Patent Publication Number: US-6712310-B2

Title: Apparatus and method for dispensing coiled metallic ribbon

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a Divisional of U.S. Application Ser. No. 09/854,387 filed on May 11, 2001, now U.S. Pat. No. 6,561,452 which is incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Technical Field 
     The present invention relates generally to apparatus and method for dispensing coiled metallic ribbon stock and, in particular, to a packaging device for packaging and dispensing coiled metallic ribbon stock, and an apparatus and method for dispensing coiled metallic ribbon stock from such packaging device. 
     2. Description of Related Art 
     Currently, coiled metallic material (e.g., steel rule stock, or any type of metallic ribbon stock) is typically packaged and distributed in standard rectangular paperboard packaging. There are various problems associated with conventional packaging techniques. For instance, a coil of metallic material typically comprises a resilient metal band that is closely wound under tension such that the coiled material comprises characteristics of a large watch spring. Unless the coiled material is adequately restrained while it is being removed from the package and placed into position into an apparatus that utilizes the coiled material, it can spring apart in disarray and cause harm to the operator. This is especially dangerous with some forms of coiled metallic ribbon stock that have a sharpened or serrated edge. 
     Another conventional method of packaging coiled metallic material comprises packaging the coiled metallic material in a box containing an opening from which to dispense the coiled material. With this packaging method, however, no measures are typically taken to reduce friction so that the coiled material can be easily drawn out of or retracted into the package. Thus, as one end of the coiled metallic rule is pulled from the opening in the package, a frictional force is generated at points of contact between the coiled material and, e.g., the sidewalls of the package as the coiled material is rotatably dispensed from the package. 
     Accordingly, more efficient and safer methods of packaging and dispensing coiled metallic ribbon stock are desired, which eliminate the need to remove the coil from the package box and greatly reduce or eliminate the frictional forces generated during a dispensing operation. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a packaging device and a dispensing apparatus, which provide safe and efficient methods for packaging and dispensing coiled material, and which are compatible with currently available systems and devices for processing the coiled metallic material. 
     In one aspect of the present invention, a device for packaging a coil of metallic ribbon stock comprises a first planar panel and a second planar panel, wherein the first and second planar panels have substantially the same shape, and a sidewall panel that interconnects the first and second planar panels along the perimeter of the first and second planar panels to form a container. The sidewall panel comprises preferably comprises a plurality of perforated regions each defining an aperture through which a roller is inserted to rotatably engage a coil of metallic ribbon stock within the container. A perforated region is removed to create an aperture in the sidewall panel. 
     The rollers engage the coil in such a way that they are tangent to the coiled material and rotate in the direction in which the coil is withdrawn from or retracted into the packaging device. Preferably, one or more perforated regions (or apertures) are formed in proximity to each point of contact between the inner surface of the sidewall panel and an outer surface of a coil of metallic ribbon stock within the packaging device. Thus, when sufficient force is applied, the roller operates to reduce or eliminate the friction at such points of contact in the packaging device, thereby enabling free movement of the material out of and into the packaging device. 
     In yet another aspect, the packaging device further comprises a low friction insert connected to the inner surface of the top and bottom panels of the package to further reduce the friction as the coil rotates in the packaging device. 
     In another aspect, the packaging device further comprises a reinforcement device connected on the inner surface of the sidewall panel in proximity to the perforated region for reinforcing the sidewall panel. 
     In yet another aspect, the packaging device is formed from a unitary flat blank comprising any suitable material such as paperboard or corrugated cardboard. 
     In another aspect of the present invention, an apparatus for dispensing lengths of metallic ribbon stock from a dispenser containing a coil of metallic ribbon stock comprises: 
     a mounting device for mounting the dispenser; 
     a plurality of roller assemblies, each comprising a roller; and 
     a positioning device operatively connected to each roller assembly, wherein for a given roller assembly, the positioning device operates to insert at least a portion of the roller through an aperture of the dispenser for rotatably engaging the roller with the coil of metallic ribbon stock. 
     In yet another aspect of the present invention, a system for dispensing lengths of metallic ribbon stock from a dispenser containing a coil of metallic ribbon stock, comprises: 
     mounting means for mounting the dispenser; and 
     friction reduction means for tangentially engaging the metallic ribbon stock through one or more apertures in the dispenser to aid in the dispensing of the stock. 
     The friction reduction means may operate under manual control or under a servo control. 
     These and other objects, features and advantages of the present invention will be described or become apparent from the following detailed description of preferred embodiments, which is to be read in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a schematic view of a device for packaging coiled metallic ribbon stock according to an embodiment of the present invention; 
     FIG. 2 is a plan view of a flat unitary carton blank according to an embodiment of the present invention from which the packaging device of FIG. 1 may be formed; 
     FIG. 3 is a top plan view of one side of a packaging device for coiled metallic ribbon stock according to an embodiment of the present invention; 
     FIG. 4 is an enlarged perspective view of a sidewall of the packaging device of FIG. 1 illustrating components within the packaging device; 
     FIGS. 5,  6  and  7  comprise schematic diagrams collectively illustrating a method and apparatus for dispensing coiled metallic ribbon stock according to an embodiment of the present invention, wherein FIG. 5 illustrates a dispensing apparatus in a state of operation prior to engaging an packaging device comprising a coiled metallic ribbon stock, FIG. 6 is a schematic of a roller assembly that is used in the dispensing apparatus to rotatably engage the coiled metal ribbon stock through apertures in the packaging device, and wherein FIG. 7 illustrates the dispensing apparatus in a state of operation after engaging the packaging device; and 
     FIG. 8 is a schematic illustrating a dispensing apparatus according to another embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIGS. 1,  2 , and  3  illustrate a packaging device (or “dispenser”) according to an embodiment of the present invention for packaging coiled metallic ribbon stock. The device comprises a container  10  comprising a first panel  11   a  (or top panel) and a second panel  11   b  (or bottom panel) and a plurality of sidewalls  13 . A coil  12  of metallic ribbon stock is contained within the container  10 . The container  10  is preferably formed of any material used by those skilled in the art (e.g., cardboard) for packaging coiled metallic ribbon stock. In the exemplary embodiment, the container  10  is shown in the form of a rectangular box, although one skilled in the art may readily envision other shapes that may be used to form the packaging device. 
     The four sidewalls  13  are preferably integrally formed with and extend at right angles from one of the upper or lower sections  11   a ,  11   b  (or both) of the container  10 . Each of the side walls  13  comprise one or more perforated portions  14 , 15  defining apertures that are employed for dispensing metallic stock from the package. In particular, as shown in FIG. 3, perforated portions  14  are preferably disposed on sidewalls  13  of the container  10  at, or in proximity to, locations where the outer surface  12   a  of the coiled metallic material  12  makes contact with the inner surface of the sidewalls  13 . Further, a perforated portion  15  defines an aperture or slot through which the free end  12   a  of the metallic coil  12  may be withdrawn from the package (either manually or via machine). The perforated portion  15  is preferably located on one sidewall  13  at one corner of the container  10 . It is to be appreciated that the perforated portions  14  and  15  preferably comprise pull-tabs that can be pulled off to form corresponding apertures in the container  10  prior to use of the metallic coil  12 . Alternatively, the container  10  may be formed such that the perforated portions  14 ,  15  are removed during manufacture of the packaging device. 
     Referring to FIGS. 5 and 7, the location of the apertures  14  preferably correspond with roller assemblies  20  of a dispensing apparatus. As explained in further detail below, when the package containing the coil is loaded onto the dispensing apparatus, rollers  22  are positioned to rotatably engage the coiled material through the open apertures  14  of the sidewalls  13  of the container  10  (i.e., the rollers make tangential contact with the coil such that the rollers will rotate in the direction in which the stock is withdrawn from, or retracted into, the container  10 ). Preferably, the rollers  22  rotatably engage the outer surface  12   b  of the coiled material by applying a force against the outer surface  12   b  of the coiled material that is sufficient to reduce or eliminate friction caused by the contact of the coil  12  and the inner surface of the sidewalls  13 , thereby enabling free movement of the coiled material out of and back into the container through aperture  15 . 
     FIG. 2 is a plan view of a flat unitary blank from which the packaging device of FIG. 1 may be formed. The flat unitary carton black shown in FIG. 2 can be folded to form the rectangular packaging device and dispenser shown in FIG.  1 . The blank may comprise any suitable material such as corrugated cardboard. The blank comprises a center section  40  having fold lines  42  that define the edges of the first panel  11   a  (FIG. 1) in the shape of a rectangle. A plurality of folding sections  42  each comprising a sidewall section  43  and a portion of a second panel  45  (bottom panel) are foldable relative to the center section  40  to form the container  10  shown in FIG.  1 . More specifically, each sidewall section  43 , which is defined by folding lines  41  and  44 , comprise rectangular flap sections that integrally extend from, and are folded at right angles to, the edges (fold lines  41 ) of the center panel  40 . Each sidewall section  43  of the unitary blank comprises one or more perforated regions  13  that define apertures in the sidewalls. Again, rollers are inserted through the apertures to rotatably engage a coil contained therein during a dispensing process. 
     The plurality of second panel sections  45   a ,  45   b ,  45   c , and  45   f , comprise rectangular flap sections that integrally extend from, and are folded at right angles to, the edges (fold lines  44 ) of the sidewall sections  43 . The second panel sections  45   a ,  45   b ,  45   c , and  45   d , which are folded to form the bottom panel  11   b  of the container  10 , provide a two-ply construction. For instance, flap sections  45   a  and  45   c  comprise an inner ply of the bottom panel  11  and are folded and secured using any suitable manner such as by securing the terminating edges of sections  45   a  and  45   c  by an adhesive sealing tap, etc. Flap sections  45   b  and  45   d  comprise an outer ply of the bottom panel  11   b  and are folded over the secured sections  45   a  and  45   c  and then secured using any suitable manner such as by gluing the second ply formed by sections  45   b  and  45   d  to the first ply formed by sections  45   a  and  45 , and/or by securing the terminating edges of sections  45   b  and  45   d  by an adhesive sealing tap, etc. 
     The unitary blank further comprises a plurality of tabs  46  that used to secure the corners of sidewalls. Each tab  46  foldably extends from a sidewall section  43  and is folded and secured (glued, etc.) to an inner surface of an adjacent sidewall  43 . The corner of the container in which the exit aperture  15  is formed does not require a tab  46  to secure the adjacent sidewall sections  43 . In addition, a view window  47  is preferably formed in center section  40  so that the amount of metal coil contained in the resulting container  10  can be readily determined. 
     As explained above, each of the rectangular sidewall sections  43  comprise one or more perforated regions  13  that define apertures. These apertures are strategically placed along these surfaces, corresponding with the rollers in the dispensing unit. 
     In another embodiment, as shown in FIGS. 2 and 4, the packaging device comprises an insert  16  comprising a low friction surface that is preferably disposed on the inner surface of the bottom panel  11   b  so as to reduce friction as the coil  12  rotates in the packaging device. The low friction insert  16  may comprise a nylon or Teflon sheet, for example, which is glued to the inner surface of the bottom panel  11   b  to reduce the friction as the metallic coil is dispensed. The low-friction insert preferably provides a lower coefficient of friction than the material that is used to form the container  10 . In addition, the insert  16  preferably matches the geometry of the bottom panel  11   b . Further, a low friction insert may be disposed between the coil  12  and the inner surface of the upper panel  11   a  to prevent wear on the top surface of the coil and to protect the top surface of the enclosure. This is preferred when the metallic coil comprises a sharpened/serrated edge  12   c.    
     In a further embodiment, packaging device may comprise point-of-contact reinforcements around or in proximity to the perforated regions  14  (or along the entire length of the sidewall) so as to provide additional strength of the sidewall to, e.g., withstand the spring force of the coil when the corresponding apertures are generated. The reinforcements may comprise any suitable rigid material such as metal or plastic and are affixed to the inside walls of the packaging. For instance, as shown in FIG. 2, a reinforcement device  48  is placed on the unitary blank (via glue, etc.) at the anticipated point of contact between the metallic coil and the sidewall sections  43  of the blank. 
     In addition, a clip or fastener may be utilized to secure the end  12   b  of the metallic material  12  when the packaging device is not positioned in the dispensing unit so as to prevent incoiling of the material during handling and storage. 
     Moreover, as noted above, the packaging device may comprise any suitable shape. For instance, the packaging device may comprise a polygonal such as an octagon or hexagon, with points of contact along the inside of the packaging and apertures located between the points of contacts to allow engaging of the rollers. Further, the packaging device may be circular in construction with inserts creating points of contact on the inside of the container and apertures located between the points of contact to allow engaging of the rollers. 
     FIGS. 5,  6  and  7  comprise schematic diagrams collectively illustrating a method and apparatus for dispensing coiled metallic ribbon stock according to an embodiment of the present invention. Referring to FIG. 5, a schematic diagram illustrates an apparatus for dispensing the coiled material  12  from the packaging device wherein the apparatus comprises a plurality of roller assemblies  20 . In a preferred embodiment, at least one roller assembly  20  is disposed at a location on each sidewall  13  of the packaging device  13  having a point of contact with the coil  12 . If the container  10  is manufactured with the perforations or apertures  14 , the roller assemblies  20  are disposed such that the rollers  22  are aligned with the apertures  14 . 
     FIG. 6 is a schematic of a roller assembly  20  according to an embodiment of the present invention. The roller assembly  20  is a component of the dispensing apparatus that is positioned (automatically or manually) to rotatably engage and disengage the coiled metal ribbon stock  12  through the apertures  14  in the container  10 . A roller assembly  20  comprises a bracket  21  on which one or more rollers  22  are mounted. The bracket  21  comprises a first plate  23  and a second plate  24  and the rollers  22  are rotatably mounted therebetween using mounting bracket  25  (e.g., bolt). The roller assembly further comprises a mounting plate  26  (connected between the first and second plates  23 ,  24 ) that is used for connecting the roller assembly  20  to a device or system (e.g., hydraulic, pneumatic, power screw, etc.) for moving the roller assembly  20  to engage or disengage the coil  12 . For instance, the mounting bracket  26  can be used to connect the roller assembly to one end of a piston rod that is used to move the roller assembly. 
     FIG. 5 illustrates the dispensing apparatus in a state of operation prior to engaging the coiled metallic ribbon stock  12  in the container  10 . The roller assemblies  20  are first positioned at locations along the sidewall comprising the apertures  14 . FIG. 7 illustrates the dispensing apparatus in a state of operation after engaging the packaging device. As shown, when the container  10  containing the coil  12  is loaded onto the dispensing apparatus, the roller assemblies  20  are controllably moved toward the sidewalls  13  until the rollers  22  make tangential contact to the coiled material through the open apertures  14  of the sidewalls  13  of the container  10 . Preferably, each roller assembly  20  is positioned such that sufficient force is applied by the rollers  20  against the coil  12  to mitigate or eliminate the frictional forces caused by the contact between the outer surface  12   a  of the coil  12  and the inner surface of the sidewalls  13  as the metallic rule is withdrawn. The rollers  20  advantageously enable free movement of the coiled material  12  out of and back into the packaging device through aperture  15 . 
     It is to be understood that the roller assembly  20  may be constructed in any suitable fashion and may comprise any number of rollers  22 . Preferably, the roller assembly  20  is constructed such that when the roller assembly  20  is engaged, the only points of contact are between the rollers  22  and the coil  12 . In other words, the roller assembly  20  is preferably designed such that during the dispensing operation, no portion of the roller assembly is in contact with the sidewall  13 , potentially resulting in exertion of inward force against the sidewall  13 . 
     FIG. 8 is a schematic illustrating a dispensing apparatus according to an embodiment of the present invention. The dispensing apparatus comprises a mounting table  30  for holding the packaging device in place during a dispensing operation. The packaging device can be mounted and positioned on the table  30  using any suitable device (e.g., adjustable brackets, etc.) Those skilled in the art can readily envision other suitable mechanisms or apparatus that may be implemented for stably mounting the packaging device prior to a dispensing operation. 
     As noted above, the dispensing unit comprises a plurality of roller assemblies  20  that are moved to engage/disengage the coil  12 . In one embodiment, the roller assemblies are each connected to a piston  32  and cylinder  31  assembly, wherein the cylinder is mounted to the table  30 . A control system  33  is operatively connected to each piston  32  and cylinder assembly to cause the pistons  32  to extend from the cylinders  31  and until contact is made between the rollers  22  and the coil with sufficient force. It is to be appreciated that the control system  33  may comprise any suitable automated system known to those skilled in the art such as a hydraulic, pneumatic, or servo system, which is operated via an application running on a computer-based system. With such systems, feedback controls could be implemented to ensure that the roller assembly applies proper force when it is engaged with the coil. These types of automated systems and feedback controls are well known in the art and can readily be implemented with the current invention. Therefore, such automated systems will not be discussed in further detail. 
     In another embodiment, movement of the roller assemblies may be performed manually using any suitable mechanical device such as a power screw system (analogous to a vise grip system), whereby the user can manually turn a crank handle that rotates a cylindrical rod (connected to the roller assembly) comprising helical or advancing spiral threads that cause a roller assembly to move along guide rail to and from the packaging device. Again, those of ordinary skill in the art may readily envision various manual mechanisms that may be implemented for positioning the roller assemblies. 
     It is to be appreciated that the dispensing apparatus shown in FIG. 8 may be oriented horizontally or vertically or at any other angle, to facilitate feeding of the material into different cutting or processing equipment. 
     One of ordinary skill in the art can readily envision other structures for implementing a dispensing apparatus based on the teachings herein. For instance, the dispensing apparatus can comprise a combination of movable and stationary roller assemblies, whereby the packaging device is positioned so that the metallic coil engages the stationary rollers and then the movable rollers are subsequently positioned to engage the coil. 
     In another embodiment, the dispensing apparatus may comprise an active roller system, whereby one or more of the roller assemblies are driven by a motor so as to move the coiled metallic ribbon stock into and out of the container. In this instance, the rollers may have a surface treatment to increase the friction between the roller and the metallic ribbon stock as the rollers drive the stock. 
     Furthermore, although preferred embodiments described above utilize a roller mechanism to engage the stock, other suitable friction reduction means that can be inserted through an aperture in the container for reducing the friction at points of contact between the coil of metallic ribbon stock and the inner surface of the container may be employed herein. For instance, a small plate comprising a compound having a suitably low coefficient of friction can be forcibly applied against the metallic ribbon stock through an aperture in the container to reduce the friction at points of contact of the metallic ribbon stock and the container. 
     Although illustrative embodiments have been described herein with reference to the accompanying drawings, it is to be understood that the present invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the invention. All such changes and modifications are intended to be included within the scope of the invention as defined by the appended claims.