Special receptacle or package – For roll or reel – With end protector
Reexamination Certificate
2000-02-28
2001-09-11
Fidei, David T. (Department: 3728)
Special receptacle or package
For roll or reel
With end protector
C206S413000
Reexamination Certificate
active
06286677
ABSTRACT:
CROSS-REFERENCES
There are no applications related to this application filed in this or any foreign country.
BACKGROUND
Aluminum stock produced by aluminum manufacturers is often sold in cylindrical coils, typically having a diameter of 10″ to 90″. As a protective measure, the circular ends of such cylindrical coils are typically covered by a fabric coil cap. Coil caps typically provide a circular end piece having a perimeter attached to a rectangular skirt piece which wraps about an end portion of the cylindrical sidewalls of the aluminum coil. In providing such a coil cap, it is important to maximize the protective nature, particularly on the circular end surface, while also minimizing the overall cost.
Known coil caps are typically constructed of a fabric skirt portion that is made of a woven polyethylene fabric which is coated with polyethylene. In most applications, the round fabric is made of a single or double layer of a spun-bonded olefin fabric. In the construction of such known coil caps, the round fabric is then glued to the coated polyethylene skirt. Where double layers of round fabric are used, it is frequently the case that hot glue is applied to both sides of an upper edge of the skirt, which is then sandwiched between the two round layers. Glue is used because welding two such dissimilar fabrics together is not possible.
Coil caps constructed according to the above method are not easily recyclable. This is primarily because of the very dissimilar nature of the polyethylene skirt and the spun bounded olefin round fabric. Additionally, the glue used to bond these dissimilar fabrics together also tends to prevent convenient recycling.
What is needed is a coil cap having a lighter-weight skirt, which can be more economically produced, combined with a heavier-weight round portion, which can better protect the cylindrical aluminum coil. The round portion and skirt portion should be made of the same material to promote recyclability. The means of connection between the two portions should not require glue, which is an expense in the manufacturing process, results in a weaker product and which prevents convenient recyclability.
SUMMARY
The present invention is directed to a coil cap that satisfies the above needs. A preferred embodiment of the coil cap of the present invention provides:
(A) A heavier-weight round portion is made of extruded polyethylene, woven and coated polyethylene, or other plastic material. In a typical embodiment, the round portion is made of extruded polyethylene, typically having a thickness of 0.003″ to 0.5″, and in a preferred embodiment a thickness of 0.1875″. Similarly, the diameter of a typical extruded round portion is 4″ to 150″, but in many applications is 60″.
(B) A lighter-weight rectangular skirt portion is made of woven, coated polyethylene fabric or extruded plastic sheet. In a preferred embodiment, the skirt portion is made of woven fabric 6 mils thick, having a coating of polyethylene of approximately 1 mil thick on each side.
(C) A welded region joins the heavier-weight extruded round portion to the upper edge of the lighter-weight skirt fabric portion. The welded region is typically circular, and concentric with the perimeter of the heavier-weight round portion.
(D) An overhang region of the heavier-weight round portion is formed radially outwardly of the welded region. In an application where the coil cap is used to cover the end of a coil of smaller diameter, the overhang region may be bent over the edge defined between the cylindrical portion of the coil and the circular end of the coil. When the coil cap is used to cover the end of a coil of larger diameter, an upper region of the skirt is carried between the top of the coil and the round portion of the coil cap, and the overhang region remains planar with the rest of the round portion.
In some versions of the coil cap, an added layer of material is attached to the lower surface of the heavier-weight round portion. The addition of such a layer tends to provide additional protection to the end surface of the coil. Preferred versions of the added layer of material include:
(A) A layer of foam bonded to the lower surface of the extruded round portion. Such a layer compliments the extruded round portion by absorbing the energy of impacts, while the extruded round portion is tear, rip and gouge resistant.
(B) A layer of corrugated plastic bonded to the lower surface of the extruded round portion. Corrugated plastic provides excellent shock protection.
(C) Where a layer of corrugated plastic has been bonded to the lower surface of an extruded round portion, a lower extruded round portion may be bonded to the lower surface of the corrugated plastic, thereby sandwiching the plastic between two layers of extruded polyethylene.
(D) A layer of kraft paper backed polyethylene bonded to the lower surface of the round portion. The kraft paper provides additional protection, and compliments the round portion by increasing rigidity and strength.
It is therefore a primary advantage of the present invention to provide a novel coil cap having a heavier-weight round portion welded to a lighter-weight skirt portion, particularly where the use of hot glue is not possible with such plastic material. A related advantage is that while the fabrics used in the present invention cannot withstand hot glue, they are otherwise more durable that known fabrics adapted for use in coil cap construction, particularly in terms of abrasion and tearing resistance.
Another advantage of the present invention is to provide a novel coil cap having a welded region that is extremely durable, and which will not separate under normal use.
Another advantage of the present invention is to provide a novel coil cap wherein the welded region joining the skirt and round portion is concentric with, but radially inwardly of, the perimeter of the heavier-weight round portion. An overhang region is formed of a plurality of curved blades separated by curved notches. The configuration of blades and notches allows the blades to be easily folded over the edge between the cylinder body and round end of smaller coil caps. As a result, the coil cap is adapted for use with coils of larger or smaller diameter.
Another advantage of the present invention is to provide a novel coil cap wherein an overhang region is formed of a plurality of curved blades separated by curved notches, allowing the blades to be folded over the edge of the coil cap, between the round top and cylindrical side. The curved blades having the advantage of being readily bent as the coil cap is wrapped with plastic wrap, and the curved notches having the advantage of allowing the blades to bend over the edge without contact between adjacent blades.
A still further advantage of the present invention is to provide a novel coil cap having a welded region that is three-dimensional in nature, and that allows some bunching, wrinkling or pleating of the upper edge of the fabric skirt portion within the welded region, while still providing a smooth, attractive and strong weld.
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Barrett Andrew N
Dolsby Craig G.
Gabrio William G.
Fidei David T.
Thompson David S.
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