispenser roll in place so that it does not pull out from the box during use. Various end locks and improvements thereon have been provided. For example: U.S. Pat. No. 10,202,255 to Sabol discloses a dispensing roll lock device having at least one rod and end caps designed to attach to ends of the rods, wherein the rod is sized to be inserted through end locks of the sides of the dispensing box and through the roll in the box to secure the rod in the box. Other dispenser adapters have been provided in the art to address securement of the roll in the dispenser, as well as increase dispensing capability. For example: U.S. Pat. No. 4,840,299 to Burns discloses a dispenser adapter to improve the dispensing of thin webs from rolls of material contained in conventional dispensing boxes is specially configured to provide its benefits of anti-recoil and risk free tearing to a wide range of dispensing boxes via an adapter particularly suited to being retrofitted to commercially available dispensing boxes, including a pressure plate, loaded by one or more metal springs. U.S. Pat. No. 6,725,753 to Bell discloses a dispenser for holding and dispensing rolls of flexible material including mounts for holding one or more rolls of flexible material, with the front wall of the box having a blade fixedly mounted thereto and is recessed within a pressure plate contactable against a portion of the sheet to be removed and held on an anvil stop surface formed by roughed edges. US Patent App. Pub. No. 20110108599 to Nottingham discloses a dispenser that includes a housing configured to receive and hold a roll of film. The housing has a dispensing opening through which a section of film can pass.
Despite the aforementioned tensioner and/or barrier wrapper devices, problems in barrier wrapper roll edge tension and deformation still exist. For example, current tensioner and/or barrier wrapper devices do not provide a mechanical device that provides a cost-effective way to prevent the roll edge of a barrier wrapper roll, such as aluminum foil, wax paper, parchment paper, etc., from falling below the roll, thereby causing it to deform and become difficult to grasp when used.
Accordingly, there exists a need in the art for a material roll dispenser systems and assemblies that include a device that maintains the position of the material edge at or near the top of the box side wall so that an end user can readily grab the material end without having to reach within the box and risk disheveling the wrapping material and/or injuring his/her fingers or hands.
The present invention provides methods and systems of manufacture of a dispensing box with a roll tensioner for housing a material roll and maintaining a material cutting edge during use, method of use, and dispensing box with roll tensioner system. The methods and systems provide a wrapping material roll tensioner for barrier wrappings or packaging wrap that is spooled onto a tube or core, typically composed of cardboard, a fibrous material, and/or a polymeric material. The subject roll tensioner provides an economical, novel approach that addresses problems in the art associated with slippage and maintenance of the cut edge of a wrapping material roll. Providing an improvement in the packaging wrap art, the roll tensioner is directed to a device that maintains the cut area of the wrapping upward and away from the front wall of the box, thereby creating a gap between the front wall of the box and the roll of wrapping material, or in some instances, above the metal cutter strip, thereby preventing the remaining wrapping end from dropping down to the bottom of the box after each use of the wrapping material. Prevention of the wrapping material edge from dropping down to the bottom of the box results in an easily accessible edge for the user to grab without needing to search around the bottom of the box, struggling with wrapping material. Wrapping material is readily accessed and advanced, and cuts and scrapes to the hand and fingers are mitigated.
The term wrapping material as used herein refers generally, but non-limiting to wrapping paper, aluminum foil, wax paper, freezer paper, parchment paper, deli wrap, paperboard (cardboard) produced from chemical pulp produced in process such as the Kraft process (for example sold under the trade name Kraft paper), butcher paper, non-stick coated materials, as well as other similar materials in both gauge and weight.
The term “slit” as used herein generally refers to a long, narrow cut or opening, line or incision. A slit can also refer to a “kiss cut”, “cut-score”, “slit-score”, “score” or a combination thereof.
The term “slot” as used herein generally refers to a narrow passage, opening or gap.
The terms “kiss cut”, “cut-score”, “slit-score” or “score” as used herein generally refers to a partial depth cut that contains a connection along a slit or cut/incision preventing the separation of a slit or incision until a force is applied. A kiss cut, cut score or slit score does not generally penetrate through the material being cut, but allows for breakaway.
The terms “connection points” or “nicks” as used herein generally refers to a link or links designed to bind or bridge one die cut part or side to an adjoining part or side that assist in holding the kiss cut/cut/slit/incision together as needed depending on slit length, resulting in a small uncut connection between the cut material (e.g. in this case a cardboard box).
The terms “hinge”, “fold”, “fold line”, “bend elbow”, “fold point”, “crease” or “elbow” refer generally to a hinge or fold point where two sections bend at an angle, engaging in relation to one another, such as a 90 degree bend, for non-limiting example.
In a first embodiment, there is provided a method of manufacture of a dispensing box with a roll tensioner for housing a material roll and maintaining a material cutting edge during use, the dispensing box comprising a front wall with a top edge having a cutter strip and a bottom edge abutting a bottom wall, back wall, top wall with closure flap and end walls adapted to form an interior for housing the material roll. In Step 1, a tensioner slide assembly is formed, integrated in the front wall of the dispensing box which is in a flat configuration. The tensioner slide assembly comprises (i) two opposing parallel slits extending on the front wall of the dispensing box, (ii) two opposing parallel slots adjoining the slits extending through the front wall of the dispensing box, the parallel slots sharing a primary assembly side wall with the parallel slits; and (iii) two opposing parallel locking flaps integrated with the parallel slots sharing a secondary assembly wall side with the parallel slots. The locking flaps have flap top and flap bottom walls that are adapted to break-away terminating at a fold line, the locking flaps being in a stored position prior to use and adapted to open to a locking position. The flap top and flap bottom walls break-away when force is applied, and the locking flaps are then appointed to be bent outward along the fold line when the dispensing box is configured for use by an end-user. Preferably the parallel slits include slits with nicks/kiss cuts/kiss cuts that break-away to open the slit when the parallel slits are ready for the roll tensioner to move therein to its second position for use. Additionally, preferably, the locking flap's top and bottom walls are slits with nicks/kiss cuts/kiss cuts that break-away when the locking flaps are pushed outward, separating to break-away from the inside of the front wall and pressed outward to bend at the bend wall at the bend, crease, fold to facilitate bend without tearing. In Step 2, preferably the cutter strip is affixed to the top edge of the front wall of the dispensing box. Next, in Step 3, a roll tensioner is inserted into the parallel slits. This is preferably done using a mandrel and saddle assembly as described hereinafter. The roll tensioner comprises distal and proximal end sections separated by a spring back/reversion section, the proximal end section having opposing bottom tabs and a center bottom tab. The distal end is adapted to extend downward via the spring back/reversion section when a force is applied. Opposing bottom tabs of the roll tensioner are inserted through the parallel slots of the tension slide assembly. The roll tensioner is adapted to rest in this position, referred to as a “first position”, during non-use and is appointed to be slid down the parallel slots into the parallel slits, referred to as a “second position”, when later engaged for use. In Step 4, the dispensing box is folded at bend or fold lines between the front wall and the bottom wall and the back wall and the top wall with closure flap. Pressure is applied to the closure flap and adhering the closure flap to the front wall by way of glue spots applied below the cutter strip. It is noted that glue spots may be applied prior to the cutter strip on the front wall. The glue spots are adapted to adhere the closure flap to the front wall. In Step 5, the material roll is inserted into the interior of the dispensing box. The roll tensioner rests in the interior of the dispensing box proximal to the top edge of the front wall in the parallel slots with its distal end curving over the material roll laying proximal to the interior of the top wall of the dispensing box. Next, at Step 6, the end walls of the dispensing box are closed and the dispensing box readied for shipment. The roll tensioner is adapted to rest in the first position until the roll tensioner is engaged to move into the second position during use. When in the second position the roll tensioner's distal end section is adapted to rest against the wrapping material proximal to the wrapping material cut edge to retain the wrapping material cut edge in an upward, substantially parallel position to the interior front wall of the wrapping material box for easy grasping of the wrapping material cut edge. It is noted that these steps are presented in a preferred order, but the order may be re-arranged to suit manufacturing systems and methods without departing from the scope of the invention.
In another aspect of the invention, there is provided a method of manufacture of a dispensing box with a roll tensioner for housing a material roll and maintaining a material cutting edge during use, the dispensing box comprising a front wall with a top edge having a cutter strip and a bottom edge abutting a bottom wall, back wall, top wall with closure flap and end walls adapted to form an interior for housing the material roll. The method comprising the step of forming a tensioner slide assembly integrated in the front wall of the dispensing box, the tensioner slide assembly comprising: (i) two opposing parallel slits extending on the front wall of the dispensing box; (ii) two opposing parallel slots adjoining the slits extending through the front wall of the dispensing box, the parallel slots sharing a primary assembly side wall with the parallel slits; (iii) two opposing parallel locking flaps integrated with the parallel slots sharing a secondary assembly wall side with the parallel slots, the locking flaps having flap top and flap bottom walls that are adapted to break-away terminating at a fold line, the locking flaps being in a stored position prior to use and adapted to open to a locking position when the flap top and flap bottom walls break-away upon application of force, bending the locking flaps outward along the fold line when the dispensing box is configured for use by an end-user. Next, the method includes the step of inserting a roll tensioner into the parallel slits, the roll tensioner comprising distal and proximal end sections separated by a spring back/reversion section, the proximal end section having opposing bottom tabs and a center bottom tab and the distal end being adapted to extend downward via the spring back/reversion section when a force is applied. The opposing bottom tabs of the roll tensioner are inserted through the parallel slots, wherein the roll tensioner is adapted to rest in the first position during non-use and to be slid down the parallel slots into the parallel slits into the second position when later engaged for use. The roll tensioner is adapted to rest in the first position until the roll tensioner is engaged to move into the second position during use, when in the second position the roll tensioner's distal end section is adapted to rest against the wrapping material proximal to the wrapping material cut edge to retain the wrapping material cut edge in an upward, substantially parallel position to the interior front wall of the wrapping material box for easy grasping of the wrapping material cut edge.
Another aspect of the invention provides a dispensing box with a roll tensioner system for housing a material roll and maintaining a material cutting edge during use, the dispensing box comprising a front wall with a top edge having a cutter strip and a bottom edge abutting a bottom wall, back wall, top wall with closure flap and end walls adapted to form an interior for housing the material roll, comprising a tensioner slide assembly adapted to receive the roll tensioner. The tensioner slide assembly is integrated in the front wall of the dispensing box in a flat configuration. The tensioner slide assembly is constructed having two opposing parallel slits located on the front wall of the dispensing box. The tensioner slide assembly includes two opposing parallel slots adjoining the slits extending through the front wall of the dispensing box, the parallel slots sharing a primary assembly side wall with the parallel slits. Two opposing parallel locking flaps are integrated with the parallel slots sharing a secondary assembly wall side with the parallel slots. The locking flaps have flap top and flap bottom walls that are adapted to break-away terminating at a fold line. The locking flaps being in a stored position prior to use and adapted to open to a locking position when the flap top and flap bottom walls break-away upon application of force, bending the locking flaps outward along the fold line when the dispensing box is configured for use by an end-user.
In another aspect of the invention there is provided a method of using a dispensing box with a roll tensioner system for housing a material roll and maintaining a material cutting edge during use, the dispensing box comprising a front wall with a top edge having a cutter strip and a bottom edge abutting a bottom wall, back wall, top wall with closure flap and end walls adapted to form an interior for housing the material roll. The method comprises the steps of: (a) opening a dispensing box to expose the material roll and the roll tensioner, the roll tensioner comprising distal and proximal end sections separated by a spring back/reversion section, the proximal end section having opposing bottom tabs and a center bottom tab and the distal end being adapted to extend downward via the spring back/reversion section when a force is applied; (b) preparing the roll tensioner for use by sliding the roll tensioner resting in a first position in a tensioner slide assembly to a second position, the tensioner slide assembly integrated in the front wall of the dispensing box, comprising: (i) two opposing parallel slits extending on the front wall of the dispensing box; (ii) two opposing parallel slots adjoining the slits extending through the front wall of the dispensing box, the parallel slots sharing a primary assembly side wall with the parallel slits; (iii) two opposing parallel locking flaps integrated with the parallel slots sharing a secondary assembly wall side with the parallel slots, the locking flaps having flap top and flap bottom walls that are adapted to break-away terminating at a fold line, the locking flaps being in a stored position prior to use and adapted to open to a locking position when the flap top and flap bottom walls break-away upon application of force, bending the locking flaps outward along the fold line when the dispensing box is configured for use by an end-user; (c) breaking away or separating the parallel slits and sliding the roll tensioner from the first position downward from the parallel slot to the second position in the parallel slits so that the opposing bottom tabs of the roll tensioner abuts a bottom end point of the parallel slits; and (d) activating the locking flaps by opening the locking flaps by breaking away the flap top and flap bottom walls bending at the bend wall to the locking position. Whereby the roll tensioner is adapted to rest in the first position until the roll tensioner is engaged to move into the second position during use, when in the second position the roll tensioner's distal end section is adapted to rest against the wrapping material proximal to the wrapping material cut edge to retain the wrapping material cut edge in an upward, substantially parallel position to an interior front wall of the wrapping material box for easy grasping of the wrapping material cutting edge.
The invention will be more fully understood and further advantages will become apparent when reference is had to the following detailed description of the preferred embodiments of the invention and the accompanying drawings, in which:
The best mode for carrying out the present disclosure is presented in terms of the embodiments herein. The embodiments described herein comprise detail used for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated, as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. The headings utilized within the description are for convenience only and have no legal or limiting effect.
The subject invention provides a roll tensioner device that maintains the cut area of the wrapping parallel with, or in some instances, above the metal cutter strip. The subject roll tensioner prevents the remaining wrapping end from dropping down to the bottom of the box after each use of the wrapping material. By preventing the wrapping material edge from dropping down to the bottom of the box, the user no longer needs to search around the bottom of the box struggling to grab the edge of the wrapping. Cuts, scrapes and abrasions to the hand and fingers are thereby prevented, and the integrity of the wrapping material is maintained. While preventing injury to the hand/fingers and maintaining the integrity of the wrapping material, the subject roll tensioner does not interfere or obstruct a normal customer use in any way. The roll tensioner is appointed to be installed to the inside/center front wall of the box in an inconspicuous position. This allows the end-user to effortlessly grip onto the wrapping, regardless of left or right-handed use. A space is created between the wrapping material and the metal cutter that allows the user to hold onto the wrapping and pull out the desired length. Once the desired length is removed, the wrapping can be cut in the usual way, and the wrapping edge will stay held up near the cutter and ready for the next use.
Packaging of the roll tensioners may be accomplished by randomly placing loose parts into a cardboard box for bulk shipments. Parts may be easily removed from the box as needed using this method. Alternately, the roll tensioners, while still attached to the main carrier, may be spooled onto a core (into a roll shape) for automated or semi-automated dispensing. Either way, boxes may be shrink-wrapped, placed on a standard pallet and bulk shipped to the intended destination via standard shipping methods.
The roll tensioner can be installed in at least two different ways, depending on the desired distribution method. Automated manufacturing methods can vary; however, a first option entails installing the part mechanically, from a spool, or individual stacked parts loaded in a hopper or magazine type dispenser, into a guided mandrel or similar device, in an automated way, at the time of wrapping material manufacture. Installation should occur prior to placing the wrapping roll into the packaging box. This will allow automation which is critical to any fast-pace modern manufacturing line. The roll tensioner can be attached to the inside of the box (first having the backer removed from the adhesive tape already on the part); the roll tensioner is mechanically bent over as the wrapping roll is placed into the box, setting the tensioner into the correct position. The box would then be closed and sealed as in a conventional manner. No changes would be required to current shipping procedures. The second method, applicable when wrapping material is sold at retail or directly to an end-user, provides for the end-user to open the box and remove the wrapping roll. Alternatively, instead of removing the wrapping/material roll, the front wall of the box may be bent out via center front to make room to install on inside front wall. The box front wall will naturally “give” providing the needed space. The end-user then peels off the adhesive backer from the roll tensioner with his/her fingers and places the adhesive (sticky side) portion of the tensioner firmly against the inside, front and center of the box. At this point, the top of the tensioner protrudes up beyond the top inside edge of the box (above the metal cutter strip). Taking the wrapping roll in hand, the end-user pushes the wrapping roll against the tensioner as he/she places the roll into the box making sure the roll tensioner gently bends over into an upside-down “u” shape (see
Costs associated with the subject roll tensioner generally depend on the method of manufacture, the number of parts per foot, rate (speed) and fluctuating raw material prices. The material used to form the roll tensioner may be FDA compliant if required for food product use. Some methods can reuse a percentage of recycled material in the raw material mixture which will affect the material costs as well. If tooling already exists for the shape required, there would be less up-front investment cost. This translates into less risk. A new product idea could be brought to market with low risk and rapidly due to an inexpensive part cost and low upfront investment cost. This would be a low-cost improvement to packaging that adds value and ease of use. The roll tensioner would be a desirable benefit to the end-user or customer. The roll tensioner would be a marketing option and sales tool that would provide product differentiation, and unique packaging that stand out with respect to other wrapping material containers using standard packaging. There is also a safety concern for wrapping material manufacturers to consider, as mentioned above. While using conventional wrapping packages, cuts, scrapes or abrasions to the hands and fingers are significantly reduced, since the user no longer needs to search around the bottom of the box, struggling to grab the edge of the wrapping material. These structural and functional features and the advantages they afford provide valuable marketing themes for the manufacturer.
The conventional box 12 (frequently household cardboard cutter box style dispensers) typically contains perforated tabs 12′ on each end that are appointed to be dented inward by the end-user to retain the wrapping material roll within the box 12. Tabs 12′ are designed to prevent the roll from pulling out of the box, but the tabs 12′ do not prevent the material roll from sliding to and fro in the box. Nor do tabs 12′ control the rolling of the material roll. Because the standard box tabs 12′ push in from the bottom (e.g. perforated “U” shape tab), not the top, they “give” and allow the roll to slide back and forth inside the box. This problem becomes more evident as the roll diminishes in diameter. The original problem attending maintenance of an easily accessible cutting edge of the wrapping material still exists whether tabs 12′ are used or not. The tabs 12′ do not prevent the wrapping material roll from sliding to the back of the box, as shown for example in
These tabs are typically in conventional household cardboard cutter box style dispensers, while commercial cardboard cutter box style dispensers are generally more sophisticated. As an example See: https://www.webstaurantstore.com/choice-18-x-500-food-service-standard-aluminum-foil-roll/12218X5ST.html. Typically, a commercial cardboard cutter box style packaging is marketed toward commercial kitchens and the wrapping material roll in this example is positioned in the box opposite of household boxes. This would appear to still have a problem, just in the opposite direction as the roll diminishes in diameter. So, the subject tensioner could be installed on the back wall if the wrapping is installed in the opposite position.
This maintains the cut area/wrapping material end 34 of the wrapping material 31 parallel with, or in some instances, above the metal cutter strip 33. The roll tensioner 21 will not allow the remaining wrapping end 34 to drop down to the bottom of the box 42 after each use. By preventing the wrapper end 34 from dropping down to the bottom of the box 42 the user no longer will need to search around the bottom of the box 42 struggling to grab the edge of the wrapping material end 34, thereby avoiding cuts, scrapes and abrasions to the hand and fingers.
Commercial wrapping or foil dispensers (permanent dispensers) do exist and are a separately purchased item from the conventional cardboard household consumer packaging. Examples of permanent dispensers can be found for example at:
Preferably, the roll tensioner 221 is composed of a thin, flexible clear material, such as Polyvinyl Chloride (PVC), and has a thickness of about 15 mm or 0.015 inches. Roll tensioner 221 is constructed having distal and proximal end sections, 210 and 211, separated by a spring back/reversion section 212, and formed having a first side 213 and a second side 214. A thin, flexible, pressure-sensitive, permanent adhesive tape 215 with a removable backer or tab 216 (see
The static tension is a result of the roll of wrapping material—the more wrapping material loaded on the roll, the greater in diameter the roll is, and therefore the greater the static tension as the force pressing against the distal end 410 is greater causing the spring back reversion section 412 to be at a greater flex angle. Conversely, as the wrapping material is used off the roll and the wrapping material roll becomes reduced in diameter, the force against the distal end 410 decreases and the static tension of the spring back reversion section 412 results in a lesser flex angle. Preferably, the spring back reversion section 412 is capable of reversion and flexing at an angle ⊖ ranging between about 5°-85° from a vertical plane, herein shown at 450 (the horizontal plane is shown herein at 451). When the wrapping roll has a larger diameter dimension, owing to a large amount of wrapping material spooled thereon, the force against the distal section 410 is great and flex angle of the spring back reversion section 412 is less, for example, ⊖=˜5° from the vertical plane 450 and the front wall of the wrapping material box, such as shown at 452. As the wrapping material is used, the wrapping roll diameter decreases, and the force against the distal section 410 decreases, along with the flex angle of the spring back reversion section 412 angle becoming greater. For example, see ⊖=˜5°→⊖=˜45°→⊖=˜65°→⊖=˜75°→⊖=˜85° (as when the roll is nearly empty of wrapping material), shown at 452, 453, 454, 455, and 456, respectively.
The term “reversion” as used herein refers to a dimensional change in plastics products or viscoelastic materials as a consequence of “material memory”. Original formed shapes of plastic products are “memorized” so that if it is subsequently distorted, it will return to its original shape. The stress/strain response for PVC (like other thermoplastic materials) is dependent on both time and temperature. As a plastic material is applied with a constant static load, there is created an immediate elastic response and the shape is fully recovered immediately when the load is removed. Additionally, a slower deformation continues while the load is applied, until rupture occurs. This is referred to as creep. Removal of the load before failure results in recovery of the original dimensions gradually over time. Temperature also influences the rate of creep and recovery. Creep rates typically increase at higher temperatures. Preferably, the roll tensioner has a “T” shape; however, a rectangular shape provides another preferred shape embodiment. Other shapes that include the same structural and functional parameters are contemplated.
Preferably, the roll tensioner 221 is constructed with a smooth surface and a low coefficient of friction material, such as PVC. PVC generally shows excellent performance under abrasive conditions. The main properties contributing to this are the low elastic modulus and coefficient of friction. This enables the material to “give” and particles tend to skid rather than abrade the surface. Materials for constructing the subject tensioner include low friction materials having flexibility properties that allow flexure of the tensioner and resiliency that provide for spring back without breakage. Representative materials include materials generally having a low coefficient of friction, such as for non-limiting example, Teflon, Nylon and Polyurethanes. The thickness of the tensioner is also a consideration when selecting materials used to construct the subject tensioner. The material forming the tensioner's spring back/reversion section should demonstrate adequate flexibility to deform elastically and return to its original shape when the applied stress (wrapping material) is removed. “Stress” is a measurement in PSI of the amount of force per area the tensioner material suffers when bent or pulled. It is also noted that the material construction of the box wherein the tensioner is mounted can have an effect on the flexibility and/or thickness of the tensioner. In cases where the box is composed of cardboard, the walls of the box may give to a degree so that the stress on the tensioner is dissipated proportionally. When the box is made of a rigid material, such as plastic or metal, the walls of the box are less likely to give and the stress on the tensioner will be greater. Thus, the tensioner material, length and/or thickness may be adjusted to counteract the material of which the box is composed.
Preferably, the subject tensioner is composed of PVC because it exhibits high hardness and mechanical properties especially well suited for its construction. The mechanical properties of rigid PVC (uPVC) are very good; the elastic modulus can reach 1500-3,000 MPa. Materials having properties similar to the empirically preferred PVC, are excellent candidates for construction of the subject tensioner. A table generally comparing mechanical properties of other materials to PVC is set forth below.
Found at:
The preferred range for the value of the dynamic coefficient of friction is between 0.10 and 0.30. Polyurethane has more than twice the coefficient of friction of the other materials; therefore its use in the subject tensioner spring back reversion section is limited. Relative to the Flexural Modulus, a material with at least 350,000 PSI is preferable. The flexural strength of PTFE (Teflon) ranges from 72,000 to 190,000 PSI depending on the type of fill used but is still half of the comparable values of the other contenders. Found at http://catalog.wshampshire.com/Asset/psg_teflon_ptfe.pdf. The subject tensioner is preferably composed of a PVC material or other materials having comparable properties to PVC, as the collective presence of these properties is especially well suited for construction and prolonged use of the tensioner.
Economics, however, are a major factor, and PVC's performance in the context of wear rate/unit cost is excellent. The Low Coefficient of Friction works well in this application so that the wrapping material slides effortlessly and without any hang-ups over the roll tensioner's surface, even under load. The pressure-sensitive adhesive backer 216 applied to the roll tensioner is of an adequate strength to permanently attach to the box and hold the roll tensioner 221 to the box while bent into the fully installed position and remain attached for continuous use as roll material is removed and the diameter of the roll material is reduced or replaced.
Referring to
Referring to
Referring to
Roll tensioner 721 is attached within the wrapping material box 742 acting as packaging, and as a dispenser for a wrapping material roll having a wrapping material 731 spooled on a tube (or core) 731′. The box 742/packaging/dispenser, preferably contains an attached metal strip 733 (metal cutter strip) with a jagged edge yielding the wrapping material end 734. The conventional household box 742 may also contain perforated tabs 742′ on each end of the box 742 which can be used by the end-user, to retain the wrapping material roll within the box 742.
In this embodiment, roll tensioner 721 has no attachment means, i.e. no adhesive tape, but does require two vertical slots 781 in either the front or rear vertical wall of box, herein shown in the front vertical wall 788 (see
The roll tensioner 721 is mechanically bent over as shown at 721′ owing to the spring back/reversion section 712 as the wrapping material 731 roll is placed into the box 742, setting the roll tensioner 721 into the correct position so that the wrapping material end 734 rests upward and away from the front box 742 wall 788, thereby creating a gap between the wall 788 and the roll of wrapping material end 734. This makes it easier to grab the wrapping material end 734.
Alternative features of the subject invention are contemplated and non-limiting including, for example: the roll tensioner may be constructed in a plethora of shapes and sizes, and from a plethora of materials and colors; etc. These features are contemplated in combination with the main embodiments shown in the Figures.
The locking flaps 940 have a flap top wall 944 and flap bottom wall 945 that terminate at fold line 942. Flap top wall 944 and flap bottom wall 945 are adapted to break-away when a pressing force is applied later by an end user. Preferably, flap top and bottom walls, 944, 945, are formed as narrow cuts having one or more kiss cuts, cut-scores, nicks or connection points (not shown, but similar to cuts 922) adapted to breakaway when force, such as pressing by an end-user/user, is applied. When the locking flaps 940 are pushed outward, separating to break-away from the inside of the front wall 913 and pressed outward to bend at the bend wall/fold line 942 bending is facilitated without tearing. Locking flaps 940 are in the stored position (as shown, for example in
In this embodiment of the roll tensioner 950 does not include adhesive tape for attachment to secure the tensioner 950 in the box, but instead the tension slide assembly 920 is utilized. The opposing bottom tabs 951 of the roll tensioner 950 flex and weave through parallel slots 930, from inside 909b of box 912, with locking flaps 940 to secure the tensioner 950 in place during use. The tensioner 950 is held correctly in position as it is slid downward from parallel slots 930 into parallel slits 921 and locked into place via engagement of locking flaps 940 (see
When inserted during assembly the opposing bottom tabs 951 are mounted in parallel slots 930 parallel to and abutting locking flaps 940 which are disengaged or still remaining unfolded on the box top wall 913. When the box 912 is formed and the roll inserted, the tensioner extends and bends to rests over the roll in the interior of the box until use (see
In Step 4, the dispensing box is folded at bend or fold lines between the front wall and the bottom wall and the back wall and the top wall with closure flap. Pressure is applied to the closure flap and adhering the closure flap to the front wall by way of glue spots applied below the cutter strip. It is noted that glue spots may be applied prior and proximal to the cutter strip on the front wall for adhering the closure flap to the front wall.
Referring to
A tensioner slide assembly 1020 is integrated in front wall 1013 having two opposing parallel slits 1021 extending on the front wall 1013 of the dispensing box 1012. Parallel slits 1021 are preferably formed as narrow cuts having one or more kiss cuts, cut-scores, nicks or connection points (see for example,
The locking flaps 1040 have a flap top wall 1044 and flap bottom wall 1045 that terminate at fold line 1042. Flap top wall 1044 and flap bottom wall 1045 are adapted to break-away when a pressing force is applied later by an end user/user. Preferably, flap top and bottom walls, 1044, 1045, are formed as narrow cuts having one or more kiss cuts, cut-scores, nicks or connection points adapted to breakaway when force, such as pressing by an end-user, is applied. When the locking flaps 1040 are pushed outward, separating to break-away from the inside of the front wall 1013 and pressed outward to bend at the bend wall/fold line 1042 bending is facilitated without tearing. Locking flaps 1040 are in the stored position prior to use and adapted to open to a locking position by an end-user (as shown, for example in
As discussed hereinabove, tensioner 1050 is mounted within a tensioner slide assembly 1020 by way of opposing bottom tabs 1051 inserted within parallel slots 1030 with locking flaps 1040 flat or disengaged. Roll tensioner 1050, in the embodiment shown, is constructed having opposing bottom tabs 1051 that flex and bend when inserted through parallel slots 1030 of box 1012 during manufacturing to secure the tensioner 1050 within the box 1012. Roll tensioner 1050 has a distal end section 1052 and a proximal end section 1053, separated by a spring back/reversion section 1054. Proximal end section 1053 includes opposing bottom tabs 1051 and, preferably, a center bottom tab 1051′ (for stability) adapted to secure the tensioner 1050 in place within the wrapping material box 1012.
In a first position, distal end 1052 bends upward and over the material roll 1060 resting against the top wall 1016 of the box 1012. In use, as discussed hereinafter, the tensioner 1050 is appointed to be moved to slide from the first position in the parallel slots 1030 downward into parallel slits 1021 to a second position and the locking flaps 1040 are pushed outward to prevent movement of the roll tensioner 1050. In this position, the second position, the roll tensioner 1050 is engaged, with the distal end 1052 extending downward via spring back/reversion section 1054 in the interior of box 1012 when a force is applied (i.e. the wrapping material roll). Preferably the distal end 1052 includes opposing top tabs 1052′ forming a “T” distal end section thereby providing greater surface area for abutting wrapping material on a material roll so that the wrapping material end is pushed upward for easy grasping by an end user.
As shown in
As illustrated by
Instead of removal of the material roll 1060, alternatively the material roll 1060 may remain in the box 1012 and the roll tensioner 1050 slid downward into the second position and fold the locking flaps outward to lock tensioner in position. The front wall of the box 1012 can be bent outward to create a space to bend the distal end of the tensioner 1050 so it can rest against the material roll.
Box 1212 has an exterior 1209a and an interior 1209b. Box 1212 is constructed generally having a front wall 1213 with a serrated cutter strip 1213′ adapted to cut the rolled material as it is being used. Front wall 1213 abuts a bottom wall 1214, which in turn abuts back wall 1215, which in turn abuts top wall 1216 abutting top flap 1217 adapted to be sealed against front wall 1213 by way of glue.
Tensioner slide assembly 1220 is integrated in front wall 1213, formed as parallel slots 1230 terminating or adjoining narrow slits 1221 or preferably having score-lines or kiss cuts, etc, and parallel to integrated locking flaps 1240. Slots 1230 are formed as two parallel lines or a narrow gap or opening extending on front wall 1213. Locking flaps 1240 are integrated along a portion of parallel slots 1230. Locking flaps 1240 have flap top wall 1240a and flap bottom wall 1240b that are preferably breakaway via kiss cuts or score-lines, etc, to be broken and deployed when the consumer opens and uses the final wrapping material with tensioner system product. Locking flaps 1240 are formed as parallel tabs abutting and flush with slots 1230 and are appointed to fold at fold line 1240c when the system is in use. Locking flaps 1240 share a side wall with parallel slot 1230.
Referring to
Other dispenser structures are contemplated, and may include magnets, etc., for magnetic attachment to a steel surface, such as the side of a refrigerator. Dispensers may come in custom made shapes, including parallelogram, cylindrical and rectangular tube-like structures, which would also provide a means of dispensing the roll tensioners.
Generally, for use in box assembly on an automated production line, the mandrel and saddle or saddle clamp principle of assembly mechanism is appointed for use during insertion of tensioner opposing bottom tabs into the parallel slots on the front of the roll dispenser box. The saddle or saddle clamp variable travel distance from the mandrel allows for adjustment between opposing bottom tabs to match the slot spacing in the roll dispensing box. Mandrel 1490 is constructed having a tensioner square or substantially flat mandrel bed 1492 with guide rails 1492′ and a cylindrical or half-round/less than half-round partial cylinder shape 1491 in the front or proximal portion of the mandrel assembly to allow a short tapered/arched adjustable forming clamp or saddle 1495 to circumferentially engage over the opposing bottom side tabs 1451 of the tensioner 1450. This causes the opposing side tabs 1451 to bend towards the roll dispenser box with their ends at the same distance from each other, as the spacing of the opposing parallel slots 1430 on the front wall 1413 of the roll dispenser box 1412. The edges of the proximal opposing side tabs, shown generally at 1451′, also need to be on a plane parallel to the parallel slots 1430 of the roll dispensing box 1412. In order to control the potential slippage of the tensioner while the proximal end opposing bottom side tabs are being bent towards the roll dispenser box via the arched clamp or saddle 1495, the rear or distal portion of the mandrel assembly preferably has a substantially flat mandrel bed 1492 or other means for holding the distal end 1452 of the tensioner 1450 flat and square to the centerline of the mandrel assembly and remains guided in the process.
In the next step, the complete mandrel 1490 and clamp/saddle 1495 assembly holding the portion of the bent tensioner 1450 is either moved towards the front parallel slots 1430 on the front of the roll dispenser box, or the table with the box is moved towards the mandrel 1490 and clamp/saddle 1495 assembly so the opposing bottom side tabs 1451 of the tensioner 1450 engage into the slots/parallel slots 1430 of the tensioner slide assembly on the front wall of the box. At this time, in one embodiment, the mandrel assembly only, releases the tensioner and slides away from the mandrel 1490 and clamp/saddle 1495, allowing the tensioner to snap into the assembled first position on the roll dispenser box due to the natural properties of the tensioner material which will cause it to want to return to its original flat shape. On the final step, the arched clamp/saddle 1495 is moved away from the box, the box/tensioner assembly is moved down the assembly line for folding and gluing the roll dispenser box lid's closure flap to the front wall of the box, and both a new box and the next tensioner can be brought to follow the same prior sequence.
In a different embodiment, the mandrel 1490 and clamp/saddle 1495 assembly is stationary, the tensioner is fed into the guided loading position as in the prior art, via drive rollers, guides or other means; the tensioner is firmly held in place over the distal end and held flat, the saddle or saddle clamp is moved over the mandrel proximal end, adjustable via a pneumatic cylinder, a solenoid coil or other means, bending the opposing bottom side tabs, causing the edges to be parallel and on the same plane as the slots of the roll dispensing box for equal engagement. The box in the flat position is fed and guided via drive rollers or other means, to the opposing bottom tabs 1451 of the tensioner. Slots 1430 rest directly aligned to the bent proximal opposing side tabs 1451 of the tensioner. The guided mechanism holding the box is moved so the proximal opposing bottom side tabs engage into the slit slots of the box; at this time, the clamp/saddle 1495 is retracted away from the tensioner and the tensioner/box assembly together is pulled away from the mandrel 1490. The next tensioner and box can now be fed for another sequential assembly. With either previous embodiments, the guided mechanism handling the roll dispenser box, preferably has a relief and taper forward, in the direction of travel of the box, behind the box slit slots at the point of engagement of the tensioner, so the proximal opposing side tabs are clear to travel unobstructed in an arch motion from the bent engaging position to near flat as the box and tensioner assembly are pulled away from the mandrel.
Once the tensioner is held flat on the mandrel assembly, via a clamp, drive roller mechanism or similar purpose device, the inside front wall of the dispenser box with the already installed serrated cutting edge (facing away from the mandrel assembly), in the flat unassembled configuration with the custom formed slit slot assembly, is positioned and held with the slit slots directly in line with the bent ends of the opposing and parallel bottom side tabs of the tensioner, with the serrated cutting edge opposite the rear portion of the mandrel which holds the spring back/reversion section of the roll tensioner.
The roll dispenser box as depicted in
In
The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.
Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to, but that additional changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.
The present application is a continuation in part of U.S. patent application Ser. No. 15/657,118, filed Jul. 22, 2017, the disclosure of which is hereby incorporated in its entirety by reference thereto.
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| Number | Date | Country | |
|---|---|---|---|
| 20200017327 A1 | Jan 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15657118 | Jul 2017 | US |
| Child | 16580073 | US |
