METHOD AND APPARATUS FOR COMPRESSING AND HOLDING IN COMPRESSION WOVEN FABRIC ARTICLES
The disclosure relates to a method and apparatus for compressing woven material or other compressible material, such as, but not limited to, a comforter set or bedding set. The bedding set or other woven material is placed into a reclosable storage bag which includes a reclosable zipper and a reclosable air valve. With the zipper open, the bag is compressed by a compression apparatus, typically in the absence of vacuum being applied, and, thereafter, the zipper is closed. Straps are wrapped around the compressed bag and the compressed bag is placed into a tote container or similar device. The result is a package with reduced volume, which reduces shipping and display costs, and is more aesthetically attractive to the consumer.
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This application claims priority under 35 U.S.C. §119(e) of provisional patent application Ser. No. 61/304,734, filed on Feb. 15, 2010, the contents of which are incorporated by reference.
BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure
The present disclosure relates to a method and apparatus for producing compact shipping for woven fabric articles or compressible materials, such as, but not limited to, bedding materials.
2. Description of the Prior Art
In the prior art, it is well known to package woven fabric articles or compressible materials, such as bedding material, in a package or bag made from polymeric or similar material. However, the resulting packaging can be bulky which increases transportation, storage and display costs throughout the chain of commerce. Similarly, a consumer may be less prone to buy an unwieldy package.
The storage of polymeric bag within a box is disclosed in U.S. Pat. No. 7,588,160, entitled “Combined Storage Apparatus”, issued on Sep. 15, 2009 to Chen.
SUMMARY AND OBJECTS OF THE DISCLOSUREIt is therefore an object of the present disclosure to provide a method and apparatus for compressing woven fabric articles or compressible materials, such as, but not limited to, bedding materials, in order to provide a compact and aesthetically pleasing package.
This and other objects are attained by the present disclosure by providing a method and apparatus wherein compressible materials are placed into a plastic storage bag, typically of the type with an air valve and a reclosable zipper. The zipper remains open, and the compressible material and plastic storage bag are compressed, typically with a pneumatic or hydraulic apparatus. After the compression step has been performed, the zipper is closed thereby retaining the package in its compressed state. The plastic storage bag, with the compressed woven cloth material therein, is then placed into a reusable tote bag, typically including a clear vinyl portion. This results in an aesthetically pleasing container for display and sale to the customer. This further results in a tote bag and plastic storage bag which may be used by the consumer after the retail sale of the compressible material within the plastic storage bag and the tote bag.
Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawings, wherein:
Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that
Compression arm 30 reciprocates vertically toward and away from tray 20. Compression arm 30 includes flat compression plate 32 (typically sixteen by sixteen inches for applications involving bedding materials) which moves toward and away from tray 20 and impinge against the package 100 (to be described). The compression plate 32 provides a compression surface and is connected by first and second horizontal cross-beams 34, 36 which are, in turn, connected to respective first and second vertical guide rods 38, 40 which are engaged by respective first and second guide apertures 39, 41 and thereby constrained to vertical motion. Vertical drive rod 37 is connected between pneumatic drive 48 and compression plate 32. Pneumatic drive 48 thereby moves compression plate 32 vertically and applies a force to compression plate 32, thereby causing a compression force to be exerted across the area of compression plate. It has been found that a force of at least 2.5 to 3.5 pounds per square inch typically is required for sufficient compression of most compressible materials, such as, but not limited to, woven textile or cloth, particularly those frequently used for bedding materials.
After the comforter set 102 is placed in the sealable storage bag 104 as shown in
The storage bag 104 is then removed from the pressing apparatus 10 and placed into the forming section 200 of the packaging shown in
Strap portions 208, 210, 218, 220 are engaged tightly around storage bag 104 and snap buckle portions 212, 214 and 222, 224 are inter-engaged to each other to form first and second straps 216, 226 which are tightly wrapped around storage bag 104, thereby constraining storage bag 104 and maintaining the size and shape of storage bag 104.
The storage bag 104, with forming section 200 engaged thereto, is then placed within cloth tote container or bag 300, which serves as an outer container typically formed as a luggage-type container, thereby further constraining storage bag 104. Tote container or bag 300 includes a bottom wall 302 with a square or rectangular shape and four side walls 304, 306, 308, 310 extending therefrom. Top wall 312 extends from side wall 304 and includes cloth zipper 315 around three sides thereof for releasable attachment with side walls 306, 308 and 310. The terms “top”, “bottom” and “side” are arbitrary in this context as the orientation of tote container or bag 300 can be easily changed. Further, top wall 312 typically includes transparent window or portion 313 so as to allow the purchaser to see the contents of storage bag 104. Side wall 308 includes handle 314 sewn or otherwise attached thereto, thereby allowing a customer to carry the tote container or bag 300, with the storage bag 104 and comforter set 102 therein.
After the storage bag 104 and comforter set 102 have been placed into the tote container or bag 300, an optional fabric sample 400 (matching in appearance to the comforter set 102) may be placed over the storage bag 104, including the comforter set 102, and the zipper 315 of tote container or bag 300 closed, so that the display through transparent top wall 102 is more aesthetically pleasing.
In this way, an appealing and compact package for the comforter set 102 (or similar woven or similar material objects) is achieved as shown in
Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.
Claims
1. A method, including the steps of:
- providing a package including a reclosable zipper;
- placing compressible material within the package;
- compressing the package thereby expelling a portion of air from the package;
- after the compressing step, rendering the package leak resistant; and
- after the rendering step, constraining the package.
2. The method of claim 1 wherein the compressible material includes woven material.
3. The method of claim 1 wherein the compressible material includes textile or cloth.
4. The method of claim 2 wherein the step of expelling air from the package is performed with the reclosable zipper in an at least partially open configuration and the step of rendering the package leak resistant is performed by closing the reclosable zipper.
5. The method of claim 4 wherein the step of compressing the package is performed in the absence of a vacuum being applied to the package.
6. The method of claim 5 wherein the step of compressing is performed with at least 2.5 pounds per square inch of force applied to the package.
7. The method of claim 5 wherein the step of compressing is performed with at least 3.5 pounds per square inch of force applied to the package.
8. The method of claim 6 wherein the package further includes an air valve with an open position and a closed position.
9. The method of claim 8 wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak-resistant seal.
10. The method of claim 9 wherein the reclosable zipper includes a slider.
11. The method of claim 5 wherein the step of constraining the package includes wrapping straps around the package.
12. The method of claim 11 further including the step of providing a forming section around the package during the step of compressing, wherein the wrapping straps extend from the forming section.
13. The method of claim 12 wherein the forming section includes rigid or semi-rigid bottom panel.
14. The method of claim 13 wherein the forming section further includes first and second rigid or semi-rigid side panels extending from the bottom panel.
15. The method of claim 14 wherein the step of constraining the package further includes the step of placing the package into an outer container after the step of wrapping straps around the package.
16. The method of claim 15 wherein the outer container is a luggage-type container.
17. The method of claim 15 wherein the outer container is a tote container.
18. The method of claim 17 wherein the tote container includes a rectangular or square bottom wall with four side walls extending therefrom, and a top wall extending from one of the side walls.
19. The method of claim 18 wherein the tote container includes a cloth zipper formed around three sides of the top wall for attaching to three of the side walls.
20. The method of claim 19 wherein the top wall includes a transparent panel.
21. The method of claim 20 wherein one of the side walls of the tote container includes a handle attached thereto.
22. The method of claim 21 further including placing a sheet of material between the package and the transparent panel of the top wall of the tote container, whereby the sheet of material is visible through the transparent panel.
23. The method of claim 22 wherein the sheet of material has an appearance which matches that of the compressible material.
24. A method, including the steps of:
- providing a package including front and rear walls, a mouth with a reclosable zipper; and an air valve with an open position and a closed position;
- placing compressible material within the package with the reclosable zipper at least partially open;
- compressing the package thereby expelling a portion of air from the package through the reclosable zipper, wherein the step of compressing is performed by a compressing device with a tray for receiving the package and a drive shaft including a compression surface thereon;
- after the compressing step, rendering the package leak-resistant; and
- after the step of rendering the package leak-resistant, constraining the package.
25. The method of claim 24 wherein the compressible material includes woven material.
26. The method of claim 24 wherein the compressible material includes textile or cloth.
27. The method of claim 25 wherein the step of compressing is performed by a pneumatic drive.
28. The method of claim 27 wherein the step of compressing is performed in the absence of a vacuum applied to the package.
29. The method of claim 28 wherein the step of compressing is performed with at least 2.5 pounds per square inch of force applied to the package.
30. The method of claim 28 wherein the step of compressing is performed with at least 3.5 pounds per square inch of force applied to the package.
31. The method of claim 30 wherein the step of compressing is performed with the zipper open and the step of rendering the package leak-resistant is performed by closing the zipper.
32. The method of claim 31 wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak-resistant seal.
33. The method of claim 32 wherein the reclosable zipper includes a slider.
34. The method of claim 32 wherein the step of constraining the package includes wrapping straps around the package.
35. The method of claim 34 further including the step of providing a forming section around the package during the step of compressing, wherein the wrapping straps extend from the forming section.
36. The method of claim 35 wherein the forming section includes rigid or semi-rigid bottom panel.
37. The method of claim 36 wherein the forming section further includes first and second rigid or semi-rigid side panels extending from the bottom panel.
38. The method of claim 37 wherein the step of constraining the package further includes the step of placing the package into an outer container after the step of wrapping straps around the package.
39. The method of claim 38 wherein the outer container is a luggage-type container.
40. The method of claim 38 wherein the outer container is a tote container.
41. The method of claim 40 wherein the tote container includes a rectangular or square bottom wall with four side walls extending therefrom, and a top wall extending from one of the side walls.
42. The method of claim 41 wherein the tote container includes a cloth zipper formed around three sides of the top wall for attaching to three of the side walls.
43. The method of claim 42 wherein the top wall includes a transparent panel.
44. The method of claim 43 wherein one of the side walls of the tote container includes a handle attached thereto.
45. The method of claim 44 further including placing a sheet of material between the package and the transparent panel of the top wall of the tote container, whereby the sheet of material is visible through the transparent panel.
46. The method of claim 45 wherein the sheet of material has an appearance which matches that of the compressible material.
47-61. (canceled)
62. The method of claim 1 wherein the step of compressing is performed with the package in a tray, the tray including side elements configured to determine a shape of the package after the step of compressing.
63. The method of claim 62 wherein the tray further includes a rear element configured to determine a shape of the package after the step of compressing.
64. The method of claim 24 wherein the tray includes side elements configured to determine a shape of the package after the step of compressing.
65. The method of claim 64 wherein the tray further includes a rear element configured to determine a shape of the package after the step of compressing.
Type: Application
Filed: Jun 25, 2010
Publication Date: Aug 18, 2011
Applicant: ILLINOIS TOOL WORKS INC. (Glenview, IL)
Inventors: Lawrence Share (Skokie, IL), Donald Lee Crevier (Essex, IL), Alan Varacins (Burlington, WI), Stanley Piotrowski (Addison, IL), Timothy Michael Arends (St. Charles, IL)
Application Number: 12/823,328
International Classification: B65B 11/52 (20060101); B65B 11/58 (20060101);