PACKAGING APPARATUS AND METHOD OF USE

FIELD

The present invention relates to an automatic packaging apparatus, and more particularly, to an automatic packaging apparatus for automatically packaging products by folding material around the products, sealing the material around the products, and separating the products.

BACKGROUND

Typically, packaging apparatuses use a preformed package (e.g., carton, mailer, or the like) or form a package (e.g., create a carton from a blank, create a mailer with an open end, or the like), and thereafter a product is packaged by supplying the product to the package. There is a need for improved packaging apparatuses and processes for packaging.

SUMMARY

The following presents a simplified summary of one or more embodiments of the present disclosure, in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments nor delineate the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments of the present disclosure in a simplified form as a prelude to the more detailed description that is presented later.

The packaging apparatus (e.g., otherwise described as a mailer apparatus when forming mailers) may comprise a material feeder assembly, a product supply assembly, a folding assembly, a sealing assembly, and/or a packaging apparatus system (e.g., including a controller thereof) for controlling the operation of the packaging apparatus. Generally, the packaging apparatus is configured for delivering products and material at the same time, and forming a package (e.g., a mailer, or other package) directly around the products. For example, a material feeder assembly of the packaging apparatus may supply material for packaging a plurality of products in-line. The folding assembly of the packaging apparatus receives the plurality of products and folds the material around one or more products of the plurality of products. The sealing assembly of the packaging apparatus seals the material around the at least one product to form packages (e.g., makes a longitudinal seam, forms a transverse seam, and/or potentially separates the material at the transverse seam at the same time as sealing to form the individual packages).

One embodiment of the invention is a packaging apparatus. The packaging apparatus comprises a material feeder assembly, a folding assembly, and a scaling assembly. The material feeder assembly is configured to supply material for packaging a plurality of products. The folding assembly is configured to receive the plurality of products and fold the material around a product of the plurality of products. The sealing assembly is configured to seal the material around the products to form a package.

In further accord with embodiments, the package is a mailer.

In other embodiments, the folding assembly comprises a folding mold and one or more folding members. The folding mold receives the material and the plurality of products. The one or more folding members receive the material in a first configuration and folds the material at least partially around the product of the plurality of products into a second configuration.

In yet other embodiments, the one or more folding members comprise a primary side folding member and a secondary side folding member. The primary side folding member and the secondary side folding member receives the material in the first configuration and folds sides of the material into the second configuration to form a material channel having a base to receive the plurality of products and a first side and a second side. The first side and the second side are orientated at an angle with respect to the base of the material.

In still other embodiments, the folding assembly further comprises a product transport assembly comprising a conveyor belt or rollers that aid in moving the plurality of products and the material to the sealing assembly.

In other embodiments, the sealing assembly comprises a longitudinal scaling assembly. The longitudinal sealing assembly seals the material adjacent to a first edge and a second edge of the material to form a longitudinal seam along a length of the material to form a material conduit around the plurality of products.

In further accord with embodiments, the second edge extends past the first edge, and the longitudinal scaling assembly comprises a seam folding member that folds at least a portion of the longitudinal seam after sealing onto the material conduit.

In other embodiments, the sealing assembly comprises a transverse scaling assembly comprising a transverse sealer and a separator. The transverse sealer receives a material conduit with the plurality of products and forms a transverse seam in the material conduit between at least two adjacent products of the plurality of products. The separator separates the material conduit at the transverse seam to form a sealed trailing end and a sealed leading end of adjacent packages.

In yet other embodiments, the transverse sealer comprises a heat sealer and the separator comprises a separator blade. The sealed trailing end and the sealed leading end of the transverse seam are sealed and separated at the same time.

In still other embodiments, the transverse sealing assembly further comprises a package transport system. The package transport system transports a plurality of packages after transverse sealing and separating of the plurality of packages.

In other embodiments, the transverse sealing assembly comprises a carriage assembly that moves the transverse sealer and the separator. Before the sealing, when the transverse sealer is disengaged, the carriage assembly is in a receiving position to receive the material conduit. During the sealing, when the transverse sealer is engaged to create the transverse seam in the material conduit, the carriage assembly moves the transverse sealer and the separator in the same direction as the movement of the material conduit. After the scaling, when the transverse scaler is disengaged, the carriage assembly returns the transverse sealer and the separator to the receiving position in the opposite direction as the movement of the material conduit.

In further accord with embodiments, the packaging apparatus further comprises a product supply assembly that is operatively coupled to the folding assembly. The product supply assembly is configured to supply the plurality of products to the folding assembly.

In other embodiments, the product supply assembly comprises one or more sensors. The one or more sensors capture product information of the plurality of products for controlling engagement of the sealing assembly.

In yet other embodiments, the material feeder assembly comprises a material supply having the material, and one or more feeder rollers configured to tension the material before folding.

In still other embodiments, the material feeder assembly further comprises an aperture forming member. The aperture forming member forms one or more apertures in the material to allow for deflation of the package.

In other embodiments, the aperture forming member comprises a projection roller that forms a plurality of apertures in the material.

In further accord with embodiments, the one or more feeder rollers comprise one or more angled rollers. The one or more angled rollers receive the material in a first orientation, transfers the material to a second orientation different than the first orientation, and supplies the material to the folding assembly.

In other embodiments, the packaging apparatus further comprises a controller comprising one or more memories storing computer-readable code and one or more processors operatively coupled to the one or more memories. When executed, the computer readable code is configured to cause the one or more processors to receive the product information from the one or more sensors for the plurality of products. The computer readable code is further configured to cause the one or more processors to engage the sealing assembly to form a plurality of transverse seams based on the product information for the plurality of products to form a plurality of packages.

Another embodiment of the invention comprises a method of forming a package. The method comprises supplying material for packaging a plurality of products using a material feeder assembly. The method further comprises receiving the plurality of products in a folding assembly. The method further comprises folding the material around a product of the plurality of products using the folding assembly. The method also comprises sealing the material around the product to form the package using a scaling assembly.

Another embodiment of the invention comprises a computer program product for forming a package. The computer program product comprising at least one non-transitory computer-readable medium having computer-readable program code portions embodied therein. The computer-readable program code portions comprising an executable portion configured to supply material for packaging a plurality of products using a material feeder assembly. The computer-readable program code portions further comprising an executable portion configured to receive product information from a plurality of products using one or more sensors. The computer-readable program code portions further comprising an executable portion configured to engage a sealing assembly to form a plurality of transverse seams based on the product information for the plurality of products for forming a plurality of packages.

To the accomplishment the foregoing and the related ends, the one or more embodiments comprise the features hereinafter described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings, where:

FIG. 1 is a perspective view of the packaging apparatus, in accordance with some embodiments of the present disclosure.

FIG. 2 is a side perspective view of a material feeder assembly, in accordance with some embodiments of the present disclosure.

FIG. 3 is a rear perspective view of the material supply of the material feeder assembly, in accordance with some embodiments of the present disclosure.

FIG. 4 is a perspective view of a set of feeder rollers of the material feeder assembly, in accordance with some embodiments of the present disclosure.

FIG. 5 is a perspective view of an angled roller of the material feeder assembly, in accordance with some embodiments of the present disclosure.

FIG. 6 is a perspective view of a set of feeder rollers of the material feeder assembly, in accordance with some embodiments of the present disclosure.

FIG. 7 is a perspective view of the folding assembly, in accordance with some embodiments of the present disclosure.

FIG. 8 is a perspective view of the product supply assembly, in accordance with some embodiments of the present disclosure.

FIG. 9 is an enlarged view of the folding assembly, in accordance with some embodiments of the present disclosure.

FIG. 10 is an enlarged view of the sensor system of the product supply assembly, in accordance with some embodiments of the present disclosure.

FIG. 11 is an enlarged side view of the product supply assembly, in accordance with some embodiments of the present disclosure.

FIG. 12 is a perspective side view of the product supply assembly and the folding assembly, in accordance with some embodiments of the present disclosure.

FIG. 13 is a perspective front view of the folding assembly, in accordance with some embodiments of the present disclosure.

FIG. 14 is a perspective view of the longitudinal sealing assembly, in accordance with some embodiments of the present disclosure.

FIG. 15 is an enlarged perspective side view of the longitudinal sealing assembly, in accordance with some embodiments of the present disclosure.

FIG. 16 is an enlarged perspective front view of the longitudinal sealing assembly, in accordance with some embodiments of the present disclosure.

FIG. 17 is a perspective rear view of seam folding member, in accordance with some embodiments of the present disclosure.

FIG. 18 is a perspective view of the transverse sealing assembly in the receiving position, in accordance with some embodiments of the present disclosure.

FIG. 19 is a perspective view of the transverse sealing assembly in one or more sealing positions when the sealer is engaged, in accordance with some embodiments of the present disclosure.

FIG. 20 is a perspective view of the transverse sealing assembly retracting and moving back to the receiving position, in accordance with some embodiments of the present disclosure.

FIG. 21 is a perspective view of the transverse sealing assembly in the receiving position, in accordance with some embodiments of the present disclosure.

FIG. 22 is a perspective side view of the transverse sealing assembly in the receiving position, in accordance with some embodiments of the present disclosure.

FIG. 23 is an enlarged perspective side view of the transverse sealing assembly, in accordance with some embodiments of the present disclosure.

FIG. 24 is a perspective side view of the package transport system, in accordance with some embodiments of the present disclosure.

FIG. 25 is a process flow for packings a plurality of products using the packaging apparatus, in accordance with some embodiments of the present disclosure.

FIG. 26 is a block diagram of a packaging apparatus environment, in accordance with some embodiments of the present disclosure.

DETAILED DESCRIPTION

The following detailed description teaches specific example embodiments of the invention. Other embodiments do not depart from the scope of the present invention. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

As illustrated by FIG. 1-24, the packaging apparatus 10 may comprise a material feeder assembly 300, a product supply assembly 800, a folding assembly 400, a scaling assembly 500, and/or a packaging apparatus system 910 (e.g., including a controller 990 thereof). Generally, the packaging apparatus 10 (e.g., otherwise described as a mailer apparatus 10, or other apparatus based on the type of packaging) is configured for delivering products 200 and material 100 for forming a package (e.g., a mailer, or other package) directly around the products, as will be described in further detail herein. For example, the material feeder assembly 300 of the packaging apparatus 10 may supply material 100 for packaging a plurality of products 200. The folding assembly 400 of the packaging apparatus 10 receives the plurality of products 200 and folds the material 100 around one or more products 200 of the plurality of products 200. The sealing assembly 500 of the packaging apparatus 10 seals the material 100 around the at least one product 200 to form a package 150. A longitudinal sealing assembly 600 of the sealing assembly 500 forms a longitudinal seam 140, while a transverse sealing assembly 700 forms a transverse seam 142. Moreover, the transverse sealing assembly 700 may also separate the material at the transverse seam 720 (e.g., forming a trailing seam and/or a leading seam depending on the package 200). The separation of the transverse seam 142 may occur before or after sealing the seam. However, in some embodiments, the separation of the transverse seam 142 may occur at the same time as transverse seam 142 is sealed.

It should be understood that the invention described herein uses the term “package”, or other similar terms, indicating that the invention can be used to form any type of package 150 around a product 200, for example, a mailer, carton, pouch, envelope or other type of package. As such, it should be understood that the term “package”, or other similar term, may be replaced with a specific type of package, such as a “mailer”, or other similar term. As such, while the invention is described generally for any type of package, the invention may be specifically used for specific packages, such as mailers.

FIGS. 2 through 6 illustrate the material feeder assembly 300, which as noted above is utilized to provide a material 100 for packaging the products 200. The material 100 may comprise any type of material 100; however, in some embodiments the material 100 may comprise kraft paper, or other like paper with a thickness of approximately 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, or other like pt., or that ranges between, falls outside of, or overlaps any of the foregoing pt. values. In some embodiments, the material 100 may be heat scalable coated paper, as will be discussed in further detail herein.

While the material 100 may preferably be paper, in order to allow for the case of recycling, the material 100 may be made of plastics or other type of material. Regardless of the type of material, the material 100 may have a leading end 102, a trailing end 104, a first edge 106, and a second edge 108. Also, it should be understood that when the material 100 is folded it may be further said to have a body 112 and one or more sides, such as a first side 114 and a second side 116 that are angled with respect to the body 112, which forms a material channel, as will be described in further detail herein.

It should be further understood that the material 100 may be a single layer 101 or may have multiple layers 101. For example, the material may include an outer layer of paper and an inner cushioning layer (e.g., tissue paper, slit-sheet expandable paper, embossed paper, bubble wrap, or any other type of cushioning layer). It should be understood that any number and type of material 100 in one or more layers 101 may be utilized in order to form the package 150.

The material feeder assembly 300 may supply the material 100 through the use of a material supply 310 in the form of a roll; however, it should be understood that the material supply 310 may include a stack of folded paper, or other like supply. In some embodiments, the material may weigh 25 to 100 lbs., or may fall outside of, overlap, and fall within this range.

The material feeder assembly 300 may comprise of a plurality of feeder rollers 320, which may or may not be driven (e.g., one or more driven rollers, one or more free rollers, or other like rollers). As such, in some embodiments the material feeder assembly 300, and in particular, the one or more feeder rollers 320 (e.g., the material supply roller 322, or the like), may have a drive 324 (e.g., a motor or the like), which rotates one or more of the feed rollers 320 in order to dispense (e.g., pull, push, unwind, or the like) the material 100 within the material feeder assembly 300. The drive 324 may be a variable drive that is able to adjust the rate at which the material 100 is dispensed. In some embodiments, the drive 324 simply unwinds the material supply 310 and a downstream assembly (e.g., the seaming assembly 500, such as the longitudinal sealing assembly 600, or the like) pulls the material 100 through the packaging apparatus 10. In other embodiments, the drive 324, alone or in combination with a downstream assembly (e.g., the seaming assembly 500, described in further detail below), both move the material 100 throughout the packaging apparatus 10. In some embodiments, the material feeder assembly 300 may be configured to communicate with the packaging apparatus system 910 (e.g., a controller 990 thereof, as will be described in further detail herein) in order to control the dispensing of the material 100 (e.g., speed, acceleration, deceleration, or the like). In some embodiments, the material 100 may be dispensed (e.g., using feeder assembly 300 and/or sealing assembly 500) at a constant (e.g., static) rate. In some embodiments, the material feeder assembly 300 may dispense the material 100 at a dynamic rate based on product information of the products 200, as will be described in further detail herein. As such, the material feeder assembly 300 may communicate with the packaging apparatus system 910 to adjust the speed of the material 100 being dispensed (e.g., unwound) from the material feeder assembly 300 (e.g., based on the products being packaged, or based on other inputs). In some embodiments, the material feeder assembly 300 may have one or more devices (e.g., sensors 50, or the like) to monitor the rate at which the packaging apparatus 10 completes the packaging process and/or to adjust the rate at which the material feeder assembly 300 dispenses the material 100. As such, the material feeder assembly 300 may be controlled by the packaging apparatus system 910 (e.g., a controller 990 thereof). In this way, the material 100 may be moved through (e.g., unwound, pushed, pulled, or the like, or combinations thereof) from the material feeder assembly 300 based on the rate at which the products are supplied to or within the packaging apparatus 10.

The one or more feeder rollers 320 of the material supply assembly 300, as illustrated in FIGS. 2 through 6, may be configured to tension the material 100 before the material 100 is folded by the folding assembly 400. As such, the one or more feeder rollers 320 may be biased (e.g., using coiled springs, leaf springs, other springs, or other biasing members) to apply tension on the material 100 as it is being feed through the material supply assembly 300. In some embodiments, the material 100 characteristics may determine the tension the one or more feeder rollers 320 apply to the material 100.

As illustrated in FIG. 5, the one or more feeder rollers 320 may comprise one or more angled rollers 328, wherein the one or more angled rollers 328 receive the material 100 in a first orientation, and transfer the material 100 to a second orientation different than the first orientation before supplying the material 100 to the folding assembly 400. The one or more angled rollers 328 may be used to reduce the footprint of the packaging apparatus 10, allow the material supply 310 to be located on the side of the packaging apparatus 10 (e.g., to allow for manual or automatic resupply of the material 100), allow for the products to be supplied to the folding assembly 400 with or without concealing all or a part of the material supply assembly 300, or provide other benefits.

It should be understood that when the material supply 310 runs out of, or is running low on, material 100, the packaging apparatus 10 may be stopped (manually by a user or automatically, for example as determined by a sensor and/or the controller). A user may cut the material 100, remove the material (e.g., core of the material roll), and replace the material 100 (e.g., with a new material roll). The user may then splice the new roll with the cut material 100 located within the material assembly 300 of the packaging apparatus 10. For example, a leading end 102 of the new material 100 (e.g., new roll) may be spliced with a trailing end 104 of the current material 100 located within the packaging apparatus 10. The user may then run the material 100 through the packaging apparatus until the splice is cleared from the packaging apparatus 10. In other embodiments, the material 100 may be replaced and spliced using an automated and/or semi-automated process. For example, using an automated material supply (e.g., pallet jack, or the like) and/or automated splicing equipment. After the splice is passed through the packaging apparatus 10, the packaging apparatus 10 may resume normal operation.

The material feeder assembly 300 may further comprise an aperture forming member 330 that is used to form one or more apertures 180 in the material 100 to allow for deflation of the package 150 after the material 100 is wrapped and sealed around the one or more products 200. The one or more apertures 180 may be made over the entire surface of the material 100 or made within a specific portion of the material 100 (e.g., different locations located longitudinally or transversely on the material 100). For example, the one or more apertures 180 may be located within the body 112 of the material 100, but not along a portion of the sides 114, 116 of the material 100 that are used to seal the material 100. The one or more apertures 180 may be a plurality of pinholes made through the material 100, however, it should but understood the one or more apertures may be of any size or shape.

As illustrated in FIG. 6, in some embodiments, the aperture forming member 330 may comprise a projection roller 332 having a plurality of projections (e.g., pins, or the like) that extend from the projection roller 332. As the material 100 passes around the projection roller 332, the one or more feed rollers 320 that tension the material and the plurality of projections of the projection roller 331 pierce the material 100 to form the apertures in the material 100. In some embodiments, the aperture forming member 330 may be operatively coupled to the material feeder assembly 300. However, it should be understood that the aperture forming member 300 may be any type of member located in other assemblies of the packaging apparatus 10, such as within the folding assembly 400, the longitudinal sealing assembly 600, or the transverse sealing assembly 700. As such, the aperture forming member 300 may form different types of apertures during different steps of the packaging process in order to allow the package 150 to be deflated after it is sealed.

While the material feeder assembly 300 is illustrated and described as having one or more feed rollers 320, it should be understood that alternatively, or additionally, the material feeder assembly 300 may utilize belts, tracks, or other types of feed mechanisms in order to aid in feeding the material 100 through the packaging apparatus 10.

In some embodiments, the material feeder assembly 300 may have an inspection system that utilizes one or more sensors (e.g., cameras, photocells, lasers, light curtains, imagining, infrared detection, or the like) to analyze the quality of the material 100. In this way, the material feeder assembly 300, such as the sensors thereof, may be used to inspect the material 100 as it is being dispensed. In some embodiments, the material feeder assembly 300 may determine that the material 100 has one or more defects (e.g., tears, missing pieces, wrinkles, holes, discolorations, and/or the like). In some embodiments, the material feeder assembly 300 may alert the packaging apparatus system 910 as to the defects in the material 100. In some embodiments, the packaging apparatus system 910 may perform a material rejection procedure. In some embodiments, the material rejection procedure may include running the defective material through the packaging apparatus 10 without a product 200. For instance, and by way of non-limiting example, the packaging apparatus 10 may keep running the defective material without stopping the process but may not allow defective material 100 to be folded around a product 200. As such, the defective material may be removed from the material without having to stop the packaging apparatus system 900.

The material feeder assembly 300 may be configured to accommodate one or more types of material 100. In some embodiments, the material feeder assembly 300 may have one or more material supplies 310 that may be used in the process. In some embodiments, the one or more types of material 100 may be run simultaneously (e.g., to create multiple layers), at different times (e.g., to use different materials based on the type of product), or in any combination (e.g., running single layers, combinations of different layers, or the like). In this way, the packaging apparatus system 910 (e.g., controller 990 thereof) may communicate with the material feeder assembly 300. For instance, and by way of non-limiting example, the packaging apparatus system 910 may determine that the product 200 requires one or more types of material 100. The packaging apparatus system 910 may then communicate with the material feeder assembly 300 to dispense the one or more types of material 100 required for the package 150 for the product 200.

FIGS. 7 through 10 illustrate the folding assembly 400, which as noted above, is utilized to fold the material 100 for packaging the products 100, and more preferably, to fold the material 100 around the product 200 as the product 200 is received from a product supply apparatus 800, as illustrated in FIGS. 8 through 12, which will be described in further detail herein. In some embodiments, the folding assembly 400 may comprise a product transport assembly, a folding mold 410 and one or more folding members 420 (e.g., one or more side folding members 430 and/or one or more edge folding members 440).

The product transport assembly may be a conveyer belt that aids in moving the material 100 (e.g., before, during, or after being at least partially folded) with the one or more products 200 located on the material 100. However, in other embodiments, the product transport assembly may be rollers, tracks, or the like that are used to aid in moving the material 100 with the products 200. However, it should be understood that in some embodiments, the material 100 and the products may be moved through the folding assembly 400 by allowing a downstream assembly, such as the sealing assembly 500 (e.g., driven rollers, or the like) to pull the material through the folding assembly 400 and allowing the folding mold 410 and the folding members 420 to shape the material 100 into the general shape of the package 150. Should a product transport assembly be used, a conveyor belt (or other components) may include a drive system (e.g., one or more motors, or the like) to aid in moving the plurality of products 200 and the material 100. In some embodiments, the drive system may be configured to match the rate at which the material 100 is being consumed by the packaging apparatus 10. In some embodiments, the product transport assembly may include undriven (e.g., unpowered) conveyers, rollers, tracks, or the like that aid in moving the material 100 and/or plurality of products 200. As such, it should be understood that the product transport assembly may receive the plurality of products 200 and/or the material 100, provide the plurality of products 200 to the material 100, and/or move the products and/or material 100 downstream.

As illustrated in the figures, the mold 410 may comprise of one or more mold members, such as a first mold member 412 and a second mold member 414 around which the material 100 is folded for forming the packages 150. The first mold member 412 and the second mold members 414 may be L-shaped members around which the material 100 may be folded while the products 200 on the base 112 of the material 100 move with the material 100. The one or more folding members 420, such as the one or more side folding members 430 receives the material 100 in a first configuration and folds the material 100 at least partially around the at least one product 200 of the plurality of products 200 into a second configuration. For example, the first configuration may be receiving the material in a flat configuration, and the second configuration may be folding the one or more sides 114, 116 of the material 100 (e.g., illustrated in FIG. 8) at an angle with respect to at least a portion of the body 112 of the material 100 located between the sides 114, 116.

As illustrated in the FIG. 9, the one or more folding members 420 may comprise one or more side folding members 430 and/or one or more edge folding members 440. The side folding members 430 may comprise a primary side folding member 432 and a secondary side folding member 434. The primary side folding member 432 may be a horizontal folding member, while the secondary side folding member 434 may be a vertical folding member. Both the primary side folding member 432 and the secondary side folding member 434 may be triangular shaped. As such, the primary side folding member 432 and the secondary side folding member 434 fold the sides 114, 116 of the material 100 from the first configuration (e.g., in-plane with the body of the material 100) to the second configuration (e.g., perpendicular with the body of the material 100) in at least two folds. However, it should be understood any number of side folding members 430 may be used to create any number of folds between the first orientation and the second orientation (e.g., 1, 2, 3, 4, 5, or the like number of folds), and moreover, the angle of the sides 114, 116 with respect to the body 112 of the material may be different than approximately 90 degrees. That is, the angle may be 10, 20, 30, 40, 45, 50, 60, 70, 80, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, or may range between, overlap, or fall outside of any of these values. Regardless of the angle, it should be understood that the one or more side folding members 430 may fold one or both sides of the material 100 around the folding mold 410 (e.g., the material is located between the side folding members and the mold 410) to form a material channel 118 having a base 119 that receives the plurality of products 200, a first side 114 and/or a second side 116.

It should be understood that the folding assembly 400 may further comprise one or more edge folding members 440, for example, as illustrated in FIG. 9. The one or more edge folding members 440 may comprise one or more edge guide members 442. The edge guide members 442 may be rods, plates, or the like that direct the edges 106, 108 of the sides 114, 116 of the material 100 towards each other and/or around the mold top 416 (e.g., attached to and/or formed by the first mold member 412 and a second mold member 414). As such, the seaming assembly 500 may be used to form a scam 140 (otherwise described as a fin seal, fin seam, or the like) between the edges 106, 108 of the material 100, as will be discussed in further detail herein. As illustrated, in some embodiments one edge (e.g., the first edge 106 or the second edge 108) of the material 100 may overlap another edge of the material 100 in order to aid in creating the longitudinal seam 140 and allowing the longitudinal seam 140 to be folded back onto the package 150.

In some embodiments, the mold 410 and/or the one or more folding members 420 may be coated with an anti-friction material to reduce frictional forces with the material 100. In some embodiments, the coating may be any type of material that reduces frictional forces. In some embodiments, the coating material may be tape, paint, sealant, and/or the like.

In some embodiments, the folding assembly 400 may fold the material 100 around one or more products 200 in a single package 150 (e.g., a single product, multiple stacked products, multiple products side by side, multiple products end to end with little to no space between, or the like). As such, the folding assembly 400 may fold the material 100 around one product in a single package 150. In other embodiments, as will be described in further detail herein, the packaging apparatus system 910 may identify (e.g., through sensors 50, product input, or the like) a specific quantity of products 200 that are required to be packaged in a single package 150 based on the products being received from the product supply assembly 800 (e.g., a product placed alone or with other products therein).

In some embodiments, the folding assembly 400 may fold the material 100 around the product 200 in a static manner. For instance, and by way of non-limiting example, the folding assembly 400 may have a static pattern which folds the material 100 in a consistent (e.g., unchanging) manner. In this way, the packages 150 produced by the packaging apparatus system 900 will have similar characteristics (e.g., dimensions, patterns, sizes, and/or the like).

In some embodiments, the folding assembly 400 may fold the material 100 around the product 200 in a dynamic manner. For instance, and by way of non-limiting example, the folding assembly 400 may be configured to adjust the folding pattern of the material 100 around the product 200 by adjusting the folding mold 410 and/or the one or more folding members 420 (e.g., move the mold 410 and/or the one or more folding members 420 up, down, toward or away from each other, or the like). In this way, the packaging apparatus system 900 may produce packages 150 that have different characteristics (e.g., dimensions, patterns, sizes, and/or the like). In some embodiments, the folding assembly 400 may adjust the folding pattern around the product 200 during the process in response to the requirements of a specific product 200. For instance, and by way of non-limiting example, the packaging apparatus system 910 may receive information that a particular product 200 requires a folding pattern different than the product that preceded it in the process. The folding assembly 400 may then adjust the one or more members (e.g., the members discussed herein) in order to change the folding pattern to match the requirements of the particular product 200. In some embodiments, the requirements of the particular product 200 may include the product's dimensions, the specifications of a consumer of the product, and/or the like. In some embodiments only the length of the packing may be changed (e.g., made smaller or longer based on the length of the product), as will be described in further detail herein. In some embodiments, the folding mold 410 and/or the one or more folding members 420 may be able to be adjusted by a user (e.g., operator, technician, employee, and/or the like). In some embodiments, the folding mold 410 and/or the one or more folding members 420 may be able to be dynamically adjusted automatically by the packaging apparatus system 910.

In some embodiments, the folding assembly 400 may include an inspection system to determine whether the material 100 contains one or more defects. In some embodiments, the inspection system may comprise one or more sensors that detect defects in the material 100 after the material 100 passes through the folding assembly 400. In this way, the one or more sensors may detect any defects (e.g., rips, tears, wrinkles, discolorations, and/or the like) in the material 100 after the material 100 has been at least partially folded around the at least one product 200. In some embodiments, in response to the inspection system determining that the material 100 contains a defect, the folding assembly 400 may perform a folded material rejection procedure. In some embodiments, the folded material rejection procedure may include communicating to the packaging apparatus system 910 that the material of concern contains a defect.

FIGS. 14 through 17 illustrate an embodiment of the sealing assembly 500, which as described above is used to form a longitudinal seam 140 in the package 150, a transverse seam 142 between packages 150, seal the packages 150, and/or separate the packages 150 in one or more assemblies. In some embodiments, the sealing assembly 500 may comprise a longitudinal sealing assembly 600 and a transverse sealing assembly 700. The longitudinal sealing assembly 600 seals the edges 106, 108 of the material 100 formed by the folding assembly 400 as previously described herein. The longitudinal seam 140 may be formed adjacent to a first edge 106 and a second edge 108 of the material 100 to form the longitudinal seam 140 along the length of the material 100. In some embodiments, longitudinal sealing assembly 600 comprises a heater that heats the first edge 106 and/or the second edge 108 of the material 100 before, during, or after pressing the first edge 106 and/or the second edge 108 together (e.g., between rollers, or the like). After creating the longitudinal seam 140, the material 100 may be described as being formed into a material conduit 130 around the one or more products 200 located within the material conduit 130 before the transverse seam 142 is formed between the one or more products 200.

As previously discussed herein, in some embodiments, the second edge 108 may extend past the first edge 106, and the longitudinal sealing assembly 600 may comprise a seam folding member 610 (e.g., otherwise described as a layover member), which may be a semi-ridged member that is able to flex, and which folds the longitudinal seam 140 onto the material conduit 130. As such, an exposed surface of the second edge 108 may stick to the material 100 in order to keep the longitudinal seam 140 in place and avoid the longitudinal seam 140 from coming apart during downstream processing. In some embodiments, the distance one edge extends over another edge may be adjusted by the folding assembly 400. In some embodiments, the distance one edge extends over another edge may be adjusted by the longitudinal sealing assembly 600.

While the longitudinal sealing assembly 600 may utilize heat to form the seam 140 by sealing the edges 106, 108 of the material 100, it should be understood that other types of sealing may be used. For example, water activated adhesives, double sided tape, liquid adhesives, mechanical fasteners, and/or other types of seals and/or sealant may be used to form the seam. Also, it should be understood that when describing that the seam is formed by “sealing”, such sealing may or may not be watertight, water resistant, or the like.

The longitudinal sealing assembly 600, alone or in combination with the material supply system 300 (e.g., a drive thereof), may be used to move the material 100 through the packaging apparatus 10. That is, driven rollers within the longitudinal sealing assembly 600 may squeeze a portion of the material and aid in pulling the material 100 through the sealing assembly 600 and deliver the material conduit 130 formed within the longitudinal sealing assembly 600 to the transverse sealing assembly 700.

Furthermore, as illustrated in FIGS. 18 through 23, and as previously described herein, the sealing assembly 500 may further comprise a transverse sealing assembly 700. The transverse sealing assembly 700 may be a part of the longitudinal sealing assembly 600 (or vice versa), or the transverse sealing assembly 700 may be a separate assembly within the packaging apparatus 10. Moreover, as will be described herein, the transverse sealing assembly 700 may include one or more transverse sealers 710 and/or one or more separators 720, such that the transverse sealing assembly 700 may both seal and sperate (e.g., to create one or more mailers 150 at a time). However, it should be understood that the separator 720 may be a part of a separate assembly that is used to separate the material conduit 130 in the transverse direction between products before or after the transverse sealing is created by the one or more transverse sealers 710 of the transverse sealing assembly 700.

The transverse sealing assembly 700 may comprise one or more transverse sealers 710 and/or one or more separators 720. The one or more transverse sealers 710 receive the material conduit 130 with the plurality of products 200 and forms a transverse seal 142 in the material conduit 130 between at least two adjacent products 200 of the plurality of products 200. The separator member 720 separates the material conduit 130 at the transverse seal 142 to form a downstream package 150 with a sealed trailing end 154 and a sealed leading end 152 of an adjacent package 150 upstream of the downstream package 150. As previously described with respect to the longitudinal sealing assembly 600, the seal formed by the one or more transverse sealers 710 may or may not be watertight, water resistant, or the like.

Moreover, like the longitudinal sealing assembly 600, the one or more transverse sealers 710 may comprise one or more heat sealer members 711 (e.g., heating tubes, heating bars, heating wires, or the like) that seal by heating the material 100, or a sealant added to the material 100, before or during the sealing and separating step. However, it should be understood that the transverse seam 142 may be formed through the use of water activated adhesives, double sided tape, liquid adhesives, mechanical fasteners, and/or other types of scals.

In the illustrated embodiments in the figures, the transverse sealing assembly 700 comprises a single sealer 710 that is supported by one or more supports 712 and is moveable through the use of sealing drive assembly 714 (e.g., motors, pullies, chains, tracks, or the like) that is able to move the sealer 710 vertically between an engaged position and one or more disengaged positions. In the engaged position, the sealer 710 forms the transverse seam 142 in the material conduit 130. Alternatively, in the one or more disengaged positions, the transverse scaling assembly 700 is able to receive additional material conduit 130 to form additional packages 150 as will be described in further detail herein. The single sealer 710 may include a single heat sealer member 711 located above or below the material conduit 130 and pinches the material conduit against a static or moveable sealing seat that is located opposite the heat sealer member 711. In other embodiments, the single sealer 710 may include heat sealing members 711 above and below the material conduit 130, of which one or both are moveable (e.g., by the drive assembly 714, or the like) to pinch the material conduit 130 and form the mailer 150.

The separator 720 of the transverse sealing assembly 700 may comprise a separator member 722 (e.g., a blade, such as a serrated blade) that is located within or adjacent to the sealer 710 above the material conduit 130 or below the material conduit 130. The separator 720 may further have separator seat 724 that is located opposite the separator member 722. The separator 720 may be static or may be dynamic. Moreover, the separator member 722 of the separator 720 may be extendable and retractable from the separator 720. As such, in some embodiments the separator 720, like the sealer 710, may be moved between the engaged position and one or more disengaged positions. For example, as the sealer 710 is moved to the engaged position, the separator 720 is also moved to the engaged position to pinch and separate the material conduit 130 between the sealer 710 and the separator 720. Alternatively, the separator 720 is static and the sealer 710 is moved until it engages with the separator 720. Regardless of the movement of the sealer 710 and/or the separator 720, or portions thereof, as the sealer 710 is forming the seam 140 or after the sealer 710 forms the seam 140, the separator member 722 is extended (e.g., from above or below) to separate the seam 142 into the trailing end 154 and the leading end 152 of adjacent packages 150, and thereafter the separator member 720 is retracted along with the sealer 710 or separately from the sealer 710.

In some embodiments the separator member 722 may be static and operatively coupled to the one or more transverse sealers 710 (or portions thereof), and thus, engaged and disengaged with the one or more sealers 710 from above or below. In some embodiments, the transverse sealer 710 and the separator 720 may be separate from each other and located on opposite sides of the material conduit 130 (e.g., above and below the material conduit). For example, the transverse sealer 710 may be engaged from below the material conduit 130, while the separator 720 may be engaged from above the material conduit 130.

In some embodiments, portions of the sealer 710 may be located above and below the material conduit 130. Moreover, the separator 720, or portions thereof may be located above and below the material conduit 130. For example, a portion of the sealer 710 (e.g., one or more heat sealing members 711, such as one or more heating tubes, or the like) may be located above the material conduit 130 and a portion of the sealer 710 (e.g., one or more heat sealing members 711, such as one or more heating tubes, or the like) may be located below the mater conduit 130. As such, the portions of the sealer 710 located above and/or below the material conduit may both be dynamic or one may be static. Moreover, the separator member 722 and the separator seat 724 may be located on opposite portions of the sealer 720 (e.g., one above and one below the material conduit 130).

Regardless of the configuration of the sealer 710 and/or separator 720, before, during, or after sealing by the one or more transverse sealers 710, the separator member 722 (e.g., blade) separates the material conduit 130 such that the sealed trailing end 154 and the sealed leading end 152 are formed (e.g., may be sealed and separated at the same time, or at different times).

In some embodiments, the heat sealer 711 may operate within an adjustable sealer temperature range. In some embodiments, the sealer temperature range may be controlled by the packaging apparatus system 910. As such, the sealer temperature range may be adjusted based on the properties of the material 100 and/or the sealant being used to form the transverse seam 142.

The transverse sealing assembly 700 may further comprise a package transport system 730 that transports a plurality of packages 150 after the transverse scaling and separating of the plurality of packages 150. The package transport system 730 may comprise a conveyor belt (e.g., otherwise described as an outbound conveyor) that is used to transport the plurality of packages downstream of the one or more transverse sealers 710 and/or the separator 720. However, in other embodiments the package transport system 730 may utilize rollers, tracks, or the like to transport the one or more packages 150. In some embodiments, the package transport system 730 may be long enough for one or more packages 150 to fit on the package transport system 730. In some embodiments, the package transport system 730 may be less than the length of a package 150, which may allow the package 150 to drop down to a storage system or another transport system.

Moreover, in some embodiments, the transverse sealing assembly 700 may comprise a carriage assembly 740 that moves the one or more transverse sealers 710, the separator 720, and/or the package transport system 730 such that the packaging apparatus 10 can continuously move the material 100 and form the material conduit 130 without having to stop the movement to create the transverse seam 142 and separate adjacent packages 150.

As illustrated in FIG. 18, when the sealer 710 is in the disengaged position the transverse sealing assembly 700 is located in the receiving position. In the receiving position, the material conduit 130 is feed to the sealer 710. When the material conduit 130 is in the correct position for sealing and separating packages (e.g., as determined by the sensors 50, controller 990, or the like), the sealer 710 squeezes the material conduit 130 (e.g., against the separator 720), as illustrated in FIG. 19. In this engaged position, the carriage assembly 740 also moves the transverse sealer 710, the separator 720, and the package transport system 730 at the same speed and in the same direction as the material 100 and material conduit 130 are moving in the packaging apparatus 10, as illustrated by Arrow A in FIG. 19. Thereafter, after sealing and separating the sealing member 710 is disengaged, the carriage assembly 740 begins to return to the receiving position by moving the transverse sealer 710, the separator 720, and the package transport system 730 in the opposite direction of the material 100 and material conduit 130, as illustrated by Arrow B in FIG. 20. At the same time the carriage assembly 740 is moving the transverse sealer 710, the separator 720, and the transport system 730 to the receiving position the material conduit 130 is being feed past the transvers sealer 710 and separator 720 for forming the next package 150. As illustrated in FIG. 21, the transverse sealing assembly 700 is in position to form the next package 150 by creating another transverse scam 142.

As previously discussed, the transverse sealer 710 and the separator 720 may be two distinct components. In some embodiments, the transverse sealer 710 may be positioned before the separator 720 in the process, or the separator 720 may be positioned before the transverse sealer 710. In some embodiments, the transverse sealer 710 and the separator member 720 may have separate carriage assemblies 740 that move the transverse sealer 710 and the separator 720 independently.

It should be understood that in some embodiments, one or more other assemblies are located downstream of and/or operatively coupled to the transverse sealing assembly 700. For example, labeling assemblies (e.g., printing assemblies, label assemblies) for forming and/or applying labels to the packages 150, transport assemblies for transporting the packages 150 to other locations in the facility, shipping assemblies for preparing the packages 150 for shipping, or the like may be located downstream of the sealing assembly 500.

Returning to FIGS. 8 through 12, in some embodiments, the packaging apparatus 10 may further comprise a product supply assembly 800, wherein the product supply assembly 800 is operatively coupled to the folding assembly 400, and wherein the product supply assembly 800 is configured to transport the plurality of products 200 to the folding assembly 400. The product supply assembly 800 may comprise of a conveyor, rollers, tracks, pullies, motors, and/or other like features to supply the plurality of products to the folding assembly 400. In some embodiments, the product supply assembly 800 may comprise a sensor system 810, wherein the sensor system 810 comprises one or more sensors 50 that captures product information for the products 200 and sends the product information to the packaging apparatus system 910. The packaging apparatus system 910 (e.g., controller 990 thereof) uses the product information for controlling engagement of the one or more transverse sealing assemblies 700 of the sealing assembly 500. The sensor system 810 may include one or more sensors 50 (e.g., photocells, lasers, light curtains, IR, cameras, scanners, code readers-barcode, QR code, or the like, or other like sensors) that are used to capture the product information. The product information may include product dimensions (e.g., length, width, height, or the like), the product shape (e.g., round, square, rectangular, non-uniform, or the like), and/or the distance between products being supplied such that the packaging apparatus system 910 can instruct the transverse sealing assembly 700 when to create the transverse seam 142 and/or separate the packages 150 along the transverse seam 142. As such, the packaging apparatus system 910 may communicate with the sensor system 810 and communicate the distance and/or time between the products 200 to the transverse sealing assembly 700, as will be described in further detail with respect to FIG. 26.

FIG. 25 illustrates a process 1000 for forming the packages 150. As illustrated in block 1002, material 100 may be fed through the material feeder assembly 300. It should be understood that the material may be fed manually by a user. In other embodiments the material may be fed automatically by operatively coupling a leading end of replacement material 100 to a trailing end of expiring material 100 that has or is about to run out.

Block 1004 of FIG. 25 further illustrates that a plurality of products 200 are supplied to the folding assembly 400. In some embodiments the plurality of product are supplied directly to the folding assembly 400 or to a product supply assembly 800 (e.g., conveyor, or other transport) that is operatively coupled to the folding assembly 400. The plurality of products 200 may be manually supplied by a user placing the plurality of products 200 by hand. In other embodiments, the plurality of products 200 are placed automatically as they are manufactured, transported robotically, received through transport systems (e.g., within a warehouse, or the like), and/or suppled through other devices. It should be understood that regardless of how the plurality of products 200 are supplied (e.g., manually, automatically, directly to the folding assembly 400, indirectly through a product supply assembly 800, or the like), one or more sensors 50 may capture product information from the plurality of products 200. The product information may include the size of the product 200 (e.g., length, or the like) and/or the distance and/or time between products, such as the distance between the product trailing end (e.g., last point of a product based on the shape and orientation of the product) of a downstream product 200 and the product leading end (e.g., first portion of a product based on the shape and orientation of the product) of an adjacent upstream product 200.

FIG. 25 illustrates in block 1006 that the folding assembly 400 folds one or more sides 114, 116 (e.g., a single side, two sides) of the material 100 around the one or more products 200 (e.g., single product, multiple products stacked, and/or series of products in-line with each other). The one or more products 200 and the material 100 are moved along the folding assembly 400 as the one or more sides 114, 116 are folded around the one or more products 200 using a folding mold 410 and/or one or more side folding members 430. The folding assembly 400 further directs the edges 106, 108 of the sides 114, 116 of the material 100 together using one or more edge folding members 440 for seaming by the seaming assembly 500. As illustrated in FIGS. 15 and 16, one edge 108 of the material 100 may extend past another edge 106 of the material 100, in order to allow the longitudinal seam 140 to be folded back onto the material 100.

As illustrated by block 1008 of FIG. 25, the longitudinal sealing assembly 600 of the sealing assembly 500 forms a longitudinal seam 140 adjacent the edges 106, 108 of the sides of the material 100. For example, a heater may heat a sealant (e.g., pre-assembled to the material 100, adding during sealing, or the like) to create the longitudinal seam 140 between the edges 106, 108 of the material 100. Moreover, a seam folding member 610 may fold the longitudinal seam 140 over and back onto the material 100 such that the inner surface of the exposed edge 108 may stick to the material 100. By folding over the seam 140, this aids in preventing the longitudinal seam 140 from catching on something and opening the package 150 during further processing and/or transport. The longitudinal sealing assembly 600 forms a material conduit 130 in which a plurality of products 200 are located. As previously discussed herein, the longitudinal seam 140 may be formed in other ways.

Block 1010 of FIG. 25 further illustrates that after the longitudinal scam 140 is formed, the material conduit 130 is fed to the transverse sealing assembly 700 of the scaling assembly 500. The transverse sealing assembly 700 creates a transverse seam 142 by sealing the material conduit 130 and/or separates the seam 142 to form a trailing end 154 of a downstream package 150 that has been formed, and a leading end 152 of an adjacent upstream package 150 that has yet to be formed since the trailing end 154 of the upstream package 150 has yet to be sealed and separated. The one or more transverse sealers 710 of the transverse sealing assembly 700 is engaged by a controller 990 (described below) based on the product information received from the sensors 50. That is, the controller 990 has the size the product 200, the distance and/or time of the product 200 from the sealing assembly 700 when the sensors 50 captured the product information, the speed at which the product 200 travels from the sensor 50 to the sealing assembly 700, and the distance and/or time between adjacent products 200. The controller 990 uses the product information in order to engage the transverse sealing apparatus 700 to form the transverse seal.

Block 1012 of FIG. 25 further illustrates that as the sealer 710 of the transverse sealing assembly 700 is engaged to create the transverse seam 142, the carriage 740 moves the sealer 710, the separator 720, and/or the package transport assembly 730 in the same direction and speed as the material 100 and material conduit 130 are moving in the packaging apparatus 10. As the carriage 740 is moving, the package transport assembly 730 (e.g., conveyor, or the like) may be paused such that any packages 150 on the package transport assembly 730 are not moving independent of the movement of the carriage 740 that is moving the package transport assembly 730.

FIG. 25 further illustrates in block 1014 that after sealing and separating the transverse seam 142 between packages 150, the sealer 710 disengages and the carriage 740 moves the sealer 710, the separator 720, and/or the package transport assembly 730 in the opposite direction of the movement of the material 100 and material conduit 130 within the packaging apparatus 10. As the carriage 740 moves towards the receiving position in the opposite direction as the material conduit 130, the material conduit 130 is further fed into position for sealing another package 150. Moreover, while the carriage 740 is moving towards the receiving position, the package transport assembly 730 is activated to move the formed packages 150 downstream for further processing. The transverse sealing and separating of the seam 142 by the transverse sealing assembly 700 described in block 1010, and the movement of the carriage 740 described in blocks 1012 and 1014 is repeated for forming a plurality of packages 150 (e.g., a plurality of mailers).

The operation of the packaging apparatus 10, including the material supply assembly 300, the folding assembly 400, the sealing assembly 500 (e.g., the longitudinal scaling assembly 600 and/or the transverse sealing assembly 700), the product supply assembly 800, and/or other assemblies, including the systems thereof, as well as the sensors 50 monitoring any of the forgoing, may be controlled by a programmable controller 990. The controller 990 may communicate with the various assemblies and/or systems of the packaging apparatus 10 and/or other systems within a facility that are used upstream or downstream of the packaging apparatus (e.g., product manufacturing systems, labeling systems, shipping systems, transport system for transporting product and/or packages, ordering systems, or the like).

As such, FIG. 26 illustrates a packaging network system 900, in accordance with embodiments of the present disclosure. As illustrated in FIG. 26, one or more packaging apparatus systems 910 of the packaging network system 900 are operatively coupled, via a network 902, to one or more user computer systems 920 and one or more other systems 930 (e.g., other equipment systems, other entity systems, or the like). In this way, the packaging apparatus systems 910 operate the packing apparatus 10 and/or may communicate with other equipment systems 930 for controlling operation of other equipment upstream or downstream of the packaging apparatus 10. The packaging apparatus system 910 may communicate with user computer systems 920 to allow the user computer systems 920 to monitor and/or control the packaging apparatus 10. Moreover, the packaging apparatus systems 910 may communicate with other systems, such as material supply systems (not illustrated) which may request and/or provide the material 100 when the packaging apparatus 10 is low on material. The communications of the systems may occur over a network 902, as will be described in further detail herein.

The network 902 may be a global area network (GAN), such as the Internet, a wide area network (WAN), a local area network (LAN), or any other type of network or combination of networks. The network 902 may provide for wireline, wireless, or a combination of wireline and wireless communication between systems, services, components, and/or devices on the network 902.

As illustrated in FIG. 26, the one or more packaging apparatus systems 910 may comprise a controller 990 that may generally comprise one or more communication components 912, one or more processing components 914, and one or more memory components 916. The one or more processing components 914 are operatively coupled to the one or more communication components 912, and the one or more memory components 916. As used herein, the term “processing component” generally includes circuitry used for implementing the communication and/or logic functions of a particular system. For example, a processing component may include a digital signal processor component, a microprocessor component, and various analog-to-digital converters, digital-to-analog converters, and other support circuits and/or combinations of the foregoing. Control and signal processing functions of the system are allocated between these processing components according to their respective capabilities. The one or more processing components 914 may include functionality to operate one or more software programs based on computer-readable instructions thereof, which may be stored in the one or more memory components.

The controller 990 components, such as the one or more communication components 912, may be operatively coupled to the packaging apparatus systems 910, one or more sensors 50, one or more user computer systems 920, and/or other systems 930, as previously described herein. The one or more processing components 914 use the one or more communication components 912 to communicate with the network 902 and other components on the network 902, such as, but not limited to, the components of the one or more user computer systems 920, and/or the one or more other systems 930. As such, the one or more communication components 912 generally comprise a wireless transceiver, modem, server, electrical connection, electrical circuit, or other component for communicating with other components on the network 902. The one or more communication components 912 may further include an interface that accepts one or more network interface cards, ports for connection of network components, Universal Serial Bus (USB) connectors, or the like. Moreover, the one or more communication components 912 may include a keypad, keyboard, touch-screen, touchpad, microphone, mouse, joystick, other pointer component, button, soft key, and/or other input/output component(s) for communicating with the users. In some embodiments, as described herein, the one or more communication components 912 may comprise a user interface, such as a graphical user interface 992 that allows a user to control and/or monitor the operation of the packaging apparatus 10, upstream apparatuses through upstream systems, and/or downstream apparatuses through downstream systems.

As further illustrated in FIG. 26, the one or more packaging apparatus systems 910 comprise computer-readable instructions 918 stored in the one or more memory components 916, which in some embodiments includes the computer-readable instructions 918 of the one or more packaging applications 917 (e.g., used to operate the packaging apparatus 10 and/or the assemblies, such as the components thereof, or the like). In some embodiments, the one or more memory components 916 include one or more data stores 919 for storing data related to the packaging apparatus 10, including, but not limited to, data created, accessed, and/or used by the one or more packaging apparatus systems 910 to operate the one or more packaging apparatuses 10, including the assemblies thereof.

As illustrated in FIG. 26, users may communicate with each other over the network 902 and/or with the packaging apparatus systems 910, and/or the other systems 930 in order to control and/or monitor the packaging apparatus 10 remotely. Consequently, the one or more users may be employees, agents, representatives, contractors, officers, or the like of an organization operating the facility. The one or more user computer systems 920 may be a desktop, laptop, tablet, mobile device (e.g., smartphone device, or other mobile device), or any other type of computer that generally comprises one or more communication components 922, one or more processing components 924, and one or more memory components 926.

The one or more processing components 924 are operatively coupled to the one or more communication components 922, and the one or more memory components 926. The one or more processing components 924 use the one or more communication components 922 to communicate with the network 902 and other components on the network 902, such as, but not limited to, the one or more packaging apparatus systems 910 and/or the one or more other systems 930. As such, the one or more communication components 922 generally comprise a wireless transceiver, modem, server, electrical connection, or other component for communicating with other components on the network 902. The one or more communication components 922 may further include an interface that accepts one or more network interface cards, ports for connection of network components, Universal Serial Bus (USB) connectors and the like. Moreover, the one or more communication components 922 may include a keypad, keyboard, touch-screen, touchpad, microphone, mouse, joystick, other pointer component, button, soft key, and/or other input/output component(s) for communicating with the users. In some embodiments, the one or more communication components 922 may comprise a user interface, such as a graphical user interface that allows a user to remotely control and/or monitor the operation of the packaging apparatus 10.

As illustrated in FIG. 26, the one or more user computer systems 920 may have computer-readable instructions 928 stored in the one or more memory components 926, which in some embodiments includes the computer-readable instructions 928 for user applications 927, such as dedicated applications (e.g., apps, applet, or the like), portions of dedicated applications, a web browser or other apps that allow access to applications located on other systems, or the like. In some embodiments, the one or more memory components 926 include one or more data stores 929 for storing data related to the one or more user computer systems 920, including, but not limited to, data created, accessed, and/or used by the one or more user computer systems 920. The user application 927 may use the applications of the one or more packaging apparatus systems 910 and/or other systems 930 in order to communicate with systems on the network 902 and take various actions described herein (e.g., operation, use, monitoring, or the like of the packaging apparatus 10).

Moreover, as illustrated in FIG. 26, the one or more other systems 930 may have components the same as or similar to the components described with respect to the one or more packaging apparatus systems 910 and the one or more user computer systems 920 (e.g., one or more communication components, one or more processing components, one or more sensors, one or more memory devices with computer-readable instructions of one or more other applications, one or more datastores, or the like). Thus, the one or more other systems 930 may include the systems of upstream and/or downstream apparatuses, or components thereof, that operate and/or communicate with the one or more packaging apparatus systems 910 and/or the one or more user computer systems 920 in same or similar way as previously described with respect to the one or more packaging apparatus systems 910 and the one or more user computer systems 920. The one or more other systems 930 may comprise the systems that operate equipment that produces, transports, and/or supplies the material 100 and/or the products, and/or handle the packages 150 (e.g., mailers, or the like) with the products 200 after being packaged by the packaging apparatus 10 (e.g., apply labels, transport the packaging, and/or process the packaging for shipping).

As will be appreciated by one of skill in the art in view of this disclosure, embodiments of the invention may be embodied as an apparatus, a system, computer program product, and/or other device, a method, or a combination of the foregoing. Accordingly, embodiments of the invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.), or an embodiment combining software and hardware aspects that may generally be referred to herein as a “system.” Furthermore, embodiments of the invention may take the form of a computer program product comprising a computer-usable storage medium having computer-usable program code/computer-readable instructions embodied in the medium (e.g., a non-transitory medium, or the like).

Any suitable computer-usable or computer-readable medium may be utilized. The computer usable or computer readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires; a tangible medium such as a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a compact disc read-only memory (CD-ROM), or other tangible optical or magnetic storage device.

Computer program code/computer-readable instructions for carrying out operations of embodiments of the invention may be written in an object oriented, scripted or unscripted programming language such as Java, Pearl, Python, Smalltalk, C++ or the like. However, the computer program code/computer-readable instructions for carrying out operations of the invention may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages.

The packaging apparatus 10 of the present invention provides improvements over traditional packaging apparatuses in which packages (e.g., mailers, cartons, envelopes, or the like) are formed and/or opened, and thereafter packed with a product. Unlike traditional packaging apparatuses, the packaging apparatus 10 of the present invention forms the package around the products. The material 100 used for the packaging apparatus 10 may be shipped in rolls, stacks of paper, and/or like to form the packages on site instead of having to ship cartons, mailers or the like that take up space and increase shipping costs. Furthermore, the steps and equipment associated with traditional processing that requires opening a package, holding the package open, and supplying the products to the open package are eliminated by the present invention. Moreover, since the packaging apparatus 10 of the present invention forms the package around the products based on product information captured from the products, the present invention allows for the creation of customized packages for products of different sizes as the products are supplied to the packaging apparatus 10. Furthermore, the scaling assembly 500, and in particular, the transverse sealing assembly 700 provides improvements over traditional sealing assemblies in that it is able to create a scam by sealing two ends of two adjacent packages 150 at the same time, and further allows for a separator to separate the scam between the two ends of the packages 150 during the creation of the seam. Additionally, the transverse scaling assembly 700 moves in the same direction and at the same speed as the material 100 in the packaging apparatus 10 while the transverse seam 142 is being formed and separated, which does not require the packaging apparatus 10 to slow or pause the movement of the material 100 while it is being sealed and separated. As such, the packaging apparatus 10 of the present invention can create packages 150 faster than traditional packaging apparatuses that have to slow or pause the movement of the material while the material is cut and scaled.

Several alternative examples have been described and illustrated herein. A person of ordinary skill in the art would appreciate the features of the individual embodiments and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the examples could be provided in combination with the other examples disclosed herein. Additionally, the terms “first” and “second,” as used herein, are intended for illustrative purposes only and do not limit the embodiments in any way.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including” when used herein, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “coupled” or “operatively coupled” (other similar phrase) to another element, the elements can be formed integrally with each other, or may be formed separately and put together. Furthermore, “coupled” or “operatively coupled” to can mean the element is directly coupled or operatively coupled to the other element, or intervening elements may be present between the elements. Furthermore, “coupled” or “operatively coupled” may mean that the elements are detachable from each other, or that they are permanently coupled together.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as top, bottom, front, rear, side, upper, lower, left, right, horizontal, vertical, upward, and downward merely describe the configuration shown in the figures. The referenced components may be oriented in an orientation other than that shown in the drawings and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. All structural and functional equivalents to the elements of the various aspects described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings.

Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

It is understood that the specific order or hierarchy of steps, operations, or processes disclosed is an illustration of exemplary approaches. Unless explicitly stated otherwise, it is understood that the specific order or hierarchy of steps, operations, or processes may be performed in different order. Some of the steps, operations, or processes may be performed simultaneously. The accompanying method claims, if any, present elements of the various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or hierarchy presented. These may be performed in serial, linearly, in parallel or in different order. It should be understood that the described instructions, operations, and systems can generally be integrated together in a single software/hardware product or packaged into multiple software/hardware products.

The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, the subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.

PACKAGING APPARATUS AND METHOD OF USE

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