Apparatus and method for packaging sheet material
An apparatus and method for packaging sheet material. The apparatus comprises a housing, a first forming guide, and a banding unit. The housing defines a cylindrical cavity which is open at both ends and includes a longitudinal opening which intersects the cylindrical cavity. The first forming guide is affixed to the housing adjacent the longitudinal opening and extends into the cylindrical cavity. The banding unit is disposed adjacent the downstream end of the cylindrical cavity. The method comprises imparting a U-shaped form upon a stack of sheet material by insertion of the stack into the upstream end of a cylindrical cavity. The U-shaped stack of sheet material is then moved toward and out of the downstream end of the cylindrical cavity. Finally, the U-shaped stack is banded as the stack emerges from the cylindrical cavity.
Priority is claimed to U.S. Provisional Patent Application No. 60/524,773, filed Nov. 21, 2003, and to U.S. patent application Ser. No. 10/772,967, filed Feb. 5, 2004, which claims priority to U.S. Provisional Patent Application No. 60/446,293, filed Feb. 10, 2003. The disclosure of each of the aforementioned documents is incorporated herein by reference.
BACKGROUND OF THE INVENTION1. Field of the Invention
The field of the present invention is sheet material packaging equipment and methods. 2. Background
Dispensers for sheet material are well known to the art and come in different forms for dispensing a wide variety of sheet materials. In some cases, the packaging in which the sheet material is initially placed by the manufacturer also serves as the dispenser. In other instances, the sheet material is packaged to facilitate placement of the package in the dispenser and to facilitate dispensation therefrom.
One common aspect of many of these dispensing methods is that the sheet material is placed into a U-shaped form before being inserted into the packaging. Different methods of forming the sheet material into the U-shaped form are disclosed in U.S. Pat. No. 6,732,492 to Osborne et al. and U.S. Pat. No. 6,202,392 to Greenwell et al. Other methods, such as the one disclosed in U.S. Pat. No. 3,919,827 to Larson et al., which discloses an apparatus for folding a stack of bags into a “W” shape prior to packaging, are adaptable to place sheet material into a U-shaped form. The solutions provided in the aforementioned patents, however, may not be well suited for all types of stacked materials or for all packaging needs.
SUMMARY OF THE INVENTIONThe present invention is directed towards an apparatus and method for packaging sheet material. Referring to the apparatus, a housing defines a cylindrical cavity which is open at both ends. A wall of the housing includes a longitudinal opening which intersects the cylindrical cavity. A first forming guide is affixed to the housing adjacent to the longitudinal opening and extends into the cylindrical cavity. A banding unit is disposed adjacent the downstream end of the cylindrical cavity. The first forming guide may extend longitudinally beyond the upstream end of the cylindrical cavity and may include parallel walls, each wall being disposed on an opposite side of the longitudinal opening. Optional features include a second forming guide which has a radially defined end affixed to the housing at the upstream end of the cylindrical cavity, a shrink-wrap unit disposed downstream of the banding unit, and a perforation unit disposed downstream of the shrink-wrap unit.
Turning to the method, a U-shaped form is imparted upon a stack of sheet material by insertion of the stack into a cylindrical cavity which has a diameter that is less than the width of the stack. The U-shaped stack is moved toward and out of the downstream end of the cylindrical cavity. The U-shaped stack is then banded as it emerges from the cylindrical cavity. When in the cylindrical cavity, a support may be inserted into the U-shaped stack, with the support and the U-shaped stack being moved together toward and out of the cylindrical cavity. After banding, heat-shrinkable wrap may be placed on the banded stack, which may also be perforated following application of heat.
Accordingly, the present invention provides an improved apparatus and method for packaging sheet material. Other advantages of the invention will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGSIn the drawings, wherein like reference numerals refer to similar components:
Turning in detail to the drawings,
The banding unit 35, the shrink wrap unit 37, and the perforation unit 39 are each of a type that are commonly used throughout the packaging industry and are thus known to those skilled in the packaging arts. As such, the details relating to these downstream units are not discussed further herein.
A forming unit 33 is illustrated in
As can be seen in
The configuration of the first forming guide 43 is best seen in
With the forming guides configured thusly, when a flat stack of sheet material passes into the rectangular end of the second forming guide and is pushed towards the radially defined end, the outer edges of the flat stack curl about either side of the extension of the first forming guide. The two forming guides thus guide the stack of sheet material into the U-shaped form that allows the stack to pass into the cylindrical cavity and is desired for the final product.
Referring to
Thus, an apparatus and a method for packaging sheet material are disclosed. While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the following claims.
Claims
1. An apparatus for packaging sheet material comprising:
- a housing defining a cylindrical cavity open at both ends and including a longitudinal opening in a wall of the housing, the longitudinal opening intersecting the cylindrical cavity;
- a first forming guide affixed to the housing adjacent to the longitudinal opening and extending into the cylindrical cavity; and
- a banding unit disposed adjacent a downstream end of the cylindrical cavity.
2. The apparatus of claim 1 further comprising a second forming guide having a radially defined end affixed to the housing at an upstream end of the cylindrical cavity.
3. The apparatus of claim 1, wherein the first forming guide extends longitudinally beyond an upstream end of the cylindrical cavity.
4. The apparatus of claim 1, wherein the first forming guide includes parallel walls, each being disposed on opposite sides of the longitudinal opening.
5. The apparatus of claim 1 further comprising a shrink-wrap unit disposed downstream of the banding unit.
6. The apparatus of claim 5 further comprising a perforation unit disposed downstream of the shrink-wrap unit.
7. An apparatus for packaging sheet material comprising:
- a housing defining a cylindrical cavity open at both ends and including a longitudinal opening in a wall of the housing, the longitudinal opening intersecting the cylindrical cavity;
- a first forming guide affixed to the housing and extending into the cylindrical cavity, the first forming guide including parallel walls, each being disposed on opposite sides of the longitudinal opening; and
- a second forming guide having a radially defined end affixed to the housing at an upstream end of the cylindrical cavity; and
- a banding unit disposed adjacent a downstream end of the cylindrical cavity.
8. The apparatus of claim 7, wherein the first forming guide extends longitudinally beyond an upstream end of the cylindrical cavity.
9. The apparatus of claim 7 further comprising a shrink-wrap unit disposed downstream of the banding unit.
10. The apparatus of claim 9 further comprising a perforation unit disposed downstream of the shrink-wrap unit.
11. An apparatus for packaging sheet material comprising:
- a housing defining a cylindrical cavity open at both ends and including a longitudinal opening in a wall of the housing, the longitudinal opening intersecting the cylindrical cavity;
- a first forming guide affixed to the housing, extending longitudinally beyond an upstream end of the cylindrical cavity, and extending radially into the cylindrical cavity, the first forming guide including parallel walls, each being disposed on opposite sides of the longitudinal opening; and
- a second forming guide having a radially defined end affixed to the housing at an upstream end of the cylindrical cavity;
- a banding unit disposed adjacent a downstream end of the cylindrical cavity;
- a shrink-wrap unit disposed downstream of the banding unit; and
- a perforation unit disposed downstream of the shrink-wrap unit.
12. An apparatus for packaging sheet material comprising:
- a housing defining a cylindrical cavity open at both ends;
- means for causing a stack of sheet material to take on a U-shaped form, wherein the cylindrical cavity is adapted to allow passage of the U-shaped form of the stack of sheet material therethrough;
- means for inserting a support into the stack of sheet material as the U-shaped stack of sheet material passes through the cylindrical cavity; and
- a banding unit disposed adjacent a downstream end of the cylindrical cavity.
13. A method of packaging sheet material comprising:
- imparting a U-shaped form upon a stack of sheet material by insertion of the stack into an upstream end of a cylindrical cavity, a diameter of the cylindrical cavity being less than a width of the stack;
- moving the U-shaped stack toward and out of a downstream end of the cylindrical cavity; and
- banding the U-shaped stack as the stack emerges from the downstream end of the cylindrical cavity.
14. The method of claim 13 further comprising
- placing a heat-shrinkable wrap about the banded stack; and
- heating the heat-shrinkable wrap.
15. The method of claim 14 further comprising perforating the heat-shrinkable wrap.
16. The method of claim 13, wherein imparting the U-shaped form upon the stack includes imparting the U-shaped form using a first forming guide extending into the cylindrical cavity from a wall defining the cylindrical cavity.
17. The method of claim 13, wherein imparting the U-shaped form upon the stack includes guiding the stack into the cylindrical cavity with a second forming guide having a radially defined end affixed to an upstream wall defining the cylindrical cavity.
18. The method of claim 13, wherein moving the U-shaped stack toward and out of the downstream end of the cylindrical cavity comprises:
- inserting a support through an opening in a wall defining the cylindrical cavity and into the U-shaped stack; and
- moving the support and the U-shaped stack toward and out of the downstream end of the cylindrical cavity.
19. A method of packaging sheet material comprising:
- imparting a U-shaped form upon a stack of sheet material by insertion of the stack into an upstream end of a cylindrical cavity, a diameter of the cylindrical cavity being less than a width of the stack, wherein a first forming guide extends into the cylindrical cavity from a wall defining the cylindrical cavity and a second forming guide is affixed to an upstream end of the wall defining the cylindrical cavity;
- moving the U-shaped stack toward and out of a downstream end of the cylindrical cavity; and
- banding the stack as the stack emerges from the downstream end of the cylindrical cavity.
20. The method of claim 19 further comprising
- placing a heat-shrinkable wrap about the banded stack after; and
- heating the heat-shrinkable wrap.
21. The method of claim 20 further comprising perforating the heat-shrinkable wrap.
22. The method of claim 19, wherein moving the U-shaped stack toward and out of the downstream end of the cylindrical cavity comprises:
- inserting a support through an opening in a wall defining the cylindrical cavity and into the U-shaped stack; and
- moving the support and the U-shaped stack toward and out of the downstream end of the cylindrical cavity.
23. A method of packaging sheet material comprising:
- imparting a U-shaped form upon a stack of sheet material by insertion of the stack into an upstream end of a cylindrical cavity, a diameter of the cylindrical cavity being less than a width of the stack, wherein a first forming guide extends radially into the cylindrical cavity from a wall defining the cylindrical cavity and a second forming guide is affixed to an upstream end of the wall defining the cylindrical cavity;
- inserting a support through an opening in the wall defining the cylindrical cavity and into the U-shaped stack; and
- moving the support and the U-shaped stack toward and out of the downstream end of the cylindrical cavity; and
- banding the stack as the stack emerges from the downstream end of the cylindrical cavity;
- placing a heat-shrinkable wrap about the banded stack; and
- heating the heat-shrinkable wrap.
24. The method of claim 23 further comprising perforating the heat-shrinkable wrap.
Type: Application
Filed: Nov 23, 2004
Publication Date: Jan 5, 2006
Inventors: Janica Behnke (Appleton, WI), Eric Stevens (Middleville, MI), Timothy Hartjes (Kimberly, WI)
Application Number: 10/996,798
International Classification: B65B 63/04 (20060101); B65B 53/02 (20060101); B65B 13/02 (20060101);