US20140083889A1 - Packaging of personal articles by banding bundles - Google Patents

Abstract

Diaper packaging having a reduced manufacturing cost may be created by bagging stacks of diapers and bundling the bags. Bands may be applied circumscribing the bundled bags of diapers. One band may be applied along a first direction perpendicular with the length of the stacked diapers. A second band may applied in a second direction parallel with the length of the stacked diapers. The bags of diapers may include several stacks of diapers, and the bundles may include several bags of diapers. For certain bundle configurations of packaged diapers, additional bands may be placed circumscribing the bundles for improved stability. Packaging by banding bundles of diapers may also be used to package other personal care articles and absorbent articles.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims the benefit of U.S. Provisional Patent Application No. 61/410,680 to Russell Ables entitled “Packaging of Personal Articles by Banding Bundles” and filed on Nov. 5, 2010, which is hereby incorporated by reference.
TECHNICAL FIELD
• The present disclosure generally relates to packaging of personal articles.
BACKGROUND
• Diapers and other personal care articles are conventionally packaged in boxes for sale in retail stores. A conventional packaging of diapers is illustrated inFIG. 1. Aretail box110 stores a number of stackeddiapers112. Theretail box110 may be a conventional cardboard box with color advertising printed on the surfaces of the box facing away from the diapers. The cost of packaging the diapers in the box represents a large percentage of the entire cost of the box of diapers and reduces the profit per diaper for a manufacturer, increases costs for the consumer, and results in unnecessary waste from discarded packaging material. The cost of the articles being packaged for retail is low enough that the cost of the retail box materials and handling is a large fraction of the final sales price of the packaged articles.
• Additionally, when packaging thediapers112 in thebox110, thebox110 may be a larger size than the minimum size necessary to fit thediapers112. That is, the total volume occupied by thediapers112 in thebox110 is smaller than the volume of thebox110. The additional volume in thebox110 ensures that thebox110 will fit the correct number ofdiapers112 with some margin for error and handling. However, the additional volume in thebox110 reduces the number of boxes fitting on pallets for shipping. Thus, the unused volume of thebox110 increases the shipping and handling costs for thediapers112.
• Thus, there is a need for cheaper packaging of diapers and a need for more efficient packaging of the diapers to address same or all of the aforementioned problems.
SUMMARY
• Accordingly, it is an object of the present disclosure to package diapers using a lower cost method.
• Another object of the present disclosure is to package diapers more efficiently and decrease shipping and handling costs for the diapers.
• Yet another object of the present disclosure is to provide a packaged bundle of diapers at a lower cost than conventional boxed diapers.
• A further object of the present disclosure is to minimize use of packaging materials for environmental reasons.
• Hence, in order to achieve these objects and others and in accordance with one aspect of the present disclosure, there is provided a method of packaging diapers. The method includes the steps of forming at least one stack of diapers, placing the at least one diaper stack in a diaper bag, bundling the diaper bag with at least one other diaper bag to form a diaper bundle, applying at least one band in a first direction of the diaper bundle, and applying at least one band in a second direction of the diaper bundle.
• In some embodiments of the disclosure: applying the at least one band in the second direction may include applying the at least one band in a direction parallel to a length of a diaper in the at least one stack of diapers; placing the at least one diaper stack in the diaper bag may include placing two diaper stacks in the diaper bag; applying the at least one band in the cross direction may include applying two bands in the first direction; and/or bundling the diaper bag with at least one other diaper bag may include bundling the diaper bag with at least three other diaper bags. Additionally, in certain embodiments, the band in the first direction may have a width between approximately 30 millimeters and approximately 70 millimeters with a tension between approximately 10 grams and approximately 7500 grams. Further, in certain embodiments, the band in the second direction comprises applying a tension between approximately 10 grams and approximately 5000 grams.
• In accordance with another aspect of the present disclosure, there is provided a method of packaging diapers. The method includes the steps of forming at least one stack of articles, placing the at least one article stack in an article bag, bundling the article bag with at least one other article bag to form an article bundle, applying at least one band in a first direction of the article bundle, and applying at least one band in a second direction of the article bundle. In accordance with a further aspect of the present disclosure, there is provided an absorbent article bundle. The bundle includes at least two bags. Each bag includes more than one absorbent article. The bundle also includes at least two bands orthogonally positioned relative to one another and encircling the bags.
• In some embodiments of the disclosure: the bundle may include a second band circumscribing the at least two bags, in which the second band is oriented substantially orthogonal to the first band; the first band may have a tension between approximately 10 grams and approximately 7500 grams; the second band may have a tension approximately 10 grams and approximately 5000 grams; each bag may also include a second stack of absorbent articles, in which the first band is substantially aligned with the first stack; the bundle may include a third band substantially aligned with the second stack, in which the second band is substantially orthogonal to the third band; and/or the absorbent article may be a diaper and the absorbent article bundle may be a diaper bundle.
• The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter that form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily used as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure as set forth in the appended claims. The novel features that are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
• For a more complete understanding of the present disclosure, reference is now made to the following descriptions taken in conjunction with the accompanying drawings.
• FIG. 1 is an illustration of conventional packaging for diapers.
• FIG. 2 is an illustration of an exemplary packaging of bundled single push bags according to one embodiment of the disclosure.
• FIG. 3 is an illustration of an exemplary packaging of bundled double push bags according to one embodiment of the disclosure.
• FIG. 4 is an illustration of an exemplary packaging of bundled double push bags according to another embodiment of the disclosure.
• FIG. 5 is a flow chart illustrating a method of packaging bundles of diapers according to one embodiment of the disclosure.
DETAILED DESCRIPTION
• Diapers and other personal care articles may be packaged at a lower cost and in a smaller volume of space by bagging stacks of diapers (or other articles), bundling the bags, and packaging the bundles. Bands may be applied around the bundles for shipping and/or retail sale. Eliminating the use of the box for packaging reduces the cost of packaging due to the box and reduces the total volume occupied by the packaged diapers, which reduces the shipping and handling costs associated with sale of the diapers. The diapers may be packaged by stacking diapers, bagging the stacks, and bundling the bags as described in more detail below with reference toFIGS. 2-5.
• FIG. 2 is an illustration of an exemplary packaging of bundled single push bags according to one embodiment of the disclosure. It should be understood that althoughFIG. 2 refers to diapers, the method of packaging can be applied to other articles and the application to other articles is within the scope of the present disclosure. A stack of diapers212 may be placed in abag214. Thebag214 may be a wrapping, such as paper or plastic, enclosing the diapers212. Thebag214 may be stacked withother bags216 and218 to create abundle222. Thebundle222 may be packaged withbands232 and234. Thebundle222 may be an assembly of bags grouped together by at least one ofband232 andband234. Thebands232 and234 may be securing mechanisms such as, for example, rope, twine, tape, or plastic wrap that extend around a bundle to group thebags214,216, and218 of thebundle222. Theband232 may be applied to thebundle222 in a first direction substantially perpendicular to the length of the diapers212. Theband234 may be applied to thebundle222 in a second direction, which may be substantially parallel with the length of the diapers212 and substantially perpendicular to theband232. Although only threebags214,216, and218 are illustrated, more or less bags may be included in thebundle222.
• Thebands232 and234 may be, for example, brown paper, white paper, and/or clear polymer film. Thebands232 and234 may be different materials or the same material. For example, theband232 may be white paper with printed advertisements, and theband234 may be a clear polymer film. Theband232 may have a width between approximately 30 millimeters and 70 millimeters and be the same or a different width as theband234. According to one embodiment, the tension of theband232 in the first direction may be between approximately 10 grams and 7500 grams. According to one embodiment, the tension of theband234 in the second direction may be between approximately 10 grams and 5000 grams. Theband232 may be applied to thebundle222 before theband234.
• Bags may include more than one stack of diapers as described with reference toFIG. 3. It should be understood that althoughFIG. 3 refers to diapers, the method of packaging can be applied to other articles and the application to other articles and the application to other articles is within the scope of the present disclosure.FIG. 3 is an illustration of an exemplary packaging of bundled double push bags according to one embodiment of the disclosure. A stack of diapers310 and a stack ofdiapers312 may be placed in abag314. Thebag314 may be stacked substantially vertically with anotherbag316 in abundle322.Bands332 and334 may circumscribe thebundle322 in substantially perpendicular directions. Again, more or less bags of diapers may be included in thebundle322. If more bags are added to thebundle322, additional bands may be placed around thebundle322 to improve stability of the packaging as described with reference toFIG. 4.
• FIG. 4 is an illustration of an exemplary packaging of bundled double push bags according to another embodiment of the disclosure. It should be understood that althoughFIG. 4 refers to diapers, the method of packaging can be applied to other articles and the application to other articles is within the scope of the present disclosure. A stack of diapers410 and a stack of diapers412 may be placed in abag414. Thebag414 may be vertically stacked withother bags416,418,420 in abundle422. Thebundle422 may be packaged with packaging means such asbands432,434, and436. Thebands432 and436 may circumscribe thebundle422 in a cross direction. Theband432 may be placed to run along the first stack of diapers410, and theband434 may be placed to run along the second stack of diapers412. If additional stacks of diapers (not shown) are placed in thebags414,416,418, and420, additional bands (not shown) may be circumscribed around thebundle422 and substantially aligned with the additional stacks of diapers. For example, if thebags414,416,418, and420 included a third stack of diapers, a third band may circumscribe thebundle422 and placed to run along the third stack of diapers.
• FIG. 5 is a flow chart illustrating a method of packaging bundles of diapers according to one embodiment of the disclosure. It should be understood that althoughFIG. 5 refers to diapers, the method of packaging can be applied to other articles and the application to other articles is within the scope of the present disclosure. Amethod500 describes a method of packaging a bundle of diaper bags. Themethod500 begins atblock510 with forming at least one stack of diapers. Atblock512, the stack of diapers is placed in a bag. Atblock514, a determination is made for bagging additional stacks. If additional bags are to be placed in the bundle, themethod500 returns to block510 to form additional stack(s) of diapers, and themethod500 then continues to block512 to place the additional stack(s) of diapers in an additional bag. According to the embodiment described inFIG. 3, theblocks510,512, and514 may be repeated three times to form three bags for bundling or more times for more bags for bundling.
• After a desired number of bags are formed, themethod500 continues to block516 to bundle the bags of diapers. For example, the bags of diapers may be stacked substantially vertically (e.g., a 2×1 stack of bags or a 3×1 stack of bags). In another example, the bags of diapers may be stacked next to each other horizontally and stacked vertically (e.g., a 2×2 stack of bags or a 3×2 stack of bags). Themethod500 continues to block518 to apply at least one band in a first direction, which may be substantially perpendicular to the length of the diapers in the stack(s) of diapers. Atblock520, at least one band is applied in a second direction, which may be substantially parallel to the length of the diapers in the stack(s) of diapers. Although the first direction band is shown inFIG. 5 applied before the second direction band, the second direction band may be applied before the first direction band.
• Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. For example, although packaging of diapers is described above, the packaging method may be applied to the packaging of other personal articles. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods, and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims (20)

What is claimed is:

1. A method of packaging diapers, comprising:

forming at least one stack of diapers;

placing the at least one diaper stack in a diaper bag;

bundling the diaper bag with at least one other diaper bag to form a diaper bundle;

applying at least one band to the diaper bundle in a first direction; and

applying at least one band to the diaper bundle in a second direction.

2. The method ofclaim 1, in which the step of applying the at least one band in the second direction comprises applying the at least one band in a direction parallel to a length of a diaper in the at least one stack of diapers.

3. The method ofclaim 1, in which the step of placing the at least one diaper stack in the diaper bag comprises placing two diaper stacks in the diaper bag, and in which the step of applying the at least one band in the cross direction comprises applying two bands in the first direction.

4. The method ofclaim 1, in which bundling the diaper bag with at least one other diaper bag comprises bundling the diaper bag with at least three other diaper bags.

5. The method ofclaim 1, in which the at least one band in the first direction of the diaper bundle has a width between approximately 30 millimeters and approximately 70 millimeters.

6. The method ofclaim 1, in which the step of applying the at least one band in the first direction comprises applying a tension between approximately 10 grams and approximately 7500 grams.

7. The method ofclaim 1, in which the step of applying the at least one band in the second direction comprises applying a tension between approximately 10 grams and approximately 5000 grams.

8. A method of packaging absorbent articles, comprising:

forming at least one stack of articles;

placing the at least one article stack in an article bag;

bundling the article bag with at least one other article bag to form an article bundle; and

applying at least one band to the article bundle in a first direction.

9. The method ofclaim 8, further comprising applying at least one band to the article bundle in a second direction.

10. The method ofclaim 9, in which the step of applying the at least one band in the second direction comprises applying the at least one band in a direction parallel to a length of an article in the at least one article stack.

11. The method ofclaim 9, in which the step of applying the at least one band in the second direction comprises applying a tension between approximately 10 grams and approximately 5000 grams.

12. The method ofclaim 8, in which the at least one band in the first direction of the diaper bundle has a width between approximately 30 millimeters and approximately 70 millimeters.

13. The method ofclaim 8, in which the step of applying the at least one band in the first direction comprises applying a tension between approximately 10 grams and approximately 7500 grams.

14. An absorbent article bundle, comprising:

at least two bags, each bag comprising a first stack of more than one absorbent article; and

a first band circumscribing the at least two bags.

15. The absorbent article bundle ofclaim 14, further comprising a second band circumscribing the at least two bags, the second band oriented substantially orthogonal to the first band.

16. The absorbent article bundle ofclaim 15, in which the first band has a tension between approximately 10 grams and approximately 7500 grams, and the second band has a tension approximately 10 grams and approximately 5000 grams.

17. The absorbent article bundle ofclaim 14, in which each bag further comprises a second stack of absorbent articles.

18. The absorbent article bundle ofclaim 17, in which the first band is substantially aligned with the first stack of absorbent articles.

19. The absorbent article bundle ofclaim 18, further comprising a third band substantially aligned with the second stack of absorbent articles, in which the second band is oriented substantially orthogonal to the third band.

20. The absorbent article bundle ofclaim 14, in which the absorbent article is a diaper and the absorbent article bundle is a diaper bundle.

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