Abstract:
A flexible package for cutting blades. A flexible first layer has at least one cavity formed therein to form a base for receiving a cutting blade. A flexible second layer is arranged over the base and proximate the base. A seal is formed about the periphery of each cavity to encapsulate a cutting blade placed into the cavity, the seal being formed by applying a predetermined combination of heat and pressure to selected portions of the second layer to cause the adhesive thereon to selectively bond to the base. Movement of each encapsulated cutting blade is deterred during transport and handling by the cavity in cooperation with the seal and the second layer, the blades becoming movable within the cavity when the seal is broken.

Description:
FIELD  
       [0001]    The present invention relates generally to cutting blades, in particular to a package for storing and handling cutting blades. 
       BACKGROUND  
       [0002]    In the meat processing industry the productivity and overall yield of a meat processing plant depends on a number of factors, including the efficiency of the meat cutting equipment being used. The efficiency of the meat cutting equipment, in turn, varies with the sharpness of the blades utilized to cut the meat. The cutting blades have a tendency to become dull after being used for a period of time, making it necessary to regularly replace them in order to maintain the desired productivity and yield. Accordingly, meat-cutting equipment is typically designed to utilize cutting blades that can be quickly removed and replaced with new ones as the need arises. 
         [0003]    A meat processing plant will usually keep a number of new blades on hand in order to facilitate their rapid replacement in the cutting equipment as they dull. Over time the processing plant will also typically accumulate a number of used blades that must be stored or disposed of in a safe manner. Storing and handling both new and used cutting blades can be problematic, since they pose a safety risk to workers due to their sharpness. 
         [0004]    It is also important to store and handle new cutting blades so that they are not contaminated by incidental contact with inappropriate materials, since the blades are intended for use in food processing. A further concern is that contact of the blades with certain contaminants may cause premature blade wear or failure. 
         [0005]    There is a need for a way to package newly-manufactured cutting blades so that they can be safely handled and transported with less risk of damage or contamination. There is a further need for a way to package used cutting blades for handling and storage. 
       SUMMARY  
       [0006]    A blade package is disclosed according to an embodiment of the present invention. The blade package includes a flexible first layer having cavities formed therein. Blades are loaded into the cavities and a second, adhesive-coated flexible layer is placed over the first layer. A vacuum is drawn, urging the second layer into the cavities and holding the blades in place. A combination of heat and pressure are applied around the periphery of the cavities to activate the adhesive and form a seal that maintains the vacuum. The seal includes a chevron-shaped portion proximate a set of tabs, the tab and chevron-shaped portion cooperating to provide ease of opening the package when a blade is to be dispensed. A plurality of score lines are made between adjacent cavities, providing packets that are separable from the package and contain a single blade. 
         [0007]    An aspect of the present invention is a flexible package for cutting blades. A flexible first layer has at least one cavity formed therein to form a base for receiving a cutting blade. A flexible second layer is arranged over the base and proximate the base. A seal is formed about the periphery of each cavity to encapsulate a cutting blade placed into the cavity, the seal being formed by applying a predetermined combination of heat and pressure to selected portions of the second layer to cause the adhesive thereon to selectively bond to the base. Movement of each encapsulated cutting blade is deterred during transport and handling by the cavity in cooperation with the seal and the second layer, the blades becoming movable within the cavity when the seal is broken. 
         [0008]    Another aspect of the present invention is a method for making a flexible package for cutting blades. The method includes the steps of cutting a flexible first layer to a predetermined length and cutting a flexible second layer to a predetermined length, the second layer having an adhesive coating. At least one cavity is formed in the first layer to form a base. A cutting blade is placed into each cavity. The second layer is placed over the base such that the adhesive coating is proximate the base. A predetermined combination of heat and pressure is applied around the periphery of each cavity to cause the adhesive to bond together the base and the second layer, forming a seal around the cavity and encapsulating the cutting blade. Movement of each encapsulated cutting blade is deterred during transport and handling by the cavity in cooperation with the seal and the second layer, the blades becoming movable within the cavity when the seal is broken. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Further features of the inventive embodiments will become apparent to those skilled in the art to which the embodiments relate from reading the specification and claims with reference to the accompanying drawings, in which: 
           [0010]      FIG. 1A  is a top plan view of a first layer of a package according to an embodiment of the present invention; 
           [0011]      FIG. 1B  is a view in section of the first layer of  FIG. 1A ; 
           [0012]      FIG. 2A  is a top plan view of a second layer of a package according to an embodiment of the present invention; 
           [0013]      FIG. 2B  is a view in section of the second layer of  FIG. 2A ; 
           [0014]      FIG. 3  is a top plan view of a base formed from the first layer of  FIGS. 1A and 1B ; 
           [0015]      FIG. 4  shows the base of  FIG. 3  with blades loaded into the cavities; 
           [0016]      FIG. 5  is a top plan view of a blade package according to an embodiment of the present invention; 
           [0017]      FIG. 6  is a top plan view of a blade package according to another embodiment of the present invention; 
           [0018]      FIG. 7  is a side elevational view of the packages of  FIGS. 5 and 6 ; 
           [0019]      FIG. 8  is an end elevational view of the packages of  FIGS. 5 and 6 ; 
           [0020]      FIG. 9  shows the general arrangement of a package according to an embodiment of the present invention; 
           [0021]      FIG. 10  shows details of a cavity for a blade package according to yet another embodiment of the present invention; and 
           [0022]      FIG. 11  shows steps of a method for packaging articles according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION  
       [0023]    Referring to  FIGS. 1A ,  1 B,  2 A and  2 B a package  10  for cutting blades comprises a first layer  12  and a second layer  14 . First layer  12  is a flexible, generally planar material as shown in  FIGS. 1A and 1B . Second layer  14  likewise comprises a flexible, generally planar material and further includes an adhesive layer  16  that is generally uniformly applied to one entire side of a substrate  18 , as shown in  FIGS. 2A and 2B . 
         [0024]    First layer  12  and substrate  18  may be made from any suitable flexible material, such as polypropylene, polyethylene and polyester. In one embodiment a low-density polyethylene (LDPE) about 0.005 inches thick is utilized. First layer  12  and substrate  18  may be clear or opaque, and may be provided in any desirable color or combination of colors, such as colors associated with a particular brand of cutting blades. 
         [0025]    Adhesive  16  may be any type of adhesive of suitable thickness that adheres to both substrate  18  and first layer  12 , serves as a moisture barrier, and exhibits suitable adhesive properties. Adhesive  16  is activated when a predetermined combination of heat and pressure is applied. Accordingly, when adhesive  16  comes into contact with first layer  12 , for example, the first layer and second layer  14  will form a seal only in those areas where the requisite heat and pressure are applied. In one embodiment adhesive  16  is an aqueous-based acrylic adhesive about 0.0003 to 0.001 inches thick. 
         [0026]    With reference now to  FIG. 3  a base  20  is made by forming a plurality of cavities  22  in first layer  12 . Cavities  22  may be formed in any conventional manner such as, without limitation, vacuum forming and molding. 
         [0027]    Package  10  is assembled by first placing articles to be packaged, such as a set of cutting blades  24 , into cavities  22  of base  20  as shown in  FIG. 4 . Second layer  14  is then arranged over base  20  and placed proximate thereto such that adhesive  16  comes into contact with the base. A predetermined combination of heat and pressure is then applied in selected areas, such as around the periphery of cavities  22 , causing adhesive  16  to bond with base  20  to form a seal  26  around the cavities as shown in  FIG. 5  and encapsulate the blades  24  therein. Seal  26  may be formed in any conventional manner, such as with a heated platen or die. In addition, the heated platen or die may have a predetermined patterning  28 , such as the crosshatched patterning shown in  FIG. 6 , to increase the effective bonding area of seal  26 . 
         [0028]    A plurality of longitudinal perforations or score lines  30  may be placed between adjacent cavities  22  as shown in  FIGS. 5 and 6 . Score lines  30  form a plurality of packets  32 , each containing a blade  24 . If desired, a user may separate one or more packets  32  from package  10  by tearing along selected score lines  30 . 
         [0029]    In some embodiments of the present invention a transverse edge of package  10  may be formed with tabs  34 , as shown in  FIGS. 5 ,  7 ,  8  and  9 . Tabs  34  are formed by corresponding portions of base  20  and second layer  14  that are not adhered together by adhesive  16 . These areas are not exposed to the heat and/or pressure utilized to form seal  26 , thereby remaining separated from each other. Tabs  34  facilitate opening of package  10  when a blade  24  is to be dispensed therefrom. 
         [0030]    In other embodiments of the present invention a vacuum is applied to cavities  22  and the space between base  20  and second layer  14 . The vacuum causes second layer  14  to be urged into cavities  22  and into intimate contact with first layer  12  and blades  24 . Seal  26  is then formed in the manner previously described to maintain the vacuum in the cavities. The vacuum seal deters movement of blades  24  encapsulated in cavities  22 , thereby reducing the risk of damage to package  10  by the blades due to their movement during transport and handling, which could cause contamination of the blades and pose a safety risk to personnel transporting and handling the package. This has an added advantage in that the blades in the package need not be arranged irregularly such that their cutting edge faces the center of the package, as is commonly done at present for safety reasons. The vacuum seal is also expected to aid in the extension of the shelf life of carbon-type blades  24  by deterring oxidation. 
         [0031]    Package  10  may include printed matter on base  20  and/or second layer  14 . The printed matter may include, without limitation, brand names, trademarks, handling instructions, manufacturing data, date codes, expiration dates, and so on. 
         [0032]    Blades  24  may be disinfected prior to or during packaging, if desired. For example, blades  24  may be dipped, sprayed or exposed to a disinfectant gas prior to loading into cavities  22 . In other embodiments of the present invention a disinfectant gas may be injected into cavities  22  after blades  24  are loaded into base  20 , prior to sealing or vacuum-sealing in the manner previously described. 
         [0033]    In still other embodiments seal  26  may further include a chevron shape  36  proximate tabs  34 , as shown in  FIGS. 5 ,  6  and  9 . Chevron shape  36  causes seal  26  to begin separating at an apex  38  of the chevron shape when tabs  34  are pulled away from each other by a user to dispense a blade from package  10 . As the user continues to pull on tabs  36  the seal  26  will continue separating along arms  40  of the chevron-shaped seal portion  36 , thereby exposing a blade  24  for dispensing. When the blade is thus exposed any vacuum present in the selected cavity  22  is released, causing the cavity to expand slightly. This allows a blade  24  packaged therein to move slidably for dispensing from between the now partially separated base  20  and second layer  14 . 
         [0034]    In some embodiments of the present invention adhesive  16  may be a re-sealable type. In such embodiments seal  26  may be re-sealed by aligning the separated portions of seal  26  on base  20  and second layer  14 , then pressing them together. This permits cavities  22  of package  10  and/or packets  32  to receive used blades and then be re-sealed for subsequent handling, transport and disposal. 
         [0035]    After package  10  is assembled it may be cut to a desired longitudinal length to provide a finished, uniform appearance. Package  10  may be cut in any conventional manner, such as manually with knives or razor blades, or automatically with rotary cutting wheels and knives. Likewise, the outer longitudinal edges  42  of package  10  may be trimmed to provide a uniform aesthetic appearance. The outer longitudinal edges  42  may be trimmed in any conventional manner, such as manually, with knives or razor blades, or automatically with rotary cutting wheels and knives. 
         [0036]    In one embodiment of the present invention base  20  may include one or more cavities  44 , shown in  FIG. 10 . Cavity  44  includes at least one relief  46  proximate at least one longitudinal end  48  of the cavity. Reliefs  46  aid to prevent corners  50  of blades  24  from piercing package  10  (see generally  FIG. 4 ) by providing a gap between the corners and the edges that delimit cavity  44 . Cavity  44  is otherwise identical in structure and function to cavity  22  and thus will not be reiterated here. Likewise, base  20  (and, in turn, package  10 ) may be formed with one or more of cavities  22  or cavities  44 , or may be formed with one or more of cavities  22  and cavities  44 . 
         [0037]    In another embodiment of the present invention adhesive  16  may be omitted from second layer  14 . In this embodiment seal  26  is formed by causing first layer  12  and second layer  14  to bond together by melting and form a seal only in those areas where the requisite heat and pressure are applied. Seal  26  may be formed in any conventional manner, such as with a heated platen or die. In addition, the heated platen or die may have a predetermined patterning  28 , such as the crosshatched patterning shown in  FIG. 6 , to increase the effective bonding area of seal  26 . Alternatively, an ultrasonic welder may be used to bond second layer  14  to first layer  12 . 
         [0038]    With reference to  FIGS. 1-10  together, in use package  10  allows blades  24  to be safely stored and transported to their ultimate point of use, such as a meat processing plant. When a blade  24  is needed a user may separate a selected packet  32  from package  10  by tearing along a corresponding score line  30 . The user pulls tabs  34  away from each other, causing seal  26  to begin separating at apex  38  of its chevron-shaped portion  36 . As the user continues to pull on tabs  34  the seal  26  will continue separating along arms  40  of the chevron-shaped seal portion  36 , thereby exposing a blade  24  for dispensing. When the blade is thus exposed any vacuum present in the selected cavity  22 ,  44  is released, causing the cavity to expand slightly. This allows a blade  24  packaged therein to move slidably for dispensing from between the now partially separated base  20  and second layer  14 . Thereafter a used blade  24  may be loaded into packet  32  for subsequent handling, transport and disposal. If a re-sealable type of adhesive  16  is present, seal  26  may be re-sealed by aligning the separated portions of the seal on base  20  and second layer  14 , then pressing them together. 
         [0039]    With general reference to  FIGS. 1-10  together a method  100  for making a blade package is shown in  FIG. 11  according to an embodiment of the present invention. At step s 102  a first layer  12  is selected. At step s 104  a second layer  14  is likewise selected. In some embodiments first layer  12  and second layer  14  may each be provided in a continuous web and unrolled or indexed to a predetermined selected length for further processing, as detailed below. 
         [0040]    At step s 106  a predetermined number of cavities  22 , which may be one or more than one, are formed in first layer  12  to form base  20 , the cavities each having a shape and depth to receive a corresponding blade  24 . Cavities  22  may be formed in any conventional manner such as, without limitation, vacuum forming using heated dies. 
         [0041]    At step s 108  blades  24  are loaded into corresponding cavities  22 . Blades  24  may be loaded into cavities  22  in any conventional manner including, without limitation, manually and with robotic pick-and-place mechanisms. 
         [0042]    At step s 110  second layer  14  is placed over base  20  in any conventional manner such as, without limitation, manually, roll feeders and robotic pick-and-place mechanisms. Second layer  14  is positioned such that adhesive coating  16  is proximate base  20 . 
         [0043]    At step s 112  a vacuum is applied to cavities  22  and the space between base  20  and second layer  14 . The vacuum causes second layer  14  to be urged into cavities  22  and into contact with base  20 . 
         [0044]    At step s 114  a predetermined combination of heat and pressure are applied to the assembly of base  20 , blades  24  and second layer  14 . The heat and pressure cause adhesive  16  to bond second layer  14  to base  20  in selected areas, thereby forming a plurality of seals  26 . Seals  26  are preferably formed as an unbroken perimeter around each cavity  22 , thereby maintaining a vacuum seal in the cavities to resist movement of encapsulated blades  24  in the cavities. 
         [0045]    At step s 116  a plurality of longitudinal perforations or score lines  30  are made between adjacent cavities  22 . The score lines may be made in any conventional manner including, without limitation, razors and scoring wheels. Score lines  30  facilitate the later separation of package  10  into one or more packets  32 . 
         [0046]    At step s 118  package  10  may be cut to a desired longitudinal length to provide a finished, uniform appearance. Package  10  may be cut in any conventional manner, such as manually with knives or razor blades, or automatically with rotary cutting wheels and knives. Likewise, at step s 120  the outer longitudinal edges  42  of package  10  may be trimmed to provide a uniform aesthetic appearance. The outer longitudinal edges  42  may be trimmed in any conventional manner, such as manually with knives or razor blades, or automatically with rotary cutting wheels and knives. 
         [0047]    While this invention has been shown and described with respect to a detailed embodiment thereof, it will be understood by those skilled in the art that changes in form and detail thereof may be made without departing from the scope of the claims of the invention. For example, although the packaging system and method disclosed herein are directed to packaging blades, it is understood that the system and method may be easily adapted to package a wide variety of articles within the scope of the invention. In addition, the order of the steps discussed above may be varied within the scope of the invention.