Abstract
A system and method for continuously forming an envelope. The method includes providing a substrate including a liner, where the substrate has a side edge; plunging the substrate into a cartridge with a pusher to a desired depth to form a U having two opposing walls, two side openings and a flap opening; squeezing the two opposing walls along the two side openings, while keeping the flap opening open; sealing the two opposing walls along the two side openings to form the envelope; retracting the pusher; and filling the envelope disposed in the cartridge via the flap opening, where the substrate is disposed on a roll.
Claims
1. A method for continuously forming an envelope, the method comprising: providing a substrate comprising a liner, wherein the substrate has a side edge; plunging the substrate into a cartridge with a pusher to a desired depth to form a U having two opposing walls, two side openings and a flap opening; squeezing the two opposing walls along the two side openings, while keeping the flap opening open; sealing the two opposing walls along the two side openings to form the envelope; retracting the pusher; and filling the envelope disposed in the cartridge via the flap opening, wherein the substrate is disposed on a roll.
2. The method of claim 1, wherein the liner is disposed on a second roll different than the roll.
3. The method of claim 1, wherein the squeezing is performed by rollers disposed to contact the substrate adjacent to the two side openings.
4. The method of claim 1, wherein the sealing comprises heating the substrate adjacent to the two side openings.
5. The method of claim 1, wherein the sealing further comprises closing and affixing the flap.
6. The method of claim 1, wherein the liner comprises a domed paper material disposed on a second roll.
7. The method of claim 1, wherein the sealing comprises activating a gum tape adhesive.
8. The method of claim 1, wherein the substrate comprises a meltable plastic and the sealing comprises heating the substrate adjacent to the two side openings.
9. The method of claim 1, further comprising selecting the liner based on a content to be disposed in the envelope.
10. The method of claim 1, wherein the liner comprises an inflatable liner.
11. The method of claim 1, further comprising disposing the flap opening for access by an operator; and filling the envelope with a content, wherein the sealing seals the flap opening.
12. The method of claim 11, further comprising moving the envelope and the cartridge to permit horizontal access to the flap opening by the operator.
13. The method of claim 1, further comprising engaging the pusher with a content to be disposed in the envelope in the cartridge; filling the content in the envelope in the cartridge with the pusher; and releasing the content in the envelope in the cartridge.
14. The method of claim 13, wherein the filling and the plunging are performed simultaneously.
15. A machine system to continuously form an envelope, the machine system comprising: a substrate comprising a liner, wherein the substrate has a side edge; a cartridge; a pusher to plunge the substrate into the cartridge to a desired depth to form a U having two opposing walls, two side openings and a flap opening; holders to squeeze the two opposing walls along the two side openings, while keeping the flap opening open; and a sealer to seal the two opposing walls along the two side openings to form the envelope, where the pusher is retracted, the envelope disposed in the cartridge is filled via the flap opening and the substrate is disposed on a roll.
16. The machine system of claim 13, wherein the liner is disposed on a second roll different than the roll.
17. The machine system of claim 13, further comprising a heater to heat and seal the substrate adjacent to the two side openings.
18. The machine system of claim 13, wherein the liner comprises a domed paper material disposed on a second roll.
19. The machine system of claim 13, further comprising a moistener and a roller, wherein the moistener moistens an adhesive on a flap prior to the roller closing the flap.
20. The machine system of claim 13, further comprising an order and product system to select the liner based on a content to be disposed in the envelope.
21. The machine system of claim 13, wherein the liner comprises an inflatable liner.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0027] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of the invention.
[0028] FIG. 1 is a drawing from co-pending patent application “Novel Manufacturing Process for Forming Domed Paper”, an isometric view indicating key areas required in a machine system to form the domes for a liner.
[0029] FIG. 2 is a drawing from U.S. Pat. No. 9,315,312 showing a continuous process for forming domed paper for further use in packaging or integrated box or envelope products.
[0030] FIG. 3 is a drawing from U.S. Pat. No. 5,454,642 showing the integration of an inflatable package with a liner.
[0031] FIG. 4a is an isometric view showing the integration of a domed paper liner to form an envelope.
[0032] FIG. 4b in an isometric view of the liner in FIG. 4a once folded to form an envelope with sealed sides.
[0033] FIG. 4c is an isometric view of the liner of FIGS. 4a and 4b with the top flap closed.
[0034] FIG. 5 is a flat three view drawing of the container used to form, seal, fill, and close the envelope per the current invention.
[0035] FIGS. 6a, 6b, and 6c are isometric drawings of the machine system used to form the liner and envelope combination.
[0036] FIG. 7 is an isometric drawing showing a machine system used to form the liner and envelope combination and the filling of the formed envelope with an object using cartridges placed for a fixed vertical insertion position.
[0037] FIG. 8 is an isometric drawing showing a machine system used to form the liner and envelope combination and the filling of the formed envelope with an object using cartridges placed for a fixed horizontal or tilted insertion position.
[0038] FIG. 9 is an isometric drawing showing the ejection of a filled and sealed lined envelope from a machine system used to form the liner and envelope combination.
[0039] FIG. 10 is an isometric drawing showing a machine system used to form the liner and envelope combination and the filling of the formed envelope with an object using cartridges placed for a variable fixed horizontal or insertion position.
[0040] FIG. 11 illustrates a method to form an envelope.
[0041] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DESCRIPTION
[0042] The present teachings disclose a novel process for manufacturing an envelope with a liner and integrating an item to be packaged.
[0043] FIG. 1 is a drawing from co-pending patent application “Novel Manufacturing Process for Forming Domed Paper”, an isometric view indicating key areas required in a machine system to form the domes for a liner. FIG. 2 is a drawing from U.S. Pat. No. 9,315,312 showing a continuous process for forming domed paper for further use in packaging or integrated box or envelope products. FIG. 3 is a drawing from U.S. Pat. No. 5,454,642 showing the integration of an inflatable package with a liner. These figures help to illustrate the existing prior art associated with forming envelopes with liners, how these liners have included such diverse materials as inflatable bladders, and the process associated with forming a paper dome material.
[0044] A common way to form an envelope is shown in FIGS. 4a, 4b, and 4c. In FIG. 4a an isometric view of the substrate 60 formed from a domed paper liner 11 (formed from sheets 5 and 6 with registration marks 3 and 4) selectively adhered to the envelope exterior 99 which may be a 40 pound kraft paper with a gum tape adhesive to eventually form envelop 106. Side areas 10 and 102 of the layer 11 will normally have adhesive and in the case of water activated gum tape will be moistened prior to folding about folding line 101. Area 100 under the liner 5,6 is left without adhesive or without being activated such that the liner can be separated from the back layer to form a sealable flap at edge 7 and 8 of materials 11 and 99 respectively. Edge 103 may also be partially non-adhered between the liner 11 and envelope exterior 99 as it forms the adjacent seem to the next liner and edges 7 and 8. In FIG. 4b the unit 1 is folded at line 101 to form edge 106 and the adhesive of side areas 10 and 11 activated so as to form the pouch and flap 105. In FIG. 4c, the liner 11 is folded into the envelope while the exterior flap 105 is moistened and secured to the surface of layer 99. In some cases, the liner 11 may be shortened so as to avoid having to insert it into the formed lined envelope 106.
[0045] FIG. 5 is a flat three view drawing of the cartridge 200 used to form, seal, fill, and close the envelope 106 per the current invention within the walls 201 of the cartridge. Substrate 60 incorporating a liner 11 is pushed downward into cartridge 200 in direction 202 using plunger 207. As the liner moves downward into the cartridge the edges 10 and 102 are pressed between rollers 205 which may be heated or used to activate the adhesive between the sheet 99. Once formed into the open envelope 106, the walls of cartridge 200 closes the gap 204 in the case 201 with mechanical, electromechanical, electric, or pneumatic means such that the envelope opens but remains held by the side rollers or holders 205. The cartridge 200 may also be fitted with sensors 700 such as a weight sensor or may have openings for applying a label directly to the envelope exterior. The case 201 may also have gearing components or holders that allow it to be moved and transported within a machine system as well as heaters or dryers to help cure or seal the envelope. A closure mechanism for the flap 105 can also be included in the cartridge as well as a mechanism to release the liner once formed.
[0046] FIG. 6a in an isometric view of machine system 300 used to form substrate 60 and envelope 106 from liner 11 and exterior layer 99. In this configuration, liner 11 is formed in press 302 from a roll 701 having two layers 5 and 6 used to form the paper dome liner. In some cases roll 11 may already be formed and in some cases more than one roll containing more than one liner material may be used and combined with envelope exterior 99 also on a roll 702. Once combined, cut knife 400 cuts the correct length of the substrate 60 and pushes it into cartridge 200 using pusher 207 as further shown in FIG. 6b. In some cases no liner is used and only the exterior 99 is used to form the envelope. Connection to the ordering and product systems may be used to manufacture the correctly lined envelope based on the items to be packed and label. For example, liners requiring additional shock protection may be used or thermal protection including foil. In addition, liners may be adhered or left without adhesive so that they can be removed after use. A label 303 may be used to label the envelope exterior 99 prior to or after it is inside the cartridge such as through face 304 of the cartridge 200.
[0047] As shown in FIG. 7, cartridge and envelope assembly 310 is moved towards individual 309 so that object 308 can be placed into opening 307 of envelope 106. The cartridge sides move inwards so as to open the envelope 106 to allow for ease of placement of the object. Once filled with object 308, the envelope top flap 105 is sealed within the cartridge. Sealing can be accomplished with a roller or other mechanical pressing and activated with a moistener applied to flap 105. If using a plastic liner, a heat seal could also be employed to for the seal. The closure of cartridge 200 can also active the top flap 105 seal closure process, and in some cases, the filled envelope can be removed from the cartridge and sealed separately. A robotic system may also be employed along side or in replacement of manual labor 309 for the product placement within the envelope. Once top flap 105 is sealed within the cartridge, the cartridge moves in direction 305 and 306 so that ample time is allowed for the flap to securely adhere prior to the envelope being ejected.
[0048] FIG. 8 is an alternate machine system 500 wherein the cartridges 200 are stacked so that their openings 307 are oriented such that worker 309 can place object 308 in a horizontal orientation.
[0049] FIG. 9 shows the ejection of the filled envelope 106 and final package 307 from the cartridge 200 using plunger 301. Package 307 may be ejected onto a conveyor belt 311 (as shown in FIG. 10) or into a hopper, tray, or a secondary container or box.
[0050] FIG. 10 shows machine 600 in which the vertical placement of cartridge 200 adjustable and can be stopped correctly to minimize the strain on a worker or to facilitate automatic placement of object 308 within the envelope.
[0051] FIG. 11 illustrates a method for forming an envelope according to various embodiments.
[0052] A method 1100 for forming an envelope may include operation 1101 to select a liner. The method 1100 may further include operation 1102 to plunge the substrate into a cartridge with a pusher to a desired depth to form a U having two opposing walls, two side openings and a flap opening. The method 1100 may further include operation 1104 to squeeze the two opposing walls along the two side openings, while keeping the flap opening open. The method 1100 may further include operation 1106 to seal the two opposing walls along the two side openings to form the envelope. The method 1100 may further include operation 1108 to retract the pusher. The method 1100 may further include operation 1110 to fill the envelope disposed in the cartridge via the flap opening. The method 1100 may further include operation 1112 to seal the flap opening.
[0053] The examples presented herein are intended to illustrate potential and specific implementations. It can be appreciated that the examples are intended primarily for purposes of illustration for those skilled in the art. The diagrams depicted herein are provided by way of example. There can be variations to these diagrams or the operations described herein without departing from the spirit of the invention. For instance, in certain cases, method steps or operations can be performed in differing order, or operations can be added, deleted or modified.
