Patent Application
20240375824
The present disclosure relates generally to packaging, such as envelopes, for holding items during, for example, shipping.
The use of shipping envelopes formed from paper has been growing in popularity in relation to poly bags, i.e., bags made of plastics such as polyethylene and polystyrene, due to the recyclability of paper. Poly bags typically are sealed closed after being loaded, by a heat seal formed by heating portions of opposing walls of the bag so that the wall portions fuse together. Sealing a paper envelope, by contrast, typically requires a separate bonding element in the form of an adhesive material deposited on one or both of the interior surfaces of the opposing walls.
In some applications, individual envelopes may be formed from a pre-formed web using automated equipment that also seals the envelope and separates the sealed envelope from the rest of the web after the envelope has been loaded. In such applications, the length of the envelope, i.e., the dimension of the envelope in the direction in which the envelope is advanced through the automated equipment, is set by the relative locations of the bonding elements on the interior surface or surfaces of the web. Thus, changing the length of the envelopes produced by the automated equipment requires that the web be changed-out to another web specifically tailored to the desired length of the envelopes to be produced.
In one aspect of the disclosed technology, an envelope for holding an item includes a first flexible wall, and a second flexible wall overlying the first flexible wall and affixed to the first flexible wall about at least a portion of a pocket border. The pocket border encloses a pocket defined at least in part by the first and second flexible walls, and is configured and dimensioned to contain the item. As least one of the first and second flexible walls defines a pocket opening allowing access to the pocket from an exterior of the envelope for loading the item into the pocket. The second wall is affixed to an adjacent portion of the envelope by at least a first seal. The envelope also includes a bonding element covering a majority of a surface of at least one of the first and second flexible walls. The the first seal is formed from the bonding element.
In another aspect of the disclosed technology, the bonding element includes a heat-activatable material.
In another aspect of the disclosed technology, the heat-activatable material includes a heat-sealable material.
In another aspect of the disclosed technology, the heat-activatable material includes a hot melt adhesive.
In another aspect of the disclosed technology, the first seal extends in a lengthwise direction of the envelope.
In another aspect of the disclosed technology, the second wall is further affixed to the first wall by a second seal extending in a direction generally transverse to the lengthwise direction of the envelope, the second seal being formed from the bonding element.
In another aspect of the disclosed technology, the second wall is further affixed to the first wall by a third seal extending in a direction generally transverse to the lengthwise direction of the envelope, the third seal being formed from the bonding element, and the second and third seals define at least a portion of the pocket border.
In another aspect of the disclosed technology, a system for forming an envelope includes the above web stock, and a bagging machine having a sealing device configured to locally heat the web stock to form, from the bonding element, the second seal and the third seal.
In another aspect of the disclosed technology, the first seal extends along a first side edge portion of the envelope, and the second and third seals extend between the first seal and a second side edge portion of the envelope.
In another aspect of the disclosed technology, the bonding element covers a substantial entirety of the surface of at least one of the first and second flexible walls.
In another aspect of the disclosed technology, the bonding element covers at least about 85 percent of the surface of at least one of the first and second flexible walls.
In another aspect of the disclosed technology, the bonding element covers at least about 90 percent of the surface of at least one of the first and second flexible walls.
In another aspect of the disclosed technology, the bonding element covers at least about 95 percent of the surface of the first and second flexible walls.
In another aspect of the disclosed technology, the bonding element covers at least about 100 percent of the surface of the first and second flexible walls.
In another aspect of the disclosed technology, the first and second walls includes paper.
In another aspect of the disclosed technology, the first, second, and third seals are formed from activated portions of the heat-activatable material.
In another aspect of the disclosed technology, a portion of the heat-activatable material is not activated.
In another aspect of the disclosed technology, a system for forming an envelope includes the above web stock, and a bagging machine having a sealing device configured to locally heat the web stock to form, from the bonding element, the second seal and the third seal.
In another aspect of the disclosed technology, a method for forming a envelope configured to hold an item to be packaged includes providing a web stock having a first wall, a second wall overlying the first wall and affixed to the first flexible wall about at least a portion of a pocket border that encloses a pocket defined between the first and second walls and configured to contain the item, and a bonding element covering a majority of a surface of at least one of the first and second walls. The bonding element forms a first seal extending in a generally lengthwise direction of the web stock. The method further includes forming, from the bonding element, a second seal and a third seal between the first and second walls. The at least the second and third seals form a portion of the pocket.
In another aspect of the disclosed technology, the second and third seals extend in a generally transverse direction of the web stock. The method further includes advancing the web stock in a lengthwise direction of the web stock by a first distance after forming the second seal and before forming the third seal, the first distance corresponding to a desired dimension of the envelope in a lengthwise direction of the envelope.
In another aspect of the disclosed technology, forming the second seal and the third seal includes forming the second seal and the third seal using a sealing device configured to apply heat to the web stock; and advancing the web stock in a lengthwise direction of the web stock by a first distance includes advancing the web stock to align a location on the web stock at which the third seal is to be formed with the sealing device.
In another aspect of the disclosed technology, the method further includes inserting the item to be packaged into the pocket after forming the second seal and before forming the third seal; and separating the envelope from the web stock by forming a line of separation through the third seal.
In another aspect of the disclosed technology, the envelope is a first envelope; and the method further includes advancing the web stock by a second distance after separating the envelope from the web stock, the second distance corresponding to a desired lengthwise dimension of a second envelope to be formed from the web stock.
In another aspect of the disclosed technology, the second distance is unequal to the first distance.
In another aspect of the disclosed technology, forming a third seal between the first and second walls includes forming the third seal at a location spaced from the second seal in the lengthwise direction of the web stock by a distance about equal to a desired dimension of the envelope in the lengthwise direction of the web stock.
In another aspect of the disclosed technology, the method further includes varying a spacing between the second and third seals to provide the envelope with a predetermined dimension in the lengthwise direction of the web stock.
In another aspect of the disclosed technology, advancing the web stock by a second distance after separating the envelope from the web stock includes advancing the web stock to align a location on the web stock at which a fourth seal is to be formed by the sealing device, and the method further includes forming the fourth seal in the generally transverse direction of the web stock using the sealing device.
In another aspect of the disclosed technology, the method further includes spacing the third seal from the second seal in the lengthwise direction of the web stock so that the pocket is dimensioned to hold the item.
In another aspect of the disclosed technology, forming a second seal between the first and second walls includes applying localized heat and pressure at a position on at least one of the first and second walls corresponding to a desired location of the second seal; and forming a third seal between the first and second walls includes applying localized heat and pressure at a position on at least one of the first and second walls corresponding to a desired location of the third seal.
In another aspect of the disclosed technology, the bonding element includes a heat-sealable material.
In another aspect of the disclosed technology, the bonding element includes a hot-melt adhesive.
In another aspect of the disclosed technology, the method further includes forming a pocket opening configured to allow access to the pocket from an exterior of the envelope for loading the item into the pocket.
In another aspect of the disclosed technology, the method further includes inserting the item into the pocket by way of the pocket opening.
In another aspect of the disclosed technology, forming a third seal between the first and second walls includes forming the third seal after inserting the item into the pocket.
In another aspect of the disclosed technology, the first seal extends along a first side edge portion of the web stock and fixes the first wall to the second wall; and the second and third seals extend between the first seal and a second side edge portion of the web stock.
In another aspect of the disclosed technology, the bonding element covers a substantial entirety of the surface of at least one of the first and second walls.
In another aspect of the disclosed technology, the bonding element covers at least about 85 percent of the surface of at least one of the first and second walls.
In another aspect of the disclosed technology, the bonding element covers at least about 90 percent of the surface of at least one of the first and second walls.
In another aspect of the disclosed technology, the bonding element covers at least about 95 percent of the surface of at least the one of the first and second walls.
In another aspect of the disclosed technology, the bonding element covers at least about 100 percent of the surface of at least the one of the first and second walls.
In another aspect of the disclosed technology, the first seal extends along a first side edge portion of the web stock, the web stock further includes a fourth seal formed from the bonding element and extending in a generally lengthwise direction of the web stock and along a second side edge portion of the web stock, and the fourth seal further affixes the first wall to the second wall.
In another aspect of the disclosed technology, the web stock includes paper.
In another aspect of the disclosed technology, providing a web stock includes providing a first and a second sheet of stock material, at least one of the first and second sheets having a surface coated with the bonding material over a majority thereof; aligning respective edges of the first and second sheets of stock material; bringing the first and second sheets of stock material into contact; and applying localized heat and pressure to at least one of the first and second sheets to form the first seal.
In another aspect of the disclosed technology, providing a web stock includes providing a sheet of stock material having a surface coated with the bonding material, folding the sheet about at least one fold line extending generally in the lengthwise direction of the web stock so that edge portions of the sheet overlap, and applying localized heat and pressure to the edge portions to form the first seal.
In another aspect of the disclosed technology, folding the sheet about at least one fold line extending generally in the lengthwise direction of the web stock so that edge portions of the sheet overlap includes folding the sheet about a first and a second fold line.
In another aspect of the disclosed technology, a system for forming an envelope includes a web stock having a first wall, a second wall overlying the first wall, and a bonding element covering a majority of a surface of at least one of the first and second walls. The bonding element forms a first seal extending in a generally lengthwise direction of the web stock. The system further includes a bagging machine having a sealing device configured to locally heat the web stock to form, from the bonding element, a second seal and a third seal between the first and second walls. The second and third seals form at least a portion of a pocket border that encloses a pocket defined between the first and second walls and configured to contain the item.
In another aspect of the disclosed technology, the second and third seals extend in a generally transverse direction of the web stock, and the bagging machine further includes a controller, a traction roller, and a drive motor communicatively coupled to the controller and configured to rotate the traction roller. The controller, the traction roller, and the drive motor are configured to advance the web stock in a lengthwise direction of the web stock by a first distance after forming the second seal and before forming the third seal, the first distance corresponding to a desired dimension of the envelope in a lengthwise direction of the envelope.
In another aspect of the disclosed technology, the controller, the traction roller, and the drive motor are further configured to advance the web stock to align a location on the web stock at which the third seal is to be formed by the sealing device.
In another aspect of the disclosed technology, the sealing device includes a cutter-sealer further configured to separate the envelope from the web stock by forming a line of separation through the third seal.
In another aspect of the disclosed technology, the envelope is a first envelope, and the controller, the traction roller, and the drive motor are further configured to advance the web stock by a second distance after separating the envelope from the web stock. The second distance corresponds to a desired lengthwise dimension of a second envelope to be formed from the web stock.
In another aspect of the disclosed technology, the second distance is unequal to the first distance.
In another aspect of the disclosed technology, the rollers are further configured advance the web stock by the second distance to align a location on the web stock at which a fourth seal is to be formed by the sealing device, and the sealing device is further configured to form the fourth seal in a generally transverse direction of the web stock.
In another aspect of the disclosed technology, the bonding element includes a heat-sealable material.
In another aspect of the disclosed technology, the bonding element includes a hot-melt adhesive.
In another aspect of the disclosed technology, the system further includes a cutting device configured to tear or cut one of the first and second walls to form a pocket opening configured to allow access to the pocket from an exterior of the envelope for loading the item into the pocket.
In another aspect of the disclosed technology, the bonding element covers a substantial entirety of the surface of at least one of the first and second walls.
In another aspect of the disclosed technology, the web stock includes paper.
In another aspect of the disclosed technology, providing a web stock includes providing a sheet of stock material having a surface coated with the bonding material; folding the sheet about at least one fold line extending generally in the lengthwise direction of the web stock so that edge portions of the sheet overlap; and applying localized heat and pressure to the edge portions to form the first seal.
In another aspect of the disclosed technology, folding the sheet about at least one fold line extending generally in the lengthwise direction of the web stock so that edge portions of the sheet overlap includes folding the sheet about a first and a second fold line.
In another aspect of the disclosed technology, a system for forming an envelope incudes a web stock having a first wall, a second wall overlying the first wall, and a bonding element covering a majority of a surface of at least one of the first and second walls. The bonding element forms a first seal extending in a generally lengthwise direction of the web stock.
The system also includes a bagging machine having a sealing device configured to locally heat the web stock to form, from the bonding element, a second seal and a third seal between the first and second walls. The first, second, and third seals form at least a portion of a pocket border that encloses a pocket defined between the first and second walls and configured to contain the item.
In another aspect of the disclosed technology, the second and third seals extend in a generally transverse direction of the web stock; and the bagging machine further includes a controller, a traction roller, and a drive motor communicatively coupled to the controller and configured to rotate the traction roller. The controller, the traction roller, and the drive motor are configured to advance the web stock in a lengthwise direction of the web stock by a first distance after forming the second seal and before forming the third seal, the first distance corresponding to a desired dimension of the envelope in a lengthwise direction of the envelope.
In another aspect of the disclosed technology, the controller, the traction roller, and the drive motor are further configured to advance the web stock to align a location on the web stock at which the third seal is to be formed by the sealing device.
In another aspect of the disclosed technology, the sealing device includes a cutter-sealer further configured to separate the envelope from the web stock by forming a line of separation through the third seal.
In another aspect of the disclosed technology, the envelope is a first envelope; and the controller, the traction roller, and the drive motor are further configured to advance the web stock by a second distance after separating the envelope from the web stock. The second distance corresponds to a desired lengthwise dimension of a second envelope to be formed from the web stock.
In another aspect of the disclosed technology, the second distance is unequal to the first distance.
In another aspect of the disclosed technology, the rollers are further configured advance the web stock by the second distance to align a location on the web stock at which a fourth seal is to be formed by the sealing device; and the sealing device is further configured to form the fourth seal in a generally transverse direction of the web stock.
In another aspect of the disclosed technology, the bonding element is a heat-sealable material.
In another aspect of the disclosed technology, the bonding element is a hot-melt adhesive.
In another aspect of the disclosed technology, the system further includes a cutting device configured to tear or cut one of the first and second walls to form a pocket opening configured to allow access to the pocket from an exterior of the envelope for loading the item into the pocket.
In another aspect of the disclosed technology, the bonding element covers a substantial entirety of the surface of at least one of the first and second walls.
In another aspect of the disclosed technology, web stock includes paper.
In another aspect of the disclosed technology, a method for forming a envelope configured to hold an item to be packaged includes providing a sheet of stock material having a majority of a surface thereof coated with a bonding material; and folding the sheet about a fold line extending in the lengthwise direction of the sheet to form a first wall and a second wall overlapping the first wall. The method also includes forming, from the bonding material, a first seal between the first and second walls. The first seal forms a portion of a pocket border that encloses a pocket defined between the first and second wall and configured to hold an item to be packaged.
The method also includes loading the item to be packaged into the pocket; and forming, from the bonding material, a second and a third seal between the first and second walls, the second and third seals forming additional portions of the pocket border.
In another aspect of the disclosed technology, the first and third seals extend in a generally transverse direction of the web stock; and the method further includes advancing the web stock in a lengthwise direction of the web stock by a first distance after forming the first seal and before forming the third seal, the first distance corresponding to a desired dimension of the envelope in a lengthwise direction of the envelope.
In another aspect of the disclosed technology, forming the first seal and the third seal includes forming the second seal and the third seal using a sealing device configured to apply heat to the web stock; and advancing the web stock in a lengthwise direction of the web stock by a first distance includes advancing the web stock to align a location on the web stock at which the third seal is to be formed by the sealing device.
In another aspect of the disclosed technology, the method further includes inserting the item to be packaged into the pocket after forming the first seal and before forming the second and third seals; and separating the envelope from the web stock by forming a line of separation through the third seal.
In another aspect of the disclosed technology, the envelope is a first envelope; and the method further includes advancing the web stock by a second distance after separating the envelope from the web stock, the second distance corresponding to a desired lengthwise dimension of a second envelope to be formed from the web stock.
In another aspect of the disclosed technology, the second distance is unequal to the first distance.
In another aspect of the disclosed technology, advancing the web stock by a second distance after separating the envelope from the web stock includes advancing the web stock to align a location on the web stock at which a fourth seal is to be formed by the sealing device; and the method further includes forming the fourth seal in a generally transverse direction of the web stock using the sealing device.
In another aspect of the disclosed technology, forming a third seal between the first and second walls includes forming the third seal at a location spaced from the second seal in the lengthwise direction of the web stock by a distance about equal to a desired dimension of the envelope in the lengthwise direction of the web stock.
In another aspect of the disclosed technology, forming a first seal between the first and second walls includes forming the first seal to extend in a direction generally transverse to the lengthwise direction of the sheet; and forming a third seal between the first and second walls includes forming the third seal to extend in a direction generally transverse to the lengthwise direction of the sheet.
In another aspect of the disclosed technology, forming a third seal between the first and second walls further includes forming the third seal at a location spaced from the first seal in the lengthwise direction of the sheet by a distance about equal to a desired dimension of the envelope in the lengthwise direction of the sheet.
In another aspect of the disclosed technology, the method further includes varying a spacing between the first and third seals to provide the envelope with a predetermined dimension in the lengthwise direction of the sheet.
In another aspect of the disclosed technology, the method further includes spacing the third seal from the first seal in the lengthwise direction of the sheet so that the pocket is dimensioned to hold the item.
In another aspect of the disclosed technology, forming a second seal between the first and second walls includes forming the second seal to extend generally in the lengthwise direction of the sheet.
In another aspect of the disclosed technology, the second seal extends along overlapping edge portions of the sheet.
In another aspect of the disclosed technology, the bonding element is a heat-sealable material.
In another aspect of the disclosed technology, the bonding element is a hot melt adhesive.
In another aspect of the disclosed technology, forming a first seal between the first and second walls includes applying localized heat and pressure at a position on at least one of the first and second walls corresponding to a desired location of the first seal; and forming a second seal between the first and second walls includes applying localized heat and pressure at a position on at least one of the first and second walls corresponding to a desired location of the second seal. Forming a third seal between the first and second walls includes applying localized heat and pressure at a position on at least one of the first and second walls corresponding to a desired location of the third seal.
In another aspect of the disclosed technology, loading the item to be packaged into the pocket includes loading the item to the pocket by way of a pocket opening defined by the first and second walls; and the method further includes sealing the pocket opening by forming the second seal.
In another aspect of the disclosed technology, the method further includes forming a line of separation in the sheet.
In another aspect of the disclosed technology, the method further includes forming the line of separation in the sheet at a location on the sheet adjacent to the third seal.
In another aspect of the disclosed technology, the bonding element covers at least about 85 percent of the surface of the sheet.
In another aspect of the disclosed technology, the bonding element covers at least about 85 percent of the surface of the sheet.
In another aspect of the disclosed technology, the bonding element covers at least about 90 percent of the surface of the sheet.
In another aspect of the disclosed technology, the bonding element covers at least about 95 percent of the surface of the sheet.
In another aspect of the disclosed technology, the bonding element covers at least about 100 percent of the surface of the sheet.
In another aspect of the disclosed technology, the sheet includes paper.
The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
The inventive concepts are described with reference to the attached figures, wherein like reference numerals represent like parts and assemblies throughout the several views. Several aspects of the inventive concepts are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the inventive concepts. One having ordinary skill in the relevant art, however, will readily recognize that the inventive concepts can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the inventive concepts.
Packaging containers can include parcel packaging and other containers to package items. Packaging containers are configured to contain and hold an item, typically enclosing the item, during shipping or storage of the item. Parcel packaging is configured for shipping and/or storing products, such as for storage in warehouse or retail shelves and displays. Examples of parcel packaging include flexible shipping containers such as envelopes, which can have varying degrees of flexibility and typically are used to ship or mail small or relatively flat items or smaller items around which the walls of the envelope can conform. Flexible shipping containers such as envelopes can be padded or non-padded, can be made of materials such as paper and flexible cardboard, can be configured with or without sidewalls or gussets, and can include larger envelopes such as mailers. Examples of parcel packaging also include bags, such as paper or poly bags, which can have a self-sealing capability and are typically used to ship small to medium-sized items; boxes, which can be formed from paperboard, cardboard, wood, or plastic, and typically have a rigid or semi-rigid structure suitable for holding medium to large-size items and heavier items; and shipping tubes or tube mailers, typically used to ship documents and paper items.
The present technology is directed to an item of parcel packaging.
Directional terms such as “top,” “bottom,” “upper,” “lower,” etc. are used in relation to the component orientations depicted in
Referring to
The walls 12, 14 can be formed from a stock material in the form of regular kraft paper. The basis weight of the paper is application-dependent, and can vary with factors such as the load to which the envelope 10 will be subjected when loaded with the item 11.
In alternative embodiments, one or both of the walls 12, 14 can be formed from extensible paper. For example, the extensible paper can have a stretch, i.e., extensibility, greater than about three percent to about 25 percent in both the machine and cross-machine directions; a tensile strength between about 25 lbs/inch to about 65 lbs/inch in both the machine and cross-machine directions; a tear strength between about 60 grams and about 180 grams in both the machine and cross-machine directions; and a TEA between about 10 ft-lb/ft2 and about 30 ft-lb/ft2 in the both the machine and cross-machine directions. An example of an extensible paper from which one or both of the walls 12, 14 can be formed is a single ply of 55-pound (ream weight) paper sold by Canadian Kraft Paper Industries Ltd. of Manitoba, Canada, as “SPX© extensible Kraft paper,” which has a stretch, i.e., extensibility, of about 6.8 percent in the machine direction and about 8.9 percent in the cross-machine direction; a tensile strength of about 45.7 lbs/inch in the machine direction and about 33.1 lbs/inch in the cross-machine direction; a tear strength of about 110 grams in the machine direction and about 120 grams in the cross-machine direction; and a TEA of about 19.2 ft-lb/ft2 in the machine direction and about and 20.9 ft-lb/ft2 in the cross-machine direction. Other types of paper can be used in the alternative. For example, the walls 12, 14 each can be formed from a single ply of 30-pound to 90-pound “SPX© extensible Kraft paper,” depending on the degree of strength of the walls 12, 14 required for a particular application. Other suitable weights can be used in other embodiments.
In other alternative embodiments of the envelope 10, one or both of the walls 12, 14 can be formed from a non-extensible paper other than regular kraft paper, or another type of material such as polyethylene.
The inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b can be formed from a bonding element in the form of a heat-activatable material. For example, the inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b can be formed from a bonding element in the form of a heat-sealable material 34, visible in
A heat seal typically is formed by sealing one thermoplastic to the same or a similar thermoplastic. The thermoplastic material(s) typically is applied to the two substrates to be fixed to each other. At the time the substrates are to be fixed, the thermoplastic material(s) on one or both substrates is subject to heat and pressure sufficient to weld the materials together, thereby fixing the substrates to each other.
In some embodiments, the heat-sealable material 34 can include one or more polymers including emulsion-based polymers. The one or more polymers can include one or more of vinyl acetate ethylene, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetate copolymers, polyvinyl alcohol copolymers, dextrin stabilized polyvinyl acetate, vinyl acetate copolymers, ethylene copolymers, vinylacrylic, styrene acrylic, acrylic, styrene butyl rubber, polyurethane, polyolefins, and biodegradable materials (e.g., cellulose and starch).
In some embodiments, the heat sealable material 34 can include a polyolefin based dispersion. The polyolefin dispersion can include polyethylene and/or polypropylene, thermoplastic polymers, polymeric stabilizing agents including at least one polar polymer, water, and/or other suitable polyolefin dispersions. A suitable polyolefin dispersion can include, for example HYPOD™, from Dow Chemical, or other suitable polyolefin dispersions.
In some embodiments, the heat-sealable material 34 is water-based. The water-based heat-sealable material 34 may include a water-based polymer. The use of a water-based heat-sealable material 34 can enhance the recyclability of the envelopes 10, since the water-based heat-sealable material 34 can be dissolved and separated easily from the paper pulp during the recycling process.
The inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b fix the walls 12, 14 to each other, and define a pocket border of the envelope pocket 15. The inter-wall seals 16a, 16b are substantially identical. As can be seen in
The inter-wall seals 18a, 18b (depicted in phantom in
The inter-wall seal 18b extends continuously along a top edge portion 23 of the envelope 10, in the transverse direction. The inter-wall seals 18a, 18b can be offset from the respective bottom edge portion 22 and top edge portion 23 in alternative embodiments. Also, the inter-wall seals 18a, 18b can extend over a distance less than the distance between the inter-wall seals 16a, 16b, and/or can be non-continuous in alternative embodiments.
As discussed below, the inter-wall seal 18b typically is formed after the item 11 has been placed in the envelope pocket 15. The inter-wall seal 18b, along with the inter-wall seal 18b and the inter-wall seals 16a, 16b, form the completed pocket border within which the item 11 is retained in the envelope 10.
The inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b can extend in directions other than the longitudinal and transverse directions in alternative embodiments. Also, the inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b can extend in non-linear directions in alternative embodiments.
The inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b each have a width of, for example, about 0.1 inch to about 0.5 inch. The inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b can have widths above or below this range in alternative embodiments.
The heat-sealable material 34 covers a majority, i.e., more than 50 percent, of the inwardly-facing surface of one or both of the walls 12, 14 to which heat-sealable material is applied. For example, the heat-sealable material 34 can be applied can be applied as a flood coat to the inwardly-facing surfaces of both of the walls 12, 14, i.e., the inwardly-facing surfaces of one or both of the walls 12, 14 can be coated with the heat-sealable material 34 in their entirety, or near-entirety. For example, in some embodiments, a substantial entirety the inwardly facing surface of each wall 12, 14 can be coated with the heat-sealable material 34. In other embodiments, the entire inwardly facing surface of each wall 12, 14 can be coated with the heat-sealable material 34. In other embodiments, at least 95 percent of the inwardly facing surface of each wall 12, 14 can be coated with the heat-sealable material 34. In other embodiments, at least 90 percent of the inwardly facing surface of each wall 12, 14 can be coated with the heat-sealable material 34. In other embodiments, at least 85 percent of the inwardly facing surface of each wall 12, 14 can be coated with the heat-sealable material 34. In other embodiments, the heat-sealable material 34 can be applied to less than a substantial entirety of the inwardly-facing surfaces of the paper sheets 32a, 32b. For example, the heat-sealable material 34 can be applied to a majority of the inwardly-facing surfaces of the paper sheets 32a, 32b, in locations or regions along the length of each paper sheet 32a, 32b at which it is anticipated that the inter-wall seals 18a, 18b will be formed.
The coating of heat-sealable material 34 is continuous, i.e., the coating is uninterrupted over the portions of the respective inwardly-facing surfaces of the walls 12, 14 on which the coating is applied. In alternative embodiments, the coating can be discontinuous. For example, the heat-sealable material 34 may be applied to the surfaces of the walls 12, 14 in longitudinally and/or transversely-extending bands located in the regions on the surfaces within which the inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b are to be formed.
The heat-sealable material 34 is activated, i.e., subjected to elevated temperature and pressure, at the specific locations on the wall 12 and/or the wall 14 at which the inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b are to be formed. This localized application of heat and pressure activates the heat-sealable material 34 at the desired locations of the inter-wall seals 16a, 16b and the inter-wall seals 18a, 18b, thereby fixing the walls 12, 14 to each other at those locations, while the remainder of the heat-sealable material 34 on the wall 12 and the wall 14 remains un-activated and therefore does not cause the walls 12, 14 to adhere each other.
The walls 12, 14, which initially are fixed to each other by the formation of the inter-wall seals 16a, 16b and the inter-wall seal 18a, can be spread apart to define an opening 26 to the envelope pocket 15 as shown in
The heat-sealable material 34 along the upper edge portion 23 of the envelope 10 can be activated after the item 11 has been inserted into the envelope pocket 15, to form the inter-wall seal 18b. The inter-wall seal 18b functions as a closure seal that fixes the upper ends of the walls 12, 14 to each other, to maintain the opening 26 in a closed state so that the packaged item 11 is retained within the envelope 10.
The envelopes 10 can be pre-formed as part of a continuous web 30.
The heat-sealable material 34 is deposited on the paper sheet 32a as a flood coat, i.e., the heat-sealable material 34 is deposited on an entirety, or a substantial entirety of one of the major surfaces of the paper sheet 32a, as shown in
The heat-sealable material 34 can be a water-based or a solvent-based formulation. The heat-sealable material 34 can be applied to the respective surfaces of the sheets 32a, 32b as a liquid, using suitable known methods such as brushing, spraying, rollers, knife over roll, reverse roll, nip roller, gravure coating, rod coating, etc. In alternative embodiments, the heat-sealable material 34 can be applied to the paper sheets 32a, 32b as a tape.
Upon drying following its application, the heat-sealable material 34 is non-tacky, or has a tackiness that is sufficiently low so as to prevent the opposing surfaces of the paper sheets 32a, 32b from adhering to each other unless and until the heat-sealable material 34 is activated. The heat-sealable material 34 subsequently can be activated by the application of heat and pressure sufficient to weld the heat seal material 34 on the respective paper sheets 32a, 32b together, thereby forming a seal between the sheets 32a, 32b. The heat-seal material 34 can be activated locally, by the focused application of heat and pressure, to form seals at specific locations the paper sheets 32a, 32b.
The heat-sealable material will not stick to other surfaces when cold because it has no, or minimal tackiness until it is activated, i.e., heated up to a sealable temperature within a lower range of temperatures. For example, this lower range of temperatures in some embodiments is below about 140° F. In other embodiments, for example, the lower range of temperatures is below about 120° F., below about 125° F., or below about 130° F.
In alternative embodiments, a low-tackiness hot-melt adhesive can be used as the bonding element in lieu of the heat-sealable material 34. Hot-melt adhesives are thermoplastic polymers that are solid at room temperature, become molten when heated to an activation temperature above their softening point, and resolidify upon loss of heat at a temperature below a solidifying point, which may be the same as or different than the activation temperature, increasing in strength as they re-solidify. Most hot-melt adhesives, upon melting into a molten state and re-solidifying, do not undergo any chemical reaction such as cross-linking or removal of a carrier, e.g., evaporation of water. Thus, hot-melt adhesives typically can be reactivated, i.e., re-melted and re-solidified, after initially being applied to a substrate.
The hot-melt adhesive, after being applied to the paper sheet 32a or the paper sheet 32b, is in a low-tackiness state in which it has a low, or no tackiness in a lower range of temperatures. The hot-melt adhesive is reactivatable. More specifically, the hot-melt adhesive is applied hot, and cools and cures in the converting process. It will not stick to other surfaces when cold because it has no, or minimal tackiness until it is reactivated, i.e., re-heated up to a sealable temperature above the lower range of temperatures at which the hot-melt adhesive initially is in a low-tackiness state, This lower range of application temperatures includes room temperature, and in some embodiments is below about 140° F. In other embodiments, the lower range of temperatures is below about 120° F., below about 125° F., or below about 130° F.
The re-heating of the hot-melt adhesive to the activation temperature causes the hot-melt adhesive to become molten. The subsequent cooling of the hot-melt adhesive, in combination with the application of pressure on the first and/or second paper sheet 32a, 32b causes the hot-melt adhesive to bond to the opposing surface of the paper sheet 32a or the paper sheet 32b, forming a seal between the paper sheets 32a, 32b. The hot-melt adhesive can be re-activated locally, by the focused application of heat and pressure, to form seals at specific locations the paper sheets 32a, 32b.
In alternative embodiments, one or more heated plates, heated presses, or other suitable devices can be used in lieu of the rollers 36 to apply heat and pressure at and near the longitudinal edges of the paper sheets 32a, 32b to thereby activate the heat-sealable material 34.
Individual envelopes 10 subsequently can be formed from the web 30, with the walls 12, 14 of the completed envelopes 10 being formed from the walls of the web 30, i.e., from the respective paper sheets 32b, 32a. Because the inwardly-facing surfaces of the paper sheets 32a, 32b have been flood-coated with the heat-sealable material 34, the inter-wall seals 18a, 18b can be formed at any locations along the length of the web 30, which in turn permits the height of each envelope 10, i.e., the dimension of the envelope 10 in the longitudinal direction of the web 30, to be varied or otherwise selected by the user. The size of the envelopes 10 thus can be tailored to the requirements of a particular application, through the selective placement of the inter-wall seals 18a, 18b along the length of the web 30.
The envelopes 10 can be formed into their final configuration, loaded, sealed, and separated from the web 30 by a bagging machine 200 depicted in
The bagging machine 200 is configured to form the inter-wall seals 18a, 18b in the web 30, so as to define a fully-formed envelope 10 at the leading end of the web 30. The bagging machine 200 also separates of the fully-formed envelope 10 from the web 30 after the envelope 10 has been loaded and sealed.
The bagging machine 200 also is configured to facilitate loading of the item 11 into the envelope pocket 15, and sealing of the envelope pocket 15 once the item 11 has been loaded. As explained in further detail below, the bagging machine 200 can make a cut, e.g., a kiss cut, in the sheet 32b of the web 30, to define the wall 12 of the envelope 10. (As an alternative to a kiss cut, for example, the cut can be made in the sheet 32b before, or as the sheet 32b is joined to the sheet 32a to form the web 30.) After forming the kiss cut, the bagging machine 200 pulls the upper end of the newly-formed wall 12 away from the wall 14 (which is formed by the underlying sheet 32a), to define the opening 26 to the envelope pocket 15, thereby allowing the item to be packaged 11 to be loaded into the envelope pocket 15. Once the item 11 has been loaded, the bagging machine 200 forms the inter-wall seal 18b, so that the item 11 is retained within the envelope pocket 15. The bagging machine 200 then separates the fully formed, loaded, and sealed envelope 10 from the web 30.
Referring to
The bagging machine 200 further includes a cutting device 230. The cutting device 230 has a cutting blade 232, and an anvil 234 that underlies the cutting blade 232. The cutting blade 232 is coupled to an actuator (not shown) configured to move to move the cutting blade 232 toward and away from the anvil 234, between a retracted position shown in
In alternative embodiments, the kiss cut and the perforations 31 can be formed at different points in the loading and sealing process, and can be offset in relation to each other (provided the kiss cut and the perforations 31 are formed at specific locations on the sheets 32a, 32b that will remain unsealed to each other after the envelope 10 is loaded and fully sealed). For example, the kiss cut and the perforations 31 can be made using separate cutting devices on opposite sides of the web 30, in lieu of the cutting device 230, with the perforations 31 being formed before the kiss cut is made, and being located upstream of the kiss cut. In other alternative embodiments, the perforations 31 can be formed after the kiss cut is made, and/or can be located downstream of the kiss cut.
After separating a fully formed, loaded, and sealed envelope 10 from the web 30, the bagging machine 200 begins the next cycle by advancing the web 30 so that the location on the web 30 at which the next inter-wall seal 18b is to be formed aligns with the cutting blade 232. As explained below, the upper half of the transversely-extending seal formed during the previous cycle is positioned at the leading end of the web 30, and forms the lower inter-wall seal 18a of the envelope 10 being produced during the current cycle.
The extent to which the web 30 is advanced is related to the desired height of the envelope 10 being formed. As noted above, the flood-coatings of heat-sealable material 34 on the paper sheets 32a, 32b permit the inter wall seals 18a, 18b, which define the respective bottom and top ends of the envelope 10, to be placed at any location along the length of the web 30. Because the already-formed inter-wall seal 18a is located at the end of the web 30, the extent to which the web 30 is advanced at this point in the cycle determines the spacing between the inter-wall seals 18a, 18b, which in turn determines the height, or lengthwise dimension of the envelope 10. This in turn permits the height and the internal volume of the envelope 10 to be varied, so that the height and the internal volume of the envelope 10 can be tailored to a particular application. Thus, a single web 30 can be used to produce envelopes 10 of different sizes and volumes, negating the need to change the web 30 when a different-sized envelope 10 is to be produced on the bagging machine.
The desired height for a particular envelope 10 or a particular series of envelopes 10 can be input to a controller (not shown) of the bagging machine 200, for example, by an operator using an input device such as a keypad. The controller is communicatively coupled to the drive motor of the traction rollers, and is configured to actuate the drive motor to cause the traction wheels to advance the web 30 automatically, by a distance that will result in the desired envelope height.
Once the location on the web 30 at which the next inter-wall seal 18b is to be formed aligns with the cutting blade 232, the cutting blade 232 is advanced toward the cutting position. As the cutting blade 232 reaches the cutting position, the cutting blade 232 presses the web 30 into, and against the anvil 234, so that the serrated cutting surface 233 of the cutting blade 232 makes a kiss cut in the paper sheet 32b, while simultaneously making a series of cuts in the underlying paper sheet 32a to form the perforations 31. The kiss cut and the perforations 31 extend in a transverse direction across the web 30, between, but not through, the inter-wall seals 16a, 16b.
The bagging machine 200 also includes a cutter-sealer 206, and a second anvil 207 that opposes the cutter-sealer 200. The cutter-sealer 206 is coupled to an actuator (not shown) configured to move the cutter-sealer 206 toward and away from the second anvil 207, between an inward or extended position (not shown), and an outward or retracted position shown in
Once the kiss cut and the perforations 31 have been formed in the web 30, the bagging machine 200 advances the web 30 until the lengthwise location on the web 30 at which the next inter-wall seal 18b is to be formed aligns with the cutter-sealer 206. As noted above, the lengthwise location at which the next inter-wall seal 18b is to be formed coincides generally with the location of the kiss cut and the perforations 31. The cutter-sealer 206 next moves inward, toward its extended position, so that the fingers 214 can grasp and pinch the upper end of the wall 12. The cutter sealer 206 then moves outward, toward its retracted position, causing the fingers 214 to pull the upper end of the wall 12 away from the upper end of the wall 14, forming the opening 26 at the top of the envelope 10, as shown in
At this point, the partially-formed envelope 10 is ready to be loaded with the item 11 to be packaged. As can be seen in
The bagging machine 200 also can include an air blower (not shown) configured to direct pressurized air at the top of the envelope 10, to aid in separating the walls 12, 14. Once the opening 26 to the envelope pocket 15 has been formed, the item to be packaged 11 can be loaded into the envelope pocket 15 manually, or by automated machinery, as denoted by the arrow 220.
The opening device can have a configuration other than the fingers 214 in alternative embodiments. For example, articulating suction cups can be used as the opening device in alternative embodiments. In other alternative embodiments, the pressurized air from the air blower 220 can be used to open the envelope 10. In other alternative embodiments, the envelope 10 can be opened manually, without the use of an opening device.
After the item 11 has been loaded into the envelope pocket 15, the cutter-sealer 206 moves inwardly, toward its extended position. The wall 12 of the envelope 10, which is still being grasped and pinched by the fingers 214, moves inwardly, toward the wall 14, in response to the inward movement of the articulating jaw 206. The continued inward movement of the cutter-sealer 206 eventually causes the adjacent portion of the web 30 to become sandwiched between the cutter-sealer 206 and the second anvil 207. The cutter-sealer 206 acts as a sealing device by locally heating a band of the heat-sealable material 34 located between the cutter-sealer 206 and the second anvil 207. The second anvil 207 may include a heating element 208 configured to apply additional heat to the band of heat-sealable material 34, through the wall 14.
The band of heat-sealable material 34 extends transversely across the envelope 10, between the inter-wall seals 16a, 16b. Also, the cutter-sealer 206 presses the web 30 into the second anvil 207. The combination of heat and pressure imparted by the articulating jaw 206, the heat sealer 210, and the heating element 208 results in the formation of a seal that extends transversely across the web 30, between the inter-wall seals 16a, 16b. As discussed below, the transversely-extending seal subsequently is cut to form the inter-wall seal 18b of the envelope 10 currently being formed, loaded, and sealed; and the inter-wall seal 18a along the bottom edge of the next envelope 10 to be formed from the web 30 during the subsequent cycle of the bagging machine 200.
The bagging machine 200 can be equipped with a foam pad 222 that is mounted on, and moves with the cutter-sealer 206, or with another mechanism to compress or squeeze the envelope 10, such as when the cutter-sealer 206 moves inward, to help drive air out of the envelope pocket 15 before the envelope pocket 15 is sealed. In embodiments that include internal venting, this step can occur at a later point in the bagging process, or can be omitted entirely. The bagging machine 200 also can include a label printer (not shown) configured to print a label 238, and fix the label 238 to the envelope 10 as shown in
At this point in the cycle, the envelope 10 has been loaded and sealed, and is ready to be separated from the web 30. The cutter-sealer 206 makes a cut through the newly-formed transversely-extending seal, and through the overlying portions of the sheets 32a, 32b (which now form the respective walls 14, 12 of the newly-formed envelope 10). The cut separates the transversely-extending seal into a lower half, which forms the inter-wall seal 18b of the envelope 10 that has just been loaded and sealed; and an upper half, which forms the inter-wall seal 18a of the next envelope 10 to be formed from the web 30 during the subsequent cycle of the bagging machine 200. In alternative embodiments, the separation of the envelope 10 from the web 30 can be performed using techniques other than cutting, such as the focused application of heat.
Once the loaded envelope 10 has been separated from the web 30, the envelope 10 can drop onto a conveyor 240, which transports the envelop 304 in the direction denoted by the arrow 241; or other means for transporting or holding the envelope 10. The loading and sealing cycle for the next envelope 10 to be produced from the web 30 can commence with the advancement of the web 30 to a position at which the articulating jaw 206 and the heat sealer 210 are aligned with the location on the web 30 at which the next transverse inter-wall seal is to be formed. The inter-wall seal 18a formed during the previous cycle, having been separated from the previously-formed envelope 10, is now located at the leading end of web 30.
The formation of the inter-wall seals 18a, 18b on the bagging machine 200 has been described for illustrative purposes only. In the alternative, the inter-wall seal 18a can be formed along with the inter-wall seals 16 during formation of the web 30, i.e., the web 30 can be supplied to the bagging machine with the inter-wall seals 18a already formed and spaced apart by a distance or distance or distances related to the height or heights of the envelopes 10 to be produced from the web 30.
Referring to
The sheet 32a can be folded about its longitudinal centerline as denoted by the arrow 101 in
Individual envelopes subsequently can be formed from the web stock 102 in a manner similar to the formation of the envelopes 10 from the web 30. The C-folded envelopes can be formed into their final configuration, loaded, sealed, and separated from the web stock 102 by a bagging machine 200 or other device as discussed above in relation to the envelopes 10. Because the inwardly-facing surface of the sheet 32a has been flood-coated with the heat-sealable material 34, the transversely-extending inter-wall seals of each envelope can be formed at any location along the length of the web stock 102, which in turn permits the height of each envelope to be varied or otherwise selected by the user.
Referring to
The web 102a then is passed between two opposing rollers 108. The rollers 108 extend transversely, across the width of the web stock 102a. The rollers 108 flatten the portion of the web 102a on which the inter-wall seal 16 is formed, onto the adjacent portion of the web 102a. The rollers 108 also help to define the fold lines 104 in the web stock 102a.
Individual envelopes subsequently can be formed from the web 102a in a manner similar to the formation of the envelopes 10 from the web 30. The double C-folded envelopes can be formed into their final configuration, loaded, sealed, and separated from the web 102a by a bagging machine 200 or other device as discussed above in relation to the envelopes 10. Because the inwardly-facing surface of the sheet 32a has been flood-coated with the heat-sealable material 34, the transversely-extending inter-wall seals of each envelope can be formed at any location along the length of the web 102a, which in turn permits the height of each envelope to be varied or otherwise selected by the user.
In other alternative embodiments, one or both of the walls 12, 14 can include one or more functional layers positioned thereon. Examples of functional layers can include, but are not limited to, waterproofing layers (configured to reduce permeability of water therethrough), an airtight layer (configured to reduce permeability of air therethrough), other suitable material layers, and/or a combination thereof.
In other alternative embodiments, the one or both of the walls 12, 14 of the envelope 10 can have a multi-layer configuration. For example, the walls 12, 14 each can be formed from two plies of relatively low basis-weight paper, such as two plies of 30 to 45-pound paper. The two plies of 30 to 45-pound paper can be used in lieu of a single ply of 90-pound paper. In such embodiments, one or both of the paper sheets 32a, 32b can have a multi-ply configuration, and can be formed into a web stock as discussed above in relation to web 30.
For example, in embodiments where the paper sheet 32a has a two-ply configuration, one or both of the inwardly-facing surfaces of the plies can be flood coated with the heat-sealable material 34. Longitudinally-extending inter-ply seals can be formed along the sides portions of the plies in the manner discussed above in relation to the inter-wall seals 16a, 16b, to fix the plies to each other. The two-ply paper sheet 32a then can be joined to the paper sheet 32b as discussed above to form the web 30.
Transversely-extending inter-ply seals can be formed in the two-ply paper sheet 32a. The transversely-extending inter-ply seals can overlay the inter-wall seals 18a, 18b, and can be formed by the heat and pressure applied to the web 30 to form the inter-wall seals 18a, 18b. The transversely-extending inter-ply seals fix and seal the plies to each other along what will become the respective top and bottom of the wall 14 of the fully-formed envelope 10.
The longitudinally-extending and transversely-extending inter-ply seals formed in the two-ply paper sheet 32a (and/or in a two-ply paper sheet 32b) border, and help to define an interlayer region, or inter-ply space (not shown) between the two plies.
The two plies face each other each other across the inter-ply space, but are not adhered to each other in the inter-ply space. Also, the inter-ply space is sufficiently empty such that the plies can abut and otherwise contact each other within the inter-ply space, and can slide in relation to each other within the inter-ply space. For example, the inter-ply space can be completely empty, i.e., the inter-ply space can be completely devoid of any filler or other material.
In other alternative embodiments (not shown), the envelope 10 can be configured with side and/or bottom gussets that facilitate expansion of the envelope 10 when the envelope 10 is loaded, for example, with the item 11.
As discussed above, the heat-sealable material 34 can be applied as a flood coat to one side of the sheet 32a, i.e., the sheet 100 can be coated with the heat-sealable material 34 over a majority of a major surface thereof, including an entirety, or near-entirety of the major surface.
The web 300 in the form of the sheet 32a can be supplied, for example, as a roll mounted on the supply side of the bagging machine 302, as depicted in
The web 300 is drawn through opposing guides 308 of the bagging machine 302, in the direction denoted by the arrow 309. The bagging machine 302 can include a pulling device (not shown) in the form of two opposing arms that reciprocate between an inward position and an outward position. The arms also translate between a lower and an upper position. The arms can grasp a lower end (or other portion) of the web 300 when the arms are in their inward and upper position. Subsequent downward movement of the arms pulls the web 300 downward, causing the web 300 to advance through the bagging machine 302. The pulling device can have other configurations in alternative embodiments.
The guides 308 cause the web 300 to assume a C-folded configuration as the web 300 is drawn through the guides 308. As can be seen in
The bagging machine 302 includes a cutting and sealing mechanism. The cutting and sealing mechanism includes two cutting and sealing units 312, and two actuators 314. Each actuator 314 is coupled to a respective cutting and sealing unit 312, and is configured to move the cutting and sealing unit 312 between an inward or extended position shown in
After passing through and being folded by guides 308, the C-folded folded web 300 travels downward, so that a location on the web stock at which a transversely-extending inter-wall seal is to be formed is positioned between the cutting and sealing units 312. The cutting and sealing units 312 are moved inward, to their respective extended positions, by their associated actuators 314, so that the noted portion of the web 300 becomes sandwiched between the cutting and sealing units 312. The cutting and sealing units 312 locally apply pressure and heat to the web 300, which activates the underlying heat-sealable material 34 and forms the transversely-extending seal in the web 300.
At this point, as depicted in
As also shown in
The cutting and sealing units 312 make a cut through the newly-formed transversely-extending seal. The cut separates the transversely-extending seal into an upper half, which forms an inter-wall seal 18a at the lower end of the partially-formed envelope 304 that has just been loaded; and a lower half, which forms an inter-wall seal 18b at the upper end of the fully formed and loaded envelope 304 at the end of the web 300. The cut also separates the fully formed and loaded envelope 304 from the web 300. In alternative embodiments, the separation of the envelope 304 from the web 300 can be performed using techniques other than cutting, such as the focused application of heat.
In alternative embodiments, each cutting and sealing unit 312 can include, for example, a rolling longitudinal sealer and a horizontal bar. In other alternative embodiments, each cutting and sealing unit 312 can include, for example, a horizontal sealer that rolls or slides across the web 300.
Once the fully formed and loaded envelope 304 has been separated from the web 300, the envelope 304 can drop onto the conveyor 240, which transports the envelope 304 in the direction denoted by the arrow 241; or onto another device for transporting or holding the envelope 10. The loading and sealing cycle for the next envelope 304 to be produced from the web 300 can commence with the advancement of the web 300 to a position at which the cutting and sealing units 312 are aligned with the location on the web 30 at which the next transversely-extending inter-wall seal is to be formed. Also, the sealer/cutters 312 are moved outwardly to their retracted positions by the actuators 314, so that the partially-formed and loaded envelope 304 can advance past the cutting and sealing units 312, and can be sealed and separated from the web 300 in the manner discussed above.
As discussed above in relation to the envelope 10, because the heat-sealable material 34 is applied as a flood coat to one side of the sheet 32a, the transversely-extending inter-wall seals 18a, 18b can be formed at any location along the length of the web 300, which in turn permits the length of each envelope 304 to be varied or otherwise selected by the user, as can be seen by the different lengths L1 and L2 (with L2 being greater than L1) of the envelopes 304 visible in
The above description of the bagging machine 302 is presented for illustrative purposes only. The C-folded envelope 304, and alternative embodiments thereof, can be formed using other type of bagging machines.
The sheets 32a, 32b are drawn through the bagging machine 402 in a horizontal direction denoted by the arrow 409. The bagging machine 402 can include traction rollers (not shown) or other devices that advance the sheets 32a, 32b through the bagging machine 402.
The sheets 32a, 32b have a vertical orientation as they leave the respective rolls and travel through the bagging machine 401. The sheets 32a, 32b are positioned so that each longitudinally-extending edge of the sheet 32a aligns with a corresponding longitudinally-extending edge of the sheet 32b.
The bagging machine 402 can include a first pair of heated rollers, such as the heated rollers 36 discussed above in relation to the envelope 10. As shown in
The bagging machine 402 also includes a cutting and sealing mechanism. The cutting and sealing mechanism includes two cutting and sealing units and two actuators, such as the cutting and sealing units 312 and the actuators 314 of the bagging machine 302. Each actuator 314 is coupled to a respective cutting and sealing unit 312, and is configured to move the cutting and sealing unit 312 between an inward or extended position shown in
After the inter-wall seal 16a is formed, the web stock 400, i.e., the partially joined sheets 32a, 32b, advances in the direction denoted by the arrow 409, until a location on the web stock 400 at which a transversely-extending inter-wall seal is to be formed is positioned between the cutting and sealing units 312. The cutting and sealing units 312 are moved inward, to their respective extended positions, by their associated actuators 314, so that the noted location on the web stock 400 becomes sandwiched between the cutting and sealing units 312. The cutting and sealing units 312 apply localized pressure and heat to the web stock 400, which activates the underlying heat-sealable material 34 and forms the transversely-extending seal between the sheets 32a, 32b.
At this point, as depicted in
As also shown in
The cutting and sealing units 312 make a cut through the newly-formed transversely-extending seal. The cut separates the transversely-extending seal into an first half, which forms an inter-wall seal 18a at the downstream end of the partially-formed envelope 304 that has just been loaded; and a second half, which forms an inter-wall seal 18b at the upstream end of the fully formed and loaded envelope 404 at the end of the web stock 400. The cut also separates the fully formed and loaded envelope 404 from the web stock 400. In alternative embodiments, the separation of the envelope 404 from the web stock 400 can be performed using techniques other than cutting, such as the focused application of heat.
Once the fully formed and loaded envelope 404 has been separated from the web 300, the envelope 404 can drop onto a conveyor (not shown); or onto another device for transporting or holding the envelope 10. The loading and sealing cycle for the next envelope 404 to be produced can commence with the advancement of the web stock 400 to a position at which the cutting and sealing units 312 are aligned with the location on the web 30 at which the next transversely-extending inter-wall seal is to be formed. Also, the cutting and sealing units 312 are moved outwardly to their retracted positions by the actuators 314, so that the partially-formed and loaded envelope 404 can advance past the cutting and sealing units 312, and can be fully sealed and separated from the web stock 400 in the manner discussed above.
As discussed above in relationship to the envelope 10, because the heat-sealable material 34 is applied as a flood coat to one side of the sheet 32a, the transversely-extending inter-wall seal can be formed at any location along the length of the web 400, which in turn permits the length of each envelope 404 to be varied or otherwise selected by the user, as denoted by the arrows L1 and L2 in
The above description of the bagging machine 402 is presented for illustrative purposes only. The envelope 404, and alternative embodiments thereof, can be formed using other type of bagging machines.
Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.
Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.
The present application claims priority of U.S. Patent Application No. 63/501,116, filed May 9, 2023, and U.S. Patent Application No. 63/518,199, filed Aug. 8, 2023, which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63501116 | May 2023 | US | |
| 63518199 | Aug 2023 | US |
