GB2270667A

GB2270667A - Packaging compressed paper rolls

Info

Publication number: GB2270667A
Application number: GB9219981A
Authority: GB
Inventors: Roger Growcott
Original assignee: FORT STERLING Ltd
Current assignee: FORT STERLING Ltd
Priority date: 1992-09-22
Filing date: 1992-09-22
Publication date: 1994-03-23
Anticipated expiration: 2012-09-22
Also published as: GB2270667B; GB9219981D0

Abstract

A package comprises a plurality of paper rolls (10) which are deformed so that their formerly circular cross-section is deformed towards a rectangular or oval shape, and a cover wrapped around the deformed rolls to hold them in the deformed condition. The packaged is formed by arranging the rolls in columns and rows and applying pressure from two opposite sides at right angles to the axes of the rolls to deform the rolls, by means of pressure plates (12, 20) or pressure rollers. Cores of the rolls may be formed from natural or synthetic rubber or plastics material such as formed or expanded plastics. <IMAGE>

Description

PACKAGING This invention relates to the packaging of deformable articles and more particularly the packaging of rolls of paper.

It has become a common trading practice for rolls of paper, such as toilet rolls or rolls of paper kitchen towels to be sold in packages containing a plurality of rolls rather than singly. The package is formed by an outer cover of, for example thin plastics sheet, which is wrapped around a plurality of rolls. The wrapping is quite loose so that it does not deform the rolls, but it is sufficiently tight so that the rolls will remain in their desired position relative to each other and the whole pack retain its shape.

The move towards larger packs of retail products received a setback when the retail outlets began to place restrictions on the shelf space in the store that would be available for a particular product.

Manufacturers have begun to look for ways of reducing the size of their products so as to gain the maximum advantage from a limited shelf space in a retail outlet.

The present invention has been made with this problem in mind.

According to the invention there is provided a package comprising a plurality of paper rolls, the circular cross-section of at least some of said rolls having been deformed so that at least one diameter thereof is reduced and an outer cover wrapped around said rolls to hold them in their deformed condition.

The invention also provides a method of packaging paper rolls comprising applying pressure to paper rolls to deform the circular cross-section thereof whereby at least one diameter is reduced, holding said rolls in the deformed condition while wrapping an outer cover around said deformed rolls to retain them in said deformed condition.

The invention additionally provides apparatus for forming a package, and for carrying out the method as defined above comprising means for applying pressure to paper rolls to deform the circular cross-section so that at least one diameter thereof is reduced, means for holding the deformed rolls in the deformed condition and means for wrapping an outer cover around said deformed rolls to retain them in said deformed condition.

In a preferred embodiment of the invention all of the rolls included in the package are deformed so that their cross-section is substantially rectangular. As a result of such deformation there is very much less wasted space in the package than is the case with rolls of circular cross-section. The deformed rolls can be packed closer together so that the overall cross-sectional area of the whole package is less than the corresponding area of a package containing rolls of circular cross-section.

It is particularly preferred that the rolls be wound on a core. Preferably the paper forming the roll, the core or both have the property of restoring the shape of the roll to a circular cross-section once the restraint of the outer cover is removed. However, that is not critical and the rolls can be restored to their original undeformed condition by other means, for example manually, after removal of the outer wrapping from the package. The preferred core is one which does not crease as a result of deformation as can be the case with paper or cardboard core. Particularly preferred cores are of natural or synthetic rubber or plastics which are deformable and which can be restored to a circular cross section by the removal of a deforming force, or by manual manipulation or a combination of both.

The package of the invention can be produced by different methods and apparatus. In one preferred embodiment rolls to form the package are assembled in rows and columns corresponding to their eventual disposition in the package. Pressure is applied in a first direction at right angles to the axes of the rolls so that the diameter of the rolls in that direction is reduced. If desired additional restraint can be applied to the rolls to prevent them from moving from their disposition relative to each other while the pressure is being applied to deform them. After the rolls have been deformed to the extent that is desired the rolls still in the deformed condition are forwarded to a wrapping machine which applies an outer cover around the rolls. The outer cover is quite tightly applied around the rolls so that they are held in their deformed state.

In another embodiment the rolls are deformed by passing them through the nip of at least one pair of pressure rollers. The deformed rolls are led through a channel which maintains the deformation applied by the pressure rollers and may further deform the rolls towards a rectangular. configuration although the rolls may not actually attain that shape. The deformed rolls are forwarded to a wrapping machine and wrapped so as to maintain the deformation.

It can happen that there is some relaxation of the deformation of the rolls before, during or. after the wrapping thereof. Provided that is not significant it is not important. Further it may be that the deformation of the rolls is modified in some way by the application of the outer cover. Again this is not of significance and may even be advantageous if it has the effect of reducing the overall size or cross-sectional area of the product.

Specific embodiments of the invention will now be described by way of example in which: Fig.1 is a diagrammatic view, in perspective, of apparatus for deforming paper rolls; Fig.2 is a view similar to Fig.1 of the apparatus after deformation of the rolls; Fig.3 is a diagrammatic perspective view of another embodiment of apparatus for carrying out the invention; and Fig.4 A-C illustrates three different cores.

Referring to Fig.1 a plurality of paper rolls 10 are assembled in columns, four in the embodiment illustrated. The number of rolls in each column is not illustrated, but is preferably the same. Each column of rolls is located in a channel 11 defined by vertical, movable, parallel walls 12, 14, 16, 18 and 20. The outermost walls 12 and 20 are each connected to a hydraulic ram 22, 24, whereby walls 12 and 20 can be moved towards and away from each other. Plates 26 and 28 are located respectively above and below the walls 12, 14, 16, 18 and 20.

In operation the rows 26 and 28 urge the walls 12 and 20 towards each other. Because intermediate walls 14, 16 and 18 are movable, the pressure applied by the rows is transmitted to all the columns of rolls. The effect is to reduce the diameter of the rolls in the plane of the applied pressure so that the rolls take up a somewhat oval cross-section as illustrated in Fig.2.

The walls 12, 14, 16, 18 and 20 move independently of the plates 26 and 28 which latter ensure that the rolls remain in place while being deformed.

The deformed rolls are held in their deformed condition and forwarded to a wrapping machine (not shown) which encloses all the rolls in an outer cover so as to hold the rolls in their deformed state. The wrapping machine is of known construction and, therefore, not further described here. There may be some slight relaxation of the-rolls from the deformed condition prior to wrapping. In addition the application of the cover by the wrapping machine may introduce some further deformation of the rolls, particularly towards a rectangular configuration.

After the deformed rolls have been forwarded to the wrapping machine the rows 22 and 24 move apart and a fresh supply of undeformed paper rolls are admitted to the channels 11.

As already indicated there are many ways in which the paper rolls can be deformed. Another apparatus and method will be described with reference to Fig.3. In this embodiment a number of pairs of pressure rollers 30 are provided. The rollers of each pair 30 are mounted with their axes parallel and substantially vertical.

Each roller is connected via a drive shaft 32 and gear box 34 to a common drive shaft 36 connected to a drive motor 38. The arrangement of gear boxes is such that the rollers of each pair are driven in opposite directions as indicated by the arrows 40.

Paper rolls 10 are led to each pair of pressure rollers 30 as a result the diameter of the rolls is reduced at least in the plane perpendicular to the axes of the rollers.

The deformed paper rolls 10 are delivered by the rollers 30 into channels 42, there being a separate channel for each pair of rollers. At the receiving end of the channels the walls 44 thereof are spaced apart so as to maintain the deformation applied by rollers 30.

The width of the channels gradually reduces in the downstream direction so that further deformation of paper rolls results. Preferably by the time the rolls 10 arrive at the end of the channels 42 the diameter in the plane perpendicular to the rollers 30 is reduced by about 30%.

The deformed rolls arse passed to the wrapping machine where an outer cover is applied to maintain the rolls in the deformed condition.

The preferred core for the rolls is one which can be deformed without permanent creasing or folding and can restore itself or be restored to a circular cross section when the roll is to be used. Examples of three such cores are illustrated in Fig.4. In Fig.4A the core is of natural or synthetic rubber. The core in Fig.4B is of flexible foamed plastics and the core of Fig.4C is of expanded or "basket weave" plastics.

The invention is not restricted to the embodiments described and many variations and modifications can bemade.

Claims

1. A package comprising a plurality of paper rolls, the circular cross-section of at least some of the rolls having been deformed so that at least one diameter thereof is reduced, and an outer cover wrapped around said rolls to hold them in their deformed condition.

2. A package as claimed in Claim 1, wherein the rolls are deformed so that their cross-section is substantially rectangular or oval.

3. A package as claimed in Claim 1 or claim 2, wherein the paper of a roll is wound onto a core.

4. A package as claimed in Claim 3, wherein the paper and/or the core is restorable towards its original shape when the outer cover is removed.

5. A package as claimed in Claim 3 or Claim 4, wherein the core does not crease when deformed.

6. A package as claimed in any of Claims 3 to 5, wherein the core is formed from natural or synthetic rubber or plastics material.

7. A package as claimed in Claim 6, wherein the core is formed from foamed plastics or from expanded plastics.

8. A method of packaging paper rolls comprising applying pressure to said rolls to deform the circular cross-section thereof whereby at least one diameter is reduced, holding said rolls in the deformed condition while wrapping an outer cover around said deformed rolls to retain them in the deformed condition.

9. A method as claimed in Claim 8, wherein the rolls are deformed so that their cross-section is substantially rectangular or oval.

10. A method as claimed in any of Claims 8 to 11, wherein rolls to form the package are assembled in rows and columns corresponding to their eventual disposition in the package.

11. A method as claimed in any of Claims 8 to 10, wherein the rolls are deformed by applying pressure to the rolls in a direction substantially perpendicular to the axes of the rolls.

12. A method as claimed in Claim 11, wherein the rolls are held while being deformed to prevent them from moving from their disposition relative to each other.

13. A method as claimed in any of Claims 8 to 12, wherein the rolls are deformed so as to reduce a diameter by about 30%.

14. Apparatus for forming a package as claimed in any of Claims 1 to 7 comprising means for applying pressure to paper rolls to deform the circular cross-section so that at least one diameter is reduced, means for holding the deformed rolls in the deformed condition and means for wrapping an outer cover around said deformed rolls to retain them in the deformed condition.

15. Apparatus as claimed in Claim 14, wherein the means for applying pressure to the rolls comprises a press.

16. Apparatus as claimed in Claim 14, wherein the means for applying pressure comprises pressure rolls.

17. Apparatus as claimed in any of Claims 14 to 16, wherein the means for holding the deformed rolls comprises a channel.

18. Apparatus as claimed in Claim 17, wherein said channel applies additional deformation to the rolls.

19. Apparatus as claimed in any of Claims 14 to 18, wherein means are provided for holding the rolls in place while they are being deformed.

20. A package substantially as described herein with reference to the accompanying drawings.

21. A method of producing a package substantially as described herein with reference to the accompanying drawings.

22. Apparatus for forming a package as claimed in any of Claims 1 to 7 or 20 substantially as described herein with reference to the accompanying drawings.