Manufacturing container or tube from paper; or other manufacturi – Bending – Crushing or crumpling
Reexamination Certificate
1999-04-20
2001-04-03
Kim, Eugene (Department: 3721)
Manufacturing container or tube from paper; or other manufacturi
Bending
Crushing or crumpling
C493S967000
Reexamination Certificate
active
06210310
ABSTRACT:
FIELD OF THE INVENTION
The present invention generally relates to a cushioning conversion machine and method. More particularly, the present invention provides an improved internal forming device for use in a cushioning conversion machine or method.
BACKGROUND OF INVENTION
In the process of shipping an item from one location to another, a protective packaging material is typically placed in a shipping case, or box, to fill any voids and/or to cushion the item during the shipping process. Some conventional protective packaging materials are plastic foam peanuts and plastic bubble pack. While these conventional plastic materials seem to perform adequately as cushioning products, they are not without disadvantages. Perhaps the most serious drawback of plastic bubble wrap and/or plastic foam peanuts is their effect on our environment. Quite simply, these plastic packaging materials are not biodegradable and thus they cannot avoid further multiplying our planet's already critical waste disposal problems. The non-biodegradability of these packaging materials has become increasingly important in light of many industries adopting more progressive policies in terms of environmental responsibility.
These and other disadvantages of conventional plastic packaging materials has made paper protective packaging material a popular alternative. Paper is biodegradable, recyclable and composed of a renewable resource; making it an environmentally responsible choice for conscientious industries. While paper in sheet form could possibly be used as a protective packaging material, it is usually preferable to convert the sheets of paper into a relatively lower density pad or cushioning dunnage product. This conversion may be accomplished by a cushioning conversion machine, such as that disclosed in U.S. Pat. No. 5,322,477. This patent is assigned to the assignee of the present application and its entire disclosure is hereby incorporated herein by reference in its entirety.
The cushioning conversion machine disclosed in U.S. Pat. No. 5,322,4775 comprises a conversion assembly which converts multi-ply sheet stock material into a three-dimensional cushioning product with a relatively lower density and a stock supply assembly which supplies the multi-ply stock material to the conversion assembly. The conversion assembly includes a forming assembly which inwardly turns the lateral regions of the stock material as it travels downstream therethrough. This inward turning results in lateral regions of the stock material experiencing edge tension which sometimes results in ripping or tearing of the stock material.
A need remains for further improvements to prevent excessive edge tension and/or the tearing associated therewith. This need is especially critical for the conversion of lesser quality and/or short fiber paper. Additionally or alternatively, a need remains for other improvements to the cushioning conversion machine to work in conjunction with tension distributing or controlling devices, or otherwise, to improve or to enhance the conversion process to efficiently produce an improved cushioning product.
SUMMARY OF THE INVENTION
The present invention is a cushioning conversion machine and method for converting sheet stock material into a relatively less dense cushioning product having improved cushioning properties, and more particularly, into a cushioning product formed from stock material having its lateral regions inwardly turned and connected along a narrow central band, leaving an increased amount of stock material in the lateral pillow portions, and providing improved cushioning properties in the pillow portions.
More particularly, the present invention provides a cushioning conversion machine including a conversion assembly which converts a sheet stock material into a relatively less dense cushioning product. The conversion assembly includes a forming assembly which inwardly turns lateral regions of the sheet stock material as the sheet stock material travels through the forming assembly in an upstream to downstream direction. The forming assembly includes an external forming device and an internal forming device positioned at least partially within the external forming device and between which the sheet stock material passes as it travels through the forming assembly. The internal forming device has a central guide portion having a bottom guide surface which guides a central region of the sheet stock material as lateral regions of the sheet stock material are inwardly turned, and a cascade portion including stages disposed above the bottom guide surface of the guide portion. The stages define therebetween relatively relieved areas which facilitate the formation of creases in the lateral regions of the sheet stock material while enabling a desired percentage of the stock material to reside in the lateral pillow portions.
The present invention also provides a method of making a cushioning product that includes converting a sheet stock material into a relatively less dense cushioning product, including inwardly turning lateral regions of the sheet stock material as the sheet stock material travels through a forming assembly in an upstream to downstream direction; passing the sheet stock material between an external forming device and an internal forming device which are included in the forming assembly; guiding a central region of the sheet stock material with a bottom guide surface of a central guide portion of the internal forming device as the lateral regions of the stock material are inwardly turned; and guiding the lateral regions of the sheet stock material in a laterally undulating motion to facilitate the formation of creases in the lateral regions of the sheet stock material with a cascade portion disposed above the bottom guide surface, the cascade portion including a plurality of stepped stages defining relatively relieved areas therebetween. The relieved areas permit lateral regions of the sheet stock material to “fold” therein to effect such undulating motion and enhanced creasing.
The internal forming device and associated method are particularly useful in combination with curved ply separator members and/or tension control mechanisms which provide for tension dampening. The invention also is directed to the provision of an internal forming device that may be used in place of existing internal forming devices in prior art or other conversion machines.
The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail one or more illustrative embodiments of the invention, such being indicative, however, of but one or a few of the various ways in which the principles of the invention may be employed.
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Kim Eugene
Ranpak Corp.
Renner , Otto, Boisselle & Sklar, LLP
LandOfFree
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