COLD SEAL PACKAGING ROLLERS

Abstract

Improved cold seal packaging rollers for packaging machines, as disclosed herein, may be configured to define a turned-up or bend along each edge portion of a packaging created by the packaging machine for avoiding jams of the packaging in automated packing systems. The improved cold seal packaging rollers may be incorporated directly into the cold seal packaging machine, replacing the standard rollers, or external to the machine to manipulate a completed packaging. The improved cold seal packaging rollers may comprise a first gear and a second gear, each having a circumferential toothed portion and a circumferential beveled portion. The circumferential beveled portion of the first gear may be angled inwardly toward a central axis as it moves away from the circumferential toothed portion. The circumferential beveled portion of the second gear may be angled outwardly away from a central axis as it moves away from the circumferential toothed portion.

Description

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND

The present disclosure relates generally to cold seal packaging machines. More particularly, the present disclosure pertains to improved rollers/gears for pressing packaging material layers together and/or curling/bending the packaging material layers.

Cold seal packaging may be accomplished through the use of a cold seal packaging machine. Cold seal packaging machines may be configured to receive an item for shipping, position the item between multiple layers of packaging material, and apply pressure to the edges of the multiple layers of packaging material. The pressure at the edges of the packaging material may couple together or otherwise seal said edges thus defining a sealed package. The sealed package may also be referred to herein as sealed packaging, cold seal packaging, or a cold seal package.

Cold seal packaging materials may comprise coated paper, plastic bubble wrap, or the like in order to provide an economical means of packaging and shipping products. Oftentimes, these packaging materials include a water-based cohesive coating that only requires pressure to form a seal. These materials are often “thin” and “rigid” and thus present a challenge in an operational environment as the materials can get caught and/or jammed in machinery, such as roller conveyors of automated packaging systems. Also, given the nature of the cold seal packaging process, the cold seal packaging often has an unintentional “curl” to it around an edge portion which can further exacerbate the tendency of the packaging to get caught within various processing equipment, such as roller conveyor or the like.

Accordingly, a need exists for improvements to cold seal packaging machines and associated equipment.

BRIEF SUMMARY

This Summary of the Disclosure is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

In an embodiment as disclosed herein, a packaging system for coupling at least a first and second layer of a plurality of layers of packaging material together, the packaging material configured to receive an item therebetween, may include: a first gear having a circumferential toothed portion and a circumferential beveled portion extending interiorly from the circumferential toothed portion; and a second gear having a circumferential toothed portion and a circumferential beveled portion extending exteriorly from the circumferential toothed portion, the circumferential toothed portion and the circumferential beveled portion of the second gear configured to mate with the circumferential toothed portion and the circumferential beveled portion of the first gear for coupling an edge portion of at least the first and second layers of the plurality of layers of packaging material together and further bending the edge portion at an angle matching that of the circumferential beveled portion of one of the first and second gears relative to an axis of the one of the first or second gears.

In an exemplary and optional aspect according to the above-referenced embodiment, the toothed portion of the first gear may include a first set of teeth and the toothed portion of the second gear includes a second set of teeth; each tooth of the first and second sets of teeth has a substantially flat distal end.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, each tooth of the first and second sets of teeth may taper down toward the substantially flat distal end.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, the toothed portion of the first gear may include a first set of teeth and the toothed portion of the second gear includes a second set of teeth, further wherein each tooth of the first and second sets of teeth is semi-circular in shape.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, each tooth of the first and second sets of teeth may have a radius in a range of from 0.2 inches to 0.5 inches.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, the toothed portion of the first gear may include a first set of recesses and the toothed portion of the second gear includes a second set of recesses, further wherein each recess of the first and second set of recesses is semi-circular in shape.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, each recess of the first and second sets of recesses may have a radius in a range of from 0.2 inches to 0.5 inches.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, the toothed portion of the first gear may include a first set of teeth and first set of recesses, wherein the toothed portion of the second gear includes a second set of teeth and a second set of recesses, and each tooth of the first and second sets of teeth are semi-circular in shape, each recess of the first and second sets of recesses are semi-circular in shape, and each tooth of the first and second sets of teeth and each recess of the first and second sets of recesses has a common radius.

In another exemplary aspect according to the above-referenced embodiment and optional aspects thereof, a distal edge of the circumferential beveled portion of the first gear may have a radius that is smaller than a radius of the circumferential toothed portion of the first gear, further wherein a distal edge of the circumferential beveled portion of the second gear has a radius that is larger than the circumferential toothed portion of the second gear.

In a second exemplary embodiment as disclosed herein, a packaging system is provided for coupling at least a first and second layer of a plurality of layers of packaging material together, the packaging material configured to receive an item therebetween. The packaging system includes: a first gear having a plurality of teeth extending radially therefrom, the plurality of teeth disposed between a first edge and second edge of the first gear, a radius of the first gear being larger at the first edge than at the second edge; a second gear having a plurality of teeth extending radially therefore, the plurality of teeth disposed between a first edge and second edge of the second gear, a radius of the second gear being smaller at the first edge than at the second edge; wherein the plurality of teeth of the first gear are configured to mate with the plurality of teeth of the second gear for coupling an edge portion of at least the first and second layers of the plurality of layers of packaging material together.

In an exemplary and optional aspect according to the above-referenced second embodiment, each tooth of the plurality of teeth of the first and second gears may have a substantially flat distal end.

In another exemplary aspect according to the above-referenced second embodiment and optional aspects thereof, each tooth of the plurality of teeth of the first and second gears may taper down toward the substantially flat distal end.

In another exemplary aspect according to the above-referenced second embodiment and optional aspects thereof, each tooth of the plurality of teeth of the first and second gears may be semi-circular in shape.

In another exemplary aspect according to the above-referenced second embodiment and optional aspects thereof, the first gear may include a plurality of recesses, each recess of the plurality of recesses disposed between each of the plurality of teeth of the first gear, and the second gear may include a plurality of recesses, each recess of the plurality of recesses disposed between each of the plurality of teeth of the second gear, wherein each recess of the plurality of recesses of the first and second gears is semi-circular in shape.

In a third exemplary embodiment as disclosed herein, a packaging system is provided for coupling at least a first and second layer of a plurality of layers of packaging material together, the packaging material configured to receive an item therebetween, the packaging system including: at least one pair of gears having a plurality of radial protrusions and a plurality of radial indentations disposed between each of the plurality of radial protrusions, the at least one pair of gears being configured to mesh together, the at least one pair of gears being configured to apply pressure to at least an edge portion of the at least first and second layers of the plurality of layers of packaging material for coupling the at least first and second layers of packaging material together, defining a wavy profile along the edge portion of the first and second layers of packaging material, and advancing the at least first and second layers of packaging material therethrough.

In an exemplary and optional aspect according to the above-referenced second embodiment, each radial protrusion of the plurality of radial protrusions of the at least one pair of gears may be semi-circular in shape.

In another exemplary aspect according to the above-referenced third embodiment and optional aspects thereof, each radial protrusion of the plurality of radial protrusions of the at least one pair of gears may have a radius in a range of from 0.2 inches to 0.5 inches.

In another exemplary aspect according to the above-referenced third embodiment and optional aspects thereof, each radial indentation of the plurality of radial indentations of the at least one pair of gears may be semi-circular in shape.

In another exemplary aspect according to the above-referenced third embodiment and optional aspects thereof, each radial indentation of the plurality of radial indentations of the at least one pair of gears may have a radius in a range of from 0.2 inches to 0.5 inches.

Numerous objects, features and advantages of a system and/or apparatus as disclosed herein will be readily apparent to those skilled in the art upon a review of the following description in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary embodiment of a packaging system in accordance with the present disclosure.

FIG. 2 is a perspective view of an exemplary embodiment of a first gear and a second gear of the packaging system of FIG. 1.

FIG. 3 is a perspective view of the second gear of the packaging system of FIG. 1.

FIG. 4 is a side elevation view of the second gear of the packaging system of FIG. 1.

FIG. 5 is a perspective view of the first gear of the packaging system of FIG. 1.

FIG. 6 is a side elevation view of the first gear of the packaging system of FIG. 1.

FIG. 7 is a side elevation view of the first gear and the second gear of the packaging system of FIG. 1.

FIG. 8 is a perspective view of a sealed edge portion of packaging material of the packaging system of FIG. 1.

FIG. 9 is a perspective view of an exemplary embodiment of a first gear and a second gear of the packaging system of FIG. 1.

FIG. 10 is a side elevation view of the first gear and the second gear of the packaging system of FIG. 1.

FIG. 11 is a perspective view of a sealed edge portion of packaging material of the packaging system of FIG. 1.

FIG. 12 is a perspective view of an exemplary embodiment of a first gear and a second gear of the packaging system of FIG. 1.

FIG. 13 is a front elevation view of the first gear and the second gear of the packaging system of FIG. 1.

FIG. 14 is a front elevation view of the first gear and the second gear of the packaging system of FIG. 1 wherein packaging material is being sealed by the first and second gears.

FIG. 15 is a perspective view of a sealed edge portion of packaging material of the packaging system of FIG. 1.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present disclosure, one or more drawings of which are set forth herein. Each drawing is provided by way of explanation of the present disclosure and is not a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the teachings of the present disclosure without departing from the scope of the disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment.

Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present disclosure are disclosed in, or are obvious from, the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

The words “connected”, “attached”, “joined”, “mounted”, “fastened”, and the like should be interpreted to mean any manner of joining two objects including, but not limited to, the use of any fasteners such as screws, nuts and bolts, bolts, pin and clevis, and the like allowing for a stationary, translatable, or pivotable relationship; welding of any kind such as traditional MIG welding, TIG welding, friction welding, brazing, soldering, ultrasonic welding, torch welding, inductive welding, and the like; using any resin, glue, epoxy, and the like; being integrally formed as a single part together; any mechanical fit such as a friction fit, interference fit, slidable fit, rotatable fit, pivotable fit, and the like; any combination thereof; and the like.

Unless specifically stated otherwise, any part of the apparatus of the present disclosure may be made of any appropriate or suitable material including, but not limited to, metal, alloy, polymer, polymer mixture, wood, composite, or any combination thereof.

To the extent that the term “includes” or “including” is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent the term “connect” is used in the specification or claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to” such as connected through another component or multiple components.

Referring now to the figures, and specifically FIG. 1, a packaging system is schematically shown and generally designated as number 100. The packaging system 100 may be associated with a plurality of layers of packaging material 110 and one or more items to be shipped 120. It may be desirable to form a sealed package 130 from the plurality of layers of packaging material 110 to surround the one or more items to be shipped 120. The packaging system 100 may be configured to couple at least a first layer 110A and a second layer 110B of the plurality of layers of packaging material 110 together wherein the one or more items to be shipped 120 is received between the first and second layers 110A, 110B of the sealed package 130.

The packaging system 100 may include a packaging machine. The packaging machine may exist in a variety of embodiments. In certain optional embodiments wherein the packaging machine is automated, the packaging machine may include a chassis configured to receive the one or more items to be shipped 120 and the plurality of layers of packaging material 110. The automated packaging machine may automatically couple the first and second layers 110A, 110B of the plurality of layers of packaging material 110 together with the one or more items to be shipped 120 disposed therebetween. The automated packaging machine may move the one or more items to be shipped 120 in the resulting sealed package 130 through the automated packaging machine without human intervention.

In other optional embodiments, the packaging machine may rely at least in part on human intervention. In one such exemplary packaging machine, a human operator may feed portions of the first and second layers 110A, 110B of the plurality of layers of packaging material 110 into the packaging machine such that the first and second layers 110A, 110B may be coupled together. The human operator may also, or in the alternative, feed the one or more items to be shipped 120 into the packaging machine.

The packaging system 100 and/or the packaging machine may be associated with and/or form a portion of a shipping process. Various conveyor belts and other machinery may be associated with the shipping process and configured to move the plurality of layers of packaging material 110, one or more items to be shipped 120, and/or the sealed package 130 in association with the shipping process.

Referring now to FIGS. 2-8, the packaging system 100, and in certain optional embodiments the packaging machine, may include a first gear 220 and a second gear 240. The first and second gears 220, 240 may be configured to mesh together and manipulate an edge portion 112 of the first and second layers of packaging material 110A, 110B. More specifically, the first and second gears 220, 240 may be configured to couple the edge portions 112 of the first and second layers of packaging material 110A, 110B together. In certain optional embodiments, the first and second gears 220, 240 may be configured to bend and/or crease the edge portion 112 of the first and second layers of packaging material 110A, 110B at an angle 114 relative to a remainder of first and second layers of packaging material 110A, 110B, thus defining a turned-up edge 116 of the first and second layers of packaging material 110A, 110B. The turned-up edge 116 may prevent the sealed package 130 from becoming caught or jammed as it moves through the shipping process (e.g., along conveyors or the like). The angle 114 may be in a range of from 2 degrees to 45 degrees, preferably from 4 degrees to 30 degrees, and most preferably from 6 degrees to 20 degrees. The first and second layers of packaging material 110A, 110B are shown sealed in FIG. 8.

In certain optional embodiments, the first gear 220 may include a circumferential toothed portion 222 and a circumferential beveled portion 224 extending interiorly from the circumferential toothed portion 222. More specifically, the circumferential beveled portion 224 at a distal edge 225 may have a radius generally smaller than the circumferential toothed portion 222 and may be angled toward a central axis 226 (shown in FIG. 6) of the first gear 220 as it extends away from the circumferential toothed portion 222. The circumferential toothed portion 222 may include a plurality of teeth 228 oriented and elongated parallel to the central axis 226. The plurality of teeth 228 of the first gear 220 may also be referred to herein as a first set of teeth 228 or a plurality of radial protrusions 228. The circumferential toothed portion 222 may also include a plurality of recesses 230 oriented and elongated parallel to the central axis 226. The plurality of recesses 230 of the first gear 220 may also be referred to herein as a first set of recesses 230 or a plurality of radial indentations 230. Each recess of the plurality of recesses 230 may be disposed between a pair of teeth of the plurality of teeth 228.

In certain optional embodiments, the second gear 240 may include a circumferential toothed portion 242 and a circumferential beveled portion 244 extending exteriorly from the circumferential toothed portion 242. More specifically, the circumferential beveled portion 244 at a distal edge 245 may have a radius generally larger than the circumferential toothed portion 242 and may be angled away from a central axis 246 (shown in FIG. 4) of the second gear 240 as it extends away from the circumferential toothed portion 242. The circumferential toothed portion 242 may include a plurality of teeth 248 oriented and elongated parallel to the central axis 246. The plurality of teeth 248 of the second gear 240 may also be referred to herein as a second set of teeth 248 or a plurality of radial protrusions 248. The circumferential toothed portion 242 may also include a plurality of recesses 250 oriented and elongated parallel to the central axis 246. The plurality of recesses 250 of the second gear 240 may also be referred to herein as a second set of recesses 250 or a plurality of radial indentations 250. Each recess of the plurality of recesses 250 may be disposed between a pair of teeth of the plurality of teeth 248.

In certain optional embodiments, each tooth of the plurality of teeth 228, 248 may taper down radially toward a substantially flat distal end. In other optional embodiments, each tooth of plurality of teeth 228, 248 may be rounded. More specifically, each tooth of plurality of teeth 228, 248 may be semi-circular in shape. Each tooth of plurality of teeth 228, 248 may have a radius in a range of from 0.2 inches to 0.5 inches, preferably from 0.25 inches to 0.37 inches, and most preferably about 0.32 inches. In certain optional embodiments, each recess of the plurality of recesses 230, 250 may be rounded. More specifically, each recess of the plurality of recesses 230, 250 may be semi-circular in shape. Each recess of the plurality of recesses 230, 250 may have a radius in a range of from 0.2 inches to 0.5 inches, preferably from 0.25 inches to 0.37 inches, and most preferably about 0.32 inches.

In certain optional embodiments, the shape of the plurality of recesses 230, 250 of the first gear 220 and second gear 240 may match or substantially match the shape of the plurality of teeth 228, 248 of the first gear 220 and second gear 240, respectively. The radius of the plurality of recesses 230, 250 of the first gear 220 and second gear 240 may match or substantially match the radius of the plurality of recesses 230, 250 of the first gear 220 and second gear 240, respectively.

The circumferential toothed portion 222 and the circumferential beveled portion 224 of the first gear 220 may be configured to mate with the circumferential toothed portion 242 and the circumferential beveled portion 244 of the second gear 240, respectively, for at least coupling and/or bending the edge portion 112 of the first and second layers of packaging material 110A, 110B together. The angle 114 of the edge portion 112, once passed through the first and second gears 220, 240, may match or substantially match an angle of the circumferential beveled portions 224, 244 relative to the respective central axis 226, 246 of each of the first and second gears 220, 240.

In certain optional embodiments, one or more of the first or second gears 220, 240 may include a scoring wheel positioned between the circumferential toothed portion 222, 242 and the circumferential beveled portion 224, 244. Alternatively, the scoring wheel may be a scoring gear or guillotine style actuator associated with the first gear 220 and/or second gear 240. The scoring wheel may be configured to add a crease line adjacent to and along an edge of the turned-up edge 116 of the sealed package 130.

Referring to FIGS. 9-11, in certain optional embodiments, the packaging system 100 may include first and second gears 320, 340. The first and second gears 320, 340 may in various embodiments be substantially identical. When the first gear 320 is coupled with the second gear 340, the first and second gears 320, 340 may in various embodiments be configured to perform substantially all of the same functions as first and second gears 220, 240, as discussed above.

The first gear 320 may include circumferential toothed beveled portion 322. The circumferential toothed beveled portion 322 may include a plurality of angled protrusions 324 and a plurality of angled indentations 326 angled relative to a central axis 328 of the first gear 320. The plurality of angled protrusions 324 may be referred to herein as a plurality of teeth 324 or a first set of teeth 324. The plurality of angled indentations 326 may be referred to herein as a plurality of recesses 326 or a first set of recesses 326. The plurality of angled protrusions 324 and the plurality of angled indentations 326 may be disposed between a first edge 330 and a second edge 332 of the first gear 320. A radius of the first gear 320 may be larger at the first edge 330 than at the second edge 332.

The second gear 340 may include circumferential toothed beveled portion 342. The circumferential toothed beveled portion 342 may include a plurality of angled protrusions 344 and a plurality of angled indentations 346 angled relative to a central axis 348 of the second gear 340. The plurality of angled protrusions 344 may be referred to herein as a plurality of teeth 344 or a second set of teeth 344. The plurality of angled indentations 346 may be referred to herein as a plurality of recesses 346 or a second set of recesses 346. The plurality of angled protrusions 344 and the plurality of angled indentations 346 may be disposed between a first edge 350 and a second edge 352 of the second gear 340. A radius of the second gear 340 may be smaller at the first edge 350 than at the second edge 352.

The circumferential toothed beveled portion 322 of the first gear 320 may be configured to mate with the circumferential toothed beveled portion 342 of the second gear 340 for at least coupling and/or bending the edge portion 112 of the first and second layers of packaging material 110A, 110B together. The angle 114 of the edge portion 112, once passed through the first and second gears 320, 340, may match or substantially match an angle of the circumferential toothed beveled portion 324, 344 relative to the respective central axis 328, 348 of each of the first and second gears 320, 340. The first and second layers of packaging material 110A, 110B are shown sealed in FIG. 11.

In certain optional embodiments, each tooth of the plurality of teeth 324, 344 may taper down radially toward a substantially flat distal end. In other optional embodiments, each tooth of the plurality of teeth 324, 344 may be rounded. More specifically, each tooth of the plurality of teeth 324, 344 may be semi-circular in shape. Each tooth of the plurality of teeth 324, 344 may have a radius in a range of from 0.2 inches to 0.5 inches, preferably from 0.25 inches to 0.37 inches, and most preferably about 0.32 inches. In certain optional embodiments, each recess of the plurality of recesses 326, 346 may be rounded. More specifically, each recess of the plurality of recesses 326, 346 may be semi-circular in shape. Each recess of the plurality of recesses 326, 346 may have a radius in a range of from 0.2 inches to 0.5 inches, preferably from 0.25 inches to 0.37 inches, and most preferably about 0.32 inches.

In certain optional embodiments, the shape of the plurality of recesses 326, 346 of the first gear 320 and second gear 340 may match or substantially match the shape of the plurality of teeth 324, 344 of the first gear 320 and second gear 340, respectively. The radius of the plurality of recesses 326, 346 of the first gear 320 and second gear 340 may match or substantially match the radius of the plurality of recesses 326, 346 of the first gear 320 and second gear 340, respectively.

Referring now to FIGS. 12-15, in certain optional embodiments, the packaging system 100 may include at least one pair of gears 400. The at least one pair of gears 400 may be configured to apply pressure to at least one edge of the at least first and second layers of packaging material 110A, 110B for coupling the at least first and second layers of packaging material 110A, 110B together. The at least one pair of gears 400 may include a first gear 400A and a second gear 400B. The first and second gears 400A, 400B may be substantially similar. The at least one pair of gears 400 may be configured to define a wavy profile 118, as shown in FIGS. 14-15, along the at least the edge portion 112 of a sealed package 130. The wavy profile 118 may help prevent the sealed package 130 made from the first and second layers of packaging material 110A, 110B from becoming caught or jammed as it moves through the shipping process (e.g., along conveyors or the like). Finally, the at least one pair of gears 400 may further be configured to advance the first and second layers of packaging material 110A, 110B, the one or more items to be shipped 120, and/or the sealed package 130 therethrough.

In certain optional embodiments, each gear of the at least one pair of gears 400 may be substantially identical. Each gear of the at least one pair of gears 400 may include a plurality of radial protrusions 410 and a plurality of radial indentations 412 disposed between each of the plurality of radial protrusions 410. The plurality of radial protrusions 410 may be referred to herein as a plurality of teeth 410 or a set of teeth 410. The plurality of radial indentations 412 may be referred to herein as a plurality of recesses 412 or a set of recesses 412. The at least one pair of gears 400 may be configured to mesh together, for example, such that radial protrusions 410 of one gear are received by the radial indentations 412 of the other, and vice versa, as the at least one pair of gears 400 rotate.

Each of the pluralities of radial protrusions and indentations 410, 412 may be rounded. More specifically, each of the pluralities of radial protrusions and indentations 410, 412 may be semi-circular. One exemplary embodiment of this soft, or rounded, shape may be that it enables the pluralities of radial protrusions and indentations 410, 412 of the at least one pair of gears 400 when meshed together to manipulate the first and second layers of packaging material 110A, 110B without ripping or tearing the material.

In certain optional embodiments, each of the pluralities of radial protrusions and indentations 410, 412 may have a common radius being from 0.2 inches to 0.5 inches, preferably from 0.25 inches to 0.37 inches, and most preferably about 0.32 inches.

Thus, it is seen that the apparatus and methods of the present disclosure readily achieve the ends and advantages mentioned as well as those inherent therein. While certain preferred embodiments of the disclosure have been illustrated and described for present purposes, numerous changes in the arrangement and construction of parts and steps may be made by those skilled in the art, which changes are encompassed within the scope and spirit of the present disclosure as defined by the appended claims. Each disclosed feature or embodiment may be combined with any of the other disclosed features or embodiments.

Claims

1. A packaging system for coupling at least a first and second layer of a plurality of layers of packaging material together, the packaging material configured to receive an item therebetween, the packaging system comprising: a first gear having a circumferential toothed portion and a circumferential beveled portion extending interiorly from the circumferential toothed portion; anda second gear having a circumferential toothed portion and a circumferential beveled portion extending exteriorly from the circumferential toothed portion, the circumferential toothed portion and the circumferential beveled portion of the second gear configured to mate with the circumferential toothed portion and the circumferential beveled portion of the first gear for coupling an edge portion of at least the first and second layers of the plurality of layers of packaging material together and further bending the edge portion at an angle matching that of the circumferential beveled portion of one of the first and second gears relative to an axis of the one of the first or second gears.

2. The packaging system of claim 1, wherein: the toothed portion of the first gear includes a first set of teeth and the toothed portion of the second gear includes a second set of teeth;each tooth of the first and second sets of teeth has a substantially flat distal end.

3. The packaging system of claim 2, wherein: each tooth of the first and second sets of teeth tapers down toward the substantially flat distal end.

4. The packaging system of claim 1, wherein: the toothed portion of the first gear includes a first set of teeth and the toothed portion of the second gear includes a second set of teeth;each tooth of the first and second sets of teeth is semi-circular in shape.

5. The packaging system of claim 4, wherein: each tooth of the first and second sets of teeth has a radius in a range of from 0.2 inches to 0.5 inches.

6. The packaging system of claim 4, wherein: the toothed portion of the first gear includes a first set of recesses and the toothed portion of the second gear includes a second set of recesses;each recess of the first and second set of recesses is semi-circular in shape.

7. The packaging system of claim 6, wherein: each recess of the first and second sets of recesses has a radius in a range of from 0.2 inches to 0.5 inches.

8. The packaging system of claim 1, wherein: the toothed portion of the first gear includes a first set of teeth and first set of recesses;the toothed portion of the second gear includes a second set of teeth and a second set of recesses; andeach tooth of the first and second sets of teeth are semi-circular in shape, each recess of the first and second sets of recesses are semi-circular in shape, and each tooth of the first and second sets of teeth and each recess of the first and second sets of recesses has a common radius.

9. The packaging system of claim 1, wherein: a distal edge of the circumferential beveled portion of the first gear has a radius that is smaller than a radius of the circumferential toothed portion of the first gear; anda distal edge of the circumferential beveled portion of the second gear has a radius that is larger than the circumferential toothed portion of the second gear.

10. A packaging system for coupling at least a first and second layer of a plurality of layers of packaging material together, the packaging material configured to receive an item therebetween, the packaging system comprising: a first gear having a plurality of teeth extending radially therefrom, the plurality of teeth disposed between a first edge and second edge of the first gear, a radius of the first gear being larger at the first edge than at the second edge;a second gear having a plurality of teeth extending radially therefore, the plurality of teeth disposed between a first edge and second edge of the second gear, a radius of the second gear being smaller at the first edge than at the second edge;wherein the plurality of teeth of the first gear are configured to mate with the plurality of teeth of the second gear for coupling an edge portion of at least the first and second layers of the plurality of layers of packaging material together.

11. The packaging system of claim 10, wherein: each tooth of the plurality of teeth of the first and second gears has a substantially flat distal end.

12. The packaging system of claim 11, wherein: each tooth of the plurality of teeth of the first and second gears tapers down toward the substantially flat distal end.

13. The packaging system of claim 10, wherein: each tooth of the plurality of teeth of the first and second gears is semi-circular in shape.

14. The packaging system of claim 10, wherein: the first gear includes a plurality of recesses, each recess of the plurality of recesses disposed between each of the plurality of teeth of the first gear;the second gear includes a plurality of recesses, each recess of the plurality of recesses disposed between each of the plurality of teeth of the second gear;each recess of the plurality of recesses of the first and second gears is semi-circular in shape.

15-19. (canceled)