WO2024044265A1 - Procédé d'emballage de papier scellable pour un produit - Google Patents

Procédé d'emballage de papier scellable pour un produit Download PDF

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Publication number
WO2024044265A1
WO2024044265A1 PCT/US2023/030950 US2023030950W WO2024044265A1 WO 2024044265 A1 WO2024044265 A1 WO 2024044265A1 US 2023030950 W US2023030950 W US 2023030950W WO 2024044265 A1 WO2024044265 A1 WO 2024044265A1
Authority
WO
WIPO (PCT)
Prior art keywords
product
edge portion
paper sheet
outer edge
bond
Prior art date
Application number
PCT/US2023/030950
Other languages
English (en)
Inventor
Joseph F. Van De Hey
Jeffery J. VANHANDEL
Alex M. ZIRBEL
Alex N. KUFFEL
Brady J. VAN DE HEY
David M. DEHAAI
Matthew J. RADLOFF
Original Assignee
C3 Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by C3 Corporation filed Critical C3 Corporation
Publication of WO2024044265A1 publication Critical patent/WO2024044265A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B61/00—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
    • B65B61/04—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages
    • B65B61/06—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages by cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B61/00—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
    • B65B61/04—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages
    • B65B61/06—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages by cutting
    • B65B61/08—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages by cutting using rotary cutters

Definitions

  • This disclosure relates to an initial seal wrapping of product in a commercial setting to aid in further packaging the same. More specifically, it concerns a sealable paper wrap and method used to seal wrap product in a flat configuration for further processing into a package that is easier and less expensive to handle, store and ship. Preferably such product is a high expansion force product that has been compressed from its original size and needs to be maintained compressed for some period of time during the packaging process.
  • Compressible foam materials such as polyurethane foam layers or other foam types as various combinations of layers like a mattress product, including pockets of coils and springs for use in mattress construction, are just a few examples of materials which are more efficiently handled in a compressed form for storage and shipping.
  • Such products are first subjected to a stage of compressing the compressible product, and in particular a mattress, in order to reduce the thickness thereof and therefore reduce the final maximum size of a packaged product when formed into a more compact configuration.
  • a stage of compressing the compressible product and in particular a mattress
  • such configurations could be subjecting the compressed flattened product to then be folded, rolled, folded and rolled, or rolled and rolled, to attain an even smaller final package size.
  • the compressible product e.g., as seen in FIG.
  • the compressed mattress product then advances along in flattened form to a machine and process for folding and/or spiral-rolling of the product.
  • a spiral roll can be formed by existing rolling equipment, and preferably, bottom surface 12b will be the outside of the rolled up product and can aid to protect the more valuable top surface 12a from damage during roll up, packaging and shipping.
  • Storage of the rolled product can then occur, for example, by insertion in a pre-formed bag or being wrapped with stretch wrap or paper wrap around a circumference of the product as part of the spiral-rolling process near the time rolling of the product concludes in the rolling machine.
  • this spiral rolled product can then be subjected to a further rolling process to further reduce the overall size of the rolled product, a so-called roll of a roll, as seen in FIG. 4. All of this is toward the goal of rolling the compressible product wound up on itself in a very tight manner so as to prevent it from occupying too great a volume during transport and storage. The greater the final compression ratio of the product, the cheaper the transport and storage.
  • a method to seal wrap a product includes providing the product having a top surface separated from a bottom surface by a height between the top and bottom surfaces. Another step is wrapping the product with a sealable paper sheet, where the sealable paper sheet has an outer paper layer joined with an inner seal layer. And there is a step of positioning the sealable paper sheet adjacent to each of the top surface and the bottom surface of the product such that the outer paper layer is separated from the top surface and the bottom surface of the product by the inner seal layer. Further, is a step locating outer edges of the sealable paper sheet to be adjacent and overlapping.
  • a next step is sealing the outer edges of the sealable paper sheet on at least one side of the product by forming a first bond between adjacent and overlapping inner seal layers along a length of the at least one side of the product. Further, there is a step holding taut laterally and cutting longitudinally an outer edge portion of the sealable paper sheets on at least one side of the product by slicing: (i) the outer edge portion with essentially no stretching of the outer edge portion and (ii) in an area of the outer edge portion essentially free of the bond between adjacent inner seal layers.
  • Additional steps that can be employed relate to use of heating and/or pressure to seal the sealable paper, forming a second bond, and how to hold and/or slice the sealable paper sheets.
  • high expansion force means a product that is (i) reduced in volume by flattening it to a flattened volume that is at least two times less than its precompressed volume, and preferably reduced to a flattened volume that is at least four times less than its pre-compressed volume, more preferably at least 6 times, at least 8 times or at least 10 times, and (ii) the product is resilient to recover to at least about 90% of its pre-compressed volume, preferably to at least about 95% of its precompressed volume and more preferably 98%, when at a temperature of about 70 degrees Fahrenheit for a period of one hour and the restrictive means causing it to be reduced in volume is removed from the product.
  • essentially means 10 percent and less, preferably means 5 percent and less, and more preferably means 2 percent and less, and most preferably means completely free of and no stretch, respectively.
  • substantially simultaneously means at the same time to at most a 10 percent difference in time, preferably means at the same time to at most a 5 percent difference in time, more preferably means at the same time to at most a 2 percent difference in time, and most preferably means at the same time.
  • Figure 1 is a side schematic view of a compressible product, like a mattress, having various layers of material, in its original uncompressed condition;
  • Figure 2 is a side schematic view of that in FIG. 1, but now in a compressed condition
  • Figure 3 is a side schematic view of that in FIG. 2 after it has been rolled up using a roll cage machine and process;
  • Figure 4 is a side schematic view of that in FIG. 3 after it has been rolled up using the roll cage machine and process, first as a full length roll and then as a roll of a roll, and before it has sealable paper wrapping securing it in that position;
  • Figure 5 is a diagrammatic side view of a tamp (or compression) machine and exemplary compression process for a product that is to be seal wrapped as described herein;
  • Figure 6 is a diagrammatic side view of that seen in FIG. 5, now with the to be packaged product in position for compression and then sealable paper sheet sealing and cutting;
  • Figure 7 is an enlarged cross-sectional view of an exemplary sealing mechanism and sharp edge mounted therein for cutting the sealed together sheets in due course. here with the sharp edge in a retracted position before (or after) cutting the sealed together sheets;
  • FIG. 8 is a diagrammatic view of that seen in FIG. 7, now with the sharp edge in an extended position and cutting through the sealed together sheets in the non-bonded area;
  • Figure 9 is a top schematic view of a compressible product wrapped in between a top sealable paper sheet that is sealed to a bottom sealable paper sheet, with a first product sealed therein and the trailing paper sheets sealed together after slicing from the preceding product to then be ready for the next product to be wrapped with the sealable paper sheets;
  • Figure 10 is a flow diagram of annotated steps of an exemplary compression, wrapping, sealing and cutting process for a product that is being seal wrapped as described herein.
  • the method includes wrapping the product 10 having a top surface 12a separated from a bottom surface 12b by a height 14a (uncompressed product), 14b (compressed product) between the top and bottom surfaces, with a sealable paper sheet, wherein the sealable paper sheet has an outer paper layer joined with an inner seal layer.
  • the inner seal layer can be a poly layer that is self-bonding when subjected to heat and/or pressure.
  • the seal layer could be an adhesive pre-applied or applied in process, to the paper sheet, and such seal layer could be continuous across the surface of the paper sheet or discontinuous like in zones that are horizontal, vertical or somewhere in between at an angle to the machine direction of the paper sheet.
  • the adhesive layer could be a "wet” or “dry” adhesive that bonds the adjacent paper sheets it is in between by pressure and/or a chemical and/or mechanical bonding together.
  • a next step includes positioning the sealable paper sheet adjacent to each of the top surface and the bottom surface such that the outer paper layer is separated from the top surface and the bottom surface by the inner seal layer. And then, there is locating outer edges 21, 22, 23, 24 of the sealable paper sheet to be adjacent and overlapping each other.
  • a further step is sealing the outer edges of the sealable paper sheet on at least one side of the product by forming a first bond between adjacent and overlapping inner seal layers along a length of the at least one side.
  • this sealing step results in all four sides of the product being sealed, but three of those seals (e.g., where bonds 26, 27, 28 are seen here) may already exist and not be needed in this process, for example, when a tube wrap is used (i.e ., so the sides are already sealed together) and the side common in between two successive products being wrapped
  • a yet further step to the method is holding taut laterally and cutting longitudinally an outer edge portion 30 of the sealable paper sheets on at least one side of the product by slicing 34: (i) the outer edge portion 30 with essentially no stretching of the outer edge portion 30 and (ii) in an area 32 of the outer edge portion 30 essentially free of the bond between adjacent inner seal layers 29, 37.
  • the gap between slice line/area 34 and the adjacent bonds 29 and 37 can vary and be closer or further apart than shown, if desired.
  • the bonds 26, 27, 28, 29 and 37 need to be close enough to completely seal the product inside from the outside environment, and may overlap more or less than shown as long as there are no gaps in the perimeter seal created by the bonds located around outer edges 21, 22, 23 and 24, preferably for their respective lengths 21b, 22b, 23b, and 24b.
  • the method described herein includes modifications discovered by the inventors to surprisingly adapt an existing product compression station (also known as a tamp section or machine) to seal - cut - seal two sealable paper sheets 20 around product 10, like a compressed mattress, prior to rolling the product in paper or plastic packaging or placing in a paper or plastic tube.
  • an existing product compression station also known as a tamp section or machine
  • the sealable paper sheet is better adapted to high tension and can result in fewer imperfections and may be more conducive to flat pack shipping of products, especially like a mattress shipped in a compressed state.
  • One exemplary sealable paper sheet used to practice the disclosed method is a substrate made from kraft paper with a low density polyethylene (LDPE) inner layer.
  • LDPE low density polyethylene
  • the sealable paper sheet preferably, it has these attributes that the inventors have devised work well (though other attributes and their ranges may be possible), and all within a range of plus or minus 20%: (i) product composition of a total weight of about 64 pounds per 3000 square feet including an about 14 pound layer of LDPE matte finish poly and about 50 pounds of natural kraft pulp paper fibers (preferably of a high performance fiber type), with the total sheet having (ii) these product performance characteristics - (a) Tear strength in the machine direction of about 90 grams, (b) Tear strength in the crossmachine direction of about 95 grams, (c) Tensile strength in the machine direction of about 40 pounds per inch, (d) Tensile strength in the cross-machine direction of about 29 pounds per inch, (e) Stretch in the machine direction of about 7%, and (f) Stretch in the cross-machine direction of about 9%.
  • a sealable paper sheet made by Owens Corning® of Mission, B.C. Canada under the trade name Inter Wrap can be employed to practice the disclosure here.
  • standard tests are employed as would be known to one of ordinary skill in the art in combination with the teachings herein.
  • a sealable paper sheet made by Mondi Orebro ® of Orebro, Sweden under the trade name Functional Barrier 95/5 can be employed to practice the disclosure here.
  • such a sheet can have these attributes that the inventors have devised work well (though other attributes and their ranges may be possible), and all within a range of plus or minus 20%: (i) product composition of a total weight of about 84 grams per square meter (GSM) including about 5% of this weight due to an outer layer of heat sealable polymeric material, with the total sheet having (ii) these product performance characteristics - (a) Tear in the machine direction of about 680 mN (as determined by test method ISO 1974) , (b) Tear in the cross-machine direction of about 770 mN (as determined by test method ISO 1974), (c) Tensile strength in the machine direction of about 9.3 N/m (as determined by test method ISO 1924), (d) Tensile strength in the cross-machine direction of about 4.6 N/m (as determined by test method ISO 1924), (e) Stretch in the machine direction of about 1.6% (as determined by test method ISO 1924), and (f) Stretch in the cross the cross
  • product enters a machine tamp area 60 (i.e., such area having a compression press 62) and conveys through the paper sheet curtain wall while feeding paper sheet around the product/mattress as it enters, for example, at a 1:1 speed rate so the sealable paper sheet is taut but not stretched or elongated beyond its formed length.
  • the sealable paper sheet roll sits on two driven paper sheet rollers, unwinding via surface contact or center driven, for example, to help achieve a more consistent speed.
  • the sealable paper sheet rolls 25 (on the driven rollers) are kept centered via end guides contacting the roll core, and rolls are aligned parallel to prevent 'walking'.
  • An air blast keeps the top sealable sheet of material 20 from folding over and keeps the web floating over the side seal area.
  • the tamp machine program calculates the distance traveled to ensure the product/mattress (size dependent) has fully entered the tamp.
  • the machine can also consider the mattress height required for the sealable paper sheet to be flat at the point of sealing. For example, this can be typically 2-4 inches more than the length or width of the product/mattress, and then a bit more or less than this dependent upon the product being wrapped and the desired wrapping process.
  • the tamp 60 can then compress the product to desired height per the program, or a maximum tonnage of about 40 tons (whichever comes first), for example, including step 104.
  • seal mechanism 40 is similar to the prior art plastic film wrap process, including one to three seal areas, it significantly differs because now also including cutting action and innovative separation of sealable paper sheets post cutting.
  • the side seal process takes 1-4 seconds, for example and can be more or less depending on the materials being sealed and the desired nature of the seal, while contacting the sealing anvil 42 to seal bar 44 (including optional cushion with or without teflon tape thereon), including use for steps 106 and 108.
  • the cross seal, including steps 108 and 109, can be driven separately, e.g., via chain and motor, or actuate pneumatically, for consistent pressure to create the final seal 29 of the product in the tamp machine and the paper sheet curtain seal 37 of the next product in two different seal areas with a gap in the middle that is unsealed, i.e., no bonding of and between the sealable sealed sheets in that location, such as gap 32 in Figure 9.
  • the cutting preferably happens in this gap 32 that is essentially free of the bond, and while the cross seal forming the two different seal areas 29, 37 on either side of the gap 32 is still contacting the sealable paper sheets under pressure, including step 108.
  • this sealing and cutting action is holding taut laterally and cutting longitudinally the outer edge portion 30 of the sealable paper sheets on a side 24 of the product by slicing at 34: (i) the outer edge portion 30 with essentially no stretching of the outer edge portion 30 and (ii) in an area 32 of the outer edge portion essentially free of the bond between adjacent inner seal layers.
  • this innovative seal wrap method is consistent and reliable for maintaining, when desired, compressed product in its vacuum sealed and compressed state for as long as needed (e.g., often 5 to 25 seconds), i.e., as the high expansion force product makes its way to its finish wrapping in final form until it arrives at an end user, who will unpackage and unwrap the compressed and rolled up high expansion force product, and then use the same as intended.
  • the compressed product in its vacuum sealed and compressed state could remain that way in a flat final form (or loosely rolled or folded, and then bagged in paper package) until it arrives at an end user, who will open the package to access the product, e.g., such as a compressed and high expansion force product, and then use the same as intended.
  • a sharp edge 50 such as a rotary knife, separates the two seals created by the cross seal with a gap 32 between them, including step 109.
  • the knife and its assembly 51 moves across the machine, as it is actuated, e.g., pneumatically via a rod-less cylinder and solenoids.
  • the knife travels approximately 120 inches in approximately 3 seconds to complete the cut all the way through the width of the paper sheets.
  • the cutting actuation can happen in both directions, so the knife does not need to return to its original position until the next product is complete and its bilayer paper sheets are ready to be cut.
  • the knife is positioned in the narrow gap 43 cut into the cross seal anvil 42 (see Figure 8). This gap provides enough room for the blade to slide through, preferably, without creating much of a void for the sealable paper sheets to dip into.
  • the knife also sits on a small air cylinder (not shown) that keeps the blade tucked inside of a gap 45 to minimize damage and safety risks.
  • the knife cylinder 51 is actuated to its raised position, exposing the blade as in FIG. 8. Further in this regard, if desired, the steps holding and sealing can start before the step cutting begins.
  • the steps holding, sealing, and cutting can occur substantially simultaneously. Because the sealable paper sheets are being held taut via the seal area on both sides of the gaps 43 and 45, the blade can cut cleanly through without resistance that comes from wrinkling/folding of the paper sheets or its layers.
  • the knife 50 is kept outside of the product path when not in motion, to prevent any hang ups or collisions with the product or sealable paper sheet webbing. In due course, the knife or rotary blade 50, will be sharpened and/or replaced to maintain the sharp cutting tool desired for the process as taught herein.
  • the cross seal lifts in step 110, and then the side seals shuttle forward and actuate down onto the paper sheet edges at the cross seal overlap at the curtain seal juncture, as in step 112, to complete the perimeter seal of the sealed and compressed product.
  • the tamp raises slowly providing enough time for the sealable paper sheets seals to strengthen (e.g., to set, to cure, and/or to cool).
  • the product conveys forward into the next sequence (i.e. folding).
  • the curtain of one seal/bond between the sealable paper sheets 20 e.g., bond 37
  • a method to seal wrap a product includes providing the product having a top surface separated from a bottom surface by a height between the top and bottom surfaces.
  • the method also includes wrapping the product with a sealable paper sheet, where the sealable paper sheet has an outer paper layer joined with an inner seal layer.
  • Another step is holding taut laterally and cutting longitudinally an outer edge portion of the sealable paper sheets on at least one side of the product by slicing: (i) the outer edge portion with essentially no stretching of the outer edge portion and (ii) in an area of the outer edge portion essentially free of the bond between adjacent inner seal layers.
  • sealing comprises heating the sealable paper sheet to form the bond between adjacent and overlapping inner seal layers along the length of at least one of the sides.
  • heating comprises applying heat directly to the outer paper layer and thereby to the inner seal layer indirectly as heat transfers through the outer paper layer to the inner seal layer.
  • heating comprises applying heat at a temperature of about 290 degrees to about 310 degrees to the outer paper layer and thereby to the inner seal layer as heat transfers through the outer paper layer to the inner seal layer.
  • sealing further comprises applying pressure in a range from about 10 pounds per square inch (psi) to about 20 psi to the outer edge portion to aid in forming the bond between adjacent and overlapping inner seal layers.
  • sealing further comprises applying pressure an amount of time in a range from about 2 seconds to 5 seconds to the outer edge portion to aid in forming the bond between adjacent and overlapping inner seal layers.
  • sealing comprises forming a second bond and the first bond is separated from the second bond by a non-bonded area along the length of at least one of the sides.
  • J. The method of any of the prior embodiments, wherein slicing comprises passing a sharp edge through each sealable paper sheets of the outer edge portion.
  • passing comprises moving the sharp edge from a first end of the length of at least one of the at least three sides to an opposite end of the length of at least one of the at least three sides.
  • heating the sealable paper sheet comprises applying heat to a top side of the outer edge portion.
  • the sealable paper sheet has (a) a Tear Strength in the machine direction of about 70 grams to 110 grams, (b) a Tensile Strength in the machine direction of about 30 pounds per inch to 50 pounds per inch, and (c) a Stretch in the machine direction of about 6.5% to 8.5%.

Abstract

Procédé pour emballer de manière étanche un produit, consistant à fournir le produit comprenant une surface supérieure séparée d'une surface inférieure. Ensuite, le procédé peut consister à emballer le produit à l'aide d'une feuille de papier scellable qui est une couche de papier externe assemblée à une couche d'étanchéité interne. Ensuite, le procédé peut consister à positionner la feuille de papier scellable adjacente à chacune des surfaces supérieure et inférieure. En outre, le procédé consiste à localiser des bords externes de la feuille de papier scellable, puis à fermer de manière étanche les bords externes de la feuille de papier scellable sur au moins un côté par formation d'une première liaison. En outre, le procédé consiste à maintenir une tension latérale et à couper de manière longitudinale une partie de bord externe des feuilles de papier scellables par tranchage : (i) de la partie de bord externe ne présentant sensiblement aucun étirement de la partie de bord externe et (ii) dans une zone de la partie de bord externe sensiblement exempte de la liaison.
PCT/US2023/030950 2022-08-24 2023-08-23 Procédé d'emballage de papier scellable pour un produit WO2024044265A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263400452P 2022-08-24 2022-08-24
US63/400,452 2022-08-24

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1996023711A1 (fr) * 1995-02-01 1996-08-08 Mcneil-Ppc, Inc. Emballage tubulaire souple
US20160214785A1 (en) * 2015-01-28 2016-07-28 Dreamwell, Ltd. Bedding product packaging and process
US20190023440A1 (en) * 2017-07-20 2019-01-24 Grantec (Xiamen) Co., Ltd. Method of packaging mattress
CN111099081A (zh) * 2019-12-31 2020-05-05 佛山市源田床具机械有限公司 一种床垫包装机的封口装置
IT202000017641A1 (it) * 2020-07-21 2022-01-21 Dolphin Pack S R L Apparato per l’avvolgimento di materassi o tappeti e relativo procedimento

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1996023711A1 (fr) * 1995-02-01 1996-08-08 Mcneil-Ppc, Inc. Emballage tubulaire souple
US20160214785A1 (en) * 2015-01-28 2016-07-28 Dreamwell, Ltd. Bedding product packaging and process
US20190023440A1 (en) * 2017-07-20 2019-01-24 Grantec (Xiamen) Co., Ltd. Method of packaging mattress
CN111099081A (zh) * 2019-12-31 2020-05-05 佛山市源田床具机械有限公司 一种床垫包装机的封口装置
IT202000017641A1 (it) * 2020-07-21 2022-01-21 Dolphin Pack S R L Apparato per l’avvolgimento di materassi o tappeti e relativo procedimento

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