METHOD FOR SEALING PACKAGES
A method of sealing packages having at least one pair of opposing flaps that are shortened or “shied.” with tape. The tape comprises two or more adhesive strips and a non-adhesive area positioned there between having a line of weakness
The present invention relates to a method for sealing packages with shortened flaps using tape having adhesive strips and a non-adhesive area including one or more lines of weakness.
BACKGROUND OF THE INVENTIONFor transport from one location to another, products are often placed in packages. Each package may accommodate either a single product or multiple products, depending on the application. Although many types of packages and package materials are readily available on the market, one of the most common packages is a corrugated cardboard container or package.
A package is generally rectangular and comprises four contiguous vertical side surfaces and two pair of flaps, commonly known as the major and minor pairs of flaps, on both the top and bottom of the package. Each of the flaps is connected to one of the vertical side surfaces, such that when the pairs of major and minor flaps are folded toward each other and toward the center of the package, the edges of at least the major flaps meet near the center of the top or bottom of the package, effectively creating the top and bottom horizontal surfaces of the package and closing the package. The flaps on the package are typically sealed in place by glue or by pressure-sensitive adhesive tape. The tape is often applied in a “C-clip” configuration.
The C-clip is so named because a cross-section of the tape along the length of the tape as it is applied to a package is in the shape of the letter “C”. Specifically, a C-clip of tape is a continuous length of adhesive tape that is applied to a portion of one vertical side of a package, across the center of one of the horizontal surfaces of the package to seal the abutting major flaps together and finally to a portion of the opposite vertical side of the package. Moreover, the tape for a C-clip is typically wide enough to be applied along the abutting flaps such that both flaps of the outermost or major pairs of flaps on the top and bottom of the package are sealed by a single piece of tape. When the package is closed and sealed with a C-clip of adhesive tape, there are no substantial gaps to allow contaminants to reach the product or products enclosed in the package.
One problem associated with a package sealed with C-clips is that the person opening the package typically needs a sharp instrument to penetrate the tape and access the objects inside the package. In addition, a package may provide more protection than the manufacturer or supplier requires for their products. Moreover, because the price of a package is directly related to the quantity of raw materials (for example, corrugated cardboard) used in manufacturing the package, the cost of using a package may be unnecessarily high for those users who do not need as complete a protection for their products.
In response to these concerns, package makers produce a second type of package with shortened or “shied” pairs of major and minor flaps that do not meet each other when the package is in a closed condition. Instead, when the package is closed, there is a gap between both the major and minor pairs of flaps. Packages of this type use substantially less raw materials, which correspondingly reduces both the costs to produce the packages and ultimately reduces the amount of waste generated when disposing of the packages.
An alternative method for sealing packages with shied flaps is to apply two C-clips of package sealing tape to the major pair of flaps, with one C-clip applied on each flap of the pair. For example, it is known to apply two C-clips of tape on opposite sides of a gap between the major flaps from two separate tape sources, each mounted on a separate taping head provided on a package sealing machine. However, because the two C-clips of tape are not applied to cover the gap between the shied flaps, the products enclosed in the package are not protected from contaminants.
Another alternative method of sealing packages is to apply tape having lateral adhesive zones and a non-adhesive area positioned there between to the major pair of flaps. However, this tape is no easier to remove than standard tape having adhesive across the entire width, as the tape is flush with the vertical package surface, forcing a worker to open the package using a sharp instrument, which could potentially damage the products contained therein. In certain forms, tabs have been placed in the non-adhesive areas of the tapes, but tabs do not ensure separating the tape along its length, as the tab could tear off or run into one of the adhesive zones.
Therefore, there is a need for a method for producing easy to open sealed packages having a gap formed by shortened or “shied” pairs of major and minor flaps.
SUMMARY OF THE INVENTIONA method for sealing a package with shortened flaps is provided. The method comprises the steps of providing a package sealing machine having a package guide path and a rotary punch; providing a package comprising two opposing vertical side surfaces, each connected to a separate and opposing flap folded toward each other to provide a gap between their nearest edges; providing a tape from a tape source having two or more adhesive strips and a non-adhesive area; moving the package along the package guide path such that the package contacts the tape and pulls the tape from the tape source; pulling the tape such that the tape moves through the rotary punch; forming a line of weakness in the tape as the tape is pulled through the rotary punch; and applying the tape to at least a portion of the pair of opposed flaps with a strip of adhesive adhered to each flap and the non-adhesive portion covering at least part of the gap.
A method for sealing a package with shortened flaps is provided. The method comprises the steps of providing a tape from a tape source having two or more adhesive strips and a non-adhesive area, wherein the non-adhesive area has a width; providing a package sealing machine having a package guide path and a rotary punch, the rotary punch comprising a punch carrier and a die holder, the die holder having a width that is equal to or lesser than the width of the tape non-adhesive area; providing a package wherein the package comprises two opposing vertical side surfaces, each connected to a separate and opposing flap folded toward each other to provide a gap between their nearest edges, moving the package along the package guide path such that the package contacts the tape and pulls the tape from the tape source; pulling the tape such that the tape moves through the rotary punch; forming a line of weakness in the tape as the tape is pulled through the rotary punch; and applying the tape to at least a portion of the pair of opposed flaps with a strip of adhesive adhered to each flap and the non-adhesive portion covering at least part of the gap.
The present invention is directed to a method of sealing packages with tape. The packages have at least one pair of opposing flaps that are shortened or “shied.” To seal the package and provide a cover for the gap created by the shortened flaps a tape is applied to the shortened flaps; wherein the tape comprises two or more adhesive strips and a non-adhesive area positioned there between. The non-adhesive area of the tape comprises at least one line of weakness. The method uses a tape source, such as a tape roll and applies the tape to the packages. After the tape leaves its source, but before the tape is applied to a package a line of weakness is formed in the tape.
The package sealing machine 50 comprises the base 56 and an upper support 57 positioned relative to the base 56 by way of a strut mechanism 58. The upper support 57 may be vertically adjustably connected with the base 56 by the strut mechanism 58 which is conventionally vertically adjustable to accommodate different height packages. The upper support 57 supports the taping head 54 to which may be connected a tape support member 60. The tape support member 60 further supports the tape source 52, which is rotatably mounted by way of a hub 62, as is known in the art.
As shown in
Also provided are means for defining a tape path, which includes a rotary punch 73 for forming one or more lines of weakness on the tape, mounted within the taping head 54, for guiding the tape from the tape source 52 through the taping head 54 and to the application roller 71. The manner of connection and operation of the application roller 71 and buffing roller 72 for applying tape is well known. The taping head 54 includes the rotary punch 73 which, with the application roll 71, define the tape path and which also assist in tension control of the tape. In
The package sealing machine 50 may be used to seal a package that is square in shape, but as shown in
As shown in
In order to close the top of the package (to go from
A package can be any suitable size or shape. In certain embodiments, the package can be made of inflexible materials, such as, for example, cardboard, paperboard, cartonboard, chipboard, plywood, SBS, metal, plastic, paper, card stock, fabric, ceramic, polymer, natural or synthetic fibers, webs, mesh, screen, wood, composite, mixtures or combinations thereof, or any other suitable material. Alternatively, or in addition, the package can be made of a flexible material, such as, blown or cast film in a blend of low density polyethylene and linear low density polyethylene, metallocenes, ethylene vinyl acetate, surlyn, polyethylene terephthalate, biaxally oriented polypropylene, nylon, combinations thereof, or any other suitable material.
The tape used in the method of the present invention can have one or more lines of weakness. A line of weakness can be located at any suitable location on the tape. As used herein, the term “line of weakness” refers to one or more weakness points arranged in any pattern suitable to facilitate the separation of a tape by providing a weakened tear point in a tape. The pattern can extend in one or more directions, for example the pattern can be straight, bent, angled, curved, irregular or combinations thereof. One or more of the individual weakness points can overlap to form a line of weakness. In addition, or alternatively, one or more of the individual weakness points can be spaced apart from one another to form a line of weakness. As used herein, the term “weakness point” refers to a region of the tape where the thickness of the tape is substantially less than the thickness of the tape surrounding the region. In certain embodiments, an individual weakness point can be weaker than the surrounding area, for example about 50% weaker, about 75% weaker, or about 100% weaker. Weakness points can be formed in any suitable manner, such as by depressions or perforations.
The term “depression” refers to a weakness point having a thickness less than the thickness of the surrounding tape but greater than zero. The depressions can extend into the tape from either the adhesive or non-adhesive surface or both of the tape. In certain embodiments, individual depressions can overlap each other when forming a line of weakness, so that a substantially continuous line of weakness formed by depressions is generated, such as a score line or groove. Additionally, the term “perforation” refers to one or more weakness points, wherein at least a portion of the region of a tape forming the weakness point can have a thickness of about zero.
In certain embodiments the tape may comprise more than two adhesive strips, more than one non-adhesive area, or both, laterally spaced across the width of a tape. For example, the tape may comprise a non-adhesive area in the central area of a tape, one longitudinal adhesive strip on each side of the non-adhesive area, and two additional longitudinal non-adhesive strips, each located on one of the edges of the tape and adjacent to one of the longitudinal adhesive strips. Other combinations of adjacent alternating adhesive and non-adhesive strips are also contemplated by the present invention.
The tape used in the present invention may comprise a backing layer with a layer of adhesive coated to one side of the backing layer. The backing layer may be comprised of paper, web reinforced paper, film, or combinations thereof. If the backing layer comprises film, the backing layer film in certain embodiments may include a tape backing layer comprising one or more of: polyethylene, polypropylene, polyester (such as polyethylene terepthalate (PET)), biaxially oriented polypropylene (BOPP), polyvinyl chloride (PVC), copolymers of propylene and ethylene, and copolymers of ethylene and olefins having four or more carbon atoms.
Examples of adhesives that may be used with the tape of the present invention include compositions such as polyvinyl ether; diene-containing rubber such as natural rubber, polyisoprene, and polybutadiene; styrene-butadiene rubber; polychloroprene; butyl rubber; butadiene-acrylonitrile polymer; thermoplastic elastomer block copolymers such as styrene-isoprene (SI) and styrene-isoprene-styrene (SIS) block copolymers, styrene-butadiene (SB) and styrene-butadiene-styrene polymers (SBS), and ethylene/propylene and ethylene-butylene-diene polymers such as styrene-ethylene/propylene-styrene (SEPS) and styrene-ethylene/butylene-styrene (SEBS); poly-alpha-olefin; amorphous polyolefin; silicone; ethylene-containing copolymer such as ethylene vinyl acetate, ethyl ethyl acrylate, and ethyl methacrylate; polyurethane; polyamide; epoxy; polyvinylpyrrolidone and vinylpyrrolidone copolymers; polyesters; and mixtures of the above. The use of many of these compositions to give specific characteristics to the adhesives may require cross-linking or curing by methods well known in the art. Additionally, the adhesives can contain additives such as tackifiers, plasticizers, antioxidants, stabilizers, curatives, and solvents.
In addition, in certain embodiments, a low adhesion top non-adhesive surface is provided on the other side of the backing layer so that the tape separates more easily when unwound from a tape roll. Such coatings and treatments are well known, and any can be used in accordance with the present invention if they are otherwise suitable for use in the desired tape construction.
In certain embodiments, a tape of the present invention, as shown in
The application of tape to packages by the package sealing machine 50 in accordance with the method of the present invention will now be described with reference to
As shown in
As shown in
While
One of the difficulties when working with a material, such as tape, having an adhesive component is the adherence of the adhesive to the machine applying the material, which in the present invention is the package sealing machine. The adhesive contacting one or more components of the package sealing machine can have several negative effects, such as the adhesive sticking to and building up in the machine components or the adhesive being substantially reduced or removed from a tape. In the present invention, as shown in
As the conveyors 64 and 66 move the package 10 over the bed 70 along the package guide path, the front vertical surface 11 of the package 10 contacts the tape 30. The application roller 71 then presses the leading edge of the tape 30 against the package 10 with the force necessary to adhere both adhesive strips 31A and 31B of the tape 30 to the package 10. While the package 10 continues to move along the package guide path, the tape 30 continues to be pulled by the taping head 54 from the tape source 52 and the application roller 71 is driven upward by the package 10 along its support guide path within the taping head 54 and vertically along the front vertical surface 11 of the package 10 toward the top horizontal surface of the package 10. As the tape 30 is pulled it passes through the rotary punch 73, which forms one or more lines of weakness 40 on the tape 30. Further, after the application roller 71 applies the tape 30, the buffing roller 72, which may be pivotally connected to the taping head 54 and interconnected by a link mechanism to the application roller support as conventionally known, rolls over the newly applied tape 30 to smooth the adhesive strips 31A and 31B onto the surface of the package 10.
The tape 30 is typically applied to only a portion of the front vertical surface 11 of the package 10. After the tape 30 is applied to a portion of the front vertical surface 11 of the package 10 and the application roller 71 has moved to the corner of the front vertical surface 11 and the top horizontal surface of the package 10, the tape 30 is then applied to the top horizontal surface of the package 10 by way of the application roller 71. After the tape 30 has been applied across the entire top horizontal surface and to a portion of the rear vertical surface 13 of the package 10, a conventional cutting means may sever the tape. When tape is applied in this manner, it is commonly said that a “C-clip” of tape has been applied to a package, since the shape of the tape as applied to the package resembles the letter “C”. In certain other embodiments, after the tape 30 has been applied to at least a portion of the top horizontal surface of the package 10, a conventional cutting means may sever the tape. If the tape 30 is severed before the tape is applied to the entire length of the top horizontal surface of the package 10, it is commonly said that an “L-clip” of tape has been applied to the package, since the shape of the tape as applied to the package resembles the capital letter “L”.
Although the above description refers specifically to sequentially applying tape to the front vertical surface, the top horizontal surface, and the rear vertical surface of a package, it is understood that this description can also be useful for operations where tape is applied to other vertical surfaces of the package, to the bottom horizontal surface of the package, or where the tape is applied in a different sequence than that described above. In addition, it is contemplated that the package sealing machine may apply either L-clips, C-clips, a combination of L-clips and C-clips, or straight sections of tape to only one surface of the package that is made up of a single section or is made up of folded flaps. It is further contemplated that multiple taping operations may be occurring simultaneously on the same package.
In addition, it should be noted in contrast to the present invention of forming one or more lines of weakness in a tape during the sealing process; a process of sealing a package using tape that has a preformed line of weakness can lead to the tape separating during its application to packages. For example, if the tape source is a tape roll, as the tape is removed from the roll the tape can separate, such that only the tape on one side of the roll may be pulled off leaving the tape on the other half of the roll in place. By forming a line of weakness after the tape is spun off the roll removes or reduces the tendency of a tape to tear, but still provides a package with a tape having a line of weakness.
Referring now to
The tape used in the present invention can have one or more lines of weakness. A line of weakness can be located at any suitable location on the tape. In certain embodiments, as shown in
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Claims
1. A method for sealing a package with shortened flaps comprising the steps of:
- a) providing a package sealing machine having a package guide path and a rotary punch;
- b) providing a package comprising two opposing vertical side surfaces, each connected to a separate and opposing flap folded toward each other to provide a gap between their nearest edges;
- c) providing a tape from a tape source having two or more adhesive strips and a non-adhesive area;
- d) moving the package along the package guide path such that the package contacts the tape and pulls the tape from the tape source;
- e) pulling the tape such that the tape moves through the rotary punch;
- f) forming a line of weakness in the tape as the tape is pulled through the rotary punch; and
- g) applying the tape to at least a portion of the pair of opposed flaps with a strip of adhesive adhered to each flap and the non-adhesive portion covering at least part of the gap.
2. The method of claim 1, wherein the tape is applied using an application roller.
3. The method of claim 1, wherein the line of weakness is formed using a rotary punch comprising a punch carrier and a die holder.
4. The method of claim 3, wherein the line of weakness is formed using a punch carrier comprising one or more punches and a die holder comprising one or more dies.
5. The method of claim 4, wherein the line of weakness is formed using one or more punches having a shape that is at least one of conical, cylindrical, or pyramidal.
6. The method of claim 1, wherein the punch carrier and die holder form a line of weakness by producing at least one of perforations or depressions.
7. The method of claim 1, wherein two or more lines of weakness are formed.
8. The method of claim 7, wherein the two or more lines of weakness are formed using a rotary punch comprising two or more punch carriers and two or more die holders.
9. The method of claim 7, wherein the two or more lines of weakness are formed using a rotary punch having two or more sets of punches and a die holder having two or more sets of dies.
10. The method of claim 1, wherein two or more lines of weakness are formed substantially parallel to one another.
11. A method for sealing a package with shortened flaps comprising the steps of:
- a) providing a tape from a tape source having two or more adhesive strips and a non-adhesive area, wherein the non-adhesive area has a width;
- b) providing a package sealing machine having a package guide path and a rotary punch, the rotary punch comprising a punch carrier and a die holder, the die holder having a width that is equal to or lesser than the width of the tape non-adhesive area;
- c) providing a package wherein the package comprises two opposing vertical side surfaces, each connected to a separate and opposing flap folded toward each other to provide a gap between their nearest edges,
- d) moving the package along the package guide path such that the package contacts the tape and pulls the tape from the tape source;
- e) pulling the tape such that the tape moves through the rotary punch;
- f) forming a line of weakness in the tape as the tape is pulled through the rotary punch; and
- g) applying the tape to at least a portion of the pair of opposed flaps with a strip of adhesive adhered to each flap and the non-adhesive portion covering at least part of the gap.
12. The method of claim 11, wherein the tape is applied using an application roller.
13. The method of claim 11, wherein the line of weakness is formed using a rotary punch comprising a punch carrier and a die holder.
14. The method of claim 13, wherein the line of weakness is formed using a punch carrier comprising one or more punches and a die holder comprising one or more dies.
15. The method of claim 14, wherein the line of weakness is formed using one or more punches having a shape that is at least one of conical, cylindrical, or pyramidal.
16. The method of claim 11, wherein the punch carrier and die holder form a line of weakness by producing at least one of perforations or depressions.
17. The method of claim 11, wherein two or more lines of weakness are formed.
18. The method of claim 17, wherein the two or more lines of weakness are formed using a rotary punch comprising two or more punch carriers and two or more die holders.
19. The method of claim 17, wherein the two or more lines of weakness are formed using a rotary punch having two or more sets of punches and a die holder having two or more sets of dies.
20. The method of claim 11, wherein two or more lines of weakness are formed substantially parallel to one another.
Type: Application
Filed: Apr 1, 2010
Publication Date: Oct 6, 2011
Inventors: Jennifer Lynn Thomas (Belleville), David Martin Empey (Belleville)
Application Number: 12/752,597
International Classification: B65B 7/00 (20060101);