Abstract:
A product package includes a shrink wrap cover at least partially enveloping a product, the shrink wrap cover having a first portion that compressively conforms at least partially to an outer three-dimensional profile of the product, and a second portion that does not compressively conform to the outer three-dimensional profile of the product, and a handle portion formed from the second portion of the shrink wrap cover, wherein the handle portion extends outward beyond the outer three-dimensional profile of the product.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The subject matter disclosed herein relates to product packaging and packaging handles. 
         [0002]    Packaging for products often includes a shrink wrapped cover that envelopes or partially envelopes the product or a plurality of products. The shrink wrapped cover often includes a plastic or polymer film that is exposed to heat to shrink the cover to conform to the product disposed therein. Some previous packaging included handles formed from a cardboard sheet product that pass through the shrink wrapped cover. 
         [0003]      FIG. 1  illustrates prior art example of a product  100  that is wrapped in a shrink wrap cover  102 . The shrink wrap cover  102  defines orifice regions  104  that are defined by edges  106  of the shrink wrap cover  102 . 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0004]    According to one embodiment of the present invention, a product package includes a shrink wrap cover at least partially enveloping a product, the shrink wrap cover having a first portion that compressively conforms at least partially to an outer three-dimensional profile of the product, and a second portion that does not compressively conform to the outer three-dimensional profile of the product, and a handle portion formed from the second portion of the shrink wrap cover, wherein the handle portion extends outward beyond the outer three-dimensional profile of the product. 
         [0005]    According to another embodiment of the present invention, a method for fabricating a product package includes forming a shrink wrap cover having an inner surface and an opposing outer surface around a product, the shrink wrap cover defining a first orifice and a second orifice, portions of the inner surface of the shrink wrap cover contacting portions of the product, inserting a first portion of a handle forming member into the first orifice, engaging a portion of the inner surface of the shrink wrap cover with the first portion of the handle forming member, and engaging an opposing portion of the outer surface of the shrink wrap cover with a second portion of the handle forming member, applying a compressive force to the shrink wrap cover with the first portion of the handle forming member and the second portion of the handle forming member, applying heat to the shrink wrap cover that is operative to reduce the surface area of the shrink wrap cover such that the shrink wrap cover substantially conforms to the product, and disengaging the first portion and the second portion of the handle forming member from the shrink wrap cover. 
         [0006]    These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0007]    The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0008]      FIG. 1  illustrates prior art example of a product  100  that is wrapped in a shrink wrap cover. 
           [0009]      FIG. 2  illustrates a perspective view of an exemplary embodiment of a product that is wrapped in a cover. 
           [0010]      FIG. 3  illustrates a side view of the product of  FIG. 2  that includes the cover and the handle portion. 
           [0011]      FIG. 4  illustrates a cut-away view of the product along the line  4  of  FIG. 3 . 
           [0012]      FIG. 5A  illustrates a detailed view of the region  5  of  FIG. 4 . 
           [0013]      FIG. 5B  illustrates another detailed view of the region  5  of  FIG. 4 . 
           [0014]      FIG. 6  illustrates an alternate arrangement of the cover. 
           [0015]      FIG. 7  illustrates an alternate embodiment of a product. 
           [0016]      FIG. 8  illustrates a detailed view of the region  8  of  FIG. 7 . 
           [0017]      FIG. 9  illustrates an alternate embodiment of a product. 
           [0018]      FIG. 10  illustrates a detailed view of the region  10  of  FIG. 9 . 
           [0019]      FIG. 11  illustrates another alternate embodiment of a product that includes a handle portion. 
           [0020]      FIG. 12  illustrates another alternate embodiment of a product that includes a handle portion. 
           [0021]      FIG. 13A  illustrates a portion of a wrapping machine. 
           [0022]      FIG. 13B  illustrates a cover loosely formed around the product. 
           [0023]      FIG. 13C  illustrates a handle form apparatus. 
           [0024]      FIGS. 14A-14F  illustrate a side view of an exemplary method and apparatus for fabricating some of the embodiments described herein. 
           [0025]      FIG. 15  illustrates a portion of a wrapping machine. 
           [0026]      FIG. 16A  illustrates an exemplary embodiment of a straight edge of the cover. 
           [0027]      FIG. 16B  illustrates an exemplary embodiment of an edge that includes an edge member. 
           [0028]      FIG. 16C  illustrates an exemplary embodiment of an edge that includes a loop. 
           [0029]      FIG. 16D  illustrates an exemplary embodiment of an edge that includes layer or strip of material. 
           [0030]      FIG. 16E  illustrates an exemplary embodiment of an edge that includes layer or strip of material that is formed over an edge member. 
           [0031]      FIG. 16F  illustrates an exemplary embodiment of an edge that includes a cover having a greater thickness in a region proximate to the edge. 
           [0032]      FIG. 16G  illustrates another exemplary embodiment of an edge. 
           [0033]      FIG. 16H  illustrates yet another exemplary embodiment of an edge. 
           [0034]      FIG. 17  illustrates a detailed frontal view of region  17  of  FIG. 15  of an alternate embodiment of an edge of the cover. 
           [0035]      FIG. 18  illustrates a perspective view of another exemplary embodiment of a product that is wrapped in a cover. 
           [0036]      FIG. 19  illustrates another detailed frontal view of region  17  of  FIG. 15  of another alternate embodiment of an edge of the cover. 
       
    
    
       [0037]    The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0038]    Product packaging may include a shrink wrapped cover that envelopes or partially envelopes a product or a plurality of products. In many instances, the products may be grouped as a plurality of products that are enveloped in the shrink wrap. Shrink wrap may include, for example, any type of plastic or polymer material that is placed around a product or plurality of products. The shrink wrap may be exposed to heat to shrink the shrink wrap material such that the material conforms to the shape of the product or plurality of products disposed therein. Often the shrink wrap material is formed in a tubular fashion such that the product may be inserted into an end of the tube of sheet product. The term “tubular” is not limited to having a cylindrical cross section, but may include any hollow elongated shape. Once the product is disposed in the tube of shrink wrap the shrink wrap may be exposed to heat, which shrinks the shrink wrap about the product and reduces the size of the openings of the tube. 
         [0039]    In many instances, the packaged products are intended to be carried by, for example, a consumer or retail employee. Due to the weight, size, and shape of the packaged products, one or more carrying handles may be desired to ease the lifting and carrying of the packaged products. Previous packaged products that included shrink wrap may have open ends defined by the shrink wrap that result from the use of a tubular arrangement of shrink wrap. The open ends, or orifices are defined by edges of the tube of sheet product. The orifices&#39; edges have a relatively small surface area, and are often uncomfortable when used to lift a packaged product. 
         [0040]      FIG. 2  illustrates a perspective view of an exemplary embodiment of a product  200  that is wrapped in a cover  202 . For the purposes of describing the embodiments disclosed herein, the product  200  and other products described herein may include portions of the packaging of a product as well as the product or products themselves. For example, a product may include a plurality of packages of sheet products that are disposed in a corrugated sheet material that is formed into a carton. The cover  202  defines orifices  204  that are defined by edges  206  of the cover  202 . Portions of the cover  202  form a handle portion  208 . The handle portion  208  has a curved or up-turned shape such that a portion of the edge  206  of the shrink wrap cover  202  extends outwardly from the product  200 . The cover  202  and handle portion  208  are formed from a shrink wrap or shrink film material that may include, for example, a polyolefin or polyvinyl chloride (PVC) polymer plastic film. 
         [0041]      FIG. 3  illustrates a side view of the product  200  that includes the cover  202  and the handle portion  208 . 
         [0042]      FIG. 4  illustrates a cut-away view of the product  200  along the line  4  (of  FIG. 3 ). 
         [0043]      FIG. 5A  illustrates a detailed view of the region  5  (of  FIG. 4 ) that includes the handle portion  208 . The handle portion  208  partially defines a portion of the orifices  204 . The edge  206  of the cover  202  has a curved profile. The cover  202  has an inner surface  501  and an outer surface  503 . The cover  202  conforms to the shape of the product  200  such that portions of the inner surface  501  of the cover  202  are in contact with the outer surface  201  of the product  200 . The handle portion  208  extends outwardly from the outer surface  201  of the product  200  such that a portion of the inner surface  501  of the cover  202  is exposed and defines a convex contact portion or surface  502  of the handle portion  208 . The outward extension of the handle portion  208  results in a concave contact portion or surface  504  of the handle portion that includes the outer surface  503  of the shrink wrap cover that opposes the contact portion or surface  502 . In the illustrated embodiment, the edge  206  of the cover  202  that partially defines the handle portion  208  defines a substantially arcuate, curved, or parabolic shape. The shape of the handle portion may vary in alternate embodiments due to any number of factors including, for example, the shape and size of the product  200 , the shape of the tubular cover  202  (prior to the shrinking of the cover  202 ) the profile of the edge of the cover  202 , and the fabrication process that will be described in further detail below. 
         [0044]      FIG. 5B  illustrates another detailed view of the region  5  (of  FIG. 4 ) that shows a person&#39;s hand  550  engaging the handle portion  208 . In this regard, the fingers  554  of the hand  550  contact the convex portion of the inner surface  501  of the cover  202  that partially defines the handle portion  208 . The thumb  552  may contact the concave outer surface  503  of the cover  202 . Though a portion of the hand  550  may contact a portion of the edge  206  of the cover  202 , the fingers  554  of the hand  550  in contact with the substantially smooth inner surface  501  of the cover  202  bear the load of the product  200 , which is supported by the cover  202 . The large surface area of the exposed portion of the inner surface  501  of the cover  202  spreads the load of the product  200  more evenly across the supporting portions of the hand  550  as opposed to the relatively small surface area of the edge  206 , thus providing a comfortable lifting arrangement for a user. The line  530  illustrates the direction of the lifting force that is applied to the handle portion  208 . 
         [0045]      FIG. 6  illustrates an alternate arrangement of the cover  202  with a handle portion  208  that partially envelopes a plurality of products  602 . In alternate embodiments, a support member or members, such as, for example, a corrugated sheet product, or tensioned bands (not shown) may be arranged with or around the plurality of products  602  to provide rigidity or support to the plurality of products  602 . 
         [0046]      FIG. 7  illustrates an alternate embodiment of a product  700  that may be wrapped in a cover  702 . The edges  706  of the cover  702  define an orifice  701  that exposes portions of the product  700 . The product  700  includes a carton  704  having a lid portion  708  and a lower portion  709 .  FIG. 8  illustrates a detailed view of the region  8  (of  FIG. 7 ). In this regard, a portion of the lid portion  708  is cut and bent inwardly to form a folded edge  710  that is exposed by the orifice  701 . The folded edge  710  provides a greater surface area as opposed to the relatively smaller surface area of an exposed edge of the lid portion  708 . The orifice  701  allows a user to access the handle portion  712  defined by the folded edge  710  and bear the load of the product  700  more comfortably. 
         [0047]      FIG. 9  illustrates an alternate embodiment of a product  900  that may be wrapped in a cover  702 . The edges  706  of the cover  702  define an orifice  701  that exposes portions of the product  900 . The product  900  includes a carton  904  having a lid portion  908  and a lower portion  909 .  FIG. 10  illustrates a detailed view of the region  10  (of  FIG. 9 ). A portion of the lid portion  908  is cut and bent outwardly to form a folded edge  910  that is exposed by the orifice  701 . The folded edge  910  provides a greater surface area as opposed to the relatively smaller surface area of an exposed edge of the lid portion  908  or the edge  706  of the cover  702 . The orifice  701  allows a user to access the handle portion  912  defined by the folded edge  910  and bear the load of the product  900  more comfortably. The handle portion may be formed substantially around the edge  706  of the cover  702  so the cover  702  bears the load of the product  900  directly, or if the handle portion is substantially separated from the edge  706 , the load may be borne indirectly from the lid portion  908  which is substantially bound by the cover  702  which in turn bears the load of the product  900 .  FIG. 11  illustrates another alternate embodiment of a product  1100  that includes a handle portion  1150 . The edges  706  of the cover  702  define an orifice  701  that exposes the handle portion  1150 . The handle portion  1150  is formed from a substantially planar body portion  1152  that is in contact with side portions  1102  and a bottom portion  1104  of the product  1100 . In alternate embodiments, the body portion  1152  may be connected to the product  1100  with an adhesive, or a mechanical connection arrangement to the side portions  1102  and/or the bottom portion  1104 . In yet another alternate embodiment, the body portion  1152  may only be attached to and in contact with the side portions  1102 . In an embodiment, the planar body portion  1152  is in the form of an uninterrupted continuous strip of material that extends from an orifice  701  on one end of the product  1100 , passing under the product  1100 , to an opposing orifice  701  (not illustrated in  FIG. 11 , but understood with reference to  FIG. 4 ) on an opposing end of the product  1100 . The line  1130  illustrates the direction of the lifting force that is applied to the handle portion  1150 . 
         [0048]      FIG. 12  illustrates another alternate embodiment of a product  1200  that includes a handle portion  1250 . The edges  706  of the cover  702  define an orifice  701  that exposes the handle portion  1250 . The handle portion  1250  is formed from a substantially planar body portion  1252  that is in contact with side portions  1202  and a top portion  1206  of the product  1200 . In alternate embodiments, the body portion  1252  may be connected to the product  1200  with an adhesive, or a mechanical connection arrangement to the side portions  1202  and/or the top portion  1206 . In yet another alternate embodiment, the body portion  1252  may only be attached to and in contact with the side portions  1202 . In an embodiment, the planar body portion  1252  is in the form of an uninterrupted continuous strip of material that extends from an orifice  701  on one end of the product  1200 , passing over the product  1200 , to an opposing orifice  701  (not illustrated in  FIG. 12 , but understood with reference to  FIG. 4 ) on an opposing end of the product  1200 . The line  1230  illustrates the direction of the lifting force that is applied to the handle portion  1250 . 
         [0049]      FIG. 13  illustrates a perspective view of an exemplary method and apparatus for fabricating some of the embodiments described herein. In this regard,  FIG. 13A  illustrates a portion of a wrapping machine  1350  that includes a first roll of cover material  1352  and a second roll of cover material  1354 . The cover material of the first roll of cover material  1352  is bonded, joined, or connected to the cover material of the second roll of cover material  1354  to form a first seam portion  1303 . The first seam portion  1303  may be formed by a compressive, thermal, vibratory, acoustic, or adhesive joining process. The product  200  may be moved relative to the first seam portion  1303  such that the first seam portion  1303  or portions of the material proximate to the first seam portion  1303  contact portions of the product  200 . Referring to  FIG. 13B , a cover  202  is loosely formed around the product  200 , joined at a second seam portion  1305 , and severed from the first roll of cover material  1352  and the second roll of cover material  1354 . The a second seam portion  1305  may remain connected to the first roll of cover material  1352  and the second roll of cover material  1354 , thus becoming a first seam portion for the next product  200  (not shown) that will be packaged subsequently. The cover  202  is substantially tubular, though the shape of the cover  202  may depend on the shape of the product  200 , and is not limited to a cylindrical shape, but rather forms a continuous elongated hollow arrangement of cover  202  material having open opposing orifices  1304  defined by the edges  206 . The edges  206  of the cover  202  are shown prior to forming an orifice  204  (of  FIG. 2 ). 
         [0050]      FIG. 13C  illustrates a handle form apparatus  1380  that includes a concave engagement surface  1382  and a convex engagement surface  1384 . In operation, a portion of the cover  202  is disposed between the concave engagement surface  1382  and the convex engagement surface  1384  by passing a portion of the edge  206  of the cover  202  between the concave engagement surface  1382  and the convex engagement surface  1384 . Though the illustrated embodiment includes a handle form apparatus  1380  that includes a concave engagement surface  1382  and a convex engagement surface  1384 , the engagement surfaces of the handle form apparatus  1380  may have alternate shapes arranged in any alternate orientation relative to the product  200 . Thus, the use of the terms concave engagement surface and convex engagement surface is a non-limiting exemplary embodiment. 
         [0051]      FIG. 14  illustrates a side view of an exemplary method and apparatus for fabricating some of the embodiments described herein. In this regard, referring to  FIG. 14A , a portion of the cover  202  is disposed between the concave engagement surface  1382  and the convex engagement surface  1384  in a similar manner as described above in  FIG. 13C .  FIG. 14B  illustrates the relative motion of the concave engagement surface  1382  and the convex engagement surface  1384  that are operative to engage and apply a compressive force on a portion of the cover  202  disposed therebetween. 
         [0052]      FIG. 14C  illustrates the positioning of the concave engagement surface  1382  and the convex engagement surface  1384  prior to shrinking of the cover  202  by the application of heat that is operative to reduce the surface area of the cover  202  such that the cover  202  substantially conforms to the outer surface of the product  202 . The compressive force of the concave engagement surface  1382  and the convex engagement surface  1384  is operative to begin the formation of the handle portion  208  (of  FIG. 2 ). The engaged concave engagement surface  1382  and the convex engagement surface  1384  may be moved relative to the product  200  to be positioned in substantially the location where the resulting orifice  701  of  FIG. 9  will be located after the heating process. In an alternate embodiment, the engaged concave engagement surface  1382  and the convex engagement surface  1384  may be moved relative to the product  200  during the heating process in a direction and at a rate of motion that corresponds to the shrinking of the cover  202 .  FIG. 14D  illustrates the position of the concave engagement surface  1382  and the convex engagement surface  1384  and the formation of the handle portion  208  in the cover  202  during the heating process. Once the handle portion  208  has been formed, and the cover  202  is shrunk a desired amount, the cover  202  may be allowed to cool. 
         [0053]      FIG. 14E  illustrates the relative motion of the concave engagement surface  1382  and the convex engagement surface  1384  as the concave engagement surface  1382  and the convex engagement surface  1384  disengage from the handle portions  208  of the cover  202 .  FIG. 14F  illustrates the resultant product  200 , cover  202  and handle portions  208 . 
         [0054]    Instead of using a handle form apparatus  1380 , a similar end result may be achieved by changing the composition of the material used to wrap the product.  FIG. 15  illustrates a portion of a wrapping machine  1350  that includes a first roll of cover material  1352  and a second roll of cover material  1354  as shown above in  FIG. 13 . The edges of the first roll of cover material  1352  and the second roll of cover material  1354  may be formed into a variety of exemplary profiles that may facilitate different edges  206  of the cover  202 . 
         [0055]    In this regard,  FIG. 16  illustrates cut away views along the line  16  (of  FIG. 15 ) of exemplary profiles of the edges  206  (of  FIG. 2 ) of the first roll of cover material  1352  (and/or the second roll of cover material  1354 ) that may be incorporated into any of the embodiments described herein and partially define the orifice  204  and a portion of the handle portion  208 .  FIG. 16A  illustrates an exemplary embodiment of a straight edge  206  of the cover  202 .  FIG. 16B  illustrates an exemplary embodiment of an edge  206  that includes a member  1602  that contacts the cover  202  and may include a different material than the cover  202  material. The member  1602  may be formed from, for example, a plastic, or pulp product and may be connected to the cover  202  with for example a joining or bonding process that may include a mechanical connection, a welded, or bonded connection, or an adhesive connection.  FIG. 16C  illustrates an exemplary embodiment of an edge  206  that includes a loop  1604  that is formed by the connection of an end of the cover  202  to a surface of the cover  202  in a region  1606  using, for example, mechanical connection, a welded, or bonded connection, or an adhesive connection. In one exemplary embodiment, air that is trapped within the loop  1604  forms a cushioned handle when the surrounding cover material  202  shrinks during the heating process.  FIG. 16D  illustrates an exemplary embodiment of an edge  206  that includes a layer or strip of material  1608  that is formed by the connection of the strip of material  1608  to a surface of the cover  202  in a region  1610  using, for example, mechanical connection, a welded, or bonded connection, or an adhesive connection.  FIG. 16E  illustrates an exemplary embodiment of an edge  206  that includes layer or strip of material  1614  that is formed over a member  1612  and is connected to the cover  202  in regions  1616  using a suitable connection process. Member  1612  may include a different material than the cover  202  and may be formed from, for example, a plastic, pulp, or fiber product such as string.  FIG. 16F  illustrates an exemplary embodiment of an edge  206  that includes a cover  202  having a greater thickness (t 1 ) in a region  1618  proximate to the edge  206  and a relatively lesser thickness (t 2 ) in interior regions of the cover  202 .  FIG. 16G  illustrates an exemplary embodiment of an edge  206  that is formed by combining a material  1622  that may include, for example, a plastic, polymer, composite, paper, or pulp product while maintaining the same thickness as the rest of cover  202 . The material  1622  may be bonded with the of the cover  202  by using, for example, co-extrusion of different raw materials, or mechanically bonding or welding abutting edges. It is also understood that the different embodiments presented herein may be combined. 
         [0056]      FIG. 16H  illustrates yet another exemplary embodiment that includes the layering of a strip of material  1626  represented with a filler strip  1624  of a similar material as the cover  202  such that the final cover  202  has a substantially uniform thickness. Alternatively, the strip of material  1608  in  FIG. 16D  or the material  1614  and member  1612  of  FIG. 16E  may be compressed to a similar thickness as the rest of the cover  202  by using, for example, the application of a set of rollers to compress the material into a substantially uniform thickness. 
         [0057]    The alternative embodiments represented by  FIG. 16A-H  above may be used to form a handle portion  208  around the entire length of edge  206  of the orifice  204  (of  FIG. 2 ). These methods could be modified, by for example, staggering the arrangement of the features on the edge, or removing portions of the edge features following the wrapping of the product  200 , to create a handle at an upper or top of the orifice  204 . 
         [0058]      FIG. 17  illustrates an exemplary detailed frontal view of region  17  (of  FIG. 15 ) of an alternate embodiment of an edge  206  of the cover  202 . In this regard, the material  1702  applied at or proximate to the edge  206  of the cover  202  provides a region of the cover  202  that when indexed to a portion of the product  200  is arranged as a handle portion on the product  202 . 
         [0059]      FIG. 18  illustrates an exemplary embodiment of the material  1702  applied to cover  202  arranged on the product  200  that includes a handle portion  1802  partially defined by the material  1702 . 
         [0060]      FIG. 19  illustrates an alternate exemplary embodiment of a cover  202  similar to the embodiment shown in  FIG. 17 , where the material  1902  is applied as a continuous strip of material having an undulating or scalloped profile that provides a handle portion similar to the embodiment shown in  FIG. 18 . 
         [0061]    The material  1702  may be used alone or in conjunction with any of the embodiments described above including the embodiments illustrated in  FIG. 16 . Though the illustrated embodiment of  FIG. 17  shows the material  1702  proximate to the edge  206 , alternate embodiments may include any alternative profile. In an alternative embodiment, the embodiments represented by  FIG. 16A-G  above may be applied to the first roll of cover material  1352  of  FIG. 13A , thereby creating a handle portion  208  on the top half of the edge  206  of orifice  204 . 
         [0062]    The technical effects and benefits of the embodiments described above include the formation of a handle portion in the cover of a product package that offers a greater surface area to more evenly distribute the weight of a product to provide a more comfortable lifting means for a user. 
         [0063]    While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.