Packaging product, method and machine for manufacturing packaging product

Abstract

The packaging product, its use, machine (413) for producing the packaging product, and manufacturing method produce a double curl, or "B" (404) or modified "B" (404a), having resilient, cushioning, form-fitting, and cohesive packaging properties. The "B" is preferably, but not necessarily, made from a dimensionally controlled strip (400) of cohesive paper having a cohesive side (401) and a non-cohesive side (402), a leading edge (407), and a trailing edge (408). The leading edge is wound into a spiral (406) in a first direction with the cohesive side of the dimensionally controlled cohesive paper facing outward, and the trailing edge is wound into a spiral (405) in a second direction opposite the first direction with the cohesive side of the cohesive paper also facing outward. The multiple "B"s provide a gathered cohesive mass around the item to be packaged. The machine (413) is capable of producing various sizes of "B" shapes to accommodate various size items and / or packages.

Description

[Technical Field]

[0001] The present invention relates to packaging products, and more particularly to sustainable, reusable and efficient packaging products for protecting packaged items. [Background technology]

[0002] A significant number of items are transported around the world every day. With the rise of online purchasing, transportation has increased significantly. However, goods damaged during transportation result in lost revenue for merchants and shippers, and frustration for recipients. Therefore, it is beneficial for shippers, merchants, and recipients that transported items arrive undamaged. Items are transported to consumers via boxes, envelopes, or other styles of containers. To ensure that items are not damaged during transportation, dunnage or packaging material is typically used to bundle items for transportation.

[0003] Various types of low-density packaging materials have been used in the past. Plastic "peanuts," plastic balls, plastic foam sheets, plastic air-filled "pillows," formfitting foam, straw, and straw-like materials have been or are being used as packaging materials. Most, if not all, of these packaging materials have drawbacks. Plastic and similar materials are generally not biodegradable and are toxic to wildlife, making them unsafe for the environment. Using many small pieces of low-density packaging material (e.g., Styrofoam balls or peanuts) is effective at enclosing and holding the packaged items, but creates problems when opening the package. Air-filled pillows do not effectively bind the items, leaving gaps within the package. Such prior art packaging materials also pose other problems.

[0004] From the above, it is clear that paper packaging is preferable to other types of packaging because paper is biodegradable, recyclable, sustainable, and has a low density. However, crumpled, twisted, lengths of paper, wads of paper, or shredded paper are not practical for wrapping items or for large-scale packaging.

[0005] Because paper converted into a low-density packaging or cushioning product is generally useful for packaging, several patents and / or patent publications provide various methods for converting paper into a low-density packaging or cushioning product. For example, U.S. Patent No. 6,626,813 discloses a cushioning conversion system and method for producing a coil of cushioning product from a sheet of paper. Figure 6 of U.S. Patent No. 6,626,813 shows the produced coil of cushioning product (the '813 coil), which has a width that is the size of the sheet of paper. The size of the '813 coil makes it impractical to form the '813 coil into a suitable packaging material that can cushion around items of various shapes without significant manipulation or cutting. This adds an additional packaging step. U.S. Patent Application Publication No. 2008 / 0153685 discloses a method for producing a dunnage (baling) product from a continuous length of stock having at least one cohesive surface. This dunnage product is a large coil of crumpled paper (the '685 coil) that relies on its cohesive properties to maintain its crumpled and rolled shape. Like the '813 coil, the '685 coil makes it impractical to form the '685 coil into a suitable packaging material that can cushion around items of various shapes without significant manipulation, which adds an additional packaging step. Furthermore, the '813 and '685 coils are unable to form a generally fused and / or coherent mass around an item or items for packaging, creating only a loose collection of paper that may shift during transport. Without limitation, such prior art packaging products are either too large, are not easily formable around items of various sizes and shapes, and / or do not easily conform in shape to the interior of the item's packaging. Summary of the Invention [Problem to be solved by the invention]

[0006] In view of the above, it would therefore be desirable to have a paper-based packaging product that alleviates the shortcomings of the prior art. It would further be desirable to have a paper-based packaging product that is formed to provide suitable volume fill for a package / wrap without being a solid mass. It would further be desirable to have a paper-based packaging product that is formed to provide structural integrity with less material than a solid mass. Furthermore, it would be desirable for the paper-based packaging product to clump or group together to create a packaging mass around an item or multiple items for packaging. [Means for solving the problem]

[0007] Paper-based packaging products, uses, machines and methods of manufacture are provided that provide protection for packaged / packaged items.

[0008] The packaging product is formed from a dimensionally controlled paper strip as either a "B-shape" or modified "B-shape" (collectively "B-shape"). The paper strip may be a cohesive paper, coated paper, or the like, having a cohesive side and a non-cohesive side. The "B-shape" is formed by wrapping or spiraling a first curl around a first end of the dimensionally controlled paper strip and a second curl around a second end of the dimensionally controlled paper strip. A small portion of the dimensionally controlled paper strip connects the first and second curls. The first and second curls are wrapped or spiraled in opposite directions, respectively. When cohesive paper is used, the first and second curls are formed so that the cohesive side faces radially outward and the non-cohesive side faces radially inward.

[0009] The multiple "B-shapes" provide a generally unified mass or group around an item or items packed within a container (e.g., interchangeably with, but not limited to, a package, container, box, envelope, case, carton, basket, chest, drawer, small packet, canister, can, etc.). When cohesive paper is used to form these "B-shapes," the multiple cohesive "B-shapes" provide a unified mass or group around an item or items within the container, with the cohesive "B-shapes" loosely attached to each other. The cohesive "B-shapes" of the unified cohesive group can be loosely attached to the item or items as well as the interior of the container. The mass or group can be compressed to reduce its volume and / or provide a tighter packing. The contraction of the mass or group may be used to create or provide blocking or bracing for items within the container. The "B-shapes" are moldable and conform to the shape of the items being packaged / wrapped.

[0010] A method of packaging an item or items using the present invention includes placing a plurality of "B-shapes" of the present invention into a container (e.g., a packaging container) with the item or items. The "B-shapes" may or may not be cohesive "B-shapes" (collectively "B-shapes" unless specifically indicated as cohesive or non-cohesive). The method may include providing a plurality of "B-shapes" dimensioned and sized according to the item or items being packaged, the size of the container, the weight of the item or items being packaged, or other parameters / considerations. Smaller and / or lighter items may use smaller "B-shapes," and larger and / or heavier items may use larger "B-shapes," and vice versa. A mixture of "B-shapes" of different sizes may also be used. Other considerations, characteristics, and / or factors may determine the dimensions of the "B-shapes" or influence the details of the "B-shapes." The "B-shape" can be used for large, medium, or small items / containers, as well as light, medium, or heavy items / containers.

[0011] In one form, the "B" is formed from a roll of paper (cohesive, non-cohesive, or cohesive / non-cohesive blend, coated, etc.) that is dimensioned controlled into strips of paper having a width preferably, but not necessarily, between 6.35 mm and 19.05 mm (one-quarter inch (1 / 4") and three-quarters inch (3 / 4")), with 12.7 mm (one-half inch (1 / 2")) being most preferred, and a length preferably, but not necessarily, between 5.08 cm and 30.48 cm (two inches (2") and twelve inches (12")). Other sizes are contemplated and may depend on the factors and / or characteristics of the item or items being packaged. The paper is preferably in the teens to the 50s. fifties), but not necessarily. The width or vertical surface of the "B" provides blocking / stacking strength to the packaged item, while the radial size or diameter of the first and second curls of the "B" provides cushioning and other benefits to the packaged item. When multiple "B"s are gathered together in random orientations, a protective mass forms around one or more items due to the interaction of the curl shapes of each "B"; when clumping paper forms "B"s, the clumping side of each "B" faces outward, naturally adhering the "B"s to one another. The "B" mass can be any size and shape, particularly around the packaged items within a corrugated box. This mass also commonly forms on the inside of the box. The "B" surrounding the item or items stabilizes and protects the items. This type of packaging keeps the items free of wear.

[0012] The "B" can be used to package single or multiple items, light or heavy, in any closed or open container. The "B" may be used in combination with an item or items wrapped in a variety of materials, including but not limited to, foam plastic sheets, tissue paper, butcher's paper, newspaper, clumping paper, colored construction paper, coated paper, cotton paper, vegetable paper, etc. Other types of wrapping, such as but not limited to, foam, can be used in place of paper wrapping.

[0013] "B-shaped" production machines can be sized according to the needs of the application. For example, a small, benchtop "B-shaped" production machine can be used to package small boxes, while a larger, freestanding "B-shaped" production machine can be used to package larger boxes. "B-shaped" production machines can be adapted for both low-volume and high-volume "B-shaped" production.

[0014] The method and machine for making the "B" of the present invention includes providing a roll of paper (i.e., a roll of a continuous sheet of paper), forming a first curl of a first diameter at a leading end of the roll of paper, cutting the roll of paper into strips of paper having the first curl to provide strips of paper having trailing ends distal to the first curl, and then forming a second curl of a second diameter at the trailing ends of the strips of paper. If cohesive paper (e.g., paper having cohesion on one face or side) is used, the first and second curls are formed with the cohesive side facing radially outward.

[0015] In one exemplary form, the machine / method for manufacturing the "B-shapes" of the present invention uses a roll of paper to continuously create "B-shapes" with preset dimensional control of the "B-shapes" being manufactured, which is preferably, but not necessarily, automatic. The "B-shape" manufacturing machine of the present invention is preferably, but not necessarily, processor-controlled (e.g., computer), which provides at least control of the various components of the machine. The processor can also enable custom or on-the-fly creation of "B-shapes" with dimensional control including, but not limited to, the length (amount) of the spiral of each curl, the width of the paper strip and each curl, the tightness of each curl (spiral), the length of the connection between the first curl and the second curl, etc.

[0016] In an exemplary embodiment of the machine / method for producing a "B" of the present invention, a paper sheet is fed through a first slot in a first slotted spindle or rod and then through a second slot in a second slotted spindle or rod; the second slotted spindle is rotated in a first rotational direction to curl a leading end of the paper sheet roll into a first curl; the paper sheet roll is cut at a location proximate the second slotted spindle to produce a paper strip having a trailing end distal to the first curl; the first slotted spindle is rotated in a second rotational direction opposite the first rotational direction to curl a trailing end of the paper sheet strip into a second curl; and the produced "B" is discharged from the first and second slotted spindles / machines. Variations are contemplated. Other steps not specifically mentioned in this paragraph may be intervened in accordance with the present principles and the present specification. The paper sheet roll may be further dimensionally controlled by cutting the paper sheet roll into one or more widths. Other dimensions may be varied.

[0017] A method and machine for packaging or cushioning one or more items in a packaging container or receptacle includes providing a machine for producing a plurality of the "B-shapes" of the present invention and then placing the "B-shapes" around or around one or more items, with or without the items initially wrapped. The "B-shapes" are preferably, but not necessarily, dimensioned and sized according to the details of the item or items and / or container being packaged. Smaller items can use smaller "B-shapes," and larger items can use larger "B-shapes," and vice versa. A mixture of "B-shapes" of various sizes can also be used. The machine for producing the "B-shapes" is adjustable to provide various lengths, widths, etc. of "B-shapes" to suit various packaging needs.

[0018] A variety of papers can be used for the "B-shape." The papers may come in colors, patterns, different weights, textures, etc.

[0019] The packaging products of the present invention are advantageous by providing efficient packaging and / or cushioning for an item or items within a container without necessarily filling the entire cavity of the container. For example, the packaging products of the present invention do not need to fill the interior corners of the container because they converge around the items within the container. This reduces the amount of packaging product required.

[0020] Furthermore, the packaging product of the present invention is lightweight. Furthermore, the volume of the packaging product of the present invention is not solid. It contains air between its curls.

[0021] The "B-Shape" of the present invention provides a simple solution to multiple packaging / wrapping needs such as general void filling, protective void filling, general cushioning, light duty cushioning, heavy duty cushioning, blocking and bracing, decoration, containment, etc. The "B-Shape" of the present invention is also sustainable, reusable and / or recyclable by the consumer and in the supply chain, reusable by industry, and reusable by the end user.

[0022] The "B-shape" of the present invention is easy and simple to use, provides faster packing / wrapping (which reduces labor), and allows for less material to be used to pack / wrap items compared to traditional / prior art packaging products. Use of the "B-shape" of the present invention can replace plastic and foam packaging, resulting in less damage to packed / wrapped items and a more positive customer experience.

[0023] Items ranging from delicate or fragile items such as glass ornaments of any shape to items of any practical weight and shape can be packaged using the "B Shapes" of the present invention, especially if the "B Shapes" are custom made for their curl size (number).

[0024] Further aspects of the present invention will become apparent from a consideration of the drawings and the following description of the invention. Those skilled in the art will recognize that other forms of the invention are possible and that the details of the invention can be modified in many respects without departing from the inventive concept. The drawings and description that follow are to be regarded as illustrative in nature and not restrictive.

[0025] The present invention and its features will be better understood with reference to the accompanying illustrations / drawings. [Brief explanation of the drawings]

[0026] [Figure 1]1 is a side view of a strip of clumped paper being formed into a packaging product made as a "B-shape" in accordance with the principles of the present invention. FIG. [Figure 2] FIG. 1 is a top view of a "B" formed in accordance with the principles of the present invention. [Figure 2A] FIG. 1 is a top view of a modified "B" shape formed in accordance with the principles of the present invention. [Figure 3] FIG. 3 is a perspective view of the "B" shape of FIG. 2. [Figure 4] FIG. 8 is a diagram of a container in which items are surrounded by chunks of the packaging product of the present invention ("B-shaped") produced by the exemplary machine of FIGS. 5-7, where the packaging "B-shaped" chunks form void fillers that cushion and protect the packaged items. [Figure 5] FIG. 1 is a side view of an exemplary machine for manufacturing the "B" of the present invention. [Figure 6] FIG. 8 is a top side view of an exemplary machine for producing the inventive "B-shape" of FIGS. 5-7. [Figure 7] FIG. 8 is an end view of an exemplary machine for producing the inventive "B-shape" of FIGS. 5-7. [Figure 8] FIG. 8 is a diagram of a paper curl rod of an exemplary machine for producing the inventive "B-shape" of FIGS. 5-7. [Figure 9] FIG. 8 is a partial view of an exemplary machine for producing the inventive "B-shape" of FIGS. 5-7, illustrating how the strip of cohesive paper of FIG. 1 is formed into the "B-shape" of FIG. 2 in accordance with the principles of the present invention. [Figure 10] FIG. 9 is a partial view of an exemplary machine for producing the "B" of the present invention of FIGS. 5-7, showing how the strip of cohesive paper is further formed into a "B" compared to FIG. [Figure 11] FIG. 8 is a partial view of an exemplary machine for producing the "B-shape" of the present invention of FIGS. 5-7, showing the formed "B-shape" beginning to be discharged from the exemplary machine for producing the "B-shape" of the present invention of FIGS. 5-7, with the end holder of the paper curl rod beginning to pivot to discharge the formed "B-shape." [Figure 12]11 is a partial view of an exemplary machine for producing the "B-shape" of the present invention in FIGS. 5-7, showing the formed "B-shape" further out of the exemplary machine for producing the "B-shape" of the present invention in FIGS. 5-7 compared to FIG. 11, with the end holder of the paper curl rod being fully pivoted to discharge the formed "B-shape." [Figure 13] FIG. 8 is a partial view of an exemplary machine for producing the "B-shape" of the present invention of FIGS. 5-7, showing the formed "B-shape" fully ejected from the exemplary machine for producing the "B-shape" of the present invention of FIGS. 5-7. [Figure 14] FIG. 8 is a partial view of an exemplary machine for producing the inventive "B-shape" of FIGS. 5-7, showing the end holders of the paper curl rod returned to their initial position. [Figure 15A] 8 is a representative diagram of a process for making the "B-shape" by an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7 in accordance with the principles of the present invention. [Figure 15B] 8 is a representative diagram of a process for making the "B-shape" by an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7 in accordance with the principles of the present invention. [Figure 15C] 8 is a representative diagram of a process for making the "B-shape" by an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7 in accordance with the principles of the present invention. [Figure 15D] 8 is a representative diagram of a process for making the "B-shape" by an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7 in accordance with the principles of the present invention. [Figure 15E] 8 is a representative diagram of a process for making the "B-shape" by an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7 in accordance with the principles of the present invention. [Figure 15F] 8 is a representative diagram of a process for making the "B-shape" by an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7 in accordance with the principles of the present invention. [Figure 16] FIG. 8 is a block diagram of the control portion of an exemplary machine for manufacturing the inventive "B-shape" of FIGS. 5-7.

[0027] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any changes and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein, are contemplated as would normally occur to one skilled in the art to which the invention pertains. DETAILED DESCRIPTION OF THE INVENTION

[0028] FIG. 1 illustrates a strip of cohesive paper 400, among various types of paper (see Summary of the Invention) that may be used for / in the present invention to form packaging in the form of a "B" (e.g., see FIG. 2) or modified "B" (e.g., see FIG. 2A) in accordance with the principles of the present invention. While cohesive paper is preferred, non-coated, coated, uncoated, paper blends, or others may be used. The cohesive paper strip 400 has a selectable width, a selectable length, a cohesive side 401, a non-cohesive side 402, a first end 407, and a second end 408, the nomenclature of which is arbitrary. The first end 407 may be considered the leading end, and the second end 408 may be considered the trailing end. The width of the cohesive paper strip 400 is determined by the particular cutter 426 used in the packaging product manufacturing machine 413 (see FIGS. 5-7), which may be set automatically or electronically. The dimensions of the cutter 426 fix the width of the cohesive paper strip 400. Various cutters are used to vary the width of the cohesive paper strips 400. For example, one cutter 426 of the packaging machine 413 can cut the sheet 420 of the rolled cohesive paper 415 into multiple strips of cohesive paper having the same width, while another cutter can cut the sheet 420 of the rolled cohesive paper 415 into multiple strips of cohesive paper 400, each having a different width. A cutter 426 need not be used such that the width of the sheet 420 of the rolled cohesive paper 415 is the width of the cohesive paper strips 400. The cutter 426 can vary the width or widths of the machine-controlled paper strips on the fly, with or without human intervention. Variations are contemplated. The length of the cohesive paper strips 400 is determined by the principles of the present invention, as described below.

[0029] 3 and 4 depict a "B-shape" 404 formed or manufactured by an exemplary packaging product manufacturing machine 413. Machines of other designs can be used to create the packaging material ("B-shape") shown and described herein using the same or other manufacturing methods. FIG. 3 provides a side view of the "B-shape" 404, and FIG. 14 provides a perspective view of the "B-shape" 404. The "B-shape" 404 is formed by a strip of cohesive paper 400 such that the cohesive side 401 preferably, but not necessarily, faces radially outward, and the non-cohesive side 402 preferably, but not necessarily, faces radially inward. If non-cohesive paper is used, both the outward and inward facing surfaces (401, 402) are non-cohesive. The "B-shape" 404 has a first curl, spiral, coil, twist, whorl, etc. 406 formed at a first end 407 (optionally, the leading end) of the strip of cohesive paper 400, and a second curl, spiral, coil, twist, whorl, etc. 405 formed at a second end 408 (optionally, the trailing end) of the strip of cohesive paper 400, the nomenclature of first and second being arbitrary, and has a connecting portion 409. The first curl 406 is wound in a first direction, and the second curl 405 is wound in a second direction opposite the first direction. Thus, one direction is clockwise and the other direction is counterclockwise. The first curl 406 has a first diameter, and the second curl 405 has a second diameter, and the first and second diameters may be the same or different, as required, needed, or desired. The tightness of the curl affects the diameter as well as the length of the paper used to create the curl. Preferably, but not necessarily, the amount or length of the spiral in each curl is sufficient to provide a spiral that will retain its shape after forming. Figure 4 illustrates a "B-shaped" 404 mass 50 within a container around and / or surrounding an item 60 for, but not limited to, packaging, cushioning, blocking, bracing, and / or void filling of the product / item.

[0030] FIG. 2A provides a variation of a packaging product of the present invention, generally designated 404a, having the same or similar components / properties / features as packaging product 404 of FIG. 2. Accordingly, the same components / properties / features have the same callout numbers, and similar components / properties / features include the designation "a." Packaging product 404a may be formed with or without aggregating paper, such as "B-shape" 404. Paper strip 400 has a leading end (first end) 407 and a trailing end (second end) 408; the nomenclature first and second is arbitrary here and throughout, unless otherwise indicated, and the designation of leading and trailing is arbitrary here and throughout with respect to "B-shape" 404. A first curl 406a of a first rotational direction and a first diameter is provided at a first / leading end 407 of the paper strip 400, while a second curl 405a of a first rotational direction and a second diameter is provided at a second / trailing end 408. The first and second diameters may be the same. Because the rotational directions of the first curl 406a and the second curl 408a are the same, an altered "B-shape" (packaged product) 404a is created.

[0031] 5-7, an exemplary packaging product making / forming machine 413 is shown. The packaging product making machine 413 includes a frame 414 having a base or bottom 418, which is preferably, but not necessarily, supported by a plurality of (here, four) feet, pads, or the like 419a, 419b, 419c, and 419d at or adjacent the four corners of the base 418. More or fewer feet may be used. The packaging product making machine 413, as well as its components, may be assembled on other types of platforms. It should also be understood that the components of the packaging product making machine 413 and / or the effective method of forming the "B" shape may differ from those shown. The frame 414 also includes an upwardly facing portion 429 on a longitudinal side of the base 418 that supports a mounting plate 434.

[0032] Packaging product manufacturing machine 413 is configured to hold a roll of cohesive paper (non-cohesive paper, coated paper, or other paper) 415 for manufacturing the packaging material of the present invention. Roll of paper 415 is held on a rotatable shaft 416 and supported for rotation by a first holding spindle 417 on a first side of roll of paper 415 and a second holding spindle 441 on a second side of roll of paper 415, the names first and second being arbitrary. First holding spindle 417 and second holding spindle 441 hold roll of paper 415 on shaft 416 so that roll of paper 415 can rotate with shaft 416. The roll of paper 415 has a continuous sheet of paper 420 that is fed into various components / mechanisms of the packaging production machine 413, which cuts the paper sheet 420 into strips 400 to size, forms one or more "B-shapes" from the strips 400, and discharges the formed one or more "B-shapes" from the packaging product forming machine 413, as described in more detail below.

[0033] The paper sheet 420 is fed into the packaged product forming portion or section 448. The paper sheet 420 extends beneath guide rollers 422, beneath a rotating cutting roller 425, and above a cutter 426. As explained above, the cutter 426 sizes the paper sheet 420 into paper strips 400 of a width corresponding to the cutter 426. The cutting roller 425 is rotated by a cutting roller motor 427 supported on a frame portion 428 that is attached to a brace 423 extending from an upwardly facing portion 429. The cutting roller motor 427 is coupled to the cutting roller 425 to rotate the cutting roller 425 and feed the paper sheet 420 over the cutter 420 to cut the paper sheet 420 into paper strips 400. The leading end 407 of the width-sized paper strip 400 is then fed into and passes through a first curl rod or spindle 450, which in turn is fed into and passes through a second curl rod or spindle 451, the nomenclature of which is arbitrary. The first curl rod 450 is coupled to a first curl rod motor 431 supported on a first frame portion 431 extending from a mounting plate 434 to rotate the first curl rod 450, and the second curl rod 451 is coupled to a second curl rod motor 433 supported on a second frame portion 432 extending from the mounting plate 434 to rotate the second curl rod 450, the nomenclature of which is arbitrary. The first curl rod motor 431 provides rotational positioning for the first curl rod 450. Additionally, the first curl rod motor 431 is controllable to rotate the first curl rod 450 a given number of revolutions to curl the trailing end 408 of the width-sized paper strip 400 as described herein. The given number of revolutions can be controlled to provide a "B-shaped" 404 second curl 405 having a given number of spirals desired for a particular packaging application or otherwise, and / or a particular diameter. The diameter can depend on the tightness of the spirals and the length of the second curl 405. The second curl rod motor 433 provides the rotational positioning of the second curl rod 451.Additionally, the second curl rod motor 433 is controllable to rotate the second curl rod 451 a given number of revolutions to curl the leading end 407 of the width-sized paper strip 400, as described herein. The given number of revolutions can be controlled to provide a "B-shaped" 404 first curl 406 having a given number of spirals desired for a particular packaging application or otherwise, and / or a particular diameter. The diameter can depend on the tightness of the spirals and the length of the first curl 406. The given number of spirals of the first curl 406 and the given number of spirals of the second curl 405 can be the same or different, again depending on the particular packaging application or otherwise. As shown in FIG. 16 , the first curl rod motor 431 (M2) and the second curl rod motor 433 (M3) are in communication with a processor 460 of the packaged product forming machine 413. Similarly, the cutoff roller motor 427 is in communication with and controlled via the processor 460 .

[0034] As shown in Figure 8, the first curl rod 450 has a first longitudinal slot 454 open at one end and a closed end at the opposite end, and the second curl rod 451 has a second longitudinal slot 455 open at one end and a closed end at the opposite end; the nomenclature of first and second is arbitrary. The leading edge of a width-sized sheet of paper is fed into the first longitudinal slot 454 of the first curl rod 450 and then threaded through the second longitudinal slot 455 of the second curl rod 451. The first curl rod 450 and the second curl rod 451 are positioned by their respective motors 431, 433 via a processor 460 so that the longitudinal slots are aligned to allow the width-sized sheet of paper to be fed through the longitudinal slots.

[0035] The packaging product making machine 413 further includes a sheet cutting motor 442, which is in communication with the processor 460 and is labeled M5 in FIG. 16 . The processor 460 controls the sheet cutting motor 442. The sheet cutting motor 442 is mounted on a support 443 and is configured to operate a sheet cutter 452 that cuts the paper sheet 420 into paper strips 400 at the appropriate time. As described herein, the packaging product making machine 413 further includes a discharge motor 435, which is mounted to a plate 434 located on the upwardly facing portion 429 and is in communication with the processor 460 and is labeled M4 in FIG. 16 . The processor controls the discharge motor 435. The discharge motor 435 controls a discharge rod 437 connected to a sliding discharge assembly 436. The sliding discharge assembly 436 is movably mounted on the underside of a rail 439 of a support plate 438 that extends transversely from the mounting plate 434. As the ejection motor 435 rotates the ejection rod 437, the sliding ejection assembly 436 is moved along the rails 439 away from the mounting plate 434. The sliding ejection assembly 436 includes an ejection plate 457 that moves with the ejection assembly 436. The ejection plate 457 extends essentially parallel to the mounting plate 434 and is configured to push or eject the formed "B-shape" from the first curl rod 450 and the second curl rod 451.

[0036] As best seen in FIG. 5 , packaged product manufacturing machine 413 includes bar 440, which supports first and second pivoting support arms 444 and 446, the nomenclature of which is arbitrary here and hereinafter. As seen in FIGS. 11-13 , for example, first pivoting support arm 444 includes a first conical protrusion 445 at the bottom thereof, which extends transversely relative to first pivoting support arm 444. First conical protrusion 445 is configured to hold the end of first curl rod 450 during the formation of the "B" shape. Also seen in FIGS. 11-13 , for example, second pivoting support arm 446 includes a second conical protrusion 447 at the bottom thereof, which extends transversely relative to second pivoting support arm 446. The second conical protrusion 447 is configured to hold the end of the second curl rod 451 during the formation of the "B" shape. The first curl rod 450, together with the first pivoting retaining arm 446, is configured to move along the bar 440 as described below during the formation of the "B" shape.

[0037] As depicted in FIG. 16 , the packaging product production machine 413 has a processor 460 for controlling the operation of its various components. The processor 460 may include memory for storing programming, in addition to other components for providing the functions and / or functionality of the packaging product production machine 413 necessary for its operation. The processor 460 may be any type of processor. The processor 460 is in communication with the cutting roller motor 427 (M1), the first curl rod motor 431 (M2), the second curl rod motor 433 (M3), the discharge motor 435 (M4), and the cutting motor 442 (M5). Although not shown, the packaging product production machine 413 may include an interface that allows a user to select various parameters for the production of the "B-shape." For example, a user may select the length of the paper sheet 404, which at least in part determines the number of turns or spirals of the first curl 406 and the second curl 405. The user can also select the number of turns or spirals, tightness, etc. of the first curl 406 and the second curl 405. The number of turns or spirals may be different. Other features and / or parameters may be modified and / or selected via the user interface UI 462.

[0038] The cutters 426 of the packaging product making machine 413 may be interchangeable to create "B-shapes" of various widths. For example, one cutter may provide a given number of "B-shapes" of the same width. Another cutter may provide a given number of "B-shapes" of different widths. Rather than interchangeable cutters, the cutter 426 may automatically change its cutting blades to set the width or widths of the "B-shapes" to be formed. In this manner, the interface allows the user to select the cutting width.

[0039] 9-14 depict the formation of one or more "B-shapes" through the operation of the packaged product making machine 413, and in particular, the first pivoting retaining arm 444, the second pivoting retaining arm 446, and the sliding discharge assembly 436. In FIG. 9, a first curl 406 of the "B-shape" 404 is formed around a second curl rod 451, with the second pivoting retaining arm 446 and its conical protrusion 447 holding the end of the second curl rod 451. A second curl 405 of the "B-shape" 404 is formed around a first curl rod 450, with the first pivoting retaining arm 444 and its conical protrusion 445 holding the end of the first curl rod 450. In FIG. 10, the paper sheet 420 has been cut into paper strips 400 with the "B-shapes" 404 formed therein. The first curl rod 450 and associated first pivoting retaining arm 444 have been translated toward the second curl rod 451 and its associated second pivoting retaining arm 446, causing the second curl 405 to become tighter wound. In FIG. 11 , the sliding ejection assembly 436 begins to slide outward along the rails 439 of the support bar 438 such that the ejection plate 457 begins to push the formed "B-shape" 404 away from the first curl rod 450 and the second curl rod 451. The first pivoting retaining arm 444 and the second pivoting retaining arm 446 are pivoted outward on the screw bar 440 via the rotation of the screw bar 440. 12, as the screw bar 440 is further rotated to pivot the first and second pivoting retaining arms 444, 446 completely outward and upward, the ejection plate 456 is further slid to push the formed "B-shape" 404 off the first and second curling rods 450, 451. In FIG. 13, the fully formed "B-shape" 404 has been completely ejected from the first and second curling rods 450, 451 and from the packaged product making machine 413.14, the screw bar 440 is rotated in an opposite direction to the previous rotation that pivoted the first pivoting retaining arm 444 and the second pivoting retaining arm 446, causing the first pivoting retaining arm 444 and its conical projection 446 to pivot back to holding the first curl rod 450 and the second pivoting retaining arm 446 and its associated conical projection 447 to pivot back to holding the second curl rod 451.

[0040] 15A-15F depict representations of the creation of multiple "B" shapes 404a, 404b, and 404c formed by packaging machine 413 of the present invention. While multiple "B" shapes are shown being formed, the same principles and procedures apply to the creation of a single "B" shape 404. FIG. 15A depicts a sheet of cohesive paper 420 being fed through a first longitudinal slot 454 of a first curl rod 450 and a second longitudinal slot 455 of a second curl rod 451. The sheet of cohesive paper 420 has been pre-cut into three widths by a cutter 426. In FIG. 15B, the leading edge of the width-cut cohesive paper sheet 420 is wrapped around second curl rod 451 by the rotation of second curl rod 451 to create first curls 406a, 406b, and 406c. In Figure 15C, the sheet of cohesive paper is cut into cohesive paper strips 400 by a sheet cutter 452. In Figure 15D, the width-sized cohesive paper strip 400 is wound around the first curl rod 450 by rotating the first curl rod 450. In Figure 15E, the first curl rod 450 is moved toward the second curl rod 451 and rotated further to tighten the formed "B-shapes." In Figure 15F, the three formed "B-shapes" 404a, 404b, 404c are ejected from the first curl rod 450 and the second curl rod 451 by a sliding ejection bar 457.

[0041] It is to be understood that other methods of producing the packaged product, "B-shape," or modified "B-shape" in accordance with the principles of the present invention may be used and are contemplated.

[0042] While the invention has been illustrated and described in detail in the drawings and foregoing description, these are to be considered illustrative and not restrictive in character, it being understood that only preferred embodiments have been shown and described, and that all changes and modifications that come within the spirit of the invention are desired to be protected. The use of words such as preferred, preferably, preferred, or more preferred, employed in the above description, indicates that the feature so described may be more desirable, but it should nevertheless be understood that it may not be necessary and that embodiments lacking it may be contemplated as being within the spirit of the invention.

[0043] [Embodiment] (1) A packaged product (404), a dimensionally controlled strip of paper (400) having a first side (401), a second side (402), a width, a length, a leading edge (407), and a trailing edge (408); a first curl (406) formed at the leading end of the dimensionally controlled paper strip; a second curl (405) formed at the trailing end of the dimensionally controlled paper strip; a segment (409) connected to the first curl (406) and the second curl (405) and located between the first curl (406) and the second curl (405); Including packaging products. (2) the first curl (405) defines a first spiral with the first side (401) of the dimensionally controlled paper strip facing radially outward; A packaging product (404) as described in embodiment 1, wherein the second curl (406) defines a second spiral with the first side (401) of the dimensionally controlled paper strip facing radially outward. (3) the first curl (406) is formed in a first rotational direction; 3. The packaging product (404) of claim 2, wherein the second curl (405) is formed in a second rotational direction opposite the first rotational direction. (4) The packaging product (404) of claim 3, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled coated paper strip. (5) The packaging product (404) of claim 3, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled cohesive paper strip.

[0044] (6) The packaging product (404) of claim 5, wherein the dimensionally controlled cohesive paper strip has a cohesive surface that constitutes the first side (401) and a non-cohesive surface that constitutes the second side (402). (7) the first curl (406) has a first curl diameter; the second curl (405) has a second curl diameter; 7. The packaging product (404) of embodiment 6, wherein the dimensionally controlled paper strip (400) further comprises a segment (409) connecting the first curl (406) and the second curl (405) and sized so that the first curl and the second curl abut at mutual tangents to a first side of the first curl diameter of the first curl and a first side of the second curl diameter of the second curl. (8) The packaged product (404) of embodiment 7, wherein the first curl diameter is equal to the second curl diameter. (9) The packaged product (404) of claim 7, wherein the first curl diameter is different from the second curl diameter. (10) A method for producing a packaged product (404), comprising: providing a roll of paper (415) having a first side (401), a second side (402), a width, and a leading edge (407); forming a first curl (406) of a first radial diameter at the leading end of the roll of paper; cutting the roll of paper into strips of paper (400) having the first curl, thereby creating a trailing edge (408) distal to the first curl; forming a second curl (405) of a second radial diameter at the trailing end of the paper strip; A method comprising:

[0045] (11) Providing a roll of cohesive paper having a cohesive side constituting the first side (401) and a non-cohesive side constituting the second side (402); forming the first curl (406) with the aggregation side facing radially outward; forming the second curl (405) with the aggregation side facing radially outward; 11. The method of embodiment 10, further comprising: (12) the first curl (406) defines a first spiral with the first side of the dimensionally controlled paper strip facing radially outward; 11. The method of claim 10, wherein the second curl (405) further comprises defining a second spiral with the first side of the dimensionally controlled paper strip facing radially outward. (13) The first curl (405) is formed in a first rotational direction; 13. The method of claim 12, wherein the second curl (406) is formed in a second rotational direction opposite the first rotational direction. (14) The method of claim 13, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled coated paper strip. 15. The method of claim 13, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled cohesive paper strip.

[0046] 16. The method of claim 15, wherein the dimensionally controlled cohesive paper strip (400) has a cohesive surface that constitutes the first side (401) and a non-cohesive surface that constitutes the second side (402). (17) The first curl (406) has a first curl diameter; the second curl (405) has a second curl diameter; 16. The method of claim 15, wherein the dimensionally controlled paper strip (400) further comprises a segment (409) connecting the first curl and the second curl and sized so that the first curl and the second curl abut at mutual tangents to a first side of the first curl diameter of the first curl and a first side of the second curl diameter of the second curl. 18. The method of claim 17, wherein the first curl diameter is equal to the second curl diameter. 19. The method of claim 17, wherein the first curl diameter is different from the second curl diameter. (20) A machine (413) for producing packaged products, a paper supply (415), the paper supply having a leading end (407); means (451) for twisting said front end into a first curl (406) in a first rotational direction; means for cutting said paper supply to produce a segment (409) connected to said first curl (406) and a trailing end (408) distal to said first curl; means (450) for twisting said trailing end into a second curl (405) in a second rotational direction opposite said first rotational direction; means (457) for ejecting said packaged products from said machine; Including, machinery.

Claims

1. A packaged product (404), comprising: a dimensionally controlled strip of paper (400) having a first side (401), a second side (402), a width, a length, a leading edge (407), and a trailing edge (408); a first curl (406) formed at the leading end of the dimensionally controlled paper strip; a second curl (405) formed at the trailing end of the dimensionally controlled paper strip; a segment (409) connected to the first curl (406) and the second curl (405) and located between the first curl (406) and the second curl (405); Including packaging products.

2. the first curl (405) defines a first spiral with the first side (401) of the dimensionally controlled paper strip facing radially outward; 2. The packaging product (404) of claim 1, wherein the second curl (406) defines a second spiral with the first side (401) of the dimensionally controlled paper strip facing radially outward.

3. the first curl (406) is formed in a first rotational direction; 3. The packaged product (404) of claim 2, wherein the second curl (405) is formed in a second rotational direction opposite the first rotational direction.

4. 4. The packaging product (404) of claim 3, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled coated paper strip.

5. 4. The packaging product (404) of claim 3, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled cohesive paper strip.

6. 6. The packaging product (404) of claim 5, wherein the strip of dimensionally controlled cohesive paper has a cohesive surface that constitutes the first side (401) and a non-cohesive surface that constitutes the second side (402).

7. the first curl (406) has a first curl diameter; the second curl (405) has a second curl diameter; 7. The packaging product (404) of claim 6, wherein the dimensionally controlled paper strip (400) further comprises a segment (409) connecting the first curl (406) and the second curl (405) and sized such that the first curl and the second curl abut at a mutual tangent to a first side of the first curl diameter of the first curl and a first side of the second curl diameter of the second curl.

8. 8. The packaged product (404) of claim 7, wherein the first curl diameter is equal to the second curl diameter.

9. 8. The packaged product (404) of claim 7, wherein the first curl diameter is different from the second curl diameter.

10. A method for manufacturing a packaged product (404), comprising: providing a roll of paper (415) having a first side (401), a second side (402), a width, and a leading edge (407); forming a first curl (406) of a first radial diameter at the leading end of the roll of paper; cutting the roll of paper into strips of paper (400) having the first curl, thereby creating a trailing edge (408) distal to the first curl; forming a second curl (405) of a second radial diameter at the trailing end of the paper strip; A method comprising:

11. providing a roll of cohesive paper having a cohesive side constituting said first side (401) and a non-cohesive side constituting said second side (402); forming the first curl (406) with the aggregation side facing radially outward; forming the second curl (405) with the aggregation side facing radially outward; The method of claim 10 further comprising:

12. the first curl (406) defines a first spiral with the first side of the dimensionally controlled paper strip facing radially outward; 11. The method of claim 10, further comprising: the second curl (405) defining a second spiral with the first side of the dimensionally controlled paper strip facing radially outward.

13. the first curl (405) is formed in a first rotational direction; The method of claim 12, wherein the second curl (406) is formed in a second rotational direction opposite the first rotational direction.

14. The method of claim 13, wherein the dimensionally controlled strip of paper (400) comprises a dimensionally controlled strip of coated paper.

15. The method of claim 13, wherein the dimensionally controlled paper strip (400) comprises a dimensionally controlled cohesive paper strip.

16. 16. The method of claim 15, wherein the dimensionally controlled cohesive paper strip (400) has a cohesive surface that constitutes the first side (401) and a non-cohesive surface that constitutes the second side (402).

17. the first curl (406) has a first curl diameter; the second curl (405) has a second curl diameter; 16. The method of claim 15, wherein the dimensionally controlled strip of paper (400) further comprises a segment (409) connecting the first curl and the second curl and sized such that the first curl and the second curl abut at mutual tangents to a first side of the first curl diameter of the first curl and a first side of the second curl diameter of the second curl.

18. 18. The method of claim 17, wherein the first curl diameter is equal to the second curl diameter.

19. 18. The method of claim 17, wherein the first curl diameter is different from the second curl diameter.

20. A machine (413) for producing packaged products, comprising: a paper supply (415), the paper supply having a leading end (407); means (451) for twisting said front end into a first curl (406) in a first rotational direction; means for cutting said paper supply to produce a segment (409) connected to said first curl (406) and a trailing end (408) distal to said first curl; means (450) for twisting said trailing end into a second curl (405) in a second rotational direction opposite said first rotational direction; means (457) for ejecting said packaged products from said machine; Including, machinery.

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