METHOD OF PACKAGING A FLEXIBLE ELONGATE ELEMENT

Abstract

Method of coiling a flexible elongate element (64) inside a container (80A) made from a flexible sheet material wherein at least part of the sheet material is tensioned by establishing a pressure differential between an inner surface (100) and an outer surface (92) of the sheet material and the flexible elongate element (64) is directed onto the tensioned sheet material to form a hole (98), the flexible elongate element being then fed through the hole to form a coil inside the container.

Claims

1. A method of packaging a flexible elongate element which has a leading end, the method including the steps of providing a container which has a wall, of flexible sheet material, which at least partly encloses a cavity of variable size, the wall including an inner surface which faces the cavity and an opposing outer surface, establishing a pressure differential between at least part of the inner surface and at least part of the outer surface thereby to tension at least a part of the flexible sheet material, directing said leading end into contact with a location on the tensioned part of the flexible sheet material thereby to form a hole at the location, in the wall, feeding said leading end through the hole into the cavity, restraining movement of the leading end, and forming a coil of the elongate flexible element inside the cavity by continuing to feed the flexible elongate element into the cavity.

2. A method according to claim 1 wherein the flexible elongate element is selected from the following: a flexible or semi-flexible wire, strand, yarn, monofilament, cord, cable, tubing and pipe, or a combination thereof.

3. A method according to claim 1 wherein the container is one of a plurality of similar containers which are formed in succession from an elongate tubular member which is made from a plastics material and which is transported past a forming and sealing station which forms the elongate tubular member continuously into a plurality of containers in succession with each container being of a predetermined size.

4. A method according to claim 1, wherein the container is formed with at least one aperture which allows for gas to flow through the aperture into, or out of, the cavity.

5. A method according to claim 1, wherein the pressure differential is established by inflating the cavity with a gas, or by applying a reduced pressure to an outer surface of the wall whereby a gas is caused to flow into the cavity.

6. A method according to claim 1, wherein the flexible elongate element is drawn from a coil, or directly from equipment which is used to manufacture or process the flexible elongate element.

7. A method according to claim 1, wherein the leading end of the flexible elongate element is directed onto the wall of the container with the application of sufficient force, to the flexible elongate element, in an axial direction of the flexible elongate element to allow the leading end to form the hole in the flexible sheet material and enter the cavity.

8. A method according to claim 7 wherein after formation of the hole movement of the flexible elongate element into the cavity is continued by continuously applying force to the flexible elongate element in the axial direction.

9. A method according to claim 1, which includes the step of physically supporting the sheet material at least at said location.

10. A method according to claim 1, which includes the step of directing the leading end of the flexible elongate element through a tubular guide member into contact with said location on the flexible sheet material.

11. A method according to claim 2 wherein the container is one of a plurality of similar containers which are formed in succession from an elongate tubular member which is made from a plastics material and which is transported past a forming and sealing station which forms the elongate tubular member continuously into a plurality of containers in succession with each container being of a predetermined size.

12. A method according to claim 2, wherein the container is formed with at least one aperture which allows for gas to flow through the aperture into, or out of, the cavity.

13. A method according to claim 3, wherein the container is formed with at least one aperture which allows for gas to flow through the aperture into, or out of, the cavity.

14. A method according to claim 2, wherein the pressure differential is established by inflating the cavity with a gas, or by applying a reduced pressure to an outer surface of the wall whereby a gas is caused to flow into the cavity.

15. A method according to claim 3, wherein the pressure differential is established by inflating the cavity with a gas, or by applying a reduced pressure to an outer surface of the wall whereby a gas is caused to flow into the cavity.

16. A method according to claim 4, wherein the pressure differential is established by inflating the cavity with a gas, or by applying a reduced pressure to an outer surface of the wall whereby a gas is caused to flow into the cavity.

17. A method according to claim 2, wherein the flexible elongate element is drawn from a coil, or directly from equipment which is used to manufacture or process the flexible elongate element.

18. A method according to claim 3, wherein the flexible elongate element is drawn from a coil, or directly from equipment which is used to manufacture or process the flexible elongate element.

19. A method according to claim 4, wherein the flexible elongate element is drawn from a coil, or directly from equipment which is used to manufacture or process the flexible elongate element.

20. A method according to claim 5, wherein the flexible elongate element is drawn from a coil, or directly from equipment which is used to manufacture or process the flexible elongate element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The invention is further described by way of examples with reference to the accompanying drawings in which:

[0034] FIG. 1 is a schematic representation of apparatus used to implement the method of the invention,

[0035] FIGS. 2A to 2F schematically illustrate successive steps in carrying out the method of the invention,

[0036] FIGS. 3, 4 and 5 depict possible modifications to the inventive process,

[0037] FIG. 6 is a perspective view of a reusable holder or housing which can be used with a product produced by the method of the invention, and

[0038] FIGS. 7A and 7B show how a flexible element can be dispensed from packaging in which it is contained.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0039] FIG. 1 of the accompanying drawings is a diagrammatic representation of apparatus 10 used to implement a method according to one form of the invention.

[0040] The apparatus embodies three workstations 12, 14 and 16 respectively which are used to process the product 20 which is to be packaged, and packaging material 22.

[0041] The packaging material, in this embodiment, includes a coil 24 of an elongate flexible tubular member 26, mounted for rotation about an axis 28. The tubular member 26 is made from flexible sheet material of any suitable kind, as referred to hereinbefore. The tubular member, in coil form, is deflated i.e. essentially pressed flat with opposing sections 30 and 32 respectively.

[0042] The workstation 12 includes components 12A and 12B respectively which are movable together, under the control of a suitable control mechanism 34, at regular intervals, in order to seal the sections 30 and 32 together. In this way sealed portions 36 are formed at regular intervals along the length of the tubular member as it is unwound from the coil 24. Simultaneously, opposed small apertures 38 and 40 are formed through the sections 30 and 32. This is done in any convenient way for example using a small punch or a heated element.

[0043] The control mechanism 34 also acts on a roller system 42 which is adjacent the third workstation 16 and which functions to draw the tubular member 26 from the coil 24 at a controlled and continuous rate.

[0044] The second workstation 14 includes a base support 46 and a cover support 48 which opposes the base support. The supports 46 and 48 have a space 50 between them and also define a mouth 52 to the space. A source 54 of a compressed gas e.g. air is connected to the workstation 14 via a tube 56. A valve 58, which is optionally used, is positioned in the tube and can be opened or closed by means of a suitable signal sent from the control mechanism 34.

[0045] The cover support 48 includes an elongate entry structure 60 which forms a guide 62 of generally tubular shape.

[0046] The product 20 is held in a suitable form adjacent the workstation 14. The product may for example be provided in coiled form, contained on the reel, in a suitable housing, or the like. Alternatively, the product is directly supplied from equipment (not shown) used to manufacture or process the product. The product comprises a flexible elongate element 64 generally of the kind described hereinbefore. The element 64 is directed by means of a suitable feed structure 66, e.g. a plurality of rollers, into a bore 68 of the guide 62.

[0047] The third workstation 16, which is positioned downstream of an exit port 70 from the space 50 contains a cutting device 72 to which product, emerging from the workstation 14, is presented. Another cutting device 76 is positioned at an entry to the guide 62. The cutting devices are controlled by the control mechanisms 34.

[0048] FIGS. 2A to 2F schematically illustrate various stages of the production of a packaged product during operation of the apparatus 10.

[0049] The working of the apparatus 10 is controlled by the control mechanism 34 which is a PLC, a microprocessor or the like. The invention is not limited in this respect.

[0050] The packaging material i.e. the tubular member 26 which is made from flexible sheet material, is drawn, in deflated form, from the coil 24 and then passes, to the workstation 12. At this workstation the member is sealed by the components 12A and 12B at regular intervals to form a succession of containers 80. As described hereinbefore, each container includes an opposed pair of apertures 38 and 40see FIG. 2A.

[0051] The tubular member 26, still in deflated form, then passes to the second workstation 14 and a given container 80A enters the space 50.

[0052] At the workstation 14 the aperture 40 of the given container 80A is brought into register with an exit port 84 from the tube 56. The base support 46 and the cover support 48 may be moved towards each other so that they closely surround the container 80A which is still in a deflated form and which is in the space 50. This however is not essential. If the valve 58 is used this is opened by means of a signal from the controller 34. Compressed air from the source 54 then flows through the exit port 84 into the space 50. Most of the air flows through the aperture 40 into a cavity 88 of the container 80A. Prior to this taking place the size of the cavity 88, defined by the flexible sheet material, is effectively zero as the container is deflated. As the air rushes through the aperture 40 into the cavity 88 the size of the cavity is increased rapidly. Additionally, the sheet material which encloses and defines the cavity is placed under tension.

[0053] The feed structure 66 is activated, as required by the control mechanism 34, to direct the flexible elongate element 64 through the guide 62. A leading end 90 of the flexible elongate element is thereby brought into contact with an outer surface 92 of the container 80A. In accordance with parameters which have been discussed hereinbefore sufficient force is applied to the flexible elongate element 64, in its axial direction 96, to allow the leading end 90 to penetrate the sheet material and so form a hole 98 in a wall of the container 80A, see FIG. 2C. The sheet material is sufficiently tensioned by the air in the cavity 88 so that it does not collapse when contacted by the leading end 90. The force exerted by the leading end on the sheet material is thus effectively concentrated over a small area of the sheet material which, consequently, is readily penetrated by the leading end.

[0054] The axially directed force (in the direction 96) is applied continuously to the flexible elongate element. The leading end 90 strikes an inner surface 100 of the container 80A (FIG. 2D) and is deflected to one side (FIG. 2E). The leading end then impinges on an area 102 of the inner surface which is curved and which effectively restrains further movement of the leading end inside the cavity 88. Although movement of the leading end may in this manner be halted, this is not necessarily a prerequisite for coiling of the element to take place. As has been indicated hereinbefore the speed of movement of the leading end, although not halted, may be slowed in relation to the speed at which the flexible element is being fed into the cavity inside the container. Generally the speed of the feed is constant due to the use of appropriate handling equipment. The material which is being fed through the hole 98 can therefore only be accommodated inside the container if coiling of the element takes placea process which occurs naturally due to the characteristics of the material from which the element is made and due to the confining effect of the container.

[0055] The supply of compressed air to the aperture 40 is maintained to ensure that the cavity 88 remains enlarged to its maximum size. The leading end 90 is not capable of again penetrating the flexible sheet material which makes up the container 80A and, consequently, as feeding of the element continues, the element is formed into a coil 104 with a plurality of overlapping windings 106, as is shown in FIG. 2F.

[0056] The length of the flexible elongate element which is fed into the cavity 88 is monitored by the feed structure 66 and when a predetermined length has been coiled into the cavity the device 76 is operated to sever the flexible elongate element.

[0057] The roller system 42 is operated by the control mechanism 34 and the container 80A emerges from the workstation 14 with a coiled length of the flexible elongate element inside the container. A trailing end 108 of the element protrudes from the hole 98.

[0058] At the workstation 16 the cutting device 72 is operated and the container 80A is severed from the upstream flow of containers and falls into a receptacle, not shown, for further processing and distribution, as may be required.

[0059] In order to inflate the deflated container use is made of the compressed air source 54 while the deflated container is positioned at the workstation 14. In a variation of the invention the compressed air source 54 is replaced by a vacuum device which draws air through the tube 56 when the respective container, in deflated form, is positioned in the space 50. A volume 112 between the outer surface 92 of the container and an opposing inner surface of the cover support 48 is thereby partly evacuated and a reduced vacuum prevails in this volume. A portion of the section 32 of the deflated tubular member is drawn towards the guide structure 60. The pressure prevailing inside the cavity 88 of the container 80A is also reduced and, as a consequence, air flows through the aperture 38 into the cavity 88. Due to the pressure differential which is thereby established the cavity 88 is increased to some extent in size. A portion of section 32 is tensioned to some extent by the pressure differential and, in a manner similar to what has been described, the feed structure 66 is actuated to drive the leading end 90 of the flexible elongate element through a location on the wall section 32. Thereafter a coiling process which is similar to what has been described in connection with FIGS. 2A to 2F follows and a coiled product is formed inside the cavity 88.

[0060] Thus, in one embodiment, positive air pressure is used to enlarge the cavity. In another embodiment negative air pressure, exerted on one outer side of the cavity 88 is used in a controlled manner to cause the cavity to be enlarged.

[0061] The apparatus 10 shown in FIG. 1 provides for a continuous production process. This is not necessarily the case though. For example if a flexible elongate element is to be packaged inside a container which is relatively large then the container may, with benefit, be separately formed, or it may be separated from a number of similar containers. For example, if a hosepipe length is to be packaged, then a suitable container may be a discrete component which is placed, using a suitable material handling system, into an appropriate workstation which is equivalent to the workstation 14. The cavity size of the container is enlarged so that at least part of the sheet material which defines the container is tensioned and, in a manner similar to what has been described, a leading end of the hosepipe is then caused to puncture a wall of the container whereafter the hosepipe is further advanced into the cavity to form a coiled structure.

[0062] The use of the cover support 48 is not essential. It is preferred though to make use of a guide to direct the leading end of the flexible elongate element to a predetermined location on the container. Similarly, if the container has significant strength when inflated, the use of the base support 46 is also not essential. With this type of arrangement the container which is to serve as the packaging device is preferably inflated with positive air pressure as opposed to using a vacuum source to produce a reduced pressure region around the container.

[0063] FIG. 3 illustrates a possible modification to the arrangement shown in FIG. 1. In this instance a reinforcing structure 120, e.g. in the form of a small washer, with a central aperture 122 is used. The cavity 88 is inflated, much in the manner described, using a compressed air source at the workstation 14. The leading end 90 of the flexible elongate element is directed through the aperture 122 into contact with the flexible sheet material which is surrounded by the washer. The washer acts to brace the sheet material which is internally pressurised. The leading end is therefore able to puncture the sheet material with relative ease and then become coiled inside the cavity.

[0064] FIG. 1 illustrates a base support 46 which has a planar or flat form. FIG. 4 shows that the base support, designated 46A, can have a deflecting surface 124 which is positioned opposite a hole 98 formed by the leading end 90 of the flexible elongate element. The deflecting surface 124 urges the leading end to one side and along a specific path. Optionally the base support can be formed with an aperture 126 which is at a location at which the leading end would normally be restrained against further movement. By correctly positioning the various components a stressed region of the packaging material is created at the aperture 126 and, as the leading end 90 strikes this region it can penetrate the wall of the container and emerge from the container. A short length of the flexible elongate element then protrudes from the container. The leading end then strikes a portion 128 of the base support which is shaped, temporarily or permanently, for the purpose, and which inhibits further movement of the flexible elongate element which then coils inside the cavity, in the manner described. The end result, in this case, is a packaged product wherein opposed ends of the element, held in coiled form in the container, protrude at different locations from the container.

[0065] FIG. 5 illustrates an example of the invention in which only the base support 46 is employed and the cover support 48, shown in FIG. 1, is not used. The container, when inflated, bears directly against an exit 62A from the guide 62 which acts much in the manner of the reinforcing structure 120 shown in FIG. 3. A portion of the wall section 32 at the exit from the guide 62 is stressed (tensioned) and the leading end 90 of the elongate element is then able to penetrate the wall of the flexible sheet material with relative ease.

[0066] From the preceding description it is apparent that a flexible element can be packaged in a flexible container with ease and with minimal operator input. The packaging medium is smaller and more compact than most arrangements which are conventionally used. The quantity of packaging material which is used is also reduced. The packaging material is also normally of reduced weight compared to prior art arrangements. Retail or display space requirements are accordingly reduced. There is no need to form the container, in which the element is to be coiled, with a hole through which the element can be introduced into the cavity that is defined by the container. The leading end of the element automatically forms the hole at a desired location. The coiling of the element inside the cavity then takes place automatically as a predetermined length of the element is fed into the cavity.

[0067] Despite the aforegoing it is possible to take a packaged product which emerges from the workstation 16 and to place it in a housing 130 which is formed for the purpose (see FIG. 6). The housing 130 may include a hinged lid 132 which is attached to a casing 134. A protruding lead of the elongate element is passed through a dispensing aperture 136. Use of the housing 130 is of course optional. Nonetheless the housing may be used to facilitate the dispensing of an elongate element, e.g. a monofilament line, under conditions which allow for measuring of a dispensed length, or to facilitate cutting of a dispensed length from the remainder of the coiled line held inside the housing. These particular applications are exemplary only and non-limiting.

[0068] As described in connection with FIG. 4 the leading end 90 of the elongate element can be allowed to protrude from the container 80. This arrangement allows the elongate element to be dispensed from the container 80 by pulling the end 90 in the direction of an arrow 134 i.e. to one side of the coil (see FIG. 7A).

[0069] FIG. 7B however illustrates an arrangement in which the trailing end 108, which protrudes from the container, is used for dispensing in that the trailing end is pulled from the container 80 in a direction 136 which is at a right angle to the direction 134 (in the illustrations).