MULTI-UNIT PACKAGE INCLUDING STACKS OF MULTI-PAD UNITS
A multi-unit package includes a plurality of layers of pads stack one on top of another to form a stack of pads and a retainer coupling the stack of pads together for shipment.
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This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/059,611 filed Jun. 6, 2008, which is expressly incorporated by reference herein.
BACKGROUNDThe present disclosure relates to a pad, and to a method for manufacturing multiple pads. More particularly, the present disclosure relates to the manufacture of pads particularly suited for generally automated manufacturing processes.
SUMMARYA pad, in accordance with the present disclosure, includes a top surface and an oppositely facing bottom surface arranged to lie in spaced apart relation to the top surface. The pad is shaped to allow manufacture with minimized operator interaction.
In illustrative embodiments, the pads are stored and transported in a multi-unit package including multiple layers of pads joined together to form a four-pad unit. The multiple layers of four-pad units cooperate to establish a four-pad unit stack. The pads are coupled together so that an operator can break the pads apart for use after removing the top four-pad unit from the opened multi-unit package.
In illustrative embodiments, the four-pad unit is formed by coupling generally octagon-shaped pads together so that each pad is coupled to two other pads along sides of the pads. The sides are joined by frangible perforated line segments formed between each pad. The perforated line segments permit the bending of a pad relative to the neighboring pads to sever the connection between the pads so that a single pad is freed for its intended use.
In illustrative embodiments, the multi-unit package is formed by a generally automated manufacturing method. A corrugated sheet is cut in two ways by a rotary die cutter wherein a first cut type severs all layers of the corrugated sheet and a second cut type severs through all the layers except one leaving the perforated line segments in the corrugated sheet. Subsequent manufacturing steps remove scrap after the cutting, stacks the blanks formed by the cutting, and breaks the stacks of blanks along break lines to form a four-pad unit stack. The four-pad unit stack is then wrapped in shrink-wrap material and heated to form the multi-unit package which is ready for storage or transportation.
Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
The detailed description particularly refers to the accompanying figures in which:
A pad 311, for use by a consumer 11, may be used illustratively to support a food item on top of the pad. As an example, a cooked pizza 48 may be placed on pad 311 as shown in
Illustratively, consumer 11 obtains a pad 311 by opening a first embodiment of a multi-unit package 10 including a four-pad unit stack 12 and a shrink-wrap cover 14 as suggested illustrated in
As suggested in
First pad 321 of second two-pad unit 32 lies above first pad 311 of first two-pad unit 31 to form a column 35 of first pads as suggested in
As shown in
As shown in
As further suggested in
Second supplemental two-pad unit 32a is arranged to lie above first supplemental two-pad unit 31a to form a supplemental two-pad unit stack 34a. First pad 321a of second supplemental two-pad unit 32a lies above first pad 311a of first supplemental two-pad unit 31a to form an auxiliary column 35a of first pads. Second pad 322a of second supplemental two-pad unit 32a lies above second pad 312a of first supplemental two-pad unit 31a to form an auxiliary column 36a of second pads. Second perforated line segment 422 of second supplemental two-pad unit 32a is arranged to lie above second perforated line segment 412 of first supplemental two-pad unit 31a. As shown in
As shown in
Third and fourth perforated line segments 413, 414 are arranged to lie in a longitudinal reference line 18. Longitudinal reference line 18 is arranged to lie between first two-pad unit 31 and first supplemental two-pad unit 31a as shown in
First and second perforated line segments 411, 412 are arranged to lie in a transverse reference line 20. Transverse reference line 20 is arranged to lie in perpendicular relation to longitudinal reference line 18. As shown in
As shown in
An illustrative use of pad 311 is shown in
As suggested in
As illustrated in
An illustrative continuous method for forming multi-unit package 10 is illustrated in
The first step is accomplished by removing corrugated sheet 50 from a sheet supply stack 53 as illustrated in
The second step is accomplished by cutting corrugated sheet 50 as suggested in
The third step is accomplished by the force of gravity pulling interior waste 60 and exterior waste 62 downward and into a scrap receiver 64. Interior waste 60 is formed as a result of interior cut lines 92. Exterior waste 62 is formed as a result of perimeter-cut line 88. Multi-pad strips 97, 98 are received by a second conveyor 55 moving at a slower speed relative to first conveyor 54. Movement of second conveyer 55 at a slower speed causes shingling of multi-pad strips 97, 98.
The fourth step is accomplished by accumulating the multi-pad strips in second station 66 to form multi-pad strip stack 72 as illustrated in
The fifth step is accomplished by breaking multi-pad strip stack 72. Multi-pad strip stack 72 is conveyed on second conveyor 55 to third station 74. Third station 74 illustratively breaks multi-pad strip stack 72 along a first break line 51 forming four-pad unit stack 12. A partial multi-pad strip stack 114 is then indexed further into third station 74 and broken along a second break line 52 forming a second and third four-pad unit stack 116, 118 as illustrated in
The sixth step is accomplished by applying shrink-wrap material 76 to four-pad unit stack 12. Shrink-wrap material 76 is applied in any suitable manner so that four-pad unit stack 12 is encased in shrink-wrap material 76 and shrink-wrap cover 14 can be formed in later steps.
The seventh step is accomplished by heating shrink-wrap material 76 to a suitable temperature to cause shrink-wrap material 76 to shrink and form shrink-wrap cover 14. Shrink-wrap cover 14 operates to protect four-pad unit stack 12 during storage or transportation.
The cutting step suggested in
First multi-pad strip 97 exits from first station 56 and second multi-pad strip 98 exits next and is positioned to lie partially overlapping first multi-pad strip 97 as illustrated in
Cutter 108 includes nicked blades 124 as illustrated in
As illustrated in
The perforating cut forms a series of perforated line segments 411, 412, 413, 414 illustrated in
As shown in
Four-pad unit 16 includes a first and first supplemental two-pad unit 31, 31a and third and forth perforated line segments 413, 414. First two-pad unit 31 is interconnected to first supplemental two-pad unit 31a along perforated line segments 413, 414. First two-pad unit 31 includes two pads 311, 312 and first perforated line segment 411.
As suggested in
Alternately, consumer 11 may use paddle 46 to place a larger cooked pizza 148 on larger pad 22. The consumer obtains larger pad 22 by opening a multi-unit package 100 comprising a two-pad unit stack 34 and a shrink-wrap cover 14. Shrink-wrap cover 14 encloses two-pad unit stack 34 during storage and transportation.
Two-pad unit stack 34 is formed by stacking a series of two-pad units 3 1, 32, 33 on top of one another. Consumer 11 removes a top two-pad unit 31 from two-pad unit stack 34. Two-pad unit 31 is substantially the same as two-pad units 32, 33. Two-pad unit 31 is then broken along first perforated line segment 411 to form two pads 22a, 22b.
An illustrative continuous method for forming multi-unit package 100 is comprised of several steps similar to the method for creating four-pad unit stack 12. The first step and second step are substantially the same. The third step is substantially the same except that only single multi-pad strip 197 is formed as a result of a different cut pattern used in the second cutting step. The fourth step is substantially the same except a multi-pad strip stack 172 is formed which is comprised of multiple two-pad unit stacks 34 rather than multiple four-pad unit stacks 12. The fifth step is substantially the same except that after breaking multi-pad strip stack 172 along a first break line 51, two-pad unit stack 34 is formed. The sixth step and seventh steps remain substantially the same.
The cutting step required to form multi-pad strip 197 begins with corrugated sheet 50 entering a first station 56. First station 56 includes a rotary die cutter 84 and scrap receiver 64. Rotary die cutter 84 includes an upper drum 85 and a lower drum 86. Corrugated sheet 50 passes between upper drum 85 and lower drum 86 and is cut by a cutter 108 coupled to upper drum 85. A series of multi-pad strips 197 exit from the rotary die cutter 84 one after another.
One difference between larger pad 22 and pad 311 is that larger pad 22 is larger in size than pad 311. Illustratively pad 311 includes a pad width 24. Pad width 24 is defined as a distance 26 between any two sides positioned to lie in parallel relation to one another as shown in
In an alternative embodiment, first two-pad unit 31 may be used by consumer 11 as support pads for a cake 47 as shown in
In yet another alternative embodiment, first two-pad unit 31 may be used by consumer 11 as end supports for spool 45 as shown in
As shown in
Four-pad unit stack 12, as shown in
As an example, first pad 311 is coupled to first neighboring pad (e.g. second pad 312) about first perforated line segment 411. First pad 311 is also coupled to second neighboring pad (e.g. third pad 311a) about separate second perforated line segment (e.g. third perforated line segment 413).
Illustratively, first pad 311 has first, second, third, fourth, fifth, sixth, seventh, and eighth sides. The sides are arranged in series to establish an octagon-shaped perimeter 28 as shown in
Joint means 41 includes a first perforated line segment 411, a second perforated line segment 412, a third perforated line segment 413, and a fourth perforated line segment 414. Each perforated line segment 411, 412, 413, 414 includes a series of nicked links 148 extending between each pad 311, 312, 311a, 312a. Each nicked link 148 is arranged to lie in spaced-apart relation to an adjacent nicked link 148a to define a nicked cut 150 therebetween.
As shown in
A multi-unit package 100 includes a shrink-wrap cover 14 and a two-pad unit stack 34. Shrink-wrap cover 14 is formed to include an interior region 15 and two-pad unit stack 34 is positioned to lie in interior region 15. Illustratively, two-pad unit stack 34 includes a plurality of two-pad units 31, 32, 33 stacked on top of one another. Each two-pad unit stack (e.g. two-pad unit stack 34) includes a first pad 22a, a second pad 22b, and joint means 41 for coupling first pad 22a to second pad 22b along first perforated line segment 411 to cause first pad 22a to be separable from second pad 22b.
Illustratively, joint means 41 includes first perforated line segment 411 having a series of nicked links 148 extending between first pad 22a and second pad 22b. Each nicked link 148 is positioned to lie in spaced-apart relation to an adjacent nicked link 148a as suggested in
First pad 22a, includes a pad width 42 defined as a distance 44 between any two sides of first pad 22a that in parallel relation to one another. Illustratively first pad 22a has a distance greater than about 12 inches.
Claims
1. A multi-unit package comprising
- a first two-pad unit including a first pad and a second pad coupled to the first pad of the first two-pad unit along a first perforated line segment,
- a second two-pad unit including a first pad and a second pad coupled to the first pad of the second two-pad unit along a first perforated line segment, the second two-pad unit being arranged to lie above the first two-pad unit to form a two-pad unit stack wherein the first pad of the second two-pad unit lies above the first pad of the first two-pad unit to form a column of first pads, the second pad of the second two-pad unit lies above the second pad of the first two-pad unit to form a column of second pads, and the first perforated line segment of the second two-pad unit is arranged to lie above the first perforated line segment of the first two-pad unit, and
- a retainer arranged to mate with the first and second two-pad units in the two-pad unit stack to retain the first pads, second pads, and first perforated line segments in aligned relation to one another.
2. The multi-unit package of claim 1, further comprising a third two-pad unit including a first pad and a second pad coupled to the first pad of the third two-pad unit along a first perforated line segment, and wherein the first, second, and third two-pad units cooperate to form the two-pad unit stack, the first pad of the third two-pad unit lies above the first pads of the first and second two-pad units, the second pad of the third two-pad unit lies above the second pads of the first and second two-pad units, and the first perforated line segment of the third two-pad unit lies above the first perforated line segments of the first and second two-pad units.
3. The multi-unit package of claim 2, wherein each of the first and second pads in the first and second two-pad units is octagon-shaped.
4. The multi-unit package of claim 2, wherein the retainer is a shrink-wrap cover formed to include an interior region containing the columns of first and second pads.
5. The multi-unit package of claim 1, wherein the retainer is a shrink-wrap cover formed to include an interior region containing the columns of first and second pads.
6. The multi-unit package of claim 1, further comprising
- a first supplemental two-pad unit including a first pad and a second pad coupled to the first pad of the first supplemental two-pad unit along a second perforated line segment,
- a second supplemental two-pad unit including a first pad and a second pad coupled to the first pad of the second supplemental two-pad unit along a second perforated line segment, the second supplemental two-pad unit being arranged to lie above the first supplemental two-pad unit to form a supplemental two-pad unit stack wherein the first pad of the second supplemental two-pad unit lies above the first pad of the first supplemental two-pad unit to form an auxiliary column of first pads, the second pad of the second supplemental two-pad unit lies above the second pad of the first supplemental two-pad unit to form an auxiliary column of second pads, and the second perforated line segment of the second supplemental two-pad unit is arranged to lie above the second perforated line segment of the first supplemental two-pad unit, and
- the retainer is arranged also to mate with the first and second supplemental two-pad units in the supplemental two-pad unit stack to retain in aligned relation the first pads, second pads, and first perforated line segments of the two-pad unit stack and the first pads, second pads, and second perforated line segments of the supplemental two-pad unit stack.
7. The multi-unit package of claim 6, wherein the first two-pad unit and the first supplemental two-pad unit are arranged to lie in side-by-side relation to one another.
8. The multi-unit package of claim 7, wherein the first pad of the first two-pad unit is coupled to the first pad of the first supplemental two-pad unit along a third perforated line segment and the second pad of the first two-pad unit is coupled to the second pad of the first supplemental two-pad unit along a fourth perforated line segment to form a four-pad unit.
9. The multi-unit package of claim 8, wherein each of the third and fourth perforated line segments lies in a longitudinal reference line arranged to lie between the first two-pad unit and the first supplemental two-pad unit.
10. The multi-unit package of claim 9, wherein each of the first and second perforated line segments lies in a transverse reference line arranged to lie in perpendicular relation to the longitudinal reference line.
11. The multi-unit package of claim 8, wherein the first and the second pads of the first two-pad unit and the first supplemental two-pad unit cooperate to form a square-shaped opening therebetween.
12. The multi-unit package of claim 7, wherein the first perforated line segment of the first two-pad unit and the second perforated line segment of the first supplemental two-pad unit lie in a transverse reference line arranged to bisect each of the first two-pad unit and the first supplemental two-pad unit.
13. The multi-unit package of claim 6, wherein each of the first and second pads in the first and second two-pad units and in the first and second supplemental two-pad units is octagon-shaped.
14. A multi-unit package comprising
- a shrink-wrap cover formed to include an interior region, the shrink-wrap cover adapted to protect the multi-unit package during transportation and
- a four-pad unit stack positioned to lie in the interior region, each four-pad unit stack including a plurality of four-pad units stacked on top of one another, each four-pad unit including a first pad, a second pad, a third pad, a fourth pad, and joint means for coupling each pad along a first perforated line segment to a first neighboring pad and along a separate second perforated line segment to a second neighboring pad to cause each pad to be separable from the companion first and second neighboring pads in response to bending of a selected pad relative to each of the companion first and second neighboring pads, wherein the first neighboring pad is one of the first, second, third, and fourth pads and the second neighboring pad is another of the first, second, third, and fourth pads.
15. The multi-unit package of claim 14, wherein the first pad has first, second, third, fourth, fifth, sixth, seventh, and eighth sides arranged in series to establish an octagon-shaped perimeter edge, each side is arranged to intersect with an adjacent side to form an obtuse angle therebetween, the first perforated line segment is established along the first side and the second perforated line segment is established along the third side.
16. A multi-unit package comprising
- a shrink-wrap cover formed to include an interior region, the shrink-wrap cover adapted to protect the multi-unit package during transportation and
- a four-pad unit stack positioned to lie in the interior region, each four-pad unit stack including a plurality of four-pad units stacked on top of one another, each four-pad unit including a first pad, a second pad, a third pad, a fourth pad, and joint means for coupling each pad along a first perforated line segment to a first neighboring pad and along a separate second perforated line segment to a second neighboring pad to cause each pad to be separable from the companion first and second neighboring pads in response to bending of a selected pad relative to each of the companion first and second neighboring pads, wherein the first neighboring pad is one of the first, second, third, and fourth pads and the second neighboring pad is another of the first, second, third, and fourth pads, and wherein the joint means includes a series of nicked links extending between each pad and the neighboring first and second pads and each nicked link is arranged to lie in spaced-apart relation to an adjacent nicked link to define a nicked cut therebetween.
17. The multi-unit package of claim 16, wherein each four-pad unit includes a top layer, a bottom layer, and a corrugated layer arranged to interconnect the top layer and the bottom layer and the series of nicked links are formed in the bottom layer of each four-pad unit along the first perforated line segment and the second perforated line segment.
18. The multi-unit package of claim 17, wherein the top layer and the corrugated layer are broken along the first perforated line segment and the second perforated line segment to cause a cut gap to be formed between each pad and the neighboring first and second pads above the series of nicked links formed in the bottom layer.
19. The multi-unit package of claim 16, wherein the first pad has first, second, third, fourth, fifth, sixth, seventh, and eighth sides arranged in series to establish an octagon-shaped perimeter edge, each side is arranged to intersect with an adjacent side to form an obtuse angle therebetween, the first perforated line segment is established along the first side and the second perforated line segment is established along the third side.
20. The multi-unit package of claim 19, wherein the first pad includes a pad width defined as a distance between any two sides positioned to lie in parallel relation to one another and the distance is less than about 12 inches.
21. The multi-unit package of claim 19, wherein the first pad, the second pad, the third pad, and the fourth pad cooperate to establish a square-shaped opening.
22. The multi-unit package of claim 16, wherein each four-pad unit includes a first two-pad unit including the first pad and the second pad coupled together along the first perforated line segment, a second two-pad unit including the third pad and the fourth pad coupled together, and the second two-pad unit is coupled to the first two-pad unit along the second perforated line segment.
23. A multi-unit package comprising
- a shrink-wrap cover formed to include an interior region and
- a two-pad unit stack positioned to lie in the interior region, the two-pad unit stack includes a plurality of two-pad units stacked on top of one another, each two-pad unit includes a first pad, a second pad, and joint means for coupling the first pad to the second pad along a first perforated line segment to cause the first pad to be separable from the second pad in response to bending of the first pad relative to the second pad and wherein the joint means includes a series of nicked links extending between the first pad and the second pad and each nicked link is arranged to lie in spaced-apart relation to an adjacent nicked link to define a nicked cut therebetween.
24. The multi-unit package of claim 23, wherein the first pad has first, second, third, fourth, fifth, sixth, seventh, and eighth sides arranged in series to establish an octagon-shaped perimeter edge, each side is arranged to intersect with an adjacent side to form an obtuse angle therebetween, the first perforated line segment is established along the first side and the second perforated line segment is established along the third side.
25. The multi-unit package of claim 24, wherein the first pad includes a pad width defined as a distance between any two sides positioned to lie in parallel relation to one another and the distance is greater than about 12 inches.
26. A method of producing a multi-unit package of pads, the method comprising the steps of
- providing corrugated sheets by a conveyor to a cutting machine,
- cutting the corrugated sheets with the cutting machine to form blanks formed to include a plurality of perforated line segments therein and waste,
- accumulating the blanks to form a multi-pad strip stack including a plurality of blanks stacked vertically on top of one another;
- breaking the multi-pad strip stack along the plurality of perforated line segments formed by the cutting machine to form a multi-pad unit stack, and
- applying packaging to the multi-pad unit stack to produce the multi-unit package.
Type: Application
Filed: Jun 5, 2009
Publication Date: Dec 10, 2009
Applicant: TIN INC. (Austin, TX)
Inventor: Michael W. Chapman (Galion, OH)
Application Number: 12/479,498
International Classification: B65D 85/62 (20060101); B65B 35/50 (20060101);