WO2003097465A1

WO2003097465A1 - Method and apparatus for packaging resilient items

Info

Publication number: WO2003097465A1
Application number: PCT/IE2003/000063
Authority: WO
Inventors: James A. Brady
Original assignee: Brady James A
Priority date: 2002-05-15
Filing date: 2003-05-06
Publication date: 2003-11-27
Also published as: AU2003269728A1; IE20020391A1

Abstract

A method and appears is provided for packaging resilient items such as sponges (12) and similar items, in particular disposable, hygienically wrapped individual sponge items. The apparatus comprises means (14, 15, 16, 17) for compressing and rolling the item (12) into a substantially cylindrical form, a combined space defined by rollers (21, 22, 23, 24) adapted to receive the compressed, rolled item (12) when the item (12) is introduced laterally thereto, the confined space being dimensioned to prevent the item (12) from unrolling and having a first open and through which the substantially cylindrically rolled item (12) can be ejected axially and means for ejecting the item (12) from the confined space through the first open end. A conduit is located adjacent the first open end of the confined space and extends axially therefrom to a packaging means, the conduit having an internal diameter sufficiently narrow to maintain the item (12) in compressed rolled form, and a packaging means adapted to package the item (12) while still in a compressed rolled state.

Description

Method and apparatus for packaging resilient items

Technical Field

This invention relates to the packaging of resilient items, in particular resilient items such as sponge and foam items .

Background Art

There is a need for hygienically packaged sponge or foam items, in particular where sponges are to be used to treat injuries, as in sports situations, or are to be used in hospitals, such as for bathing patients. In such situations there is a need for disposable, hygienically wrapped individual sponge items .

Packaging sponges and similar items presents particular difficulties. If packaged under normal conditions a highly compressible sponge is many times larger than it could be if it were compressed. This leads to increased packaging and freight costs. However, the resilience of sponges and other foam items prevents them being easily compressed and then packaged - the tendency to revert to the relaxed shape presents particular handling difficulties in a packaging section of a production line.

Proposals have been made to vacuum pack sponges or foam items, but the apparatus involved in such procedures is complicated and expensive. Furthermore, the vacuum process results in the foam material becoming wrinkled and it may take a considerable time for the wrinkles to disappear and the foam to revert to its relaxed shape. It has been proposed to roll sponges and package them in a rolled condition. US-A-3, 927, 504 (Forrister) discloses a method in which a foam sheet is rolled onto itself, and the rolled sheet is itself rolled back onto an adhesive plastics sheet, such that the plastics sheet adheres around the rolled foam and prevents it from unrolling.

US-A-4,003, 469 (Findlay) discloses a method in which a large foam sheet is rolled in compressed form onto a take-up roller. When the desired length has been rolled on from a supply roll, the trailing end is cut and the rolled compressed foam is hand-tied with string and then wrapped in an enclosing sheet.

US-A-4, 550, 547 (Wagner, Sr.) discloses a method in which a foam sheet is rolled onto itself and a plastics sheet is then rolled around the exterior of the rolled foam, as part of the rolling method (similar in many ways to the method of Forrister described above) . The plastics sheet is sprayed with adhesive to retain the foam in rolled compressed form.

US-A-4, 597, 895 (Blauhϋt) discloses a method in which a rolled foam sheet is compressed by being fed axially into a series of rollers which taper in the direction in which the roll is fed, such that as the roll progresses through the rollers axially, it is compressed radially. The compression is made permanent by wrapping at the narrowest point of the space through which the roll passes.

US-A-4, 748,792 (Jeffrey) discloses a method in which a foam sheet is rolled and compressed and the rolled sheets are held in position by introducing a label or wrapper at the trailing end of the sheet as it is rolled. It is an object of the present invention to provide a method which is particularly suitable for foam items which are too small to be rolled into an extensive roll, such as sponges which when rolled and compressed describe less than two complete revolutions of a spiral. In such cases the problems of handling are greatly magnified relative to many of the prior art methods which are suitable only for foam sheets long enough to form well defined spiral rolls having five, ten or more revolutions .

It is also an object of the invention to provide a method in which the packaging of the resilient item is hygienic, i.e. the item remains totally enclosed in sealed packaging until used, and to provide such a packaging step as part of a continuous method adapted for large scale mass production.

Disclosure of Invention

The invention provides a method of packaging a resilient item, comprising the steps of:

a) compressing and rolling the item into a substantially cylindrical form;

b) introducing the compressed, rolled item laterally into a confined space which prevents the item from unrolling, said space having a first open end through which the substantially cylindrical rolled item can be ejected axially;

c) ejecting the item from said space axially through said first open end into a conduit located adjacent said first open end and extending axially therefrom to a packaging means, said conduit having an internal diameter sufficiently narrow to maintain said item in compressed rolled form; and

d) transporting said item through said conduit directly to an automated packaging means such that the item is packaged by the packaging means while still in a compressed rolled state.

The method according to the invention allows rapid transfer of the rolled item from rolling means to packaging means without the item unrolling. Because of the use of a confined space into which the item is introduced laterally and from which the item is ejected axially, it is possible to quickly transfer the item from a rolling means to a confining conduit. Unlike the situation with prior art methods it is possible to package the item without either having to roll the packaging around the item or to hand-tie a restraining string to prevent unrolling.

Preferably, step a) comprises introducing the item between opposed surfaces and moving said surfaces relative to one another so as to roll and compress the item.

Further, preferably, one of said surfaces forms part of a conveyer belt on which the item is carried, and the other of said surfaces comprises a fixed surface mounted above the conveyer belt .

The item is carried by the conveyer belt until it meets the fixed surface. Suitable gripping means prevent the item from sliding and thus the top surface of the item, which meets the fixed surface, is held stationary while the bottom surface is moved by the conveyer belt. This has the effect of rolling the item onto itself. The spacing between the surfaces determines the degree of compression of the roll. The spacing can taper if necessary to further compress the roll.

Suitably, the confined space is defined between three or more rollers which are rotated while the item is within the space to maintain the item in rolled form.

Preferably, at least one of the rollers is provided with a roughened surface.

In a preferred embodiment, four parallel rollers are used to define a confined space between themselves. The item is introduced into this space and the rotation of the rollers about their axes helps maintain the item in rolled compressed form.

Suitably, step c) comprises ejecting the rolled item into the conduit using pneumatic or hydraulic means.

Preferably, said pneumatic or hydraulic means comprises a pneumatically driven reciprocating member which periodically extends through the length of the confined space from a second open end opposite the first open end, whereby any rolled items located in said confined space are ejected into said conduit.

A reciprocating pneumatically driven ejecting member can operate at high speeds. Preferably, it operates to eject the rolled item immediately after it arrives in the confined space, thereby speeding the overall operation. Preferably, the rolled item is transported through said conduit by a conveyer-driven pushing member.

Further, preferably, the conduit comprises a pipe having a slot extending along its length such that a pushing member can be driven along the length of the pipe to push any rolled items therethrough.

For example, a three-quarters pipe can be mounted over a conveyer belt, the belt carrying a plurality of pushing members which extend into the pipe. The pushing members may be spaced and the belt speed timed such that immediately after each successive rolled item arrives into the pipe, a pushing member arrives behind the item to carry it along the length of the pipe.

Preferably, the packaging means feeds a length of thermoplastics material around the rolled item and seals opposed edges thereof to form a tube in which the item is located, and said tube is sealed at either end thereof and severed adjacent the sealed ends to provide a packaged compressed rolled item.

Heat sealing of a thermoplastics material is the preferred packaging method as it is inexpensive, reliable and rapid. Suitably, the sealing of the ends of the tube and the severing of the ends of the tube occur simultaneously.

Preferably, the length of thermoplastics material is fed around the exterior of the conduit carrying the rolled item such that when the opposed edges are sealed to form a tube, the tube contains the conduit therewithin. In this way it is possible to ensure a good seal being made between the opposed edges without the interference from the resilient item tending to expand and open the seal.

In preferred methods, the item is a sponge or foam pad.

Preferably, the pad is dimensioned such that it can form a closed compressed spiral roll describing less than two full revolutions. More preferably, the pad is dimensioned such that it can form a closed compressed spiral roll describing approximately one full revolution.

As indicated above, many prior art methods are suitable only for large scale resilient bodies or extended lengths of foam. The present invention, on the other hand is particularly useful when dealing with sponge or foam pads for which the ratio of thickness to length and breadth makes multiple-revolution rolls impractical.

In a further aspect of the invention, there is provided a rolled, compressed, resilient item packaged according to the method of the invention.

Preferably, the rolled, compressed, resilient item of the invention is in the form of a sponge pad.

Most preferably, the pad is dimensioned to be held in the hand for bathing or treating a body surface.

As previously indicated, the invention has particular value in providing individually packaged hygienic sponges for use in hospitals or in treating sports injuries on the playing field. In a further aspect, the invention provides apparatus for packaging a resilient item, comprising means for compressing and rolling the item into a substantially cylindrical form, a confined space adapted to receive the compressed, rolled item when the item is introduced laterally thereto, said confined space being dimensioned to prevent the item from unrolling and having a first open end through which the substantially cylindrical rolled item can be ejected axially, means for ejecting the item from said confined space through said first open end, a conduit located adjacent said first open end of said confined space and extending axially therefrom to a packaging means, said conduit having an internal diameter sufficiently narrow to maintain said item in compressed rolled form, and a packaging means adapted to package the item while still in a compressed rolled state.

As will be readily appreciated such apparatus is adapted to carry out the method of the present invention. Preferred features of the apparatus will be evident from the foregoing description and from the detailed description below.

The invention will be further illustrated by the following description of embodiments thereof, given by way of example only with reference to the accompanying drawings .

Brief Description of the Drawings

Fig. 1 is a side elevation of a first section of a sponge packaging apparatus according to the invention;

Fig. 2 is a sectional elevation of a roller arrangement forming part of the apparatus of figure 1; Fig. 3 is a sectional side elevation of the first half of a second section of the apparatus of figure 1;

Fig. 4 is a cross-sectional elevation of the apparatus shown in figure 3, taken along the line IV-IV;

Fig. 5 is a sectional side elevation of the second half of the second section of the apparatus of figure 1;

Fig. 6 is a plan view of a detail of the apparatus of figure 5;

Fig. 7 is a cross-sectional elevation of the apparatus of figure 5, taken along the line VII- VII;

Fig. 8 is a cross-sectional elevation of the apparatus of figure 5, taken along the line VIII- VIII; and

Fig. 9 is a cross-sectional elevation of the apparatus of figure 5, taken along the line IX-IX;

Modes for Carrying out the Invention

In figure 1 there is indicated, generally at 10, a first section of a packaging apparatus according to the invention. A conveyer belt 11 carries a plurality of sponge pads 12 from a cutting machine (not shown) , which cuts individual pads 12 from a length of sponge material, to a rolling apparatus, indicated generally at 13.

Rolling apparatus 13 comprises a moving roller belt 14, a static roller belt 15, and a feeder belt 16. Moving roller belt 14 and feeder belt 16 feed the pads sequentially under the static roller belt 15. Both moving roller belt 14 and static roller belt 15 are provided with rubber protrusions 17 which increase grip. The moving roller belt 14 pulls the lower surface 18 of each pad 12 forward, while fixed roller belt 15 grips and holds the upper surface 19 of the pad 12. This causes the pad to be rolled onto itself and compressed as it is rolled.

The pad 12 rolls along the belt in this manner and on reaching the end of the moving roller belt 14 it is forced by a guide 20 to drop into a confined space defined between four rollers 21,22,23,24 arranged in trapezoidal (almost rectangular) configuration. The speed of the moving roller belt 14 is sufficiently high to shoot the pad 12 into this confined space before the pad

12 has time to relax and expand or unroll. Typically, the belt moves at a variable speed of between 35 and 100 r.p.m. The rolled sponge thus enters the confined space laterally, i.e. in a direction normal to the longitudinal axis of the substantially cylindrical sponge.

Referring additionally to figure 2, two of the rollers 23,24 can be seen in frontal elevation, in a section taken along the line II-II in figure 1. Thus it can be seen that pad 12 is held between the two rollers 23,24 visible in figure 2 and the other two rollers 21,22 (see figure 1) . Rollers 23,24 are mounted at one end on spindles 25 held in a frame 26, and at the other end in a gear arrangement, indicated generally at 27.

A chain-driven driving gear 28 meshes with a gear 29 mounted on roller 23, which in turn meshes with a first intermediate gear 30 to drive a gear 31 mounted on roller 24. The latter gear 31 in turn drives a second intermediate gear 32 which transmits the driving force to the other two rollers 21,22 (figure 1). The gear arrangement causes the rollers to turn in an anticlockwise direction when viewed as in figure 1.

One of the rollers 21 is provided with a knurled surface which enhances its grip on the pad 12 to prevent it from slipping on the smooth surface of the other rollers.

The rotation of the rollers maintains the sponge pad 12 in a rolled compressed condition. However, the pad 12 only remains in the compressed space between the rollers 21,22,23,24 momentarily.

Referring to figure 3, the sponge pad can be seen in sectional elevation with the rollers 23,24. A piston 33 mounted on a piston rod 34 is dimensioned to fit into the confined space between the four rollers 21,22,23,24. Piston rod 34 is pneumatically driven and causes the piston 33 to reciprocate into and out of the confined space. In this reciprocating action, piston 33 moves throughout the length of the confined space so as to completely eject sponge pad 12 from the confined space and into a conduit 35.

The pneumatic driving means (not shown) , which reciprocates the piston rod 34, is timed to coincide with the arrival of successive sponge pads 12 into the confined space between the rollers 21,22,23,24, thereby ejecting each pad 12 immediately after it arrives in the confined space.

A series of pushing members 36 mounted on a conveyer belt

37 catch behind successive sponge pads 12 when they arrive in conduit 35, and cause the sponge pads 12 to be pushed along conduit 35. Referring additionally to figure 4, the pad 12, conduit 35, and conveyer belt 37 can be seen in cross-section. Thus, it can be seen that conduit 35 is in the form of a pipe having an open slot 38 along its underside through which pushing member 36 mounted on conveyer belt 37 protrudes. Because of the dimensions of the conduit 35, when pad 12 is ejected into conduit 35 it is still in a rolled and compressed condition, and conduit 35 prevents any substantial unrolling or expansion of the pad 12.

The conduit 35 is mounted above a surface 39 which also has a longitudinal slot 40 therein. The purpose of the longitudinal slot 40 in surface 39 is twofold: it allows the pushing member 36 to project therethrough, and it enables the sponge pads to be packaged in an external sealed wrapping, as explained below.

Referring next to figure 5, the end of the conduit 35 can be seen. The sponge pads 12 emerging from the conduit emerge into a tube of thermoplastics material 42 which is sealed along a longitudinal seam by a heated roller arrangement 43. The thermoplastics material 42 is drawn from a roll 44 suspended above conduit 35, at a speed which matches the rate at which successive sponge pads 12 emerge from the conduit 35. Because the dimensions of the tube of thermoplastics material 42 are slightly larger than the interior of the conduit 35, the sponge pads 12 expand slightly to fill the tube and are thereby carried along by the thermoplastics material. The sponge pads 12 are still highly compressed relative to their relaxed state.

The tube of thermoplastics material 42 proceeds to a heat sealing and cutting apparatus (not shown) which seals and cuts the tube between successive pads, thereby providing separate sealed packets each containing a single rolled compressed sponge.

As can be seen from figure 5, the tube of thermoplastics material 42 is sealed by a heated roller arrangement 43 located under the surface 39. The manner in which the thermoplastics material 42 is brought into a tube-like shape from its initial flat shape (as it is supplied from the roll 44) can be seen with reference to Figs. 6-9.

Figure 6 shows the end of conduit 35 from above. Conduit 35 is mounted on surface 39, and covers longitudinal slot 40 which extends past the end of conduit 35. A widened cut-out 45 is provided in the surface 39 which allows the width of the thermoplastics material 42 to pass into the cut-out 45.

Referring additionally to Figs. 7-9, the surface 39 is shown in cross section at three points, indicated by the lines VII-VII, VIII-VIII and IX-IX, respectively on figure 5. Figure 7 shows the surface at a point before the cut-out 45 (i.e. where the thermoplastics material 42 is still above the surface 39) , figure 8 shows it at the cut-out 45 (i.e. where the edges 46 of the material 42 are passing below the surface 39 through cut-out 45) , and figure 9 shows it after the cut-out 45 (i.e. towards the end of conduit 35, at a point where the edges 46 of the material 42 have been brought together for heat sealing to form a tube) .

Thus, the configuration of the cut-out 45 allows the material to be sealed into a tube around the conduit 35, enabling the sponge to be ejected in rolled condition into the tube.

Claims

1. A method of packaging a resilient item, comprising the steps of: a) compressing and rolling the item into a substantially cylindrical form; b) introducing the compressed, rolled item laterally into a confined space which prevents the item from unrolling, said space having a first open end through which the substantially cylindrical rolled item can be ejected axially; c) ejecting the item from said space axially through said first open end into a conduit located adjacent said first open end and extending axially therefrom to a packaging means, said conduit having an internal diameter sufficiently narrow to maintain said item in compressed rolled form; and d) transporting said item through said conduit directly to an automated packaging means such that the item is packaged by the packaging means while still in a compressed rolled state.

2. A method according to Claim 1, wherein step a) comprises introducing the item between opposed surfaces and moving said surfaces relative to one another so as to roll and compress the item.

3. A method according to Claim 2, wherein one of said surfaces forms part of a conveyer belt on which the item is carried, and the other of said surfaces comprises a fixed surface mounted above the conveyer belt.

4. A method according to any preceding claim, wherein the confined space is defined between three or more rollers which are rotated while the item is within the space to maintain the item in rolled form.

5. A method according to Claim 4, wherein at least one of the rollers is provided with a roughened surface.

6. A method according to any preceding claim, wherein step c) comprises ejecting the rolled item into the conduit using pneumatic or hydraulic means.

7. A method according to Claim 6, wherein said pneumatic or hydraulic means comprises a pneumatically driven reciprocating member which periodically extends through the length of the confined space from a second open end opposite the first open end, whereby any rolled items located in said confined space are ejected into said conduit.

8. A method according to any preceding claim, wherein the rolled item is transported through said conduit by a conveyer-driven pushing member.

9. A method according to any preceding claim, wherein the conduit comprises a pipe having a slot extending along its length such that a pushing member can be driven along the length of the pipe to push any rolled items therethrough.

10. A method according to any preceding claim, wherein the packaging means feeds a length of thermoplastics material around the rolled item and seals opposed edges thereof to form a tube in which the item is located, and wherein said tube is sealed at either end thereof and severed adjacent the sealed ends to provide a packaged compressed rolled item.

11. A method according to Claim 10, wherein said length of thermoplastics material is fed around the exterior of the conduit carrying the rolled item such that when the opposed edges are sealed to form a tube, the tube contains the conduit therewithin.

12. A method according to any preceding claim, wherein the item is a sponge or foam pad.

13. A method according to Claim 12, wherein the pad is dimensioned such that it can form a closed compressed spiral roll describing less than two full revolutions.

14. A method according to Claim 12, wherein the pad is dimensioned such that it can form a closed compressed spiral roll describing approximately one full revolution.

15. A rolled, compressed, resilient item packaged according to any preceding claim.

16. A rolled, compressed, resilient item according to Claim 15 in the form of a sponge pad.

17. A rolled, compressed, resilient item according to Claim 15, wherein the pad is dimensioned to be held in the hand for bathing or treating a body surface.

18. Apparatus for packaging a resilient item, comprising means for compressing and rolling the item into a substantially cylindrical form, a confined space adapted to receive the compressed, rolled item when the item is introduced laterally thereto, said confined space being dimensioned to prevent the item from unrolling and having a first open end through which the substantially cylindrical rolled item can be ejected axially, means for ejecting the item from said confined space through said first open end, a conduit located adjacent said first open end of said confined space and extending axially therefrom to a packaging means, said conduit having an internal diameter sufficiently narrow to maintain said item in compressed rolled form, and a packaging means adapted to package the item while still in a compressed rolled state.

19. Apparatus according to Claim 18, wherein the rolling means comprises a pair of opposed surfaces and means for moving said surfaces relative to one another so as to roll and compress the item.

20. Apparatus according to Claim 19, wherein one of said surfaces forms part of a conveyer belt on which the item is carried, and the other of said surfaces comprises a fixed surface mounted above the conveyer belt.

21. Apparatus according to any one of Claims 18-20, wherein the confined space is defined between three or more rollers and wherein means are provided for rotating the rollers while the item is within the space to maintain the item in rolled form.

22. Apparatus according to Claim 21, wherein at least one of the rollers is provided with a roughened surface.

23. Apparatus according to any one of Claims 18-22, wherein the ejecting means is pneumatically or hydraulically driven.

24. Apparatus according to Claim 23, wherein said pneumatic or hydraulic means comprises a pneumatically driven reciprocating member which is extendible through the length of the confined space from a second open end opposite the first open end, whereby any rolled items located in said confined space are ejected by said reciprocating member into said conduit.

25. Apparatus according to any one of Claims 18-24, wherein a conveyer-driven pushing member is provided to transport the rolled item through said conduit.

26. Apparatus according to any one of Claims 18-25, wherein the conduit comprises a pipe having a slot extending along its length such that a pushing member can be driven along the length of the pipe to push any rolled items therethrough.

27. Apparatus according to any one of Claims 18-26, wherein the packaging means comprises means for feeding a length of thermoplastics material around the rolled item, means for sealing opposed edges of the length of material to form a tube in which the item is located, means for sealing said tube at either end thereof, and means for severing the tube adjacent the sealed ends to provide a packaged compressed rolled item.

28. Apparatus according to Claim 27, wherein said length of thermoplastics material is fed around the exterior of the conduit carrying the rolled item such that when the opposed edges are sealed to form a tube, the tube contains the conduit therewithin.

29. Apparatus according to any one of Claims 18-28, when adapted to package a sponge or foam pad.

30. Apparatus according to Claim 29, wherein the pad is dimensioned such that it can form a closed compressed spiral roll describing less than two full revolutions.