Packing Material, Use, and Methods of Manufacture

Abstract

A packing material, its use, method of manufacture, and method of production creates a curl or spiral having elastic, cushioning, form-fitting, and coherent packing properties. The curl is created from a dimension-controlled strip of cohesive paper having a cohesive side and a non-cohesive side, and formed with a leading end that is bent upon itself such that a cohesive side of the leading end contacts the cohesive side of the dimension controlled strip of cohesive paper, and a trailing end opposite the leading end that is bent upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the dimensioned strip of cohesive paper, wherein the dimensioned strip of cohesive paper is wound into a spiral with the cohesive side of the dimensioned strip of cohesive paper facing outward. A plurality of curls provides a clumped, cohesive mass around a packed item.

Claims

1. A dunnage product comprising: a curl formed of a strip of cohesive paper having a first end, a second end opposite the first end, a cohesive side extending from the first end to the second end, a non-cohesive side opposite the cohesive side and extending from the first end to the second end, a leading end formed at the first end of the strip of cohesive paper, and a trailing end formed at the second end of the strip of cohesive paper, the strip of cohesive paper wound into a spiral such that the cohesive side of the strip of cohesive paper is facing radially outward.

2. The dunnage product of claim 1, wherein: the leading end of the strip of cohesive paper is folded upon itself such that a cohesive side of the leading end contacts the cohesive side of the strip of cohesive paper; and the trailing end of the strip of cohesive paper is folded upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the strip of cohesive paper.

3. The dunnage product of claim 2, wherein the strip of cohesive paper has a width that is from one quarter inch (¼″) to three quarters inch (¾″), and a length of from two inches (2″) to six inches (6″).

4. The dunnage product of claim 3, wherein the width of the strip of cohesive paper is one half inch (½″).

5. A method of producing packing material comprising: providing a roll of a continuous sheet of cohesive paper having a cohesive side and a non-cohesive side; cutting the continuous sheet of cohesive paper into individual cohesive paper sheets with each individual cohesive paper sheet having a first end and a second end; folding the first end of the individual cohesive paper sheet into a trailing end with a non-cohesive side of the trailing end abutting the non-cohesive side of the individual sheet of cohesive paper; folding the second end of the individual cohesive paper sheet into a leading end with a cohesive side of the individual sheet of cohesive paper abutting and adhering to the cohesive side of the individual sheet of cohesive paper; cutting the end-folded individual sheet of cohesive paper into a plurality of end-folded strips of cohesive paper each having a width and a length; and curling each one of the plurality of end-folded strips of cohesive paper into a spiral with its cohesive side facing radially outward.

6. The method of claim 5, wherein each one of the plurality of strips has a width from one quarter inch (¼″) to three quarters inch (¾″) and a length from two inches (2″) to six inches (6″).

7. The method of claim 6, wherein each one of the plurality of strips has a width of one half inch (½″).

8. A machine for producing packing material comprising: a cohesive paper receiver configured to receive a continuous sheet of cohesive paper from a roll of a continuous sheet of cohesive paper having a cohesive side and a non-cohesive side; a first cutting section configured to receive the continuous sheet of cohesive paper from the cohesive paper receiver and to cut the continuous sheet of cohesive paper into individual cohesive paper sheets with each individual cohesive paper sheet having a first end and a second end; a folding section configured to receive the individual cohesive paper sheets from the first cutting section and to fold the first end of the individual cohesive paper sheet into a trailing end with a non-cohesive side of the trailing end abutting the non-cohesive side of the individual sheet of cohesive paper, and to fold the second end of the individual cohesive paper sheet into a leading end with a cohesive side of the individual sheet of cohesive paper abutting and adhering to the cohesive side of the individual sheet of cohesive paper; and a cut and curl section configured to receive the folded individual cohesive paper sheets from the from the folding section, cut the end-folded individual sheets of cohesive paper into a plurality of end-folded strips of cohesive paper each having a width and length, and curl the plurality of end-folded strips of cohesive paper into a plurality of spirals each having its cohesive side facing radially outward.

9. The machine of claim 8, wherein each one of the plurality of strips has a width from one quarter inch (¼″) to three quarters inch (¾″) and a length from two inches (2″) to six inches (6″).

10. The machined of claim 9, wherein each one of the plurality of strips has a width of one half inch (½″).

Description

BRIEF DESCRIPTION OF THE FIGURES

[0016] The present invention and its features will be better understood by reference to the accompanying illustrations/drawings, wherein:

[0017] FIG. 1 is diagrammatic view of an exemplary machine for producing packing curls (curls) from a supply of cohesive paper in accordance with the principles of the present invention;

[0018] FIG. 2 is a view of an individual packing curl that can be made by the machine of FIG. 1 and a method of manufacture as described herein;

[0019] FIG. 3 is a view of a packaged item surrounded by a mass (plurality) of packing curls (curls) made by the exemplary machine of FIG. 1, the mass of packing curls creating a void filler that cushions and protects the packaged item;

[0020] FIG. 4 is a view of a roll of cohesive paper used for the present packing curls;

[0021] FIG. 5 is a schematic view of another exemplary machine for producing packing curls (curls) from a supply of cohesive paper in accordance with the principles of the present invention;

[0022] FIG. 6 is a side view of an exemplary cut and folded strip of cohesive paper ready for curling;

[0023] FIGS. 7A-E depict a sequence of curling of the exemplary cut and folded strip of cohesive paper of FIG. 6 into a packing curl in accordance with the principles of the present invention;

[0024] FIG. 8 is a perspective view of a packing curl produced by the principles of the present invention;

[0025] FIG. 9 is a diagrammatic view of the exemplary folding section of the exemplary machine of FIG. 5;

[0026] FIG. 10 is an enlarged view illustrating the flow of cohesive paper through the exemplary folding section of FIG. 9; and

[0027] FIG. 11 is a top view of an exemplary roller for curling and cutting the curls.

[0028] For the purposes of promoting an understanding of the principles of this invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

DETAILED DESCRIPTION OF THE INVENTION

[0029] Referring to FIG. 1, there is shown a diagrammatic view of an exemplary machine, mechanism, apparatus or the like (collectively, machine) 10 for producing one form of curls 30 in accordance with the present principles. It should be understood that the machine 10 of FIG. 1 depicts only basic components and/or features for producing the curls 30. The machine 10 has a housing 12 to which is connected a paper holder 16. A roll of cohesive paper 14 (cohesive paper being paper with a cohesive on one side only) is held by the paper holder 16 such that the roll of cohesive paper 14 may freely rotate about an axle 17 of the paper holder 16. The paper holder 16 is configured to allow various sizes (length and width) of rolls of cohesive paper to be retained. The paper holder 16 is also configured to allow replacement of cohesive paper rolls.

[0030] Cohesive paper (a continuous cohesive paper sheet), collectively cohesive paper P, from the cohesive paper roll 14 is received by/into a paper feed/feeder/feed mechanism (collectively, feed) 18 which directs the cohesive paper P into the housing 12 and to a paper guide 19. The paper guide 19 includes first and second feed rollers R1, R2 disposed opposite one another such that the cohesive paper P is properly received and aligned for curling and cutting. The first and second rollers R1, R2 lead the cohesive paper P over a third roller R3 such that the cohesive paper P is received onto a shaft 20. A rotation mechanism 21, here shown as a first motive roller 22 and a second motive roller 23 connected by a belt or belt drive 25, rotates the shaft 20 and cohesive paper to provide wound cohesive paper 24 about the shaft 20.

[0031] The wound cohesive paper 24 travels about the shaft 20 where it encounters a cutter 26, here shown as two cutting blades C1 and C2, that cuts the wound cohesive paper 24 into cohesive paper packing curls (curls) 30, one of which is shown in FIG. 2. Preferably, but not necessarily, each curl has a width of one quarter inch (¼″) to three quarters inch (¾″) with one half inch (½″) being most preferable, and a length of two inches (2″) to six inches (6″) long. The curls 30 are released into a director 28 which dispenses the curls 30 into a hopper (not shown) or directly into a box as shown in FIG. 3 which contains an item 60. FIG. 3 shows a mass 50 of curls 30 about and/or around the item 60 for product/item packing, cushioning, blocking, bracing, and/or void fill.

[0032] While the machine 10 cuts the wound cohesive paper 24 into curls 30 after winding on the shaft 24, it should be appreciated that a machine may produce the present curls by first cutting the cohesive paper into the desired size (width and length) of strips before curling. Moreover, the roll of cohesive paper may already have a width of one quarter inch (¼″) to three quarters inch (¾″), which is then cut to a length of two inches (2″) to six inches (6″) long for curling.

[0033] Variations in the curl producing machine 10 are contemplated such as, but not limited to, placement and numbers of cohesive paper guide/feed rollers, the manner of rotating the curling shaft, the manner of feeding the cohesive paper into the curling and cutting mechanisms, and the like. Other variations are contemplated, the end result of which is to make/produce curls 30.

[0034] Referring now to FIG. 4, there is depicted an illustrative roll of cohesive paper 100 such as can be used in the curl producing machine 10 of FIG. 1 and the exemplary curl producing machine 101 of FIG. 5 that produces curls 150 from cut and end-folded strips 200 (see, e.g., FIG. 6) of cohesive paper. The roll of cohesive paper 100 is formed by a wound continuous sheet 102 of cohesive paper of a given width. The machine 101 can accommodate rolls of various widths. As shown in FIG. 5, the sheet of cohesive paper 102 has a cohesive side 104 and a non-cohesive side 105. The exemplary curl producing machine 101 feeds the sheet of cohesive paper 102 through various drive rollers (D.R.) to a cutter or cutting section 110 (labeled Sheet Cut in FIG. 5). The cutting section 110 cuts the sheet of cohesive paper 102 into individual sheets of a given length, the given length of which will be (is) the total length of a curl 150. The cutting section 110 is configured to adjust length size of each individual sheet. Same length individual sheets may be produced in succession or variations in individual sheet length.

[0035] The individual length-cut sheets are conveyed to a folder or folding section 120 via drive rollers (D.R.). The folding section 120 is designed to create a folded leading end or edge 202 and a folded trailing end or edge 204 opposite to the folded leading end 202 to each individual length-cut sheet of cohesive paper 200 (see, e.g., FIG. 6). The leading end 202 is folded back onto itself such that the cohesive side 104 of the folded leading end 202 contacts and adheres to the cohesive side 104 of the sheet of cohesive paper 200, while the trailing end 204 is folded back onto itself such that the non-cohesive side 105 of the folded trailing end 204 contacts to the non-cohesive side 105 of the sheet of cohesive paper 200. An individual end folded length of cohesive sheet 200 is depicted in FIG. 6. At this point, the sheet 200 is ready to be cut and curled, although not necessarily in that order. Cutting and curling can also be performed simultaneously such as with a cutting/curling roller 320 of FIG. 11.

[0036] In FIGS. 7A-7E, the formation of a curl 150 is illustrated. It should be appreciated that this illustration does not show the mechanism (e.g. rollers, cutters, etc.) for curling, but rather illustrates the manner in which the sheet of cohesive paper 200 is curled. In FIG. 7A the individual sheet of cohesive paper 200 is shown before its ends/edges have been folded. In FIG. 7B, the leading end/edge 202 has been folded such that its cohesive side adheres to the cohesive side 104 of the sheet of cohesive paper 200, while the trailing end/edge 204 of the sheet of cohesive paper 200 has been folded such that its non-cohesive side abuts the non-cohesive side 105 of the sheet of cohesive paper 200. In FIG. 7C, the end-folded sheet of cohesive paper 200 is beginning to be coiled, wound, spiraled, twisted, curled, or the like into a curl 150. The leading end 202 is being curled under itself such that the cohesive side 104 faces outward (is radially outward with respect to the curl 150) and the non-cohesive side 105 faces inward (is radially inward with respect to the curl 150). FIG. 7D illustrates further curling of the end-folded sheet of cohesive paper 200 from that of FIG. 7C. FIG. 7E illustrates a final or near final curling of the sheet of cohesive paper 200. FIG. 8 depicts a final curl 150 cut in a desired strip width. It should be appreciated that the end-folded strip of cohesive paper 200 may be wound or spiraled opposite, or differently, to that shown in FIGS. 7A-E while achieving the same result of having the cohesive side of the curls 150 facing outward.

[0037] FIGS. 9 and 10 provide a more detailed depiction of a manner in which the length-cut sheets of cohesive paper gets folded. Drive rollers direct or feed the length-cut sheets of cohesive paper into the folder. Initially, the nomenclature first and second are arbitrary and interchangeable here and throughout. A first end of the sheet 200 is directed by meshing of folding roller 1 (FR1) and folding roller 2 (FR2) into a first stop 300 which bends the first end onto itself such that the non-cohesive side 105 of the first end is adjacent to the non-cohesive side 105 of the sheet 200. As the first end is folded by the first stop 300, a crease is formed in the sheet 200, the crease of which is then fed/conveyed into meshing folding roller 2 (FR2) and folding roller 3 (FR3). The crease of the sheet 200 then becomes the crease of a folded trailing end 204. The folded trailing end 204 is fed into a second stop 310. The second end of the sheet 200 that is now opposite the trailing end 204 will be folded upon itself by meshing folding roller 3 (FR3) and folding roller 4 (FR4) when the trailing end 204 bottoms out in the second stop 310 to form a folded leading end 202. The leading end is folded such that a cohesive side of the second end contacts and adheres to the cohesive side 104 of the sheet 200. The length of the second stop 310 is adjustable. Direction of sheet travel is depicted in FIG. 10. The cohesive paper is fed into the machine 101 with the cohesive side in one direction, with the folded sheets of cohesive paper flipped for cutting. The end-folded sheet of cohesive paper 200 is then sent to the curler and cutter 130.

[0038] FIG. 11 depicts an exemplary curling and cutting roller 320 of the curl and cut section 130. A curling and cutting roller 320 is characterized by a cylinder 322 having a plurality of radial blades 323 spaced to provide a given strip width. Different rollers can provide a difference strip width. The curling and cutting section 130 may use more cutting rollers, and/or different manners of curling and cutting the sheets 200. The process of selecting strip width may also be automatic. As the sheets 200 are wound onto the roller 322, the blades 323 cut the width. Other manners may be used.

[0039] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only a preferred embodiment has been shown and described, and that all changes and modifications that come within the spirit of the invention are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention.