PORTABLE APPARATUS FOR DISPENSING A CONTINUOUS WEB OF PACKAGING MATERIAL

FIELD OF THE INVENTION

[0001] The present invention relates generally to packaging materials for use in protecting articles during shipping, and more specifically, to a portable apparatus for dispensing a continuous web of such packaging material.

BACKGROUND OF THE INVENTION

[0002] Packaging is often provided to protect articles during shipping. The packaging typically includes an outer box-like container and a filler material for packing and supporting the article within the container. The filler material is used to occupy the voids or spaces between the container and the article, and serves to cushion the article during transport. To mitigate freight charges, filler material with low density (i.e. high volume/ low weight) characteristics have often been selected. Examples of such materials include polystyrene foam peanuts, foams and shredded sheet materials such as paper, cardboard, plastic and the like.

[0003] While commonly used, polystyrene foam peanuts have recently become less popular. Their poor biodegradability tends to make it difficult to dispose of the packing peanuts in an environmentally-friendly manner. On the field, additional drawbacks have been associated with the packing peanuts. While bulky, the loose form of the packing peanuts tends to make their use in packaging and unpackaging activities quite messy. Moreover, they tend to do little to prevent migration of the article within the container during transport unless the container is overfilled with the packing peanuts, which tends not to be desirable because it adds to the weight of the shipping container. Provision of the packing peanuts to the packaging site may also present certain challenges. The manufacture of packing peanuts requires specialized machinery. As a result, the peanuts are often manufactured off-site and then delivered to, and stored at, the packaging site for use, thereby incurring further freight charges and occupying storage space on site.

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[0004] Foamed in place packaging material has also been employed. Such materials may be poured and expanded to fill the voids between the article and the container. However, this type of packing material typically requires a separate packaging layer, as by a plastic bag, to prevent the packing foam from contacting the shipped article.

[0005] Using biodegradable shredded materials as packing materials has recently become more popular. The most common of these materials is shredded paper which tends to be readily available and generally inexpensive. It may be produced relatively easily using a conventional paper shredder. However, shredded paper tends to be structurally weak and unless it is over- packed, it tends to have little or no ability to prevent migration of the packaged article within the container. Shredded paper may also be difficult and messy to handle when packing and unpacking the container.

[0006] Various attempts have been made to overcome some of the aforementioned disadvantages. An example of one such attempt is described in United States Patent No. 5,088,972 to Parker. This patent discloses a packaging material consisting of a plurality of shredded, elongate, interconnecting strips of a sheet material (such as Mylar™, paper or cardboard) which have been folded and crimped. The folds within the crimped strips interlock with one another to form a resilient mass of intertwined and interconnected strips of bulk packaging material.

[0007] Parker also describes an apparatus for producing this packaging material. The apparatus includes a conveyor belt, a conventional shredding device and a crimping attachment in the nature of a movable barrier. The conveyor belt transports the sheet material to the conventional shredding device. As the sheet material passes through the conventional shredding device, serrated cutting blades cut the sheet material into elongate strips. The elongate strips are then expelled into a confined area which extends between the cutting blades and the movable barrier. As the strips accumulate in the confined barrier and bear against the movable barrier, they become folded, crimped and compacted. A cutting device may be provided to cut the crimped strips into preselected lengths. Additionally, a chute or ramp may be used to facilitate the movement of the crimped strips toward a receiving bin.

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[0008] The folds in the crimped strips tend to occupy a greater volume of space than that of simply shredded paper. Accordingly, the enhanced bulking characteristics of the crimped strips constitute an improvement over simply shredded paper. However, migration of the article during transport still remains a concern. In addition, the crimped strips are in a loose form and thus can be inconvenient to clean up as they tend to get scattered throughout the packaging/unpacking site. The apparatus of Parker tends not to be compact and may not be convenient for use in a packing station where space may be limited. Moreover, controllably jamming the emerging paper stock tends to be an inherently unstable operation requiring skilled operators and tends to be prone to failure by over jamming.

[0009] Another approach was taken in United States Patent No. 5,906,280 to Weder. This patent discloses a packaging material in the form of "Easter grass" or "decorative grass". The package material consists of a plurality of strips coated with a bonding material such as an adhesive or cohesive. The adhesive coating could be applied at randomly disposed spots on either sides of the strips, or could be applied to substantially cover one or both sides of the strips. The strips tend to stick together when amassed in a tuft. The tuft can adhere or cohere to the article to be packed or to the container. Weder further discloses a system for making his packaging material. A roll of sheet material provides a web of sheet material which is fed through a slitter wherein it is cut into strips. The bonding material is then applied onto the slitted web with a spray assembly. After the application of the bonding material, the slitted web is passed into a cutter where it is cut into predetermined lengths so as to form the strips of packaging material. From the cutter, the strips are conveyed by a centrifugal blower to a storage bin.

[0010] While the packaging material of Weder tends to exhibit enhanced bulking characteristics and tends to avoid the mess typically associated with loose packing materials, the crush resistance and cushioning characteristics of the packaging material may still be further improved. Additionally, where an adhesive is applied, the packaging material of Weder may be difficult to wield as it may have a tendency to stick on various surfaces (including the surfaces of machinery). Adhesive residue may remain on the machinery or the article to be packed - both of which tend to be undesirable. Furthermore, the system of Weder tends not to be well-adapted for the rapid deployment of packaging material for immediate use. Its operation tends to be complicated and may require experienced operators to monitor production of the packaging

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material. Moreover, the system of Weder tends not to be compact or portable and may require a large permanent space for deployment. It may also be expensive to πianufacture, as it requires a dedicated spraying station for applying the adhesive onto the strips. In addition, using a centrifugal blower to convey the packaging material may not be practical as it may tend to cause the packaging material to stick to itself to form large unwieldly clumps. Such a complex system may not be suitable for use in a small-scale packaging operation.

[0011] United States Patent No. 6,189,699 of Weder describes another packaging material generally similar to that described in United States Patent No. 5,906,280. The packaging material consists of sheet having a plurality of strips interconnected to one another along a border. The border and/or the strips are coated with a bonding material such as an adhesive or cohesive. The adhesive coating could be applied at randomly disposed spots on either sides of the border/strips, or could be applied to substantially cover one or both sides of the border/strips. The adhesive serves to secure the border onto a container. The packaging material can take the shape of a plurality sheets stacked and bonded together along their respective borders. Weder further discloses a system for making his packaging material. A roll of sheet material provides a web of sheet material which is fed through a slitter wherein slit portions are cut along the web at intermittent locations so as to allow the formation of the border portions. The bonding material is then applied onto the border portions of the slitted web with a spray assembly. The strips may also be coated with an ϊidhesive. After the application of the bonding material, the slitted web is passed into a cutter where it is cut into predetermined lengths so as to form the individual sheets of the packaging material. From the cutter, packaging material is conveyed by a conveyor unit to a packaging area. This packaging material and the system used to produce it tend to suffer from the same drawbacks associated with the other packaging material and system of Weder previously described.

[00121 United States Patent No. 6,546,701 to Weder describes still another approach to packaging material. The patent describes a sheet of material provided with a plurality of slits. The sheet material is coated with a bonding material such as an adhesive or cohesive. The adhesive coating could be applied at randomly disposed spots on either sides of the sheet, or could be applied to substantially cover one or both sides of the sheets. A cushioning member may be formed from the sheet of material by crumpling the sheet into a cubical, rectangular, Spherical, or otherwise globular configuration. The crumpling causes portions of the sheet with adhesive to bond with other like portions. The crumpling operation could be performed manually

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or with the purpose-built machine disclosed in United States Patent No. 2,924,154 of Russell. Weder further teaches positioning a plurality of cushioning members within a container so as to substantially surround the article being packed within the container. The plurality of cushioning members may be bondably connected to the exterior surface of the article or the interior surface of the container. While the packaging material and packaging methods disclosed by Weder may be suitable for use in some applications, they may not to be appropriate for field use where rapid deployment and limited operator manipulation are required. The performance of the crumpling activity requires the operation of complex and expensive equipment. If crumpling is carried out manually, it tends to be a time-consuming and labour-intensive task, the performance of which tends to be impractical on a packing site.

[0013] In light of the foregoing, it would be advantageous to have a versatile packaging material with improved crush resistance and resiliency, while maintaining enhanced bulking characteristics. It would be further desirable if such a packaging material could be produced on- site rapidly and efficiently and dispensed on demand in a packaging area using a relatively simple to operate machine. Moreover, there exists a real need for a practical method of packing an article within a container using such a packaging material.

SUMMARY OF THE INVENTION

[0014] In accordance with a broad aspect of the present invention, there is provided a portable apparatus for dispensing a continuous web of packaging material. The apparatus includes a support frame and means for supporting at least one roll of the packaging material. The roll supporting means is connected to the support frame. Also provided is a rotary cutting assembly supported on the support frame. The rotary cutting assembly is operable to draw from the at least one roll a continuous web of the packaging material and to cut in the continuous web a plurality of spaced apart slits. The portable packaging apparatus further includes a drive assembly for driving the rotary cutting assembly and a cutter assembly supported on the support frame for selectively cutting a length of the continuous web outputted from the rotary cutting assembly. A protective housing is mounted over the support frame to enclose the roll supporting means, the rotary cutting assembly, the drive assembly and the cutter assembly. Additionally, the portable

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dispensing apparatus has an outlet through which the cut length of the continuous web may be dispensed.

[0015] In an additional feature, the portable dispensing apparatus further includes a plurality of feet for supporting the support frame above a support surface on which the portable dispensing apparatus is placed.

[0016] In another feature, the support frame has a front support plate, a rear frame member disposed opposite the front support plate, and a pair of spaced apart, first and second side frame members. Each side frame member extends between, and is connected to, the front support plate and rear frame member. The roll supporting means extends between the pair of first and second side frame members. In still another feature, the roll supporting means is pivotably mounted to the side frame members adjacent the rear frame member. The front support plate, the rear frame member and the pair of side frame members define a footprint of the support frame. The roll supporting means is moveable between an out-of-use, roll loading position and an in-use position, hi the out-of-use position, the roll supporting means extends partially out of the footprint; and in the in-use position, the roll supporting means is contained within the footprint.

[0017] In an additional feature, the roll supporting means includes a framework. The framework has at least one arm and at least one roll retaining member. The at least one arm has a first end and a second end. The first end thereof is pivotally connected to one of the side frame members. The at least one roll retaining member is carried by the at least one arm at a location intermediate the first and second ends thereof. Further still, the at least one arm includes a first arm and a second arm. The first arm is pivotally connected to the first side frame member and the second arm is pivotally connected to the second side frame member. The at least one roll retaining member extends between the first and second arms. When the roll supporting means is in the in- use position, the first and second arms are inclined toward the rotary cutting assembly; and when the roll supporting means is in the out-of-use position, the first and second arms are inclined away from the rotary cutting assembly.

[0018] In still another feature, the at least one roll retaining member is detachably removable from between the first and second arms. Optionally, the at least one roll retaining member may be a shaft. The shaft has a first longitudinal end and a second longitudinal end. Each arm

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includes a plurality of stations for receiving one of the first and second longitudinal ends of the shaft. The plurality of stations being disposed at spaced apart locations intermediate the first and second ends of each arm.

[0019] Additionally, the portable dispensing apparatus further includes at least one roll of the packaging material. The at least one roll being is on the roll supporting means. The packaging material of the at least one roll is made from a material selected from the group consisting of: (a) kraft paper; (b) newsprint; (c) tissue paper; (d) polyethylene film; and (e) polyethylene foam. The packaging material of the at least one roll has a first face and an opposed second face. The first face of the packaging material is coated with a cohesive, such as latex.

[0020] In an additional feature, the continuous web outputted from the rotary cutting assembly is a single-ply continuous web having a plurality of spaced apart longitudinal slits. In yet another feature, the at least one roll includes first and second rolls. Each roll has an axis of rotation. The axis of rotation of the first roll is carried higher than the axis of rotation of the second roll relative to a support surface upon which the portable dispensing apparatus is placed. The continuous web outputted from the rotary cutting assembly is a two-ply continuous web having a plurality of spaced apart longitudinal slits. The packaging material of each roll has a first face and an opposed second face. The first face of the packaging material of each roll is coated with a cohesive. The first face of the packaging material of the first roll is oriented away from the first face of the packaging material of the second roll.

[0021] In yet another feature, the rotary cutting assembly includes a pair of first and second, rotatable members mounted to extend between the first and second frame members. Each rotatable member has a plurality of spaced apart, circular cutting elements disposed along its axis of rotation. The cutting elements of the first rotatable member are offset from the cutting elements of the second rotatable member so as to allow the cutting elements of the first rotatable member to pass between the cutting elements of the second rotatable member during operation of the rotary cutting assembly. Each of the rotatable members has an axis of rotation. The axis of rotation of the first rotatable member is carried above the axis of rotation of the second rotatable member relative to a support surface on which the portable dispensing apparatus is placed. Additionally, the drive assembly includes a motor and a gear box connected to the rotary cutting

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assembly. The motor is operatively connected to the gearbox to transmit a drive force to the rotary cutting assembly.

[0022] In a further feature, the cutter assembly is carried on the front support plate of the support frame. Moreover, the front support plate has a first face disposed opposite the rotary cutting assembly and a second face. The cutter assembly is carried on the second face of the front support plate.

[0023] In another feature, the front support plate has first, second, third and fourth edges. The he first edge is disposed opposite the second edge and adjacent the side frame members. The second edge is carried forwardly of the first edge. The third edge is disposed opposite the fourth edge. The third and fourth edges extending between the first and second edges of the front support plate. In addition, the front support plate has a longitudinal slot defined therein through which the continuous web of the packaging material may pass. The longitudinal slot extends between the third and fourth edges at a location intermediate the first and second edges.

[0024] In a further feature, the cutter assembly includes a first stationary cutting edge fixed to the front support plate adjacent the slot and a second cutting edge movable relative to the first stationary cutting edge. The second cutting edge is movable between a first cutting position and a second position. In the first cutting position, the second cutting edge overlaps the first stationary cutting edge and obstructs the slot. In the second position, the second cutting edge is spaced away from the first stationary cutting edge such that the slot remains unobstructed to thereby allow the continuous web of the packaging material to pass through. The cutter assembly further includes a plate slideably moveable relative to the front support plate. The second cutting edge of the cutter assembly is carried on the plate. The cutter assembly is also provided with guide means for directing the movement of the plate relative to the front support plate. The plate includes a pair of third and fourth edges extending between the first and second edges thereof. The guide means includes a pair of spaced apart guide rails fixed to the second face of the front support plate. Each guide rail is adapted to engage one of the third and fourth edges of the plate.

[0025] In yet another feature, the cutter assembly is also provided with means for urging sliding movement of the plate relative to the front support plate. The urging means includes a gear drive operatively connected to the plate and a motor for powering the gear drive.

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[0026] In an additional feature, the protective housing has a hinged lid portion. The hinged lid portion is moveable between an open and closed position. In the open position, the hinged lid portion permits access to the roll supporting means disposed within the housing.

[0027] In still another feature, the portable dispensing apparatus is further provided with means for feeding an end of the continuous web into the rotary cutting assembly. The feeding means is a manual feeding means. Furthermore, the rotary cutting assembly includes a pair of first and second, rotatable members. Each rotatable member has a plurality of spaced apart, circular cutting elements disposed along its axis of rotation. The cutting elements of the first rotatable member are offset from the cutting elements of the second rotatable member so as to allow the cutting elements of the first rotatable member to pass between the cutting elements of the second rotatable member during operation of the rotary cutting assembly. The manual feeding means is a hand crank connected to the first and second rotatable members. The hand crank is accessible from outside the housing.

[0028] In a further feature, the portable dispensing apparatus has means for actuating the rotary cutting assembly. The actuating means includes one of a foot pedal and a hand actuator.

[0029] In accordance with another broad aspect of an embodiment of the invention, there is provided a two-ply continuous web packaging material of determinate length. The continuous web includes a first packaging material web and a second packaging material web superimposed on the first packaging material web. Each packaging material web has a first longitudinal edge, a second longitudinal edge opposed to the first longitudinal edge and a plurality of spaced apart slits running continuously from the first longitudinal edge to the second longitudinal edge. Moreover, each packaging material web has a first face and an opposed second face. The first face of each packaging material web is coated with a cohesive. The first face of the first packaging material web is oriented away from the first face of the second packaging material web while the second face of the first packaging material web at least partially abuts the second face of the second packaging material web. In an additional feature, the first packaging material web is made from a first material and the second packaging material web is made from a second material. The first material is different from the second material. Alternatively, the first material is the same as the second material.

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[0030] In accordance with yet another broad aspect of the invention, there is provided a method of producing a two-ply continuous web packaging material. The method includes the step of providing first and second rolls of packaging material. The packaging material of each roll has a first face and an opposed second face. The first face of the packaging material of each roll has a cohesive coating. Also provided is the step of drawing simultaneously packaging material from each roll into a rotary cutting assembly. The first face of the packaging material of the first roll is oriented away from the first face of the packaging material of the second roll. The method further includes the following steps: urging the second face of the packaging material of the first roll to at least partially abut the second face of the packaging material of the second roll to thereby form in the rotary cutting assembly a two ply-continuous web; cutting in the two-ply continuous web a plurality of spaced apart slits; and selectively cutting a length of the two-ply continuous web.

[0031] In an additional feature the method includes pulling apart the two-ply continuous web to thereby increase the bulk of the packaging material. The step of pulling apart includes manually pulling apart the two-ply continuous web in a direction generally transverse to the plurality of slits. In a further feature, the step of pulling apart includes manually separating the second face of the packaging material of the first roll from the second face of the packaging material from the second roll.

[0032] In still another broad aspect of an embodiment of the invention, there is provided a method of producing a high bulk packaging material. The method includes providing first and second rolls of packaging material. The packaging material of each roll having a first face and an opposed second face. The first face of the packaging material of each roll has a cohesive coating. Also provided is step of drawing simultaneously a continuous web of packaging material from each roll into a rotary cutting assembly. The first face of the packaging material of the first roll is oriented away from the first face of the packaging material of the second roll. The method further includes the steps of: urging the second face of the packaging material of the first roll to abut at least partially the second face of the packaging material of the second roll to thereby form in the rotary cutting assembly a two ply-continuous web; cutting in the two-ply continuous web a plurality of spaced apart slits; selectively cutting a length of the two-ply continuous web; and

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urging the two-ply continuous web to repeatedly fold onto itself so as to cause the first faces to bond to each other at a plurality of contact locations thereby forming a packing body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The embodiments of the present invention shall be more clearly understood with reference to the following detailed description of the embodiments of the invention taken in conjunction with the accompanying drawings, in which:

[0034] FIG. 1 is a front perspective view of an apparatus for dispensing packaging material according to an embodiment of the present invention with a housing shown transparently for clarity and the lid of the housing shown in its closed position;

[0035] FIG. 2 is a rear right perspective view of the portable apparatus for dispensing packaging material illustrated in FIG. 1 with the lid of the housing shown in its open position;

[0036] FIG. 3 is rear right perspective view similar to that illustrated in FIG. 2 showing the housing removed for clarity, a framework supporting two rolls of packaging material shown its in-use-position and a rotary cutting assembly shown without the packaging material engaged therein;

[0037] FIG. 4 is rear right perspective view similar to that illustrated in FIG. 3 showing the framework moved to its out-of-use, loading position with the two rolls of packaging material being omitted for clarity;

[0038] FIG. 5 is rear right perspective view of an alternate embodiment to that illustrated in FIG. 3 showing the framework supporting a single, large-diameter roll of packaging material;

[0039] FIG. 6 is a rear left perspective view of the portable dispensing apparatus illustrated in FIG. 3 with the rolls of packaging material being omitted for clarity;

[0040] FIG. 7 is an isolated front end view of the encircled portion "7" illustrated in FIG. 6 showing the arrangement of first and second rollers of the rotary cutting assembly;

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[0041] FIG. 8 is a front elevation view of the portable dispensing apparatus illustrated in FIG. 4 with the chute removed for clarity;

[0042] FIG. 9 is a sectional view of the portable dispensing apparatus illustrated in FIG. 2 taken along line "9-9" with the housing removed for clarity and the packaging material shown continuously flowing out from the chute;

[0043] FIG. 10 is a conceptual, simplified view of the rollers of the rotary cutting assembly illustrated in FIG. 9 showing a continuous web of packaging material from each roll being fed through the rotary cutting assembly to form a two-ply continuous web of packaging material;

[0044] FIG. 11 is an enlarged view of the encircled portion "11" illustrated in FIG. 9 showing the movable cutting edge of the cutter assembly moved to its retracted, out-of use position;

[0045] FIG. 12 is a bottom right, partial perspective view of the cutter assembly shown in FIG. i i;

[0046] FIG. 13 is an enlarged view similar to that illustrated in FIG. 11 showing the movable cutting edge of the cutter assembly moved to its extended, in-use-position whereat it cuts a determinate length of the two-ply continuous web;

[0047] FIG. 14 is a bottom right, partial perspective view of the cutter assembly shown in FIG. 13;

[0048] FIG. 15 is a perspective view of a mobile packaging station in accordance with an embodiment of the invention;

[0049] FIG. 16 is a front right perspective view of the portable dispensing apparatus illustrated in FIG. 1 showing the apparatus dispensing a two-ply continuous web into a container in accordance with one embodiment of the invention;

[0050] FIG. 17 is a side elevation view of the portable dispensing apparatus and container shown in FIG. 16;

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[0051] FIG. 18 is a side elevation view of the portable dispensing apparatus and container similar to that illustrated in FIG. 17 showing an article placed onto the packaging material within the container;

[0052] FIG. 19 is a side elevation view of the portable dispensing apparatus and container similar to that illustrated in FIG. 18 showing the article in the container being completely covered by the packaging material;

[0053] FIG. 20 is a front right perspective view of the portable dispensing apparatus illustrated in FIG. 1 showing the apparatus dispensing a two-ply continuous web into a container in accordance with an alternative embodiment of the invention;

[0054] FIG. 21 is a view similar to that illustrated in FIG. 20 showing an article placed onto the packaging material within the container;

[0055] FIG. 22 is a view similar to that illustrated in FIG. 20 showing the article in the container being completely covered by the packaging material;

[0056] FIG. 23 is a cross-sectional view of a continuous web of packaging material in accordance with an embodiment of the invention, shown longitudinally compressed; and

[0057] FIG. 24 is a cross-sectional view similar to that illustrated in FIG. 23 showing a continuous web of packaging material that has been subjected to additional longitudinal compression.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

[0058] The description which follows, and the embodiments described therein are provided by way of illustration of an example, or examples of particular embodiments of principles and aspects of the present invention. These examples are provided for the purposes of explanation and not of limitation, of those principles of the invention. In the description that follows, like parts are marked throughout the specification and the drawings with the same respective reference numerals.

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[0059] Referring to FIGS. 1 to 4, there is shown a portable apparatus for dispensing a continuous web of packaging or packing material, designated generally with reference numeral 20. Broadly speaking, the portable dispensing apparatus 20 includes: a support frame 22; means 24 connected to the support frame 22 for supporting at least one roll 26 of packaging material 28; a rotary cutting assembly 30 connected to the support frame 22 and operable to draw from the at least one roll 26 a continuous web 32 of packaging or packing material 28 and to cut in the continuous web 32 a plurality of spaced apart slits 34; a drive assembly 36 for driving the rotary cutting assembly 30; a cutter assembly 38 carried on the support frame 22 for selectively cutting a length of the continuous web 32 outputted from the rotary cutting assembly 30; and a protective housing 40 mounted over the support frame 22 to enclose the roll supporting means 24 the rotary cutting assembly 30, the drive assembly 36 and the cutter assembly 38. The protective housing 40 has an opening 42 which defines an outlet 43 defined therein through which the cut length of the continuous web may be dispensed.

[0060] Referring specifically to FIGS. 1 and 2, the protective housing 40 has a shell 44 that is adapted to conform generally to the shape of the portable dispensing apparatus 20. The shell 44 is defined by a front wall 46, a rear wall 48 and a pair of sidewalls 50 and 52 that bound the front and rear walls 46 and 48 on either side. The front wall 46 includes a bottom front wall portion 54 and a top front wall portion 56 that is joined to the rear wall 48. The bottom front wall portion 54 and the top front wall portion 56 cooperate with each other to define the generally convex profile of the front wall 46.

[0061] Defined in the bottom front wall portion 54 is the opening 42. In the preferred embodiment, the opening 42 is a generally rectangular slot 60 that is sized slightly larger than the width of the continuous web 32. It will however be appreciated that this need not be the case in every application, hi alternative embodiments, the shape and size of the slot may be modified. For instance, in certain applications it may be desirable to restrict the size of the slot so as to create a choke. Such a constriction could be designed to alter the manner in which the continuous web 32 is dispensed from the portable dispensing apparatus 20.

[0062] The rear wall 48 includes a straight, bottom rear wall portion 62, a short inclined transition wall portion 64 and a movable wall portion 66. The bottom rear wall portion 62 is

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joined to the transition wall portion 64 along a first margin 68 thereof. The movable wall portion 66 extends from the transition wall portion 64 to the top front wall portion 56 and is pivotally connected to the transition wall portion 64 along a second margin 70 thereof to define a hinged curved Hd 72 for the protective housing 40. The curved lid 72 is moveable between an open position 74 (shown in FIG. 2) and a closed position 76 (shown in FIG. 1). When in the open position 74, the curved lid 72 permits access to the interior 77 of the protective housing 40.

[0063] The shell 44 may be made of a hard, durable material, such as a molded plastic or metal. The material is preferably lightweight so as not to adversely impact on the portability of the dispensing apparatus 20.

[0064] A plurality of spacer pad members 78 are fixed to the support frame 22 at various locations to help ensure the protective housing 40 fits snugly over the support frame 22 and to impart improved vibration resistance to the shell 44 during operation of the portable dispensing apparatus 20. The pad members 78 may be made of rubber or any other suitably resilient material.

[0065] The support frame 22 has a front support plate 80, a rear frame member 82 disposed opposite the front support plate 80, and a pair of spaced apart, first and second side frame members 84 and 86. The side frame members 84 and 86 extend between, and connect to, the front support plate 80 and rear frame member 82. In cooperation with the side frame members 84 and 86, the front support plate 80 and the rear frame member 82 define a generally rectangular footprint 88 of the support frame 22. As best shown in FIG. 3, the frame members 82, 84 and 86 are joined to each other in a generally U-shaped configuration. Each side frame member 84, 86 has a proximal end 90 and an opposed terminal end 92. The rear frame member 82 is welded to each end 90 of the side frame members 84, 86 along a mitre joint. In this embodiment, each frame member 82, 84 and 86 is an angle iron 98 having a first horizontal leg 100 and a second vertical leg 102.

[0066] In the present embodiment, the front support plate 80 is a steel plate having a generally rectangular shape defined by a pair of first and second, opposed edges 110 and 112 which run generally parallel to the rear frame member 82, and another pair of third and fourth, opposed edges 114 and 116 that run from the first edge 110 to the second edge 112. Defined in the front

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support plate 80 at a location intermediate the first and second edges 110 and 112, is a slot 120 (best shown in FIG. 8). The slot 120 runs longitudinally between the third and fourth edges 114 and 116 and is sized slightly larger than the width of the continuous web 32. As will be explained in greater detail below, the continuous web 32 passes through the slot 120 as it exits the rotary cutting assembly 30,

[0067] The front support plate 80 further includes a first face 122 oriented toward the rear frame member 82 and an opposed second face 124 oriented away from the rear frame member 82. The front support plate 80 extends upwardly from the side frame members 84 and 86 on an incline such that the second edge 112 of the front support plate 80 is carried forwardly of the first edge 110. Preferably, the angle θ formed between the horizontal leg 100 of the side frame member 84, 86 (as the case may be) and the second face 124 of the front support plate 80, is 45° degrees (as best shown in FlG. 9). In alternative embodiments, however, the angle could be varied.

[0068] Adjacent the third and fourth edges 114 and 116, the first edge 110 has been trimmed back on an angle so as to provide a pair of abutting faces (not shown.) for welding the front support plate 80 to the first horizontal legs 100 of the side frame members 84 and 86. A section of the third edge 114 is also welded to the second vertical leg 102 of the side frame member 84. On the opposite side, the front support plate 80 is fixed to the side frame member 86 by way of an angle member 126.

[0069] Welded to the side frame members 84 and 86 in a forwardly canted orientation are additional angle members 127 and 128 (best shown in FIG. 4). As will be explained in greater detail below, these members serve to fixedly secure the rotary cutting assembly 30 and the drive assembly 36 to the support frame 22,

[0070] While in this embodiment the various components of the support frame 22 are assembled by welding, it will be appreciated that other fastening means may be used. For example, the frame members and the front support plate may be joined to each other using conventional fasteners such as screws, nuts, bolts, nails, rivets and the like. Other modifications to the support frame are also possible. For instance, in an alternative embodiment, hollow structural steel (HSS) sections may be used for the frame members instead of the angle irons. In another embodiment,

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the steel frame members may be replaced with a lighter material, such as aluminum or a rigid plastic. Other materials exhibiting similar strength and stiffness characteristics may also be used to similar advantage to fabricate the support frame.

[0071] A plurality of feet 130 allows the support frame 22 to be carried above a relatively flat, support surface. In the present embodiment, the portable dispensing apparatus 20 has four feet - one located at each of the proximate and terminal ends of the side frame member 84 and 86. Preferably, the feet 130 are vibration-resistant and self-leveling to accommodate for any unevenness in the support surface.

[0072] Referring now to FIGS. 3 and 4, the roll supporting means 24 extends between the pair of first and second side frame members 82 and 84. The roll supporting means 24 includes a framework 132 that is defined by a pair of opposed, first and second arms 134 and 136 connected to each other by an upper cross-member 138 and a lower cross-member 140. The space between the first and second arms 134 and 136 is sized to accommodate the width of a roll 26 of packaging material. Each arm 134 and 136 of the framework 132 has a first end 142 attached to the lower cross-member 140 and a second end 144 connected to the upper cross-member 138.

[0073] The framework 132 further includes a pair of mounting brackets 148 and 150 for connecting the arms 134 and 136 to the support base 22. Each mounting bracket 148, 150 has a generally L-shaped profile defined by a hori∑ontal leg 152 and a vertical leg 154 joined to the horizontal leg 152, Adjacent the rear frame member 82, the horizontal leg 152 of each mounting bracket 148, 150 is welded onto the horizontal leg 100 of each side frame member 84, 86. A pivot connection 156 between the first end 142 of each arm 134, 136 and the vertical leg 154 allows the framework 132 to rotate between an in-use position 160 (shown in FIG. 3) and an out- of-use (or roll loading/unloading) position 162 (shown in FIG. 4). In the in-use position 160, the framework 132 is contained within the generally rectangular footprint 88 of the support frame 22 and is carried at an incline angle Co of 45° degrees relative to the horizontal legs 100 of the side frame members 84 and 86 (as best shown in FIG. 9). In alternative embodiments, however, the angle could be varied.

[0074] A stop (not shown) fixed to each of the mounting brackets 148, 150 prevents the framework 132 from being pivoted beyond the in-use position 160. In other embodiments, the

DM_TOR/366748-00003/2U39 ^β 86.1

stop may be disposed at a different location. Alternatively, other means could be used to similar advantage. For instance, the framework could be provided with an abutment or support leg that is designed to come to rest against a portion of the support frame when the framework is moved to the in-use position.

[0075] In the event, the source roll needs to be restocked or maintenance and servicing of the rotary cutting assembly 30 are required, the curved lid 72 may be moved to its open position 74 and the framework 132 can be pivoted rearwardly to its out-of-use position 162 thereby providing a clear working space within the interior 77 of the housing 40. The provision of such a working space tends to facilitate loading of the source rolls 26 onto the framework and the manual feeding/loading of an end of the continuous web 28 into the rotary cutting assembly. When in the out-of-use position 162, the framework extends partially out of the support frame footprint 88.

[0076] Each roll 26 is retained on the framework 132 by a shaft 164 that extends between, and is removably detachable from, the first and second arms 134, 136. At spaced apart locations intermediate the first and second ends 142 and 144, the arms 134 and 146 have notches 170 formed therein. The notches 170 define a plurality of stations 172 for receiving the ends 174 and 176 of the shaft 164. In this embodiment, the arms 134 and 136 are provided with first, second and third stations 172a, 172b and 172c, respectively. However, in alternative embodiments, the number of stations may be reduced or increased to suit a particular application or to enhance versatility.

[0077] While in the preferred embodiment, the roll supporting means 24 is defined by two spaced apart arms 134 and 136 and a detachable shaft 164 mounted therebetween, it will be appreciated that the roll supporting means could take many different forms. For instance, it may be possible to replace the full-length shaft with a pair of short stubs extending from each arm of the framework. In such an embodiment, each stub would support one end of the roll. In another embodiment, the dual arm configuration of the framework could be replaced with a single arm having a cantilevered retaining member mounted thereto at a location intermediate its first and second ends.

DM TOR/266748-00003/2037721.1

[0078] Referring back to FIG. 3, in this configuration, the framework 132 can accommodate one, two or three rolls 26 of packaging material 28 at any given time. FIG. 5 shows a single large- diameter roll 178 mounted in the station 172b. When loaded with the single roll 178, the portable dispensing apparatus 20 will produce a single-ply continuous web of packaging material. Preferably, however, the framework 132 supports two mid-size rolls 180 and 182 in stations 172a and 172c as shown in FIG. 3 for the production of a two-ply continuous web of packaging material. The two-ply continuous web tends to be preferred because it affords greater rigidity and crush resistance than the single-ply embodiment, thereby tending to provide improved cushioning effect. Additionally, enhanced versatility and increased bulking may be achieved by using a two-ply continuous web.

[0079] With reference to FIGS. 3, 9 and 10, each roll 180, 182 has an axis of rotation R ₁ , R ₂ . The axis of rotation R ₁ of the roll 180 is carried higher than the axis of rotation R ₂ of the roll 182. Each roll 180, 182 additionally has a continuous web 32a, 32b (identified generically with reference numeral 32) of packaging material 28a, 28b (identified generically with reference numeral 28).

[0080] The packaging material 28 may be made from a variety of materials including, but not limited to, paper (i.e. kraft paper, newsprint, tissue paper), foil, polyethylene film and polyethylene foam. Preferably, the packaging material 28 is made of kraft paper having a basis weight of 401bs. Although, kraft paper having either a higher or lower basis weight could also be used. While packaging materials 28a and 28b may be made of different materials, in most applications the packaging materials 28a and 28b will be fabricated from the same material. Each continuous web 32a, 32b has a first inner face 184 and a second outer face 186. The inner face 184 of each continuous web 32a, 32b is coated with a cold seal adhesive (also known as cohesive). Preferably, the entire face 184 is coated with the cold seal adhesive. Although, in alternative embodiments, less than the entire face may be coated. It is further preferred that the cold seal adhesive is latex (natural or synthetic).

[0081] When loaded onto the roll supporting means 24, the roll 180 is mounted for rotation in a direction, opposite to that of roll 182 such that the inner faces 184 of the continuous webs 32a and 32b are oriented away from each other while the outer faces 186 thereof are disposed

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opposite one another. In the view shown in FIG. 9, the roll 180 unwinds with a clockwise rotation, whereas the roll 182 may be unwound by a counterclockwise rotation.

[0082] In an alternative embodiment, a different configuration may be used. For instance, it may be possible to have the outer face of each roll coated with the cold seal adhesive, while the inner face remains uncoated. In such an embodiment, the direction of rotation for each roll would be reversed. The roll 180 would be rotated counterclockwise while the roll 182 would have a clockwise rotation. As in the previous embodiment, the coated faces of the continuous webs would be directed away from each while the uncoated faces would be place opposite one another.

[0083] Cold seal adhesive is used because of its propensity for adhering only to itself and not to surfaces which have no such adhesives on them. Advantageously, the packaging material 28 does not adhere to the components of the rotary cutting assembly 30 and the cutter assembly 38 and more importantly, to the container and article with which it will be used. Accordingly, it is not necessary to segregate the packaging material from the article to be packed or from the container.

[0084] Referring now to FIGS. 4, 6 and 7, the rotary cutting assembly 30 includes a pair of first and second, elongate, overlapping shear cut rollers 190 and 192 mounted to extend between the side frame members 84 and 86. Each roller 190, 192 is supported for rotation at one end thereof on bearing assemblies (not shown) seated within the pedestal bearing 194. The opposite end of each roller 190, 192 extends into a drive housing 196 for connection to the drive assembly 36. Each roller 190, 192 has a shaft 198, 200 and a plurality of circular cutting elements 202, 204 disposed at spaced apart locations along its respective shaft 198, 200. The cutting elements 202 of the first roller 190 are longitudinally offset from the cutting elements 204 of the second roller 192 so as to permit the cutting elements 202 to pass between the cutting elements 204 during operation of the rotary cutting assembly 30. The cutting element 202 has a first cutting edge 210, a second cutting edge 212 and a connecting body 214 joining the first and second cutting edges 210 and 212. Similarly, the cutting element 204 has first and second cutting edges 216 and 218 and a connecting body 220. As best shown in FIG. 10, when the rotary cutting assembly is actuated, the roller 190 is driven to rotate (clockwise) in a direction opposite to the rotation of

DM TOR/266748-00003/2037721.1

roller 192 (counterclockwise) thereby drawing the continuous webs 32a and 32b into the rotary cutting assembly 30. The shearing action of the cutting edges 210, 212, 216 and 218 cuts longitudinally extending slits 34 into the continuous web 32 (see FIG. 12). The slits 34 define a plurality of continuous longitudinal strands or filaments 219 which, as will be explained in greater detail below, may be urged to fold, twist and adhere to each other to thereby form a mass of folded, interlaced and/or intertwisted strands having increased bulk.

[0085] While in the preferred embodiment the rotary cutting assembly 30 is configured to cut spaced apart longitudinal slits 34 in the continuous web 32, it will be appreciated the slits may be oriented differently. Other modifications are also possible. For instance, in another embodiment, it may be desirable to provide the rollers of the cutting assembly with cutting edges adapted for cross-cutting (i.e. cutting slits in the continuous web in two directions). Alternatively, the rotary cutting assembly could be modified so that instead of defining edge-to edge continuous slits in a continuous web of a determinate length, it could cut slits of a shorter length or the slits could be provided only at intermittent locations, hi a further alternative, the cutting assembly could define scoring or perforations in the continuous web instead of slits.

[0086] As best shown in FIGS. 1 and 4, the drive housing 196 extends between, and is retained by, the angle members 126 and 127. Portions of the drive housing 196 are also supported by, and abut the horizontal leg 102 of the first side frame member 84 and the first face 122 of the front support plate 80. On the opposite side of the rotary cutting assembly 30, the bearing pedestal 194 is mounted between the angle member 128 and the front support plate 30 and is supported on the horizontal leg 102 of the second frame member 86.

[0087] The drive assembly 36 includes a drive motor 222 carried on the drive housing 196, and a gearbox (not shown) disposed within the drive housing 196. The drive motor 222 is operatively connected to the gearbox to transmit the drive force to the rollers 190 and 192 of the rotary cutting assembly 30. In an alternative embodiment, the gearbox could be a variable speed gearbox. Such a gearbox would tend to permit the delivered speed to be selectively adjusted to achieve a desired feed/output rate for the roller cutting assembly 30. Additionally, it could permit the rotational speed of the roller 190, 192 to be optimized to accommodate the specific type of packaging material 28a, 28b. hi other embodiments, the gearbox of the drive assembly could be

DM TOR/266748-00003/2037721.1

used in conjunction with, or replaced altogether by, other drive mechanisms such as, a drive belt arrangement or a chain and sprocket arrangement.

[0088] Preferably, the motor 222 is an electrical motor. A fan 224 driven by the motor 222 is also provided to cool the interior space of the protective housing 40 and to discourage the motor 222 from overheating during operation of the portable dispensing apparatus 20.

[0089] The portable dispensing apparatus 20 possesses two limit switches 226 and 228 for inhibiting actuation of the drive assembly 36. Both limit switches 226 and 228 are operable to cut the supply of power to the motor 222 if a certain event occurs. In the case of limit switch 226, the triggering event is a "lid open" condition, that is, the lid 72 of the protective housing 40 is in the open position 74. Disabling the rotary cutting assembly 30 when the "lid open" condition is realized tends to mitigate the risk of accidental injury which may occur when rolls 180 and 182 are loaded/unloaded onto the roll supporting means 24 and when the ends of these rolls are initially inserted into the rotary cutting assembly 30. In this embodiment, the limit switch 226 is positioned on the top margin 229 of the sidewall 50 at a location closer to the rear wall 48 than the front wall. It is operable to detect whether the lid 72 is in the open position 74 or the closed position 76. As will be explained in greater detail below, the second limit switch 228 is triggered if the cutter assembly malfunctions, for instance, and its cutting portion obstructs the outlet 43.

[0090] To facilitate the initial insertion of the continuous webs 28a and 28b between the rollers 190 and 192, the portable dispensing apparatus is provided with feeding means 230 in the nature of a hand crank 232. The hand crank 232 is accessible from outside the protective housing 40 and presents a relatively large, easy to grasp handle portion 234 which an operator can turn to cause manual rotation of the rollers 190 and 192 to advance the continuous webs 28a and 28b into the rotary cutting assembly 30. In this manner, the continuous web of each source roll 26 may be safely fed into the rotary cutting assembly with minimal risk of physical injury to the operator of the portable dispensing apparatus.

[0091] While in this embodiment, the feeding means 230 is a manual feeding means, it should be appreciated that automated feeding means could also be used to similar advantage. Such automated feeding means could include optical, pressure or other types of sensors to detect the presence of the continuous web in a predetermined location. With the presence of the continuous

DM TOR/266748-00003/2037721.1

web detected and the lid of the housing closed, the rollers could automatically rotate a small number of revolutions to draw in a small portion of packaging material. This automatic loading feature could be combined with an alignment/centering function whereby the continuous web is automatically centered or aligned within the rotary cutting assembling. Other feeding/loading mechanisms and techniques could also be employed.

[0092] With reference to FIGS. 8 and 11 to 14, the cutter assembly 38 is now described in greater detail. The cutter assembly 38 is mounted to the second face 124 of the front support plate 80. The cutter assembly 38 includes a first stationary cutting edge 240 and a second cutting edge 242 movable relative to the first stationary cutting edge 240. The cutting edge 240 is carried on a thin, elongate first blade member 244 that is fixed by fasteners (not shown) to the front support plate 80. The first blade member 244 extends between the third and fourth edges 114 and 116 of the front support plate 80 with the cutting edge 240 disposed substantially flush with the lower margin of the slot 120.

[0093] The cutting edge 242 is carried on a second blade member 246 that is fastened to a plate 248 along its lower edge. As best shown in FIG. 8, the cutting edge 242 is mounted to extend generally diagonally such that its first end 250 is carried higher than its second end 252 in guillotine-like fashion. The plate 248 is slideably moveable relative to the front support plate 80. More specifically, the plate 248 is mounted for reciprocating movement between the third and fourth edges 114 and 116 of the front support plate 80, along a plane parallel to that defined by the second face 124. The movement of the plate 248 is constrained by guide means 250 in the nature of a pair of spaced apart guide rails 254 and 256. The plate 246 is mounted between the guide rails 254 and 256 where it is retained by guide rail flanges 258.

[0094] Cutter driver means 260 is provided to urge the second movable cutting edge 242 to move between a retracted position 262 and an extended cutting position 264. In the retracted position 262 (shown in FIG. 11 and 12), the second cutting edge 242 is spaced away from the first stationary cutting edge 240 such that the slot 120 is clear of obstructions and the continuous web 32 may pass through it. In its extended, cutting position 264 (shown in FIGS. 13 and 14), the second cutting edge 242 overlaps with the first stationary cutting edge 240 to thereby generate a shearing force that cuts the continuous web 32 across its width in a direction

DM TOR/2 ₆ 6748-00003/2037721.1

transverse of the longitudinal slits 34. In this position, the slot 120 of the front support plate 80 is obstructed by the plate 248 such that no more packaging material may exit through the slot 120.

[0095] The cutter driver means 260 includes a drive motor 270 and a spur gear drive arrangement 272 operatively connected to the drive motor 270 to impart reciprocating motion to the plate 248 (and cutting edge 242). The drive motor 270 is supported on the first face 122 of the front support plate 80 and preferably, is an electric motor. The spur gear drive arrangement 272 includes a pair of spaced apart follower gears 274 and 276 and a driver gear 278 mounted therebetween. The driver gear 278 receives the output shaft (not shown) from the drive motor 270 and transmits the torque to each of the pivotally mounted follower gears 274 and 276. Arms 280 and 282 are themselves pivotally connected to the plate 248 and to the follower gears 274 and 276 at eccentric pivot connections 284 and 286. The arms 280 and 282 serve to convert the torque to a directional force for reciprocation. To move the cutting edge 242 from its retracted position 262 to its cutting position 264, the eccentric pivot connections 284 and 286 travel 180° degrees (see FIGS. 12 and 14).

[0096] The second limit switch 228 is operable to detect whether the second cutting edge 242 is in the cutting position 264 and if so, to inhibit actuation of the rotary cutting assembly 30 so as to prevent the output of continuous web 32 from the rotary cutting assembly 30. In this embodiment, the limit switch 228 is mounted to the front support plate 80 adjacent the guide rail 254. In another embodiment, the limit switch could be mounted at an alternate location.

[0097] While in this embodiment, the cutter drive means employs spur gears to drive the cutting mechanism, it will be appreciated that this need not be the case in every application. In alternative embodiments, other drives could be used to similar advantage.

[0098] The portable dispensing apparatus 20 further includes a chute 290 attached to the support frame 22. The chute 290 communicates with both the slot 120 of the front support plate 80 and the outlet 43 and serves to direct the two-ply continuous web 32 outputted from the rotary cutting assembly 30 toward the outlet 43. In this embodiment, the chute 290 is generally rectangular and sized larger the width of the continuous web 32. However, in some embodiments, it may be

DM TOR/266748-00003/2037721.1

desirable to alter the form of the continuous web dispensed by creating a constriction (or choke) in the chute.

[0099] In the further alternative, the chute 290 could be replaced with a curved output ramp. Such an output ramp could be provided with constrictions so as to encourage partial jamming of the output flow to produce kinking in the continuous web in the direction of travel to thereby increase the bulk of the packaging material. When viewed in cross-section, the kinking in the continuous web could define a generally corrugated profile. FIG. 23 shows a length of one such continuous web designated generally with reference numeral 292. The continuous web 292 is similar to continuous web 32 in that it is a two-ply continuous web formed by superimposed first and second continuous webs 294 and 296. Each of these continuous webs has a first face 298 and a second face 300 coated with cold seal adhesive. The second faces of the continuous webs 294 and 296 are oriented away from each other. The corrugated profile of continuous web 292 is defined by a plurality of furrows 302 and ridges 304. In this embodiment, adjacent ridges 304 do not abut; the second face 300 of the continuous web 294 does not fold onto itself. However, further longitudinal compression of the continuous web 292 would result in the second face 300 being folded onto itself as shown in FIG. 24. The cohesive coating on the second face 300 would tend to cause the adjacent ridges 304 to remain in an abutting relationship.

[00100] As shown in FIG. 16, the portable dispensing apparatus 20 is intended to be placed on a relatively flat support surface 310 of a loading platform (or a table top) 312. Preferably, the portable dispensing apparatus 20 is disposed near an edge of the loading platform 312 such that the continuous web 32 may exit the outlet 43 and free fall unimpeded into a container.

[00101] However, in an alternative embodiment, the portable dispensing apparatus may be carried or suspended above the ground on a purpose built frame. FIG. 15 shows one such embodiment. In that embodiment, a mobile packaging station designated generally with reference numeral 314 includes a portable dispensing apparatus 316 generally similar to portable dispensing apparatus 20 and a frame 318 upon which a container to be packed may be placed. The frame 318 has a generally rectangular base 320 which sits on casters 322 to permit wheeled movement of the mobile packaging station 314 and to facilitate relocation of same as desired.

DM TOR/266748-00003/203772U

Extending upwardly from the base 320 is a pair of spaced apart support legs 324 and 326 between which run upper and lower cross-members 328 and 330. Each leg 324, 326 has at its upper extremity a pivotally connected arm 332, 334. Welded to the arms 332 and 334 is a mounting bracket 336. The portable dispensing apparatus 316 is securely fastened to the mounting bracket 336.

[00102] The height at which the portable dispensing apparatus 316 is carried above the base 320 may be adjusted using height adjustment means 338. In this embodiment, the height adjustment means 338 takes the form of a ratchet mechanism 340 having a pawl 342 and a rack member 344. The rack member 344 is pivotally connected at one end to the leg 324 and at the other end to the arm 332. A relatively long handle 346 is provided to allow manual actuation of the height adjustment means 334. With this functionality, the mobile packaging station 314 tends to be readily adaptable for dispensing packaging material to containers of varying shapes and sizes.

[00103] An exemplary use of the portable dispensing apparatus 20 to produce a continuous web packaging material 32 is now described. Prior to actuation, the portable dispensing material 20 is supplied with rolls 180 and 182. The lid 72 is moved to its open position 74 to provide access to the interior 77 of the protective housing 40. The framework 132 is pivoted rearwardly to its out-of-use, loading position 162 and the shafts 164 supporting the rolls 180 and 182 are placed within the stations 172a and 172c. The rolls 180 and 182 are loaded manually onto the framework 132 for rotation in opposite directions (as best shown in FIG. 9). Thereafter, the continuous webs 32a and 32b may be manually drawn out with continuous web 32a superimposed on continuous web 32b such that the outer faces 186 of web 32a, 32b abut each other. The respective ends of the rolls 180 and 182 are then manually fed into the rotary cutting assembly 30 and the hand crank 232 is turned to cause the continuous web 32 to advance further between the rollers 190 and 192. Once the ends of the rolls 180 and 182 have been properly loaded, the lid 72 is moved to its closed position 76 and the portable dispensing apparatus 20 is now operation ready.

[00104] The portable dispensing apparatus 20 may be actuated by a variety of means, hi this embodiment, the actuating means is a foot pedal (not shown). However, in another

DM TOR/266748-00003/2037721.1

embodiment, a hand actuator may be used instead. Other actuation means could also be employed. When the portable dispensing apparatus 20 is actuated, the continuous web 32 is urged to pass between the rollers 190 and 192 where the cutting elements 202 and 204 cut longitudinally extending slits 34 in the continuous web 32. The now slitted continuous web 32 exits the rotary cutting assembly 30 through the slot 120 defined in the front support plate 80 and is conveyed towards the outlet 43 by the chute 290.

[00105] Using the cutter assembly 38, the operator may selectively cut a desired length of the continuous web 32. When the cutter assembly 38 is actuated, the second cutting edge 242 moves to its cutting position 264. The shearing action of the first and second cutting edges 240 and 242 cuts the continuous web 32 along its width. Preferably, there is a relatively, short delay between actuation and the movement of the cutting edge 242. This allows the rollers 190 and 192 of the rotary cutting assembly 30 to come to a full stop before the continuous web 32 is cut so as to reduce wastage of the continuous web. Alternatively, operation of the cutter assembly 38 may be configured to eliminate the aforementioned delay.

[00106] Depending on the strength of the cold seal adhesive and the characteristics of the source packaging material 28, it may be possible for the continuous web 32 outputted through outlet 43 to maintain at least partially its sheet-like integrity (that is, to have a plurality of strands 219 lying in a common plane). The tackiness and stretchiness of the cold seal adhesive may cause at least some cross-adhesion between adjacent strands 219 of the continuous web 32 which would tend to discourage adjacent strands 219 from splitting apart. The operator could, however, easily pull apart the strands 219, if desired.

[00107] FIGS. 16 to 20 shows a sequence of images depicting the packing of an article

350 within a container 352 using the continuous web 32 dispensed by the apparatus 20. As the continuous web 32 is discharged from the portable dispensing apparatus 20 it collects at the bottom of the container 352 (see FIG. 16). The momentum of the continuous web 32 causes the web to repeatedly fold onto itself thereby forming a bulky, packing mass or body 354 defined by a plurality of alternating ridges 356 (see FIG. 17). As it does so, the faces 184 coated with cold seal adhesive are brought together at certain contact points 358 whereat an adhesive bond is formed which tends to maintain the arrangement of ridges 356 in place (as best seen in FIG. 10).

DM TOR/266748-00003/2037721.1

The packing body 354 has voids 360 defined between non-abutting portions of the continuous web 32. These voids impart increased bulk and improved cushioning characteristics to the packing body 354, while the adhesive bond and the two-ply structure of the continuous web 32 tend to provide improved shock resistance and structural rigidity thereto.

[00108] The operator allows a certain quantity of the continuous web 32 to partially fill the container 352 until a first packing body 354 of a desired (or sufficient) size/height is formed. In this manner, the container 352 may be filled one third or one half of the way up, for example (see FIG. 17). More specifically, once the desired amount of continuous web 32 has been urged into the container 352, the operator actuates the cutter assembly 38 to cut the continuous web 32. Rotation of the rollers 190 and 192 is ceased to prevent further packaging material 28 to be drawn from the rolls 180 and 182. Thereafter, the operator places the article 350 onto the first packing body 354 for cushioning contact (see FIG. 18). Due to the resiliency of the packaging material, the first packing body 354 may conform at least generally to the shape of the article 350 for improved migration control. However, the two-ply packaging material tends to resist compressive forces which would otherwise flatten the folds and collapse the ridges 356.

[00109] The operator then actuates the portable dispensing apparatus 20 again to output more continuous web 32 to fill the container 352. As the continuous web 32 accumulates over top the article 350, a second packing body 356 generally similar to the first packing body 354 is formed. The second packing body also tends to conform at least partially to the shape of the article 350. Once the second packing body 356 reaches the top edge of the container 352 (or near thereto), the operator actuates the cutter assembly 32 to cut the continuous web 32. The top of the container 352 may then be sealed and made ready for shipping. As shown in FIG. 19, the article 350 is safely cushioned between the first and second packing bodies 354 and 356 thereby tending to obviate the need for compression packing or overfilling.

[00110] While more than two packing bodies may be employed to pack an article in a container, the use of only two packing bodies tends to be preferred because of the simplicity of packaging operations associated therewith. The formation of these packing bodies does not require additional machinery or extensive operator manipulation. As a further advantage, clean up of the packaging material once the container has been opened and the article has been

DM TOR/266748-00003/2037721.1

removed, tends to be relatively easy as the packaging material is not in loose form. With only two packing bodies to dispose of, messes in the packaging/unpackaging sites may be mitigated. The biodegradability of the packaging material further tends to make it an environmentally- friendly packaging solution. Advantageously, the opportunity exists with this packaging material to remold or reshape the packing bodies as required for reuse or to create another bulk configuration. This may be achieved, for instance, by manually pulling apart the packing bodies to separate the coated faces of the continuous web or pulling strands 219 away from each other.

[00111] While the continuous web 32 described above was used to form packing bodies

354 and 356 having a generally folded structure, this need not be the case in all applications. It will be appreciated that in other embodiments the packing bodies may take other forms. Similarly, other packing techniques could be employed to similar advantage.

[00112] FIGS. 20 to 22 show another sequence of images depicting the packing of an article 360 within a container 362 in accordance with an alternate embodiment of the invention. The continuous web output from the portable packaging apparatus 20 shown in FIGS. 20 to 22 is designated generally with reference numeral 364. Contrary to continuous web 32, in this embodiment, the continuous web 364 does not maintain its sheet-like integrity as it exits the outlet 43. The strands 366 of the continuous web 364 do not lie in a common plane. Instead, the strands 366 may be partially twisted onto themselves and randomly oriented away/towards each other and/or separated from other strands. Additionally, the ply of the continuous web 364 may be separated one from the other. This configuration of the output web 364 effect may be achieved by using a relatively weak cohesive in combination with a relatively light-weight packaging material. Alternatively, a similar result may be obtained with somewhat minor operator manipulation. In such a case, the operator would manually pull the continuous web 364 apart in a direction generally transverse to the slits and/or would pull the ply apart. Advantageously, high bulk configurations may be achieved in this manner.

[00113] As the continuous web 364 is discharged from outlet 43 it collects at the bottom of the container 362 (see FIG. 20). The momentum of the continuous web 364 causes the strands 366 to repeatedly intertwist, fold and interlace with each other to thereby form a bulky, tangled or matted packing body 368 (see FIG. 20). As the strands 366 intertwine, the faces thereof coated

DM TOR/266748-00003/2037721.1

with cold seal adhesive are brought together at certain contact points whereat an adhesive bond is formed. The matted packing body 368 has voids or spaces 370 defined between the strands 366. As with voids 358 in the folded packing body 354, the voids 370 impart increased bulk and improved cushioning characteristics to the matted packing body 368. The adhesive bond, the two-ply structure of the strands 366 tend to provide improved shock resistance and structural rigidity to the matted packing body 368.

[00114] The operator allows a certain quantity of the continuous web 364 to partially fill the container 362 until a first matted packing body 368 of a desired (or sufficient) size/height is formed. In this manner, the container 362 may be filled one third or one half of the way up, for example. Once the container 362 has been filled with the desired amount of continuous web 364, the operator can cut the web 362. Thereafter, the operator places the article 360 onto the first matted packing body 368 for cushioning contact (see FIG. 21). Due to the resiliency of the packaging material, the first matted packing body 368 may conform at least generally to the shape of the article 360 for improved migration control.

[00115] The operator then actuates the portable dispensing apparatus 20 again to output more continuous web 364 to fill the container 362. As the continuous web 364 accumulates over top the article 360, a second matted packing body 372 generally similar to the first matted packing body 368 is formed. The second matted packing body 372 also tends to conform at least partially to the shape of the article 360. Once the second matted packing body 372 reaches the top edge of the container 362 (or near thereto), the operator actuates may cut the continuous web 364. The top of the container 362 may then be sealed and made ready for shipping. As shown in FIG. 22, the article 360 is safely cushioned between the first and second matted packing bodies 368 and 372 thereby tending to obviate the need for compression packing or overfilling.

[00116] As will be appreciated by a person skilled in the art, the portable dispensing apparatus 20 and 304 tends to be simple to manufacture, maintain and install and may be easily operated by unskilled labour. Its compact size tends to make it easy to transport to a desired location where it can be deployed quickly as a mobile packaging station. Until deployment, the packaging material is kept in a roll format which occupies relatively little space whether in transit to the packing site or in storage. Moreover, the continuous web of packaging material

DM TOR/266748-00003/2037721.1

produced by the portable dispensing apparatus is highly moldable and capable of adopting a variety of high bulk configurations to suit different packing requirements. Advantageously, it can be readily formed into a mass of folded, interlaced and/or intertwisted strands that tends to exhibit a high degree of cushioning and shock resistance.

[00117] Although the foregoing description and accompanying drawings relate to specific preferred embodiments of the present invention as presently contemplated by the inventor, it will be understood that various changes, modifications and adaptations, may be made without departing from the spirit of the invention.

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