Abstract:
The present invention involves an apparatus and a method of making slotted tubular dunnage. The method of the present invention includes providing a tube having a pair of flanges at opposite sides extending along the length of the tube, and holding the tube by gripping the flanges at opposite sides of the tube and squeezing sides of the tube together. The method further includes moving the tube into a slotting position between a steel rule die and a kissing plate while holding the tube with the sides squeezed together. The method further includes shifting the die against and through the sides of the tube forming a slot therein surrounding a cutout slug of the tube. The method further includes withdrawing the die from the tube while retaining the slug within the slot. Furthermore, the method includes moving the tube to a discharged position and discontinuing the squeezing of the tube.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention is related to an apparatus and a method of making slotted tubular dunnage for supporting products in a shipping container.  
           [0003]    2. Background Art  
           [0004]    Typically, a shipping or storage carton in which dunnage may be placed for supporting parts comprises a conventional cardboard or similar box having four connected sidewalls, a connected bottom wall, and four hinged lid flaps. The box is sized to accept the length of particular products being shipped or stored. Specifically, within the box is disposed laterally spaced apart lengths of tubular dunnage, wherein the lengths of the dunnage are such as to slidably fit between walls of the box. The dunnage may be laterally arranged in pairs which cooperatively support a plurality of products being shipped or stored.  
           [0005]    It is known that the auto industry in the United States has been moving toward the elimination of foam packaging such as polystyrene and other foams for automotive parts. This includes a substantial elimination of dunnage used in the automotive industry for handling and shipping automotive parts. Generally, such parts have been shipped in boxes having a bottom wall, side walls, and a lid wherein dunnage is placed to support the parts against abrasion and damage during shipment.  
           [0006]    As provided in U.S. Pat. No. 5,267,652 to Carroll which is herein incorporated by reference, dunnage is made by a method of placing a tube into a clamp shell fixture having upper and lower platens movable between open and closed positions. As the tube is inserted therein, the clam shell fixture is closed and engages the sides of the tube with the platens to form slots on the tube, forming the dunnage.  
           [0007]    Although the current methods are adequate, the industry continues to look to more time and cost effective ways.  
         SUMMARY OF THE INVENTION  
         [0008]    Thus, it is an object of the present invention to provide an improved apparatus and method of making slotted tubular dunnage for supporting products in a shipping container. The present invention provides a more efficient way of making slotted tubular dunnage. The present invention is more efficient because it saves time and costs in making such dunnage.  
           [0009]    It is another object of the present invention to provide an improved method of making slotted tubular dunnage for supporting products. The method comprises providing a tube having a pair of flanges at opposite sides extending along the length of the tube, and holding the tube by gripping the flanges at opposite sides of the tube and squeezing the sides of the tube together. The method further includes, while holding the tube with the sides squeezed together, moving the tube into a slotting position between a steel rule die and a kissing plate and in such position shifting the steel rule die against and through the sides of the tube, forming a slot therein surrounding a cut-out slug of the tube. The method further comprises withdrawing the steel rule die from the tube while retaining the slug within the slot, and while squeezing the tube, moving the tube to a discharge position where at the squeezing the sides of the tube is discontinued.  
           [0010]    It is yet another object of the present invention to provide an improved apparatus for stamping a tube to make a slotted tubular dunnage for supporting products in a shipping container. The apparatus comprises a fixture for holding a steel rule die with a face for stamping the tube to make the slotted tubular dunnage, and a movable base plate having clamps with notches formed thereon to hold the tube on the movable base plate, wherein the movable base plate is movable along a substantially parallel plane relative to the face of the die. The apparatus further comprises a conveying mechanism for moving the movable base plate to and from the steel rule die along the substantially parallel plane relative to the face of the die, wherein the conveying mechanism is connected to the movable base plate. The apparatus further includes a sensor for determining the presence of the tube held on the movable base plate in an indexing position, wherein the sensor is in communication with the movable base plate, and a microprocessor for controlling the fixture to cut an opening on the tube after the presence of the tube on the movable base plate is determined, wherein the microprocessor is in communication with the sensor, the fixture, and the conveying mechanism.  
           [0011]    It is still another object of the present invention to provide an improved method of making slotted tubular dunnage for supporting products in a shipping container. The method comprises providing a tube including a pair of opposed side walls integrally connected to each other, wherein each side wall has a terminal edge. The terminal edges are bridged together by a bottom wall, wherein the bottom wall has ends. Each end extends past one edge to define lateral flanges. The method further comprises providing a steel rule stamping apparatus having a plurality of steel rule stamping dies horizontally aligned, wherein each die has a face for stamping the tube to make the slotted tubular dunnage. The apparatus has a movable base plate in a home position, wherein the movable base plate has clamps attached thereto. Each of the clamps has notches formed thereon to receive one of the flanges. The movable base plate is movable along a substantially parallel plane relative to the face of each die. The method further includes sliding each of the flanges within one of the notches to position the tube on the movable base plate in the home position, and clamping the tube to substantially evenly hold the tube on the base plate in the home position, allowing the tube to be movable with the movable base plate. The method further includes moving the tube toward the die from the home position to an indexing position at which the tube is to be sensed, sensing the tube clamped on the base plate in the indexing position, moving the tube a first predetermined distance toward the die along the substantially parallel plane relative to the face of the die, and flattening the tube by engaging the opposed side walls. The method further includes cutting a first set of openings on the tube along the first predetermined distance to form a first set of horizontally aligned slots on the tube and respective cut-out slugs of the slots, defining the slotted tubular dunnage.  
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0012]    [0012]FIG. 1 is a perspective view of an apparatus for stamping a tube to make slotted tubular dunnage for supporting products in a shipping container;  
         [0013]    [0013]FIG. 2 is a side view of the apparatus of FIG. 1 in accordance with the present invention;  
         [0014]    [0014]FIG. 3 is a top view of the apparatus of FIG. 1;  
         [0015]    [0015]FIG. 4 is a cross-sectional view of the apparatus having clamps in an open position shown in FIG. 3 taken along lines  4 - 4 ;  
         [0016]    [0016]FIG. 5 is a cross-sectional view of the apparatus having clamps in a closed position shown in FIG. 3 taken along lines  5 - 5 ;  
         [0017]    [0017]FIG. 6 is a perspective view of the apparatus capable of moving a tube into a slotting position in accordance with the present invention;  
         [0018]    [0018]FIG. 7 is a cross-sectional view of the apparatus partially shown in FIG. 6 taken along lines  7 - 7 ;  
         [0019]    [0019]FIG. 8 is a front view of the apparatus of FIG. 1;  
         [0020]    [0020]FIG. 9 is a cross-sectional view of the apparatus partially shown in FIG. 8 depicting a steel rule die taken along lines  9 - 9 ;  
         [0021]    [0021]FIG. 10 is a cross-sectional view of the steel rule die of FIG. 9 taken along lines  10 - 10 ; and  
         [0022]    [0022]FIG. 11 is a perspective view of a slotted tubular dunnage made by the apparatus shown in FIGS.  1 - 10 .  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    [0023]FIG. 1 illustrates an apparatus  12  for stamping a tube  13  to make slotted tubular dunnage for supporting products in a shipping container (not shown). As shown, fixture  14  is configured to hold and support a number of members of apparatus  12  such that slotted tubular dunnage may be made from stamping tube  13 . As shown in FIGS. 1 and 2, fixture  14  includes a body portion  16  which holds and supports steel rule die  21  and backing or kissing plate  23  disposed on body portion  16 . Steel rule die  21  and backing plate  23  are attached to body portion  16  in a manner such that die  21  and plate  23  face each other to allow die  21  to shift toward plate  23  and contact plate  23 . Steel rule die  21  has face or blade  22  (shown in FIG. 9) which is configured to a desired shape in accordance to a desired configuration of the slotted tubular dunnage to be made. Backing or kissing plate  23  oppositely faces blade  22  such that blade  22  contacts or “kisses” backing plate  23  during operation of apparatus  12 . As described in greater detail below, when tube  13  is placed between die  21  and backing plate  23 , blade  22  of die  21  shifts against and through tube  13  and contacts backing plate  23 , thereby forming the slotted tubular dunnage. As shown in FIGS. 1 and 3, body portion  16  of fixture  14  further includes rollers  24  which, in operation, receive and flatten tube  13  to be stamped to make the slotted tubular dunnage.  
         [0024]    As shown in FIGS.  1 - 3 , lower portion  18  holds and supports track  31  which is disposed along a substantially parallel plane relative to the face  22  of steel rule die  21 , and is disposed between die  21  and plate  23 . As shown, movable belt  32  is disposed along track  31  and moves along the substantially parallel plane relative to the face  22  of die  21 . Movable base plate  33  is disposed on track  31  and along an area of movable belt  32 . Thus, movable base plate  33  moves along a distance which the area of movable belt  32  moves. As shown in FIGS. 4 and 5, movable base plate  33  further includes clamps  34  disposed thereon. Clamps  34  are configured to have an open position (FIG. 4) and a closed position (FIG. 5). Each of clamps  34  has notch  62  formed thereon. In the open position (FIG. 4), tube  13  may be disposed between clamps  34  by sliding tube  13  through notches  62 . Then, clamps  34  are placed together in the closed position engaging sides  52  of tube  13  together, thereby securing tube  13  onto base plate  33 . It is to be noted that clamps  34  may both be configured to move together to engage sides  52  together. However, as shown in FIG. 5, in this embodiment, one of clamps  34  moves as the other remains stationary. Clamps  34  are movable with movable base plate  33 .  
         [0025]    As shown in FIG. 1, an electronic eye  42  is attached to track  31  and adjacent rollers  24 . Electronic eye  42  may be any suitable electronic dye capable of sensing tube  13  as tube  13  is moved along track  31 . As shown in FIGS.  1 - 3 , apparatus  12  further includes motor  40  disposed on lower portion  18 . Motor  40  provides power to movable belt  32  and movable base plate  33  to move base plate  33  along the substantially parallel plane relative to the face  22  of each die  21 . Motor  40  may be any motor known in the art suitable to move base plate  33  along the substantially parallel plane relative to the face  22  of each die  21 , such as a servo motor.  
         [0026]    As shown in FIGS. 1, 3,  6 , and  10 , steel rule die  21  is shifted against and through tube  13 , thereby contacting backing plate  23 . In this embodiment, steel rule die  21  is moved hydraulically by air cylinder  41  which is disposed on lower portion  18  and provides compressed air configured in any known fashion to move steel rule die  21  against and through tube  13 , thereby contacting backing plate  23 . Additionally, in this embodiment, air cylinder  41  provides compressed air in any known fashion to one of the clamps  34  to move the clamps  34  in the open and closed positions.  
         [0027]    Apparatus  12  further includes control panel  45  and program panel  49 . Control panel  45  includes control switches  46  which, when activated, allows movement of belt  32  along track  31 . Program panel  49  may include a microprocessor (not shown) which controls various parameters in operating apparatus  12 . For example, a microprocessor in program panel  49  may be capable of controlling parameters, such as speed of belt  32 , number of shifts of die  21 , distance traveled between each shift, and distance of total travel, for example. Thus, for operation of apparatus  12 , program panel  49  is in communication with control panel  45 .  
         [0028]    The operation of apparatus  12  includes of a method of making the slotted tubular dunnage for supporting products in a shipping container. The method comprises providing tube  13 , shown in FIG. 4, which has a pair of flanges  60  at opposite sides  52 , wherein flanges  60  extend along the length of tube  13 . Tube  13  includes a pair of sides or side walls  52  which are integrally connected to each other. Each side wall  52  has a terminal edge  54 , wherein the terminal edges  54  are bridged together by a bottom wall  56 . The bottom wall  56  has ends  58 , each of which extend past one edge  54  to define lateral flanges  60 . Bottom wall  56  also includes a groove  57  formed along the length of tube  13 . A user of apparatus  12  disposes or slides each of flanges  60  within one of notches  62  to position tube  13  on movable base plate  33  in a home position as shown in FIGS. 1 and 4. In this embodiment, the home position may be defined as a starting location for the tube  13  prior to making the slotted tubular dunnage. In this embodiment, apparatus  12  has a plurality of steel rule dies  21  which are horizontally aligned with each other, wherein each die has face  22  for stamping tube  13  to make the slotted tubular dunnage having sets of slots surrounding sets of cut-out slugs.  
         [0029]    Then, the method includes holding the tube  13  by gripping or clamping flanges  60  with clamps  34  in the closed position (FIG. 5) at opposite sides  52  of the tube  13  and squeezing the sides  52  of the tube  13  together. Control panel  45  is configured to control such clamping and squeezing. In this embodiment, this is accomplished by depressing one of switches  46  on control panel  45 . The tube  13  is clamped substantially evenly with clamps  34  to hold tube  13  on base plate  33  in the home position. This allows tube  13  to be movable with movable base plate  33 . Then, tube  13  is moved toward steel rule dies  21  from the home position to an indexing position at which tube  13  is to be sensed by electronic eye  42 . The indexing position of base plate  33  may be defined as a position at which tube  13  is sensed by electronic eye  42 . Electronic eye  42  then senses the tube clamped on the base plate  33  in the indexing position.  
         [0030]    Then, tube  13  is moved toward the steel rule die  21  to a first slotting or cut position as described below. As shown in FIGS.  5 - 8 , as tube  13  moves toward die  21 , tube  13  is received between rollers  24  which flattens tube  13 . Thus, the tube  13  is flattened by fully engaging the opposed side walls  52  during movement from the indexing position to the first cut position. While flattening and holding tube  13  with sides  52  squeezed together, tube  13  is moved into the first slotting or cut position which may be defined as a position of base plate  33  disposed between steel rule die  21  and backing plate  23 . Thus, tube  13  is moved along a first predetermined distance from the indexing position toward die  21  along the substantially parallel plane relative to the face of each die. In the first slotting position, as shown in FIGS.  8 - 10 , the steel rule die  21  is shifted against and through sides  52  of tube  13 , forming a slot  36  therein which surrounds a cut-out slug or a set of cut-out slugs  38  of tube  13 .  
         [0031]    Then, steel rule die  21  is withdrawn from tube  13  while retaining slugs  38  within slots  36 . While squeezing tube  13 , tube  13  is moved a second predetermined distance from the first slotting position to a second slotting position which may be defined as another position of plate  33  disposed in the steel rule die  21  and the backing plate  23 . In the second slotting position, the steel rule die  21  is again shifted against and through sides  52  of tube  13 , forming a second slot or second set of slots  37  therein which surrounds a second cut-out slug or a second set of cut-out slugs  39  of tube  13 . Then, steel rule die  21  is withdrawn from tube  13  while retaining sets of slugs  38 ,  39  within sets of slots  36 ,  37 , respectively. While squeezing tube  13 , tube  13  is moved to a discharge position where the squeezing of the sides  52  of tube  13  is discontinued.  
         [0032]    Then, as tube  13  moves toward the discharge position, stopper  64  sufficiently contacts tube  13  to remove set of slugs  38 ,  39  from within set of slots  36 ,  37 . In the discharge position, clamps  34  are moved into the open position to release resulting slotted tube  13 ′ (FIG. 11) therefrom, allowing tube  13 ′ to be gathered and retained. In this embodiment, sets of slugs  38 ,  39  have been sufficiently contacted by stopper  64  and are received by slide  66  and conveyor  67 . In this embodiment, conveyor  67  is any suitable conveyor system which conveys both the slugs and the resulting slotted tubular dunnage  13 ′ to be conveyed to the operator of apparatus  12 .  
         [0033]    As shown in FIG. 11, each length of the tubular dunnage has been transversely slotted to provide product configured openings or slots  36 . The slots  36  are adapted to receive the product in nesting relation. The slots also receive the product for cushioning purposes in a box (not shown). For this purpose, the slots  36  are designed to conform to the shape of the product so that when the product is inserted in the slots  36  the product is closely supported therein by the tube walls  52 .  
         [0034]    The tubes from which the dunnage is formed is preferably made by extrusion in a well-known fashion. It is made of a recyclable resilient plastic. The wall thickness should be such as to permit the tube to flex in use and during its manufacture, while still supporting the products out of contact with the other products in the box. The preferred but not necessary plastic for manufacture of the tubes is low density polyethylene (LDPE). This material may be chopped after use, remelted, and re-extruded with some additional virgin LDPE added, and then reformed for use as mentioned above.  
         [0035]    While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.