U.S. patent application number 14/936123 was filed with the patent office on 2017-05-11 for polymer encapsulations for item shipping.
The applicant listed for this patent is Amazon Technologies, Inc.. Invention is credited to Babak Amir Parviz, Douglas Weibel.
Application Number | 20170129630 14/936123 |
Document ID | / |
Family ID | 57389532 |
Filed Date | 2017-05-11 |
United States Patent
Application |
20170129630 |
Kind Code |
A1 |
Weibel; Douglas ; et
al. |
May 11, 2017 |
POLYMER ENCAPSULATIONS FOR ITEM SHIPPING
Abstract
Described are systems, methods, and apparatus for replacing the
corrugated containers and dunnage to facilitate packaging of items
in foam containers, referred to as "polymer encapsulations," that
can be used to protect and contain the item during shipment. When
one or more items are ordered for delivery to a destination, the
item(s) is picked from inventory and a rapidly setting polymer foam
is injected around the bagged item to encapsulate and protect the
item. For example, at packing, rather than placing the item in a
corrugated container, temporary walls may be positioned around the
bagged item and a pre-polymer injected into the space between the
walls that surround the item such that a polymer forms that encases
the item. After the polymer sets, the walls are retracted and the
item is protected by the formed polymer encapsulation and available
for transport to the destination.
Inventors: |
Weibel; Douglas; (Verona,
WI) ; Parviz; Babak Amir; (Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amazon Technologies, Inc. |
Seattle |
WA |
US |
|
|
Family ID: |
57389532 |
Appl. No.: |
14/936123 |
Filed: |
November 9, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 59/001 20190501;
B65B 55/20 20130101; B29C 33/0016 20130101; B29K 2105/0005
20130101; B29K 2027/06 20130101; B29C 39/24 20130101; B29K 2995/002
20130101; B29K 2033/04 20130101; B65B 2210/04 20130101; B29C 67/246
20130101; B29L 2031/712 20130101; B29K 2025/06 20130101; B29C 44/60
20130101; B29K 2623/06 20130101; B29C 44/1266 20130101; B29K
2023/12 20130101; B65B 5/02 20130101; B29C 39/006 20130101; B29C
39/44 20130101; B65B 61/26 20130101; B65B 67/04 20130101; B65D
81/052 20130101; G06Q 10/08 20130101; B29C 39/10 20130101; B65B
25/002 20130101; B29K 2023/06 20130101; B65B 31/00 20130101; B29K
2075/00 20130101; B65B 57/10 20130101; B65D 2203/00 20130101 |
International
Class: |
B65B 5/02 20060101
B65B005/02; B65B 57/10 20060101 B65B057/10; B65B 61/26 20060101
B65B061/26; B65B 31/00 20060101 B65B031/00 |
Claims
1. A method for preparing an item for shipping, comprising:
receiving an order for an item that is to be shipped to a
destination; placing the item in a protective bag such that the
protective bag contains the item; positioning an encapsulation
cavity around the protective bag that contains the item; injecting
a pre-polymer into the encapsulation cavity to form a polymer that
expands and substantially encases the protective bag that contains
the item, thereby forming a polymer encapsulation around the
protective bag that contains the item, wherein: the polymer that
forms the polymer encapsulation has a mechanical strength
sufficient to enable the polymer encapsulation to function as a
protective physical barrier for the item and as a transportation
container for the item; determining that a defined period of time
has elapsed following injection of the pre-polymer into the
encapsulation cavity; removing the encapsulation cavity; and
applying shipping information to the polymer encapsulation that
indicates the destination.
2. The method of claim 1, further comprising: placing the
protective bag that contains the item on a preformed base; and
wherein positioning the encapsulation cavity around the protective
bag includes positioning the encapsulation cavity around the
protective bag and the preformed base such that the pre-polymer,
when injected into the encapsulation cavity, will expand and bond
with the preformed base.
3. The method of claim 2, wherein the preformed base includes an
access mechanism incorporated into at least a portion of the
preformed base, such that the access mechanism, when activated,
will cause at least a portion of the preformed base to separate
from the polymer encapsulation.
4. The method of claim 1, wherein the protective bag includes an
access mechanism that extends outside of the polymer encapsulation,
wherein the access mechanism, when activated, will form an opening
in the polymer encapsulation such that the item can be removed.
5. A polymer encapsulation forming apparatus, comprising: a base
surface upon which an item to be encased in a polymer encapsulation
may be positioned; an encapsulation cavity that may be removably
positioned around the item when the item is positioned on the base
surface; and an injection port configured to inject a pre-polymer
into a cavity formed by the encapsulation cavity and the base
surface when the encapsulation cavity is positioned on the base
surface, the pre-polymer operable to expand within the cavity and
substantially encompass the item forming a polymer encapsulation
around the item, wherein: the polymer that forms the polymer
encapsulation has a mechanical strength sufficient to enable the
polymer encapsulation to function as a protective barrier for the
item and as a transportation container for the item.
6. The apparatus of claim 5, further comprising: a second injection
port configured to inject a gas into the cavity as the pre-polymer
is injected such that at least a portion of the gas is entrained
within the polymer that forms the polymer encapsulation.
7. The apparatus of claim 6, wherein the gas is at least one of
air, hydrogen, helium, oxygen, nitrogen, or carbon dioxide.
8. The apparatus of claim 5, further comprising: a second injection
port configured to inject a colored dye into the cavity as the
pre-polymer is injected such that the colored dye alters a color of
the polymer that forms the polymer encapsulation.
9. The apparatus of claim 5, the encapsulation cavity further
including: a plurality of surfaces that may be positioned around
the item to form the cavity, wherein a position of each of the
plurality of vertical surfaces is determined based at least in part
on a dimension of the item.
10. The apparatus of claim 5, wherein a volume of the cavity formed
by the encapsulation cavity is determined based at least in part on
a size of the item, a dimension of the item, a fragility of the
item, a planned position in a stacking configuration for the
polymer encapsulation, or a customer preference.
11. The apparatus of claim 5, wherein: a preformed base is
positioned between the base surface and the item; and the
pre-polymer, when injected into the cavity, bonds with the
preformed base.
12. The apparatus of claim 5, further comprising: a release agent
applicator configured to apply a release agent to an inner-side of
the encapsulation cavity such that the polymer does not adhere to
the encapsulation cavity.
13. A computing system, comprising: one or more processors; and a
memory coupled to the one or more processors and storing program
instructions that when executed by the one or more processors cause
the one or more processor to at least: determine a dimension value
for an item to be encased in a polymer encapsulation based at least
in part on a measurement of the item, wherein the polymer
encapsulation is formed of a polymer that has a mechanical strength
sufficient to enable the polymer encapsulation to function as a
protective barrier for the item and as a transportation container
for the item; determine polymer encapsulation dimensions for the
polymer encapsulation such that the polymer encapsulation will
encase the item and provide a protective barrier around the item;
cause an encapsulation cavity to be positioned around the item;
cause a pre-polymer to be injected into the cavity to form a
polymer that expands and forms the polymer encapsulation around the
item; and cause shipping information to be applied to the polymer
encapsulation.
14. The computing system of claim 13, wherein the program
instructions that when executed by the one or more processors to
cause shipping information to be applied to the polymer
encapsulation include instructions that further cause the one or
more processors to at least: cause the shipping information to be
imprinted into a side of the polymer encapsulation.
15. The computing system of claim 13, wherein the program
instructions that when executed by the one or more processors
further cause the one or more processors to at least: determine
that a distance between the item and a surface of the encapsulation
cavity is less than a minimum distance; and cause a size of the
encapsulation cavity to be adjusted such that the distance between
the item and the surface is equal to or greater than the minimum
distance.
16. The computing system of claim 13, wherein the program
instructions that when executed by the one or more processors
further cause the one or more processors to at least: determine
that a defined time has elapsed since the polymer was injected into
the cavity; and cause the encapsulation cavity to be removed from
around the item and the polymer encapsulation.
17. The computing system of claim 13, wherein: the polymer
encapsulation, when formed, includes an access mechanism, and the
access mechanism, when activated, will form an opening in the
polymer encapsulation such that the item can be removed from the
polymer encapsulation.
18. The computing system of claim 13, wherein the program
instructions that when executed by the one or more processors
further cause the one or more processors to at least: determine
that a defined time has elapsed since the polymer was injected into
the cavity; and release the polymer encapsulation to a shipping
operation.
19. The computing system of claim 13, wherein the program
instructions that when executed by the one or more processors
further cause the one or more processors to at least: cause the
item to be placed in a protective bag such that the protective bag
contains the item; cause a gas to be injected into the protective
bag such that the protective bag is expanded around the item; and
cause the protective bag to be sealed such that the gas and the
item are entrained in the protective bag.
20. The computing system of claim 13, wherein the program
instructions that when executed by the one or more processors
further cause the one or more processors to at least: cause the
item to be placed in a protective bag such that the protective bag
contains the item; cause a gas to be removed from the protective
bag such that the protective bag is compressed around the item; and
cause the protective bag to be sealed such that the protective bag
remains compressed around the item.
Description
BACKGROUND
[0001] Many companies package items and/or groups of items together
for a variety of purposes, such as e-commerce and mail-order
companies that package items (e.g., books, CDs, apparel, food,
etc.) to be shipped to fulfill orders from customers. Retailers,
wholesalers, and other product distributors (which may collectively
be referred to as distributors) typically maintain an inventory of
various items that may be ordered by clients or customers. This
inventory may be maintained and processed at a materials handling
facility which may include, but is not limited to, one or more of:
warehouses, distribution centers, cross-docking facilities, order
fulfillment facilities, packaging facilities, shipping facilities,
or other facilities or combinations of facilities for performing
one or more functions of material (inventory) handling.
[0002] When one or more items are ordered for delivery to a
destination, the item(s) is picked from inventory, a corrugated
container that is of a size sufficient to contain the item(s) is
selected, the item(s) is packed into the container, dunnage is
added to protect the item(s) during shipment, the container is
closed and sealed, and the item is shipped to a destination in the
container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The detailed description is set forth with reference to the
accompanying figures. In the figures, the left-most digit(s) of a
reference number identifies the figure in which the reference
number appears.
[0004] FIG. 1 illustrates a broad view of the operations of a
materials handling facility, according to an implementation.
[0005] FIG. 2 illustrates an example view of a bagging station and
a polymer encapsulation station, according to an
implementation.
[0006] FIG. 3 illustrates an example of a polymer encapsulation
that includes an item for shipping, according to an
implementation.
[0007] FIG. 4 is a block diagram of a stacking configuration,
according to an implementation.
[0008] FIG. 5 is a flow diagram illustrating an example polymer
encapsulation determination process, according to an
implementation.
[0009] FIG. 6 is a flow diagram illustrating an example polymer
encapsulation process, according to an implementation.
[0010] FIG. 7 is a block diagram illustrating an example computer
system, according to an implementation.
[0011] While implementations are described herein by way of
example, those skilled in the art will recognize that the
implementations are not limited to the examples or drawings
described. It should be understood that the drawings and detailed
description thereto are not intended to limit implementations to
the particular form disclosed, but on the contrary, the intention
is to cover all modifications, equivalents and alternatives falling
within the spirit and scope as defined by the appended claims. The
headings used herein are for organizational purposes only and are
not meant to be used to limit the scope of the description or the
claims. As used throughout this application, the word "may" is used
in a permissive sense (i.e., meaning having the potential to),
rather than the mandatory sense (i.e., meaning must). Similarly,
the words "include," "including," and "includes" mean including,
but not limited to.
DETAILED DESCRIPTION
[0012] Described are systems, methods, and apparatus for replacing
the corrugated containers and dunnage to facilitate packaging of
items in foam containers, referred to herein as "polymer
encapsulations," that can be used to protect and contain the item
during shipment. When one or more items are ordered for delivery to
a destination, the item(s) is picked from inventory, placed in a
protective bag, such as a polyethylene bag, and a rapidly setting
pre-polymer is injected around the bagged item that will polymerize
into a foam to encapsulate and protect the item. For example, at
packing, rather than placing the item in a corrugated container,
temporary walls may be positioned around the bagged item and a
pre-polymer injected into the space between the walls that surround
the item. The injected pre-polymer polymerizes into a polymer
encapsulation that contains the item and has the approximate shape
of the space between the walls. After the polymer sets, the walls
are retracted and the item is protected by the formed polymer
encapsulation and available for transport to the destination. The
polymer encapsulation provides protection for the item and operates
as the container for the item, thereby removing the need for
traditional dunnage or corrugated containers.
[0013] In some implementations, the item may be placed on a
preformed base and the pre-polymer injected around the item and on
top of the base. The bonding between the preformed base and the
polymer provides an access point such that the item can be accessed
upon delivery. In still other examples, an access mechanism may be
included prior to or during encapsulation of the item, so that the
item can be removed from the polymer encapsulation upon delivery.
For example, the access mechanism may be a strong flexible
material, such as a cord, wire, plastic, string, etc., that is
included on or in the preformed base and/or included on the
flexible package and remains partially exposed after the item is
encased in the polymer encapsulation. When the item is to be
removed, the exposed portion of the access mechanism may be pulled,
thereby disrupting or tearing the polymer encapsulation and
providing access to the item.
[0014] A packaging information system configured to facilitate
picking, packing and/or shipping operations may include various
components used to facilitate efficient and/or cost-effective
operations in a materials handling facility. For example, in
various implementations, a packaging information system may include
a planning service, a product dimension estimator, and one or more
polymer encapsulating stations. For example, the planning service
may provide information as to the size and/or shape of the polymer
encapsulation that is to be formed around an ordered item. The size
and shape may be based on, for example, the size of the item, the
fragility of the item, the planned position for the polymer
encapsulated item in a stacking configuration within a
transportation unit, etc.
[0015] In some implementations, the size, shape, color, and/or
polymer material used to encapsulate ordered items may also be
dependent on the customer to whom the item is to be shipped, an
applicable service level agreement, the destination of the item,
the carrier selected for transporting the item, a fragility of the
item, a weight of the item, and/or an environmental constraint
associated with the item and/or the transport of the item (e.g., a
restriction on the temperature and/or humidity at which the item
should be held during transport).
[0016] As used herein, the term "item package" may refer to a
single item to be stored, shipped, or otherwise enclosed within a
polymer encapsulation, alone, or to multiple items that have been
grouped for shipping, storing or for any other operations within a
materials handling facility, such as for storing in inventory or
transporting to a packing or shipping station.
[0017] The term "polymer encapsulation" refers to any
dimensionally-constrained polymer formed environment that may
encompass one or more items. The polymer encapsulation may be any
type of polymer or other injectable material that can be used to
surround and protect an item during transport. For example, the
polymer may be polyethylene (low and high density), polyurethane,
polystyrene, polypropylene, polyimide, polyesters, silicones,
siloxanes, polyvinylchloride, phenolics, polyetherimides,
polyphenylene oxide, polychloropren, epoxies, polyacrylates,
cellulose acetate, etc., or be a copolymer of these different
polymer classes. Likewise, the polymer material used may be
biodegradable such that the bonds degrade through natural
processes, such as hydrolysis, in the presence of moisture and/or
heat. Likewise, the polymer material may be entirely composed of,
utilize or include natural molecules, such as polysaccharides found
in starch and cellulose, polyamides found in proteins, combinations
of natural materials such as starch, cellulose fiber, and calcium
carbonate, etc. Use of such natural materials promotes
decomposition of the polymer encapsulation, thereby making the
polymer encapsulation recyclable and/or compostable. As discussed
further below, the polymer encapsulation, in addition to being
formed of any one or more types of polymers, may be of any size,
shape, density, and/or color.
[0018] As discussed further below, a polymer encapsulation may be
formed by injecting or blowing one or more pre-polymers into a
cavity formed around an item package that is to be encased in the
polymer encapsulation such that the pre-polymer will foam and phase
transition into a solid polymer encapsulation that encases the
item.
[0019] In some implementations, as the pre-polymer is injected into
the cavity, one or more blowing agents may be added or mixed with
the pre-polymer to produce a cellular structure within the formed
polymer encapsulation as the pre-polymer phase transitions from a
liquid form to a solid polymer. The resulting cellular structure
reduces the density and weight of the formed polymer encapsulation,
and may increase the mechanical strength of the polymer
encapsulation. The introduced blowing agents may be physical,
chemical, or a combination thereof. For example, a physical blowing
agent of liquid carbon dioxide (CO.sub.2), nitrogen, air, etc., may
be added, and/or a chemical blowing agent, such as isocyanate and
water, hydrazine, sodium bicarbonate, etc., may be added as the
blowing agent to form different densities of cells within the
polymer encapsulation.
[0020] In some implementations, a volatile hydrocarbon or other low
molecular weight solvent with a low boiling point may be added to
form cells within the resulting polymer encapsulation. For example,
propane, butane, isopentane, methylene chloride etc., may be added
as the pre-polymer is injected into the cavity. As the polymer
foams, the added solvent boils off, creating cells in the resulting
polymer encapsulation. In still other examples, one or more
volatile fluorocarbons may be added to form the cells within the
polymer encapsulation as the polymer foams.
[0021] The term "transportation unit" may refer to any environment
onto or into which items and/or polymer encapsulations may be
stored or placed for conveying or transporting. For example, a
transportation unit may be a pallet, truck, trolley, trailer,
gaylord, partial-gaylord, railroad car, etc.
[0022] A block diagram of a materials handling facility which, in
one implementation, may be an order fulfillment facility configured
to utilize various systems and methods described herein, is
illustrated in FIG. 1. In this example, multiple customers 100 may
submit orders 120 to a distributor, where each order 120 specifies
one or more items from inventory 130 to be shipped to the customer
or to another entity specified in the order. An order fulfillment
facility typically includes receiving operations 180 for receiving
shipments of stock from various vendors and storing the received
stock in inventory 130. To fulfill the orders 120, the one or more
items specified in each order may be retrieved or "picked" from
inventory 130 (which may also be referred to as stock storage) in
the order fulfillment facility, as indicated by picking operations
140. In some implementations, the items in an order may be divided
into multiple item packages for fulfillment by a planning service
before item package fulfillment instructions are generated (not
shown).
[0023] In some implementations, the picking operations 140 may
communicate with a central control system, and receive a sequence
for which items of an item package should be picked and delivered
to a sorting and bagging operation 150. The central control system,
in some instances, may communicate with a stacking engine that is
part of the shipping operations 170. The stacking engine may
determine the sequence in which ordered items should be picked so
that they will progress through picking operations 140, sorting and
bagging operations 150, and polymer encapsulation operations 160
and be routed by routing operations 165 to arrive at a stack
station within the shipping operations 170 in a manner that will
facilitate stacking of the polymer encapsulations that contain the
items according to a planned stacking configuration. The stacking
configuration may be determined by a stacking engine such that the
stacking configuration will be stable and potentially allow
stacking of additional polymer encapsulations on or in the
transportation unit.
[0024] The stacking engine may provide the picking and sorting
sequence for items to the central control system, directly to the
picking operations 140 and/or directly to the sorting and bagging
operations 150, so that the ordered items may be picked, sorted,
and bagged according to the sequence specified by the stacking
engine.
[0025] In this example, picked items may be delivered to one or
more stations in the order fulfillment facility for sorting
operations 150 into their respective orders or item packages,
bagged, and then transferred to one or more polymer encapsulation
operations 160 for encasing the items into polymer encapsulations.
Any type of flexible material may be utilized as a protective bag.
For example, the protective bag may be a polyethylene bag, a
plastic bag, etc. In other implementations, the protective bag may
be a plastic wrapping that is placed around the item prior to the
item being encased in a polymer encapsulation. In general, the
protective bag may be any material that separates or generates a
physical and/or chemical barrier between the item and the
pre-polymer that is used to form the polymer encapsulation around
the item so that portions of the polymer do not contact and adhere
to the item.
[0026] In different configurations, one or more items of an item
package may be placed in the same bag and/or placed in separate
bags. For example, in some implementations, each item of an item
package may be placed in its own protective bag prior to the items
being encased in a polymer encapsulation so that each item is
individually protected by the polymer encapsulation, both from
exterior forces and from other encased items. In other
implementations, multiple items of an item package may be placed in
the same protective bag prior to being encased in a polymer
encapsulation.
[0027] When the item is placed into the protective bag, the
protective bag may be closed or otherwise sealed so that the
injected pre-polymer that is used to form the polymer encapsulation
around the bagged item does not enter the interior of the
protective bag and contact and adhere to the item(s) in the
protective bag. In some implementations, a gas may be introduced
into the protective bag prior to sealing the protective bag so that
the gas is entrained within the protective bag. When the polymer
encapsulation is formed around the bagged item, a void is created
within the polymer encapsulation in which the item(s) is encased.
The gas may be air, oxygen, hydrogen, helium, nitrogen, carbon
dioxide, etc. In implementations where the entrained gas is lighter
than air, the overall weight of the polymer encapsulation may be
reduced and, thus, the cost to transport the item may be
reduced.
[0028] In other implementations, gasses may be removed or vacuumed
from the bag and the protective bag sealed so that the protective
bag is compressed around the item(s) within the protective bag. In
such an implementation, when the polymer encapsulation is formed
around the bagged item, there is no void between the item and the
polymer encapsulation. Removing gasses from the protective bag
results in the item being securely positioned within the polymer
encapsulation when formed so it does not move within the polymer
encapsulation.
[0029] The routing operations 165 may sort formed polymer
encapsulations that contain items to one of two or more stack
stations within the shipping operations 170. At the stack stations,
polymer encapsulations may be stacked onto or into a transportation
unit according to a stacking configuration and shipped to the
customers 100.
[0030] The package routing operations 165 may communicate with the
central control system and receive an indication of a stack station
to which each polymer encapsulation is to be routed. The central
control system, in some implementations, may communicate with the
stacking engine. The stacking engine may determine a stack station
for each polymer encapsulation dependent on the destination of the
encased items, the size of a polymer encapsulation and/or the size
of other polymer encapsulations allocated to the same stack
station.
[0031] The stacking engine may provide an indication of the stack
station to the central control system, and/or directly to the
package routing operations 165, so that the polymer encapsulation
may be diverted to an appropriate stack station within shipping
operations 170. For example, the stacking engine may determine
stacking configurations for multiple different transportation
units, such as pallets, so that the stacks of polymer
encapsulations are stable. When determining stacking configurations
for multiple transportation units, the stacking engine may
opportunistically route polymer encapsulations of various sizes to
different stack stations for stacking onto the various
transportation units. In some implementations, the stacking engine
may provide feedback to the polymer encapsulation operations 160 to
alter a size and/or shape of a planned polymer encapsulation to
include in a stacking configuration so that the stacking
configuration stability is improved and/or to increase the quantity
of polymer encapsulations that can be stacked on or in a
transportation unit. For example, rather than making all of the
polymer encapsulations rectangular in shape with approximately
ninety degree angles, the stacking engine may send instructions to
the polymer encapsulation operations 160 to form a top surface of a
polymer encapsulation with a curved edge so it will fit in an upper
corner of a transportation unit.
[0032] In still other examples, the polymer encapsulations may be
formed such that, when the polymer encapsulations are stacked
and/or stored together, they interlock or join, thereby further
improving the stability of the stacking configuration. For example,
the tops of the polymer encapsulations may include male extensions
and the bottoms of the polymer encapsulations may include female
indentations. When polymer encapsulations are stacked, the male
extensions mate with the female indentations, thereby interlocking
the polymer encapsulations together. In other examples, different
forms or interconnects may be utilized.
[0033] By altering the size and/or shape of the polymer
encapsulations based on the size and shape of the encased items
and/or the size and shape of the transportation unit in which the
polymer encapsulation is to be placed, the utilization of the
transportation unit can be improved.
[0034] In some implementations, to aid in routing of polymer
encapsulations to different transportation units, the polymer
encapsulations may be color coded. For example, when the
pre-polymer is injected around the bagged item to be encased, a
colored dye (e.g., red, blue, green, orange, yellow) may be
introduced that colors the polymer as it sets. During routing
operations 165, polymer encapsulations may be routed according to
color.
[0035] In still other examples, other materials, such as fillers,
identifiers, decorative materials, etc., may also be introduced and
included in the polymer encapsulation. For example, in addition to
or as an alternative to color, other decorative materials (e.g.,
glitter, confetti) may be added as the pre-polymer is injected
around the bagged item to be encased such that the decorative
material is entrained in the formed polymer encapsulation. In
another example, one or more identifiers, such as a radio frequency
identification ("RFID") tag may be included and encased in the
polymer encapsulation to aid in tracking and/or identification of
the polymer encapsulation.
[0036] Note that not every fulfillment facility may include both
sorting and polymer encapsulation stations. In certain
implementations, picked items may be transferred directly to a
polymer encapsulation station, while in other implementations
picked items may be transported to a combination sort, bag and
polymer encapsulation station. This may result in a stream and/or
batches of picked items for multiple incomplete or complete orders
being delivered to a sort and bag station for sorting and bagging
operations 150 into their respective item packages for polymer
encapsulation and shipping, according to some implementations. In
other implementations, items and/or polymer encapsulations that
have been formed around bagged items may be routed directly to a
shipping operation 170 and/or stacking stations from receiving
operations 180.
[0037] Still further, in some implementations, items may be bagged
and polymer encapsulated as part of the receiving operations 180
such that the items are stored in inventory 130 after the items
have been encased in a polymer encapsulation. In such an
implementation, when an item is ordered, it may be picked from
inventory and routed directly to shipping operations 170 for
shipment.
[0038] Because portions of an item package may be received at
different times, sorting and bagging operations 150 and polymer
encapsulation operations 160 may have to wait for one or more items
of some item packages to be delivered to the sort and pack
station(s) before processing of the item package completes.
Likewise, if items arrive at sorting and bagging operations 150 out
of the sequence specified by the stacking engine, those items may
be held at sorting and bagging operations 150 until other items
arrive before releasing the items to polymer encapsulation
operations 160. Releasing items from the sorting and bagging
operations 150 in the sequence provided by the stacking engine
allows for items to be picked in parallel by multiple picking
agents and delivered to sorting and bagging independent of one
another without disrupting the sequence specified by the stacking
engine. By restoring the sequence during sorting and bagging
operations 150, the items will be delivered to the polymer
encapsulation operations 160 and arrive at the stack stations in,
or approximately in, the sequence specified by the stacking engine
so that the polymer encapsulations encasing the items can be
stacked according to the planned stacking configuration.
[0039] In implementations with multiple polymer encapsulation
stations in the polymer encapsulation operations 160, items may be
encased in polymer encapsulations and delivered to routing
operations out of sequence due to the different speeds at which the
polymer encapsulation stations may encase the items and/or if the
items were not sequenced during sorting and bagging operations 150.
In such instances, the routing operations 165 may include a buffer,
such as a loop conveyor belt, that can be used to temporarily hold
polymer encapsulations before delivery to a stack station. For
example, as polymer encapsulations are provided from polymer
encapsulation operations 160 to routing operations 165, the polymer
encapsulations may remain on a loop conveyor belt, or other
temporary holding zone, and be released to the shipping operations
170 in the sequence order specified by the stacking engine.
[0040] In another implementation, the polymer encapsulations may be
released from routing operations 165 as they arrive and, if needed,
buffered or otherwise placed in a temporary holding zone within the
shipping operations 170 until they are stacked according to the
stacking configuration provided by the stacking engine. For
example, the polymer encapsulations may be received at a stack
station and either placed on a transportation unit according to the
stacking configuration or placed in a temporary holding zone until
they are ready to be added to the stacking configuration.
[0041] In some implementations, polymer encapsulations may be
retained in a buffer, such as on the loop conveyor belt or the
temporary holding zone discussed above, until a determined cure
time has elapsed or desired cure degree has been reached. A cure
time corresponds to an amount of time necessary for the polymer
material to toughen or harden into a solid state by cross-linking
polymer chains. For example, a time necessary for the polymer
encapsulation to reach approximately a 75% cure degree may be
determined and used as the cure time that is to elapse before the
polymer encapsulation is released for stacking or transport. In
other implementations, the cure time may correspond to a higher or
lower cure degree depending on the structural strength to be
reached by the polymer encapsulation. Likewise, the cure time
needed for a polymer encapsulation to reach a desired cure degree
may vary depending on the pre-polymer configuration and/or external
factors (e.g., heat) introduced into the polymerization or curing
process.
[0042] While the above example is described with respect to polymer
encapsulations of ordered items and stacking of polymer
encapsulations, in some implementations, polymer encapsulation
operations may be used in conjunction with traditional packaging of
items in containers such that some ordered items are picked and
routed to packing stations for packing in traditional containers
while other items are picked and routed to polymer encapsulation
stations for encasing in a polymer encapsulation. In such a
configuration, traditional containers containing items and polymer
encapsulations encasing items may be stacked and/or transported in
the same or different transportation units.
[0043] Note that a picked, polymer encapsulated, and shipped item
package does not necessarily include all of the items ordered by
the customer; a shipped polymer encapsulation may include only a
subset of the ordered items available to ship at one time from one
fulfillment facility. Also note that the various operations of an
order fulfillment facility may be located in one building or
facility, or alternatively may be spread or subdivided across two
or more buildings or facilities.
[0044] The arrangement and order of operations illustrated by FIG.
1 is merely one example of many possible implementations of the
operations of an order fulfillment facility. Other types of
materials handling, manufacturing, or order fulfillment facilities
may include different, fewer, or additional operations and
resources, according to different implementations. For example, in
some implementations, one or more polymer encapsulation stations
may be utilized at receiving 180 such that received stock is
encased in a polymer encapsulation prior to placement in
inventory.
[0045] FIG. 2 illustrates an example view of a bagging station 250
and a polymer encapsulation station 260, according to an
implementation. As discussed above, the bagging station 250 may
also include sorting operations and/or the bagging station and the
polymer encapsulation station 260 may be combined. For explanation
purposes, the example will utilize a single item 210.
[0046] When an item is ordered, it is picked from inventory and, in
this example, arrives at the bagging station 250. The item
progresses to the bagging station via a first conveyor 202(1) and
is dropped or otherwise placed into a protective bag 208A. As
discussed above, the protective bag 208A may be any type of
material that provides a barrier between the item 210 and the
polymer encapsulation that will be formed around the bagged item.
In some instances, the item may already be packaged in a way that
makes putting it in a protective bag unnecessary. For example, an
item's packaging could act as a sufficient barrier (e.g. clamshell
plastic casing). In example implementations where the item is
bagged, the item 210 may be placed into the protective bag 208A in
an automated manner, such as illustrated below, using robotics to
position the item into the protective bag 208A, by a human and/or
robotic agent positioned at the bagging station 250, or by other
means. For example, if the protective bag is a flexible material
that is wrapped around the item, the item may be moved by the
conveyor 202(1) onto the protective material and a robotic arm may
wrap the protective material around the item.
[0047] Once the item 210 is positioned within the protective bag
208A, the protective bag is sealed to form a chemical and/or
physical barrier so that the pre-polymer used to form the polymer
encapsulation cannot contact the item 210 and adhere to the item.
In some implementations, a gas may be introduced into the
protective bag 208A as the protective bag is sealed so that the gas
and the item are entrained within the protective bag when sealed.
The gas may be air, oxygen, hydrogen, helium, nitrogen, carbon
dioxide, etc. In other implementations, gasses may be removed or
vacuumed from the bag and the protective bag sealed so that the
protective bag is compressed around the item(s) within the
protective bag.
[0048] Upon sealing, the bagged item is released from the bagging
station 250 and progresses to the polymer encapsulation station 260
via a second conveyor 202(2). In some implementations, each time an
item is sealed in a protective bag and the sealed protective bag is
released, a protective bagging device 207 may automatically
position or otherwise prepare another protective bag at the bagging
station 250 for the next item or items that are to be bagged.
[0049] In some implementations, the second conveyor 202(2) may
originate or extend from a base forming device 203 that generates
or places a preformed base 201 on the second conveyor 202(2) so
that bagged items 210B are positioned on the preformed base when
they arrive at the polymer encapsulation station 260. The preformed
base may be formed of one or more materials such as, polymer,
plastic, corrugate, metal, ceramic, cellulose, paper, etc. In some
examples, as illustrated, the preformed base may be in the form of
a continuous sheet that is cut to size at the polymer encapsulation
station. In other implementations, the polymer base forming device
203 may form or position preformed bases according to the planned
polymer encapsulation dimensions for each item, and the second
conveyor 202(2) may be coordinated with the bagging station 250
such that, when an item is bagged, sealed and released onto the
second conveyor 202(2), the bagged item is positioned onto the
preformed base.
[0050] In other examples, a preformed base may be positioned under
a bagged item as part of the polymer encapsulation process. In
still other examples, as discussed further below, a preformed base
may not be used. In such examples, the bagged item may be
positioned or lifted such that the injected pre-polymer (discussed
below) that forms the polymer encapsulation around the bagged item
expands around all sides of the item and encases the entire
item.
[0051] In some implementations, the protective bag 208B when sealed
around an item 210B may include one or more access mechanisms 204.
The access mechanism may be, for example, a strong flexible
material, such as a cord, wire, plastic, string, etc., that is
attached to the protective bag and positioned such that it will
extend beyond the polymer encapsulation that is formed around the
protective bag. When the item is to be removed from the polymer
encapsulation, the exposed portion of the access mechanism may be
pulled, thereby disrupting or tearing the polymer encapsulation and
providing access to the item and/or the protective bag that
contains the item. In some implementations, the access mechanism
may be configured to, when activated, disrupt or tear the polymer
encapsulation and open the protective bag.
[0052] When the protective bag that contains an item arrives at the
polymer encapsulation station, an encapsulation cavity 209 is
positioned around the bagged item so that the bagged item is
positioned within a cavity formed by surfaces of the encapsulation
cavity. The encapsulation cavity 209 may be any configuration of
walls or surfaces that may be positioned around the bagged item to
form a cavity. In the illustrated example, the encapsulation cavity
is raised or lowered from above a polymer encapsulation table 213.
Multiple different sizes of polymer encapsulation cavities 209 may
be positioned above the table and lowered onto the polymer
encapsulation table 213 depending on the size and/or dimensions of
the bagged item 208C.
[0053] In other examples, the encapsulation cavity may be a series
of temporary walls or surfaces that may be lowered from above the
polymer encapsulation table 213, that extend upward from within the
polymer encapsulation table 213 and/or that move laterally on the
polymer encapsulation table 213. In general, the encapsulation
cavity may be any size, shape, and/or type of surface that may be
positioned around the bagged item 208 to form a cavity into which a
pre-polymer may be injected to form a polymer encapsulation that
encases the bagged item. The surfaces of the encapsulation cavity
209 may be rigid or flexible, straight, curved, etc., and formed of
any one or more materials. For example, the surfaces of the
encapsulation cavity 209 may be metal, plastic, glass, etc.
[0054] In some implementations, the encapsulation cavity may
include a non-stick surface (e.g., perfluorinated) or be prepared
with a release agent (e.g., carnauba wax, canola oil, olive oil,
vegetable oil, silicone, etc.) so that the pre-polymer used to form
the polymer encapsulation around the bagged item does not adhere to
the surfaces of the encapsulation cavity. For example, the polymer
encapsulation station 260 may include a release agent applicator
that periodically applies a release agent to the surfaces of the
encapsulation cavity so that the polymer used to form the polymer
encapsulation does not adhere to the surfaces of the encapsulation
cavity.
[0055] In some implementations, the edges of one or more surfaces
of the encapsulation cavity 209 may be sharp or include a blade
that may be used to cut or form the preformed base 201 to the size
of the cavity. For example, as the encapsulation cavity 209 is
lowered onto the polymer encapsulation table 213 around the bagged
item 208C, the lower edges of the encapsulation cavity may cut the
preformed base 201 to correspond to the size of the cavity formed
by the surfaces of the encapsulation cavity 209. In other
implementations, the polymer encapsulation table 213 may include
blades or other mechanisms to cut or otherwise shape the preformed
base to a size and/or shape of the cavity formed by the surfaces of
the encapsulation cavity 209.
[0056] As discussed further below, the size and/or shape of the
polymer encapsulation that is to be formed around a bagged item may
vary depending on, for example, the size and/or dimensions of the
bagged item, the fragility of the item, the position in a stacking
configuration in which the formed polymer encapsulation will be
placed, etc. To form the desired size and/or shape of the polymer
encapsulation, the surfaces of the encapsulation cavity may be
independently positioned around the bagged item or, as illustrated,
one of multiple different sizes and/or shapes of encapsulation
cavities may be positioned around the bagged item 208C.
[0057] In some examples, one or more distance determining elements
may be included at the polymer encapsulation station 260 that can
measure a distance between the bagged item and one or more surfaces
of the encapsulation cavity. Likewise, in some examples, the
polymer encapsulation table 213 may include a load cell or other
pressure sensor that can measure the position of the bagged item.
As an illustrative example, when the bagged item is positioned at
the polymer encapsulation stations 260, a pressure sensor of the
polymer encapsulation table 213 may determine a position of the
bagged item 208C. Planned polymer encapsulation dimensions may be
provided to the polymer encapsulation station as part of a polymer
encapsulation plan for the item package contained in the protective
bag, as discussed further below with respect to FIG. 5. Based on
the planned polymer encapsulation dimensions, the surfaces of the
encapsulation cavity are temporarily positioned around the bagged
item. The distance determining elements of the polymer
encapsulation station measure a distance between the protective bag
and the surfaces of the encapsulation cavity to confirm that the
thickness of the formed polymer encapsulation will be within a
minimum and/or maximum polymer encapsulation dimension specified
for the item package (see FIG. 5). If the distances are not within
the minimum and/or maximum polymer encapsulation dimensions, one or
more of the surfaces of the encapsulation cavity may be
repositioned and/or the bagged item may be repositioned. The item
package and/or the surfaces of the encapsulation cavity may be
automatically adjusted and/or manually adjusted.
[0058] Once the surfaces of the encapsulations and/or the item
package are properly positioned, a pre-polymer is injected from one
or more injection ports 211 into the cavity formed by the
encapsulation cavity 209 and expands around the bagged item 208C to
form a polymer encapsulation that encases the bagged item 208C.
Depending on the polymer encapsulation plan for the item package
contained within the protective bag, any one or more of a variety
of pre-polymers and/or blowing agents may be injected into the
cavity to form the polymer encapsulation. For example, the polymer
may be polyethylene (low and high density), polyurethane,
polystyrene, polypropylene, polyimide, polyesters, silicones,
siloxanes, polyvinylchloride, phenolics, polyetherimides,
polyphenylene oxide, polychloropren, epoxies, polyacrylates,
cellulose acetate, etc., or be a copolymer of these different
polymer classes. The blowing agent may be a physical and/or
chemical blowing agent that causes cells to form within the polymer
encapsulation.
[0059] In some implementations, the polymer may be selected to take
advantage of rapid, exothermic polymerization reactions that
entrain gas within cells of the formed polymer to create a
biodegradable and/or recyclable polymer encapsulation. For example,
if the polymer is polyurethane, it may be configured to be
biodegradable, set rapidly (e.g., in approximately 1-2 minutes), be
mechanically strong (e.g., tensile strength of approximately 10-100
megapascals ("MPa"); tear strength of 10-200 kilonewtons per meter
("kN/m")). Regardless of the polymer used, the polymer that forms
the polymer encapsulation has a mechanical strength sufficient to
enable the polymer encapsulation to function as a protective
barrier for the items of the item package and as a transportation
container for the items of the item package so that they do not
need to be placed in a traditional corrugated box for shipping.
[0060] In some implementations, the mechanical strength of the
polymer may be adjusted depending on a planned position in a
stacking configuration for the polymer encapsulation. For example,
polymer encapsulations that will be positioned on a bottom of a
stacking configuration may be configured to have a higher
mechanical strength so that they can support more polymer
encapsulations stacked on top of the polymer encapsulation.
[0061] In implementations where the bagged item is positioned on a
preformed base, the injected polymer bonds with the preformed base
such that the injected polymer and the preformed base encompass the
bagged item and adhere to each other. In implementations that do
not utilize a preformed base, the bagged item may be positioned so
that the injected pre-polymer can surround all sides of the bagged
item and encase the bagged item. For example, the bagged item may
be raised a defined distance above the surface of the encapsulation
table 213 by a series of pins or extension arms so that the
injected pre-polymer can expand under a bottom of the bagged item,
in addition to around the sides and top of the bagged item. After a
defined period of time (e.g., when the polymer has partially set),
the pins or arms may be withdrawn. By withdrawing the pins or arms
before the polymer has fully set, the polymer will expand partially
or completely into the voids left by removal of the pins or
arms.
[0062] In some implementations, the polymer encapsulation station
may include additional injection ports that are configured to
introduce gasses, solvents, colored dyes, fillers, colloidal
materials, etc. into the cavity while the pre-polymer is being
injected into the cavity. For example, if the polymer encapsulation
plan specifies that a gas is to be entrained in the polymer, the
specified gas may be emitted from one or more injection ports into
the cavity while the pre-polymer is being injected into the cavity
so that the gas is entrained in the cells of the formed polymer.
The gas may be, for example, air, oxygen, hydrogen, helium,
nitrogen, carbon dioxide, etc. Likewise, one or more colored dyes
may be introduced to color the polymer and the resulting polymer
encapsulation.
[0063] Returning to FIG. 2, after the pre-polymer has been injected
into the encapsulation cavity 209, it is determined when a defined
amount of time has elapsed that is needed for the polymer to set.
As will be appreciated, depending on the polymer used, and/or the
polymer properties, the set time may vary. In some implementations,
the set time may be reduced by, for example, heating the surfaces
of the encapsulation cavity, spraying water or a solvent on the
polymer, etc. Once the set time has elapsed, the surfaces of the
encapsulation cavity are removed and the polymer encapsulation 200
is routed from the polymer encapsulation station 260. For example,
the polymer encapsulation may be routed to shipping operations for
shipping to a destination.
[0064] In some implementations, the polymer encapsulation may
include multiple types of polymers and/or layers of polymers. For
example, the polymer encapsulation may be formed of a polymer with
large cells that entrain a lighter than air gas. After the polymer
encapsulation has formed (e.g., subsequent to the set time) and the
encapsulation cavity removed, a secondary polymer may be layered
over the polymer encapsulation. The secondary polymer may form a
water protective laminate around the polymer encapsulation and/or
increase the structural integrity of the polymer encapsulation. For
example, if the item is being delivered to a location in which it
may remain outside for a period of time, the water protective
laminate may be beneficial. Similarly, if the polymer encapsulation
is planned to be on or near a bottom of a stacking configuration
(e.g., other polymer encapsulations will be stacked on top of the
polymer encapsulation), the secondary polymer may be configured to
increase the strength of the polymer encapsulation so that it will
not crush from the weight of the stacking configuration.
[0065] In some implementations, after the polymer has set and/or
after multiple layers of polymer have been applied to form the
polymer encapsulation, the polymer encapsulation may be held in a
buffer or other temporary storage until a second, cure time, has
elapsed. The cure time may be a defined time that is needed for the
polymer to sufficiently harden before it can be stacked or
transported. In some implementations, the cure time may correspond
to an approximate cure degree (e.g., 75% cured). Once the cure time
has elapsed, the encapsulation cavity may then be routed to
shipping or other operations.
[0066] As illustrated, and as discussed further below with respect
to FIG. 3, one or more access mechanisms 204 may protrude from the
polymer encapsulation to enable access to the item(s) encased
within the polymer encapsulation.
[0067] In some implementations, shipping information may be applied
to the polymer encapsulation 200. For example, a printed shipping
label may be affixed to the polymer encapsulation 200 so that the
polymer encapsulation can be shipped to a destination. In other
implementations, a laser or other etching device may be utilized to
etch or imprint shipping information directly into a surface of the
polymer encapsulation 200. In still another example, the shipping
information may be printed or applied directly onto the surface of
the polymer encapsulation.
[0068] In another example, the shipping information may be applied
to an exposed side of the preformed base. For example, either
before, during, or after the polymer encapsulation is formed,
shipping information may be applied to the preformed base. By
applying the shipping information to the preformed base, it is not
visually discernable by individuals located within the facility
because it is on the surface of the conveyor and not exposed.
[0069] FIG. 3 illustrates an example of a polymer encapsulation 300
that includes an item 310 for shipping, according to an
implementation. In this example, the item 310 has been placed in a
protective bag 308 and positioned on a preformed base 302B. A
pre-polymer was injected around the bagged item and expanded to
form the upper portion of polymer encapsulation 302A, which bonded
with the preformed base 302B to fully encase the protective bag 308
and the item 310 in a polymer encapsulation 300. Likewise, shipping
information 312 has been applied to the polymer encapsulation 300
so that the polymer encapsulation 300 that contains the item 310
can be shipped to a destination.
[0070] In this example, the polymer encapsulation 300 includes two
access mechanisms 304, 306. The first access mechanism 304 extends
from the protective bag 308, through the upper portion of the
polymer encapsulation 302A and is exposed outside of the polymer
encapsulation 300 so that it can be activated by a customer. For
example, the customer may pull on the access mechanism 304 which
will cause a disruption or tear in the polymer encapsulation,
thereby providing access to the item.
[0071] The second access mechanism 306 is incorporated into the
bond formed between the preformed base 302B and the upper portion
of the polymer encapsulation 302A. In some implementations, the
mechanical strength of the bond between the upper portion of the
encapsulation 302A and the preformed base 302B may be the weakest
portion of the polymer encapsulation, thereby making activation of
the access mechanism easier. In this example, the access mechanism
306 is a string that is woven within the bond formed between the
upper portion of the polymer encapsulation 302A and the preformed
base 302B. When the access mechanism 306 is activated (e.g., pulled
by a customer), that string disrupts the bond separating at least a
portion of the upper portion of the polymer encapsulation 302A from
the preformed base 302B so that the encased item can be accessed by
the customer.
[0072] FIG. 4 is a block diagram of a stacking configuration 400
situated on a transportation unit 402, in one implementation. In
this example, stacked polymer encapsulations 404, 406, 408, 410,
412, 414, 416, 418, 420, represented as non-shaded blocks, are
polymer encapsulations that have already been placed on the
transportation unit 402 according to a stacking configuration.
Planned polymer encapsulations 422, 424, 426, 428, 430, 432, 434,
represented by the cross-hatched blocks, are polymer encapsulations
that have not yet been stacked on the transportation unit but have
been planned for stacking at the respective positions in the
stacking configuration for the transportation unit 402.
[0073] As illustrated in FIG. 4, for some of the planned polymer
encapsulations, there is a sequence to which they need to be added
to the stacking configuration. For example, planned polymer
encapsulation 430 needs to be added to the stacking configuration
400 before planned polymer encapsulation 432. However, other
planned polymer encapsulations may be added in any order with
respect to each other. For example, planned polymer encapsulations
422, 424, 426, 428 and 434 may be added to the transportation unit
independent of one another. For planned polymer encapsulations that
need to be added in sequence with respect to one another, they may
be sequenced at picking, sorting, bagging, polymer encapsulation,
and/or stacking, as discussed above.
[0074] As also illustrated by the stacking configuration 400, the
stacking engine may plan placement of polymer encapsulations to
generate level surface areas for the next layer of polymer
encapsulations. For example, planned polymer encapsulation 432 has
been selected and has dimension values so that, when placed on the
stacking configuration 400, its top surface will be level with the
top surface of stacked polymer encapsulation 418, thereby providing
a larger, level surface area onto which another layer of polymer
encapsulations may be stacked. Likewise, planned polymer
encapsulations 422, 424, 426, 430 have been selected and arranged
adjacent to stacked polymer encapsulation 412 to provide a larger,
level surface area that can be used for additional layers of
polymer encapsulations. To provide this configuration, planned
polymer encapsulation 426 may not include an item package. Instead,
its formation was instructed by the stacking engine for placement
adjacent to planned polymer encapsulations 424, 430 to provide a
larger, level top layer surface. Alternatively, one or both of the
polymer encapsulations may have been planned to be larger and/or
have a different shape. Likewise, the height of planned polymer
encapsulation 428 may have been increased to match the height of
planned polymer encapsulation 434 and stacked polymer encapsulation
416.
[0075] In some implementations, standards or policies may be
considered in planning a stacking configuration, such as a default
placement for certain polymer encapsulations or a specific stacking
algorithm to be assumed when planning polymer encapsulations,
and/or polymers to use in forming polymer encapsulations. For
example, various policies may specify that the polymer
encapsulations with the largest and/or heaviest items be placed
horizontally along the bottom of the transportation unit and that
polymer encapsulations with smaller and/or lighter items be placed
on top of the larger items. Likewise, policies may specify that
polymer encapsulations that contain heavier items, and/or polymer
encapsulations that are positioned toward the bottom of a stacking
configuration, be formed with a polymer having a higher mechanical
strength than those encasing lighter items or positioned toward a
top of a stacking configuration.
[0076] Providing larger, level surface areas onto which additional
polymer encapsulations may be stacked helps improve stability of
the stacking configuration and allows for additional polymer
encapsulations to be stacked. As can be appreciated, multiple
configurations may be made with polymer encapsulations and the
illustration provided in FIG. 4 is only one example. Likewise, as
discussed above, in some implementations, the polymer
encapsulations may be formed so that when stacked they mate or
interlock, further increasing the stability of the stacking
configuration.
[0077] FIG. 5 is a flow diagram illustrating an example polymer
encapsulation determination process 500, according to an
implementation. The process is illustrated as a collection of
blocks in a logical flow graph. Some of the blocks represent
operations that can be implemented in hardware, software, or a
combination thereof. In the context of software, the blocks
represent computer-executable instructions stored on one or more
computer-readable media that, when executed by one or more
processors, perform the recited operations. Generally,
computer-executable instructions include routines, programs,
objects, components, data structures and the like that perform
particular functions or implement particular abstract data
types.
[0078] The computer-readable media may include non-transitory
computer-readable storage media, which may include hard drives,
floppy diskettes, optical disks, CD-ROMs, DVDs, read-only memories
(ROMs), random access memories (RAMs), EPROMs, EEPROMs, flash
memory, magnetic or optical cards, solid-state memory devices, or
other types of storage media suitable for storing electronic
instructions. In addition, in some implementations, the
computer-readable media may include a transitory computer-readable
signal (in compressed or uncompressed form). Examples of
computer-readable signals, whether modulated using a carrier or
not, include, but are not limited to, signals that a computer
system hosting or running a computer program can be configured to
access, including signals downloaded or uploaded through the
Internet or other networks. Finally, the order in which the
operations are described is not intended to be construed as a
limitation, and any number of the described operations can be
combined in any order and/or in parallel to implement the process.
Likewise, additional or fewer operations than those described may
be utilized with the various implementations described herein.
[0079] The example process 500 begins by determining stored item
dimensions and characteristics for items of an item package that is
to be encased in a polymer encapsulation for shipment, as in 502.
Stored item dimensions and/or characteristics may be provided by
manufacturers, sellers, or vendors of items, measured by a
dimension measurement tool within the facility, estimated based on
received information, and/or based on a process of successive
approximation as the items are handled within the facility. Item
characteristics may specify a weight of the item, a fragility of
the item, handling requirements, whether the item is hazardous,
etc.
[0080] In some implementations, assumptions about item dimensions
may be made or item dimensions may be assigned according to a
standard algorithm, or company policy, in order to facilitate the
planning of the polymer encapsulation. For example, in one
implementation, the item dimension having the largest value may be
designated to be the "length," the dimension having the second
largest value may be designated to be the "height," and the
dimension having the smallest value may be designated to be the
"width" of the item.
[0081] In one implementation, the volume of an item package may be
defined to be equal to the volume of a three-dimensional bounding
box having length, width, and height equal to the length, width,
and height of the items contained in the item package when placed
in a protective bag. In some implementations, the volume and
dimensions of a group of items may be defined, respectively, to be
the volume and corresponding dimensions of a three-dimensional
bounding box having sufficient length, width, and height to encase
all the items in the item package. For example, a volume of a
bounding box surrounding the items of the item package may be
calculated. This may be done according to guidelines and
conventions for arranging items for shipment (e.g., the algorithm
may specify that the largest and/or heaviest item should be placed
horizontally on the bottom and additional items may be placed on
top of, or next to, this item in order of their largest dimension
value, their weight, etc.).
[0082] Based on the stored item dimension values and
characteristics, initial polymer encapsulation dimensions are
determined, as in 504. For example, initial polymer encapsulation
dimensions may be made such that the polymer encapsulation is a
defined percentage larger than the item dimension values. The
defined percentage may be based on a classification or fragility of
the item, a weight of the item, etc. For example, if the item is
fragile, the polymer encapsulation dimensions may be larger so the
protective barrier formed around the item is thicker. In some
implementations, a minimum polymer encapsulation dimension may be
established that specifies a minimum size and/or minimum distance
between the item and an external portion of the polymer
encapsulation. Likewise, a maximum polymer encapsulation dimension
may be specified. For example, the maximum polymer encapsulation
dimension may be specified dependent on a type or position of the
access mechanism that is used to disrupt the polymer encapsulation.
If the polymer encapsulation is too thick, activation or use of the
access mechanism may be hindered.
[0083] A transportation unit into which the item, when encased in a
polymer encapsulation, will be placed for shipment and a position
in the stacking configuration within the transportation unit is
also determined, as in 506. Upon determining the initial polymer
encapsulation dimensions, the dimensions may be provided to a
stacking engine that plans a position for the polymer encapsulation
based on the initial dimensions. The stacking engine, upon
determining a position in a stacking configuration for a
transportation unit, may provide the information back to the
example process 500. In some implementations, the stacking
configuration may also increase one or more dimensions of the
polymer encapsulation dimension values and/or adjust a shape/size
of the polymer encapsulation to improve the stability of a stacking
configuration that will include the polymer encapsulation and/or so
that the polymer encapsulation will fit in or on a transportation
unit according to a stacking plan.
[0084] Customer preferences for a polymer encapsulation may also be
determined and considered by the example process 500, as in 508.
Customer preferences may indicate a preferred shape, size, color,
amount of space between the item and the polymer encapsulation,
whether the polymer encapsulation should be biodegradable,
recyclable, the type and/or location of an access mechanism,
etc.
[0085] Based on the polymer encapsulation dimensions, item
dimensions, item characteristics, transportation unit, planned
position in a stacking configuration, and/or customer preferences,
polymer properties for the polymer encapsulation are determined, as
in 510. Polymer properties may include the type of polymer to be
used, the cell density of the polymer, cell volume, open/closed
cell structure, tear strength, tensile strength, crush resistance,
bursting strength, puncture resistance, waterproof or water
repellant properties, buoyancy, heat stability and insulation,
stability, shelf life, whether the polymer is biodegradable,
renewable, bio-compatible, compostable, malleability, non-toxic,
recyclable, whether and/or a type of gas to be injected into the
polymer so that it is entrained in the cells of the polymer, a
color of the polymer, a set time for the polymer, a cure time for
the polymer, etc.
[0086] Based on the collected information and determined polymer
properties, a polymer encapsulation plan is established that
specifies the polymer encapsulation dimensions, polymer
encapsulation shape, a maximum polymer encapsulation dimension, a
minimum polymer encapsulation dimension, polymer properties, a
label type and/or position, whether to inject or remove gas from
the protective bag, a set time, a cure time, etc., as in 512.
[0087] As discussed above, the polymer encapsulation plan may be
used by the polymer encapsulation station to position the surfaces
of the encapsulation cavity around the item package, to select an
appropriate polymer, gas, color, etc., for injecting and forming
the polymer encapsulation, when to remove the encapsulation cavity,
etc. Likewise, the polymer encapsulation plan may be utilized by
the bagging station to determine whether to inject gas into the
protective bag or remove gas from the protective bag, etc.
Likewise, the polymer encapsulation process 600 may utilize the
polymer encapsulation plan, as discussed further below with respect
to FIG. 6.
[0088] Upon generating the polymer encapsulation plan, the example
process 500 completes, as in 514.
[0089] FIG. 6 is a flow diagram of an example polymer encapsulation
process 600, according to an implementation. The example process
begins upon receipt of a bagged item (or bagged item package) at a
polymer encapsulation station, as in 602. As discussed above, a
bagged item may arrive at a polymer encapsulation station via
automated means, such as a conveyor, and/or be positioned at the
polymer encapsulation station manually by an agent.
[0090] When the bagged item is at the polymer encapsulation
station, an encapsulation cavity is positioned around the bagged
item, as in 604. Any variety of techniques may be used to position
an encapsulation cavity around the bagged item. For example, as
discussed above with respect to FIG. 2, one of many different
sized/shaped encapsulation cavities may be positioned around the
bagged item. Alternatively, one or more vertical surfaces or walls
may be independently moved or positioned around the bagged item to
form the encapsulation cavity.
[0091] As the surfaces of the encapsulation cavity are moved into
position, a determination is made as to whether a distance between
the surfaces of the encapsulation cavity and the bagged item are
less than a minimum polymer encapsulation distance specified for
the polymer encapsulation, as in 606. For example, if the distance
between one of the vertical surfaces of the encapsulation cavity is
less than a minimum distance from the bagged item, it is determined
that the distance between the encapsulation cavity and the bagged
item is less than the minimum distance.
[0092] If it is determined that the distance between the
encapsulation cavity and the bagged item is less than the minimum
distance, one or more surfaces of the encapsulation cavity and/or a
position of the bagged item is adjusted. For example, if only one
of the surfaces of the encapsulation cavity is less than the
minimum distance from the bagged item, the position of that surface
may be adjusted so it is not less than the minimum distance from
the bagged item. In another example, if one of the surfaces of the
bagged item is less than the minimum distance and one of the
surfaces is greater than the maximum distance, the bagged item may
be repositioned so that the minimum distances and maximum distances
are satisfied. Alternatively, or in addition thereto, the positions
of the surfaces of the encapsulation cavity may also be adjusted,
as in 610.
[0093] In some implementations, a similar determination and/or
adjustments may be made to ensure that the distance between the
bagged item and one or more surfaces of the polymer encapsulation
cavity does not exceed a maximum distance.
[0094] After adjusting the position of one or more of the surfaces
of the encapsulation cavity and/or the position of the bagged item,
or upon determining that the distance between the surfaces of the
encapsulation cavity and the bagged item is not less than the
minimum distance, a pre-polymer is injected into the cavity formed
by the encapsulation cavity surfaces such that the formed polymer
fills the cavity and surrounds the bagged item, as in 612.
Injection of the pre-polymer may continue until the polymer has
expanded and filled the cavity and/or until a defined amount of
pre-polymer has been injected.
[0095] In some implementations, other additives, such as gasses,
colored dyes, etc., may also be injected into the cavity while the
pre-polymer is being injected so those additives are entrained in
the cells of the polymer and/or affect the polymer in other ways
(e.g., by altering a color of the polymer).
[0096] After the pre-polymer has been injected into the cavity, the
formed polymer is allowed to set for a predetermined period of
time, as may be specified in the polymer encapsulation plan. The
example process 600 will determine if the defined time (polymer set
time) has elapsed, as in 614. If the defined time has not elapsed,
the example process 600 returns to block 614 and continues.
[0097] When it is determined that the defined set time has elapsed,
the surfaces of the encapsulation cavity that formed the cavity are
removed from around the polymer encapsulation that has been formed
by the injected pre-polymer, as in 616. Additionally, shipping
information is added to the polymer encapsulation so that the
encased item may be shipped to a destination, as in 618. As
discussed above, the shipping information may be etched, imprinted,
or printed directly onto the polymer encapsulation. Alternatively,
the shipping information may be printed on a label that is applied
to the polymer encapsulation. In some implementations, the shipping
information may be applied to a preformed base that is positioned
underneath the bagged item and bonded with the polymer to form the
polymer encapsulation.
[0098] If the shipping information is applied to the preformed
base, it may be applied to the preformed base before, during, or
after the pre-polymer is injected into the cavity around the item
and the polymer encapsulation formed.
[0099] After removing the surfaces of the encapsulation cavity, a
determination is made as to whether a second defined time, referred
to as a cure time, has elapsed, as in 619. The cure time is a
defined time necessary for the polymer encapsulation to reach a
cure degree (e.g., 75% cured). This cure time and/or the cure
degree may vary for different polymer encapsulations based on the
item encased in the polymer encapsulation, the position of the
polymer encapsulation in a stacking configuration, based on the
polymer properties, etc. For example, if the polymer encapsulation
will be positioned toward a bottom of a stacking configuration and
other polymer encapsulations stacked on top of the polymer
encapsulation, the cure time may be longer so that the cure degree
is higher, resulting in increased mechanical strength. In
comparison, if the polymer encapsulation will be at the top of the
stacking configuration, it may have a reduced cure time.
[0100] If it is determined that the cure time has not elapsed, the
example process returns to decision block 619 and awaits expiration
of the cure time. Once the cure time has elapsed, the polymer
encapsulation is released to other operations, as in 620. For
example, upon expiration of the cure time, the polymer
encapsulation may be released to shipping operations for stacking
in a stacking configuration. In some examples, the polymer
encapsulation may be removed from the polymer encapsulation station
and retained in a buffer or remain on a conveyor until the cure
time has elapsed before it is released to other operations. By
removing the polymer encapsulation from the polymer encapsulation
station while the polymer encapsulation is curing, other polymer
encapsulations may be formed.
[0101] As will be appreciated, other aspects may be incorporated
into or omitted from the examples processes 500 and/or 600 and the
order in which the processes are performed are only exemplary. For
example, the example process 600 may also include steps for
positioning and/or including the access mechanism in the polymer
encapsulation, elevating the bagged item with one or more pins
and/or arms prior to injecting the polymer, removing the pins
and/or arms prior to the polymer setting, etc.
[0102] Various operations of a packaging information system, such
as those described herein, may be executed on one or more computer
systems, interacting with various other devices in a materials
handling facility, according to various implementations. One such
computer system is illustrated by the block diagram in FIG. 7. In
the illustrated implementation, a computer system 700 includes one
or more processors 710A, 710B through 710N, coupled to a
non-transitory computer-readable storage medium 720 via an
input/output (I/O) interface 730. The computer system 700 further
includes a network interface 740 coupled to the I/O interface 730,
and one or more input/output devices 750. In some implementations,
it is contemplated that a described implementation may be
implemented using a single instance of the computer system 700
while, in other implementations, multiple such systems or multiple
nodes making up the computer system 700 may be configured to host
different portions or instances of the described implementations.
For example, in one implementation, some data sources or services
(e.g., stacking engine) may be implemented via one or more nodes of
the computer system 700 that are distinct from those nodes
implementing other data sources or services (e.g., routing
operations).
[0103] In various implementations, the computer system 700 may be a
uniprocessor system including one processor 710A, or a
multiprocessor system including several processors 710A-710N (e.g.,
two, four, eight, or another suitable number). The processors
710A-710N may be any suitable processor capable of executing
instructions. For example, in various implementations, the
processors 710A-710N may be general-purpose or embedded processors
implementing any of a variety of instruction set architectures
(ISAs), such as the x86, PowerPC, SPARC, or MIPS ISAs, or any other
suitable ISA. In multiprocessor systems, each of the processors
710A-710N may commonly, but not necessarily, implement the same
ISA.
[0104] The non-transitory computer-readable storage medium 720 may
be configured to store executable instructions and/or data
accessible by the one or more processors 710A-710N. In various
implementations, the non-transitory computer-readable storage
medium 720 may be implemented using any suitable memory technology,
such as static random access memory (SRAM), synchronous dynamic RAM
(SDRAM), nonvolatile/Flash-type memory, or any other type of
memory. In the illustrated implementation, program instructions and
data implementing desired functions, such as those described above,
are shown stored within the non-transitory computer-readable
storage medium 720 as program instructions 725 and data storage
735, respectively. In other implementations, program instructions
and/or data may be received, sent or stored upon different types of
computer-accessible media, such as non-transitory media, or on
similar media separate from the non-transitory computer-readable
storage medium 720 or the computer system 700. Generally speaking,
a non-transitory, computer-readable storage medium may include
storage media or memory media such as magnetic or optical media,
e.g., disk or CD/DVD-ROM coupled to the computer system 700 via the
I/O interface 730. Program instructions and data stored via a
non-transitory computer-readable medium may be transmitted by
transmission media or signals such as electrical, electromagnetic,
or digital signals, which may be conveyed via a communication
medium such as a network and/or a wireless link, such as may be
implemented via the network interface 740.
[0105] In one implementation, the I/O interface 730 may be
configured to coordinate I/O traffic between the processors
710A-710N, the non-transitory computer-readable storage medium 720,
and any peripheral devices, including the network interface 740 or
other peripheral interfaces, such as input/output devices 750. In
some implementations, the I/O interface 730 may perform any
necessary protocol, timing or other data transformations to convert
data signals from one component (e.g., non-transitory
computer-readable storage medium 720) into a format suitable for
use by another component (e.g., processors 710A-710N). In some
implementations, the I/O interface 730 may include support for
devices attached through various types of peripheral buses, such as
a variant of the Peripheral Component Interconnect (PCI) bus
standard or the Universal Serial Bus (USB) standard, for example.
In some implementations, the function of the I/O interface 730 may
be split into two or more separate components, such as a north
bridge and a south bridge, for example. Also, in some
implementations, some or all of the functionality of the I/O
interface 730, such as an interface to the non-transitory
computer-readable storage medium 720, may be incorporated directly
into the processors 710A-710N.
[0106] The network interface 740 may be configured to allow data to
be exchanged between the computer system 700 and other devices
attached to a network, such as other computer systems, or between
nodes of the computer system 700. In various implementations, the
network interface 740 may support communication via wired or
wireless general data networks, such as any suitable type of
Ethernet network.
[0107] Input/output devices 750 may, in some implementations,
include one or more displays, projection devices, audio output
devices, keyboards, keypads, touchpads, scanning devices, voice or
optical recognition devices, or any other devices suitable for
entering or retrieving data by one or more computer systems 700.
Multiple input/output devices 750 may be present in the computer
system 700 or may be distributed on various nodes of the computer
system 700. In some implementations, similar input/output devices
may be separate from the computer system 700 and may interact with
one or more nodes of the computer system 700 through a wired or
wireless connection, such as over the network interface 740.
[0108] As shown in FIG. 7, the memory 720 may include program
instructions 725 which may be configured to implement one or more
of the described implementations and/or provide data storage 735,
which may comprise various tables, databases and/or other data
structures accessible by the program instructions 725. In one
implementation, the program instructions 725 may include various
software modules configured to implement a stacking engine, an item
dimension estimator, etc. The data storage 735 may include various
data stores for maintaining one or more item lists, data
representing physical characteristics of items and/or other item
parameter values, polymer characteristics, item package
information, etc. The data storage 735 may also include one or more
data stores for maintaining data representing delivery related
feedback, such as customer ratings, customer preferences,
experiences and the like.
[0109] Those skilled in the art will appreciate that the computing
system 700 is merely illustrative and is not intended to limit the
scope of implementations. In particular, the computing system and
devices may include any combination of hardware or software that
can perform the indicated functions, including computers, network
devices, internet appliances, wireless phones, tablets, etc. The
computing system 700 may also be connected to other devices that
are not illustrated, or instead may operate as a stand-alone
system. In addition, the functionality provided by the illustrated
components may in some implementations be combined in fewer
components or distributed in additional components. Similarly, in
some implementations, the functionality of some of the illustrated
components may not be provided and/or other additional
functionality may be available.
[0110] Those skilled in the art will appreciate that, in some
implementations, the functionality provided by the methods and
systems discussed above may be provided in alternative ways, such
as being split among more software modules or routines or
consolidated into fewer modules or routines. Similarly, in some
implementations, illustrated methods and systems may provide more
or less functionality than is described, such as when other
illustrated methods instead lack or include such functionality
respectively, or when the amount of functionality that is provided
is altered. In addition, while various operations may be
illustrated as being performed in a particular manner (e.g., in
serial or in parallel) and/or in a particular order, those skilled
in the art will appreciate that, in other implementations, the
operations may be performed in other orders and in other manners.
The various methods, apparatus, and systems as illustrated in the
figures and described herein represent example implementations. The
methods and systems may be implemented in software, hardware, or a
combination thereof in other implementations. Similarly, the order
of any method may be changed and various elements may be added,
reordered, combined, omitted, modified, etc., in other
implementations.
[0111] From the foregoing, it will be appreciated that, although
specific implementations have been described herein for purposes of
illustration, various modifications may be made without deviating
from the spirit and scope of the appended claims and the elements
recited therein. In addition, while certain aspects are presented
below in certain claim forms, the inventors contemplate the various
aspects in any available claim form. For example, while only some
aspects may currently be recited as being embodied in a
computer-readable storage medium, other aspects may likewise be so
embodied. Various modifications and changes may be made as would be
obvious to a person skilled in the art having the benefit of this
disclosure. It is intended to embrace all such modifications and
changes and, accordingly, the above description is to be regarded
in an illustrative rather than a restrictive sense.
* * * * *