CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Application No. 63/283,070, filed November 24, 2021, the contents of which is herein incorporated by reference in their entirety.

FIELD

[0001] The present teachings generally relate to paper tubes, and more particularly, to perforated paper tubes and a manufacturing process thereof.

BACKGROUND

[0002] Tubes of cardboard, paper, and other sheet material are commonly used in various industries for packaging containers, such as in the food and beverage industry. These tubes may be generally circular in cross-section to receive one or more food or beverage -related items. For example, these tubes may often form an outer packaging for a beverage bottle. However, due to ongoing industry demands, these tubes may often be manufactured in a variety of sizes, shapes, and/or cross-sections.

[0003] One particular method of manufacturing often found in food and beverage tube packaging requires a sheet material (e.g., paper or cardboard) to be spiral wound. During a spiral winding process, the sheet material may be wound and at least partially adhered to itself, thereby forming the overall tube structure. Additionally, one or more end caps may be secured to an opening of the tube, thereby forming a partially or fully enclosed package for the food or beverage to be packaged.

[0004] However, often times the spiral wound tubes may be difficult to recycle. While the cardboard, paper, or other sheet material used to form the tube may be recyclable, the tube may be rigid and difficult to compress. As a result, the tubes may often be disposed of improperly or otherwise be inefficiently recycled due to the large dimensions. To combat such an issue or similar issues, some conventional spiral wound tubes may be punctured or split along the spiral seams to further compress the tube for recycling. However, puncturing or splitting of the spiral seams may often require excess force and may be difficult to do manually. [0005] While such improvements may decrease an overall dimension of the tube when compressed along the seams, recycling of the tube may still frequently be difficult. As mentioned above, the tubes may include one or more end caps to create the packaging. These end caps may often be made from a dissimilar material to that of the tube, such as aluminum, tin, plastics, or a combination thereof. Therefore, the end caps may need to be removed from the tube before the tube may be recycled with similar paper or cardboard products. However, removal of such end caps may be difficult due to joining of the end caps to the tube. Thus, the tubes and end caps may be improperly disposed of. Similarly, manufacturing of more readily recyclable tubes may often be difficult or costly.

[0006] As such, there remains a need for a tube that may be compressed or otherwise broken down more easily. What is needed is a tube having one or more perforations to more easily compress the tub for recycling. Similarly, there remains a need for a tube that provides a more robust manner of recycling. What is needed is a tube having the ability to separate different recyclable material within the tube. Moreover, there remains a need for a tube that may be manually compressed and/or broken down by a user. Thus, what is needed is a tube having one or more perforations that allow a user to manually apply a force to the perforated region, thereby breaking apart the tube.

SUMMARY

[0007] The present teachings meet one or more of the present needs by providing a spiral wound tube comprising: (a) perforations extending transversely to a longitudinal axis of the tube; and (b) an end cap secured to an opening of the tube, wherein the perforations are positioned adjacent to the end cap to separate the end cap from the tube.

[0008] The end cap may be tin. The tube may be made from paper, cardboard, or both. The tube and the end cap may both be recyclable and separation of the end cap from the tube may be completed along the perforations to recycle the end cap and the tube. The tube may include a cover disposed along an outer surface of the tube. The perforations may extend through the cover. The perforations may extend through an entire wall thickness of the tube. The perforations may extend through a portion of a wall thickness of the tube to create a score line therein. The tube may be spiral wound to include a plurality of bond lines along the tube where a material of the tube may be adhered to itself, thereby forming an overall shape of the tube.

[0009] The present teachings meet one or more of the present needs by providing a method of manufacturing a tube with a machine, comprising: (a) placing a stick of material on a mandrel of the machine; (b) applying a cover to the stick of material; (c) pressing the stick of material with a roller by applying a force to the stick of material with the roller, thereby compressing the cover along an outer surface of the stick of material; (d) forming perforations within the stick of material using a knife of the machine; (e) cutting the stick of material using one or more additional knives of blades to form a plurality of tubes having a desired length; and (f) removing the plurality of tubes from the mandrel.

[0010] Step (a) may be completed at a first station. Step (b) may be completed at a second station. Steps (c)-(e) may be completed at a third station. Steps (c)-(e) may be completed simultaneously. Additionally, the force applied to the stick of material by the roller may deflect the stick of material into the knife to form the perforations. The roller may rotate the stick of material when engaging the knife and the knife may rotate about a bar to form the perforations. Moreover, the mandrel may be rotated between the first station, the second station, and the third station. Furthermore, step (f) may be completed at a fourth station. The method may comprise step (g) for securing an end cap to each of the plurality of tubes. The end cap and the plurality of tubes may be formed from dissimilar materials.

[0011] The present teachings meet one or more of the present needs by providing: a tube that may be compressed or otherwise broken down more easily; a tube having one or more perforations to more easily compress the tub for recycling; a tube that provides a more robust manner of recycling; a tube having the ability to separate different recyclable material within the tube; a tube that may be manually compressed and/or broken down by a user; a tube having one or more perforations that allow a user to manually apply a force to the perforated region, thereby breaking apart the tube; or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG.1 is a perspective view of a paper tube manufacturing machine in accordance with the present teachings.

[0013] FIG. 2 is a perspective view of a tube manufactured in accordance with the present teachings.

[0014] FIG. 3 is a perspective view of a manufacturing machine illustrating various manufacturing stations.

[0015] FIG. 4 is a sectional view of the third manufacturing station of FIG. 3.

[0016] FIG. 5 is a close-up view of the knife of FIG. 4.

[0017] FIG. 6 is a manufacturing process flowchart in accordance with the present teachings. DETAILED DESCRIPTION

[0018] The present teachings generally relate to manufacturing of tubes. The tubes may be utilized for packaging in various industries, such as the food and beverage industry. The tubes may be configured to package or otherwise secure one or more bottles, one or more food items, or both. The tubes may function as a protective covering for the food or beverage stored therein. Similarly, the tubes may provide additional structural integrity to the food or beverage therein to prevent damage.

[0019] The tubes may also be utilized in any number of other industries. For example, the tubes may be configured to package and/or protect one or more rolled products, such as a poster, map, etc. The tubes may also contain one or more additional consumer goods, such as toys, ornaments, construction materials, etc. As such, it should be noted that the tubes are not limited to a particular item to be stored therein.

[0020] As discussed in further detail below, the present teachings may be particularly beneficial for recyclable tubes. That is, the tubes may be manufactured using one or more recyclable material, such as paper, cardboard, metal (e.g., aluminum, tin, steel, etc.). As a result, the manufacturing processed described herein - and the features describe in the present teachings - may advantageously provide an end-recipient of the tube the ability to easily recycle the tube. To ease recycling by the recipient, the tube may provide means for easily compressing the tube into a smaller overall size to decrease packaging space needed while recycling. Similarly, the tube may allow for easy separation of dissimilar materials of the tube to proper recycling of each material in the appropriate stream.

[0021] The tubes may include one or more bond lines. The bond lines may function to adhered portions of the tube to each other. For example, the tubes may be spiral wound such that a material is wound to adhere at least partially to itself to form an overall shape of the tube. While cylindrical tubes are described herein, it should be noted that any shape may be manufactured. For example, a substantially rectangular or square tube may be formed. The bond lines may include an adhesive to form the bond. The bond lines may be substantially rigid to prevent separation of the tube along the bond lines. However, the bond lines may also provide a means for puncturing of the tube is desired.

[0022] The tube may include one or more perforations. As described in further detail below, the perforations may be formed utilizing one or more knives during a manufacturing process. The perforations may function to allow a user to separate portions of the tube. The perforations may provide a localized region that dictates the manner of separation of the tube. That is, separation of the tube may be limited to only separation on and/or near the perforations. Similarly, the perforations may allow a user to apply a lesser force to separate the tube when compared to other regions of the tube free of perforations.

[0023] The perforations may be any desired length, width, depth, or a combination thereof. The perforations may be uniform or non-uniform. The perforations may be positioned anywhere along the tube at any desired angle. The perforations may be substantially linear, arcuate, angled, or a combination thereof. The knife of the manufacturing process may at least partially dictate a shape of the perforations.

[0024] The tube may include a cover. The cover may function as a label or outermost shell of the tube. The cover may be disposed along all or a portion of the tube. The cover may be coextensive with the tube. The cover may be adhered or otherwise secured to the tube. The cover may include text, one or more images, or both. The cover may provide protection to the tube. For example, the cover may be moisture-resistant, impact-resistant, or both. The cover may provide an aesthetically pleasing outer surface for a customer or recipient.

[0025] The tube may include one or more end caps. The end caps may function to close one or more openings of the tube. The end caps may be of a dissimilar material to that of the tube. For example, the tube may be paper or cardboard while the end caps may be tin or aluminum. Thus, separation of the end caps may be required for recycling of both the end caps and the tube - a feature that may be possible due to the perforations described herein. The end caps may be press-fit to the tube, may be adhered to the tube, or both. The end caps may also provide support for one or more items stored within the tube.

[0026] The tube may be at least partially formed or manufacturing using a machine. The machine may receive an intermediate material to create the tubes. For example, the machine may receive a stick of spiral wound material having a greater length than any given finished tube. As such, the machine may cut the stick into a plurality of tubes for a finalized product. However, the machine may also include forming of the stick.

[0027] Turning now to the figures, FIG. 1 illustrates an exemplary machine 10 in accordance with the present teachings. The machine 10 may be configured to complete one or more stages of a manufacturing process for forming a tube (see FIG. 2). For instance, as shown, the machine 10 may include a plurality of mandrels 12. The mandrels 12 may be adapted to receive and/or support a material stock that eventually gets formed into a tube. That is, the mandrels 12 may receive a stick of product that is eventually cut during a stage of manufacturing within the machine 10. As such, the stick of product may be received by the mandrel 12 in a substantially complete shape. For example, the stick of product may be a long hollow cylindrical shape (e.g., a longer tube) that is inserted around an outer surface of the mandrel 12. The long hollow cylindrical shape may ultimately be cut into desired lengths, thereby forming one or more finished tubes.

[0028] As discussed above, the machine 10 may perform one or more steps of a manufacturing process. The one or more steps may be completed at various locations - or stages - within the machine 10 (see FIG. 2). For example, as discussed in further detail below, a stage of the machine 10 may include taking a cover 14 and securing the cover 14 to an outer surface of the stick of product. However, as discussed in further detail below, the machine 10 may conduct any number of operations, such as cutting, assembly, pressing, adhering, forming, punching, or a combination thereof.

[0029] FIG. 2 illustrates a perspective view of a manufactured tube 16 in accordance with the present teachings. It is envisioned that the manufacturing and machine as discussed herein may be particularly fit for manufacturing a spiral wound tube 16. That is, the process as described herein may be used with a tube 16 formed from a material being wound in a spiral fashion and adhered to itself along a plurality of bond lines 20. The material may ultimately be trimmed or cut at some point during the process to form the overall cylindrical and hollow structure of the tube 16. However, it should be noted that manufacturing process described herein may also be utilized for manufacturing or other types of tubing, such as pressed or otherwise pre-formed tubes, injection molded tubing, extruded tubing, pultruded tubing, etc.

[0030] The material used for forming the tube 16 may vary. The spiral wound material may be paper, cardboard, or another pliable material that facilitates winding and adherence to itself. However, other materials, such as plastics, may also be used in a similar manufacturing process.

[0031] Additionally, the finished tube 16 may also include one or more materials in addition to the spiral wound material. For example, as shown in FIG. 2, the tube 16 may include one or more caps 18. The caps 18 may be secured near a terminal end of the tube 16. As it is envisioned that the tube 16 may be substantially or at least partially hollow, the caps 18 may provide a substantially enclosed inner cavity of the tube 16. That is, the caps 18 may be a cover or access panel for the interior of the tube 16.

[0032] The caps 18 may be the same material as the tube 16, but it is envisioned that the caps 18 may have a dissimilar material. For example, the caps 18 may be tin, aluminum, steel, copper, plastic, other materials, or a combination thereof. As a result, the caps 18 may beneficially provide a more structurally rigid material for the tube 16, thereby increasing structural rigidity of the overall packaging formed by the tube 16. For example, the tube 16 may receive a bottle, such as a glass bottle, and at least one of the caps 18 may support the glass bottle. As a result, the cap 18 may provide improved structural support to that of just the more pliable paper or cardboard used for manufacturing the tube 16.

[0033] The tube 16 may advantageously be manufactured from materials that are substantially or entirely recyclable. That is, all or a majority of the tube 16 may be recycled in a conventional manner. However, often times, traditional tubes may unfortunately be difficult to recycle. For example, if a cap of dissimilar material to that of the tube is utilized, it is often impossible or very difficult to separate the cap from the tube 16. As a result, an end recipient of the tube 16 may be unable to properly recycle the tube 16 and/or the cap 18, thereby resulting in the end user simply disposing of the tube 16 as waste in the garbage.

[0034] To combat such deficiencies in conventional tubes 16, the tube 16 as described herein may have one or more perforations 22. The perforations 22 may extend along one or more outer surfaces of the tube 16. The perforations 22 may be a plurality of sequential cuts or punctures through a wall thickness of the tube 16. However, the perforations 22 may advantageously make minimal impact on the overall structural integrity of the tube 16 unless a user desires to impose a force specifically along the perforations 22.

[0035] The perforations 22 may extend through an entirety of the wall thickness of the tube 16 or may only extend partially through the wall thickness of the tube 16. As such, the perforations 22 may also be one or more score lines along an outer surface of the tube 16. Thus, it may be gleaned from the present teachings that the perforations 22 as described herein may advantageously be configured for a desired application.

[0036] While the perforations 22 may provide a localized region for compressing or breaking down the tube 16 for recycling, it may be desirable to position the perforations 22 in a strategic location for separation of dissimilar materials. For example, as shown in FIG. 2, the perforations 22 may be positioned adjacent to or near the cap 18 of the tube 16. As a result, a user my puncture the perforations 22 and easily separate the cap 18 from the tube 16. Thus, a user may easily recycle the cap 18 and the tube 16 without intermingling dissimilar materials. [0037] As shown in FIG. 2, the perforations 22 may extend substantially orthogonal to a linear axis (A) of the tube 16. The perforations 22 may extend substantially linearly or may include one or more bends and/or one or more arcuate portions. Similarly, while the perforations 22 may be formed in a substantially uniform or continuation manner, it is also envisioned that the perforations 22 may also be discontinuous or non-uniform. For example, one or more gaps along a line of perforations 22 may exist. Additionally, each perforation 22 may be uniform or substantially uniform in length and/or width, or perforations 22 may vary in size (e.g., length and/or width).

[0038] Furthermore, while a single perforation line 22 is shown in FIG. 2, any desired number of perforations 22 may exist. The tube 16 may include one or more perforations 22, two or more perforations 22, three of more perforations 22, or four or more perforations 22. The tube 16 may include eight or less perforations 22, seven or less perforations 22, six or less perforations 22, or five or less perforations 22. Moreover, each perforation 22 may include any desired number of puncture holes, score lines, etc. Additionally, while the perforation 22 is shown extending substantially orthogonal to the longitudinal axis (A) of the tube 16, the perforation 22 may extend in any desired relationship (i.e., angle) relative to the longitudinal axis (A). For example, the perforation 22 may extend substantially axially or coaxially to the longitudinal axis (A) of the tube 16.

[0039] FIG. 3 illustrates a manufacturing machine 10 in accordance with the present teachings. Various components of the machine 10 have been removed for simplicity.

[0040] As discussed above, the machine 10 may include a plurality of mandrels 12. Depending on a given manufacturing process, any number of mandrels 12 may be utilized. As shown, the mandrels 12 may have a substantially cylindrical shape to receive a substantially cylindrical stick of product that may ultimately be cut into one or more tubes. However, it should also be noted that any desired mandrel 12 shape may be utilized to accommodate various packaging shapes other than cylindrical.

[0041] The mandrels 12 may be configured to rotate or otherwise move about a central axis in a direction of rotation (M). The direction of rotation (M) may rotate the mandrels 12 in a clockwise direction, a counterclockwise direction, or both. However, other similar movement may also be conducted to move the mandrels 12 between positions within the machine 12, such as linear and/or axial movements.

[0042] During movement, the mandrels 12 may be rotated or otherwise articulated between a plurality of designated stations. As shown in FIG. 3, the machine 10 may designate a first station 30, a second station 32, a third station 34, and a fourth station 36. However, it is also conceivable that the machine 10 may designate less than four stations or greater than four stations as well. Each of the stations may be designated for all or a portion of the manufacturing process to create the tubes as described herein, which is further detailed below.

[0043] Automatically or manually, one or more sticks of material (e.g., elongated tubes requiring cutting to a desired length) are inserted onto one or more of the mandrels 12. The insertion of the sticks of material may be done at the first station 30. While it may be designated as the first station 30, one or more prior manufacturing steps may be conducted within the machine 10 or remote from the machine 10 prior to the stick of material being inserted at the first station 30. That is, the stick of material may be formed (e.g., spiral wound) into an overall shape of the tubes prior to insertion onto the mandrels 12. A single stick of material or a plurality of sticks of material may be inserted onto each mandrel 12. It is envisioned that the stick of material is inserted onto each mandrel 12 once the mandrel 12 reaches the first station 30 based on the rotation (M) of the mandrels 12. As such, FIG. 3 illustrates an exemplary machine 10 configuration in which each of the four mandrels 12 shown may individually reach the first station 30, thereby allowing four sticks of material to be inserted onto the four mandrels 12. However, as mentioned above, various other configurations may be possible based on the present teachings.

[0044] Once the stick of material is inserted onto the mandrel 12 at the first station 30, the mandrel 12 may be rotated (M) to the second station 32. At the second station 32, the stick of material may receive a cover 14 that is manually or automatically moved in a direction (C) to contact the stick of material. It is envisioned that the cover 14 may include an adhesive to at least partially secure the cover 14 to the stick of material at the second station 32. Similarly, one or more mechanical interlocks or fasteners may also be present to secure the cover 14 to the stick of material. For example, one or more push-type fasteners (e.g., clips) may be present on the cover 14 and/or the stick of material to secure the cover 14.

[0045] The cover 14 may be any desired material to provide a finished surface along the outer surface of the stick of material. However, it is envisioned that the cover 14 may be pliable enough to be at least partially wrapped around the stick of material. The cover 14 may be a laminate, paper, or other material that provides text and/or images to the outer surface of the stick of material for designation of the tube and a product therein. As the stick of material may ultimately be cut into a plurality of tubes (e.g., at the third station 34), each cover 14 may include repetitive text and/or images with designated spacing for each of the cut tubes.

[0046] To facilitate automated manufacturing, the covers 14 may be positioned in a stack or row to be continuously applied to each of the sticks of materials as the mandrels 12 are each moved (M) to the second station 32. As such, it is envisioned that the covers 14 may be beneficially applied and adhered or otherwise secured to the sticks of material, yet the covers 14 may not adhere or otherwise be secured to each while positioned in a stick or row.

[0047] Once the cover 14 has been at least partially applied to the stick of material at the second station 12, the mandrel 12 may be moved (M) to the third station 34. As further discussed in detail below, once the mandrel 12 reaches the third station 34, the cover 14 may be pressed onto the stick of material using one or more rollers applying a force to the cover 14 and stick of material. Such application of force may ensure proper adherence or securement of the cover 14 to the stick of material in a substantially uniform manner. Additionally, perforation and/or cutting of the stick of material may also be completed at the third station 34. Such cutting may be done to finalize a length and/or shape of each tube created from the stick of material. Similarly, the perforations formed therein may be present in each of the finalized tubes. However, it should be noted that rolling of the cover 14, perforation of the stick of material, cutting of the stick of material, or a combination thereof may be completed at different stations. But advantageously, the present teachings provide a manufacturing process in which one or more conventional stations may be removed or combined to improve manufacturing time, thereby improving overall cost of the tubes.

[0048] After the aforementioned steps are completed at the third station 34, the mandrel 12 may be moved (M) to the fourth station 34. At the fourth station 34, the cut pieces of finalized stick (e.g., the finalized tubes) may be removed from the mandrel 12 along with any trim waste created during the manufacturing process. Such trim waste may be recycled or otherwise disposed of. Once the material is removed from the mandrel 12, the mandrel 12 may be once again rotated (M) back to the first station 30 or another designated intermediate position, thereby starting the manufacturing process again and preparing to receive another stick of material.

[0049] As such, it may be gleaned that the machine 10 may complete a continuous process in which the mandrels 12 are moving between the stations in a substantially continuous manner. Similarly, the mandrels 12 may each be positioned in one of the stations such that the manufacturing process being completed at each station is substantially simultaneous. For example, the cover 14 may be disposed onto a first stick of material at the second station 32 at substantially the same time that a second stick of material is being pressed and/or cut at the third station 34. Even further, a third stick of material may be removed as finalized tubes at the fourth station 36 at substantially the same time as the processes of the second station 32 and the third station 34 are being completed.

[0050] However, it should also be noted that the process may be done sequentially, whereby a mandrel 12 is moved between the stations and each process is completed sequentially instead of simultaneously if desired.

[0051] FIG. 4 illustrates a sectional view of the third manufacturing station 34 shown in FIG. 3. As discussed above, the mandrel 12 may reach the third station 34 during a movement of the machine. At this point, the stick of material 24 may be disposed on the mandrel 12 and have a cover 14 at least partially disposed over the stick of material 24. It is envisioned that the cover 14 may be adhered to the stick of material 24 to form a bond therebetween. While at a previous station (e.g., the second station) the cover 14 may be secured to the stick of material 24, proper adherence between the cover 14 and the stick of material 24 may be further ensured by pressing a roller 38 against the stick of material 24 and cover 14 thereof.

[0052] The roller 38 may be positioned adjacent to the mandrel 12 in the third station 34. To compress the cover 14 along the stick of material 24, the roller 38 may apply a force (F) directly to the cover 14 and the stick of material 24. The force vector may be applied substantially orthogonally to an axis of the mandrel 12. That is, the force (F) may be applied orthogonally to the surface of the cover 14 and the stick of material 24. However, any angle of the force (F) may also be possible is desired.

[0053] To ensure the cover 14 is fully adhered around a circumference - or outer perimeter of the stick of material 24 if a shape other than cylindrical - the roller 38 may also rotate in a direction (R) during application of the force (F). As a result of the rotation (R) of the roller 38, the mandrel 12 may also rotate in the direction (S). Thus, the force (F) applied by the roller 38 may be applied to an entirety or substantially all of the outer circumference of the stick of material 24, thereby ensuring proper adhesion between the cover 14 and the stick of material 24.

[0054] Once completed with a pressing step, the roller 38 may articulate or otherwise move away from the mandrel 12 to disengage the stick of material 24. However, the present teachings may beneficially provide a cutting and/or perforation process simultaneously to the pressing step without needing to disengage the roller 38 from the stick of material 24.

[0055] As the roller 38 applies the force (F), the mandrel 12 and thus the stick of material 24 may be deflected towards a knife 42. The knife 42 may be coaxial with a bar 40 and configured to rotate in a direction (K) around an axis of the bar 40. The knife 42 may include a plurality of teeth 44 that contact the stick of material 24 to form perforations (see FIG. 2). Beneficially, due to the application of force (F) being applied by the roller 38, the roller 38 may dictate contact between the teeth 44 of the knife 42 and the stick of material 24, and thus determine the perforations within the stick of material 24. As such, the knife 42 configuration may advantageously be simplified due to the knife 42 only requiring rotational movement and not lateral movement.

[0056] However, it is also envisioned that the knife 42 may move laterally if desired and/or axially. For example, the knife 42 may move axially along the bar 40 to complete perforations at various locations along a length of the stick of material 24. [0057] As shown, the knife 42 may be positioned to create perforations along an outer surface or circumference of the stick of material 24 transversely to a length or longitudinal axis of the stick of material 24 (See FIG. 2). Such positioning of the perforations may beneficially allow for separation of portions of the finalized tubes along a length of the tube. For example, the perforations may allow for easy removal of an end cap of the tube from the rest of the tube. However, the knife 42 may be positioned at any angle relative to the stick of material 24. For example, the knife 42 may be positioned to form perforations along a length of the stick of material 24 substantially parallel to the longitudinal axis of the stick of material 24.

[0058] It is envisioned that one or more aspects of the third station 34 may be tuned for various configurations of the perforations. One such modification may be the force (F) applied by the roller 38. The force (F) may be increased and/or decreased to tune the resultant force applied between the stick of material 24 and the knife 42. As a result, the knife 42 may cut through the stick of material 24 at different depths. That is, a lighter application of force (F) from the roller 38 may result in a shallower cut by the knife 42 through the stick of material 24. Thus, a scoring or partial cut through the stick of material 42 may be possible. Similarly, the knife 42 may only cut through the cover 14 disposed on the stick of material 24 if desired. [0059] In addition to tuning of the application of force (F) of the roller 38, a diameter of the mandrel 12, a diameter of the stick of material 24 (D _s ), a diameter of the knife (DK), or a combination thereof may impact dimensions and/or characteristics of the perforations formed. Surprisingly, it is found that if the diameter of the stick of material (Ds) is equal to the diameter of the knife (DK), the teeth 44 of the knife may continue to contact the same positions along the stick of material 24. However, if the diameter of the stick of material 24 or the knife 42 are modified to be unequal, the knife 42 may beneficially form a greater number of perforations along the stick of material 24.

[0060] Similarly, to further tune the perforation process, it is envisioned that the diameter of the knife 42 may be adjusted to optimize the perforations formed in the stick of material 24. For example, it may be desirable to complete the desired number of perforations within a specified time or number of rotations (S) of the stick of material 24. To do so, the knife 42 diameter may be modified to ensure that the desired number of perforations are completed within about two full rotations or more, about three full rotations or more, or about four full rotations or more of the stick of material 24. The knife 42 diameter may also be modified to ensure that the desired number of perforations are completed within about seven full rotations or less, about six full rotations or less, or about five full rotations or less of the stick of material 24. [0061] It should also be noted that while a knife 42 forming perforations in the stick of material 24 have been discussed with respect to the third station 34, cutting of the stick of material 24 into desired lengths 24 may also be completed at the third station 34. Such cutting may be done by one or more blades or additional knives located within the third station 34. The cutting may be completed to form a desired length of each finished tube. The cutting may be completed simultaneously with the perforations formed. The cutting may also be completed substantially orthogonally to a longitudinal axis of the stick of material 24 or may be completed at any desired angle relative to the

[0062] FIG. 5 illustrates a close-up view of the knife 42 of FIG. 4. As discussed above, the knife 42 may include a plurality of teeth 44 that form perforations in the stick of material. The teeth 44 may be spaced apart by seats 46 of the knife 42. While the teeth 44 may be configured to contact and cut the stick of material, the seats 46 may be adapted to remain free of contact with the stick of material or otherwise prevent cutting of the stick of material by the seats 46. As a result, the teeth 44 may form perforations at a desired interval with spacing between perforations at least partially due to the seats 46.

[0063] Advantageously, the knife 42 may be modified to adjust the size of the perforations formed in the stick of material. The size of the perforations formed may include a width of each perforation, a length of each perforation, an interval between perforations, or a combination thereof. To adjust the size of the perforations, each tooth 44 may be a desired width (WT). The teeth may be wider to create a shorter perforation. Conversely, the teeth 42 may be narrower to form a shorter perforation in the stick of material.

[0064] Similarly, to adjust the intervals of the perforations along the stick of material, the seats 46 may have a designated width (Ws). By adjusting the width (Ws) of the seats 46, the perforations formed by the teeth 44 may be spaced apart at greater or smaller intervals. Thus, it may be gleaned from the present teachings that the manufacturing process herein may advantageously allow for robust customization of the perforation process.

[0065] Surprisingly, by fine-tuning the parameters as discussed above, a knife 42 having teeth 44 with a designated width (WT) may from perforations within the stick of material having a length greater than the width (WT) of the teeth 44. That is, based upon a designated diameter of the stick of material, a designated diameter of the knife 42, a width (WT) of the teeth 44, a width (Ws) of the seats 46, or a combination thereof, the teeth 44 may form an initial rotation on a first rotation of the stick of material. Unexpectedly, upon rotation of the stick of material thereafter, the teeth 44 may continue to contact the stick of material with at least partial overlap to an existing perforation formed on the initial rotation of the stick of material. As a result, the perforations may be increased in length to be greater than a width (WT) of the teeth 44.

[0066] Based on the above, it is envisioned that a diameter of the knife 42 may be about 50 mm or more, about 65 mm or more, or about 80 mm or more. The diameter of the knife 42 may be about 110 mm or less, about 95 mm or less, or about 80 mm or less. For example, the knife may have a diameter of approximately 77 mm. However, it should be noted that any desired diameter may be implemented.

[0067] Similarly, a diameter of the stick of material and thus the resultant tubes may be about 25 mm or more, about 50 mm or more, or about 75 mm or more. The diameter of the stick of material may be about 150 mm or less, about 125 mm or less, or about 75 mm or less. For example, the stick of material may have a diameter of about 96 mm. However, it should be noted that any desired diameter may be implemented.

[0068] Additionally, the teeth 44 of the knife 42 may have a width (WT) of about 0.2 mm or more, about 0.4 mm or more, or about 0.6 mm or more. The width (WT) may be about 1 mm or less, about 0.8 mm or less, or about 0.6 mm or less. For example, the width (WT) may be about 0.5 mm for each tooth 44. Moreover, the seats 46 of the knife 42 may have a width (Ws) of about 1 mm or more, about 2 mm or more, or about 4 mm or more. The width (Ws) may be about 8 mm or less, about 6 mm or less, or about 4 mm or less. For example, the width (Ws) may be about 3.6 mm for each seat 46. However, it should be noted that any desired width for the teeth 44, any desired width for the seats 46, or both may be implemented. Similarly, the width of the teeth 44, the width of the seats 46, or both may be uniform or non- uniform.

[0069] FIG. 6 is a flowchart illustrating the manufacturing process described herein. As discussed above, a stick of material may be formed to create one or more tubes. Particularly, the stick of material may be spiral wound and adhered to itself to form the stick. Once a stick is formed, the stick is inserted onto a mandrel at station 1. Upon insertion, the mandrel - and thus the stick of material - is rotated or otherwise moved to station 2. At station 2, a cover may be applied to the stick of material either automatically or manually. Once applied, the mandrel is moved or rotated to station 3. At station 3, one or more of the following processes may be completed: pressing of the cover; cutting perforations; and cutting tubes to a desired final length. As discussed above, the pressing of the cover may include utilizing a roller to apply a force to the cover and ensure proper adhesion between the cover and the stick of material. Concurrently with the pressing, the stick of material may contact one or more knives, one or more blades, or both. A portion of the knives may form perforations in the stick of material (see FIGS 4 and 5). Similarly, another portion of knives and/or blades may cut the stick of material into desired tube lengths. After the processes of station 3 are completed, the mandrel may move to station 4. At station 4, the cut and perforated tubes may be removed from the mandrel - either automatically or manually - along with any scrap material formed thus far. Once the tubes have been removed, an operation may be completed to apply one or more end caps to the tubes, thereby forming the finalizing packaging.

[0070] ELEMENT LIST

[0071] 10 Machine

[0072] 12 Mandrel

[0073] 14 Cover

[0074] 16 Tube

[0075] 18 Cap

[0076] 20 Bond Line

[0077] 22 Perforation

[0078] 24 Stick

[0079] 30 First Station

[0080] 32 Second Station

[0081] 34 Third Station

[0082] 36 Fourth Station

[0083] 38 Roller

[0084] 40 Bar

[0085] 42 Knife

[0086] 44 Tooth

[0087] 46 Seat

[0088] WT Width of the Tooth

[0089] Ws Width of the Seat

[0090] M Direction of Rotation for the Stations

[0091] C Direction of Application of the Cover

[0092] R Direction of Rotation of the Roller

[0093] F Force of the Roller

[0094] S Direction of Rotation of the Stick

[0095] K Direction of Rotation of the Knife [0096] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0097] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0098] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of" to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. By use of the term “may” herein, it is intended that any described attributes that “may” be included are optional.

[0099] Unless otherwise stated, a teaching with the term “about” or “approximately” in combination with a numerical amount encompasses a teaching of the recited amount, as well as approximations of that recited amount. By way of example, a teaching of “about 100” encompasses a teaching of 100 +/- 15.

[00100] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps. [00101] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.