U.S. patent application number 17/108507 was filed with the patent office on 2021-06-10 for package forming systems and related methods.
This patent application is currently assigned to Automated Solutions, LLC. The applicant listed for this patent is Automated Solutions, LLC. Invention is credited to Robert L. Campbell.
Application Number | 20210171226 17/108507 |
Document ID | / |
Family ID | 1000005406122 |
Filed Date | 2021-06-10 |
United States Patent
Application |
20210171226 |
Kind Code |
A1 |
Campbell; Robert L. |
June 10, 2021 |
PACKAGE FORMING SYSTEMS AND RELATED METHODS
Abstract
Packaging forming system and related methods are provided. A
packaging forming system can include a controller and nip rollers
in communication with the controller. The nip rollers are
positioned on either side of a product pathway on which products
being packaged travel. The packaging forming system can include a
top sheet material guide system that is configured to feed a top
sheet material and a bottom sheet material guide system that is
configured to feed a bottom sheet material to the nip rollers to
form sides of packages around one or more products traveling along
the pathway. The packaging forming system can include an adjustable
table in communication with the controller and positioned along the
pathway to provide support to the product being packaged such that
the height of the table is movable to adjust a height position of
each individual product to be packaged relative to the nip
rollers.
Inventors: |
Campbell; Robert L.;
(Hickory, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Automated Solutions, LLC |
Sawmills |
NC |
US |
|
|
Assignee: |
Automated Solutions, LLC
Sawmills
NC
|
Family ID: |
1000005406122 |
Appl. No.: |
17/108507 |
Filed: |
December 1, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15684887 |
Aug 23, 2017 |
10850877 |
|
|
17108507 |
|
|
|
|
62378432 |
Aug 23, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 41/16 20130101;
B65B 59/02 20130101; B65B 57/00 20130101; B65B 59/001 20190501;
B65B 45/00 20130101; B65B 9/02 20130101; B65B 35/24 20130101; B65B
25/14 20130101; B65B 9/026 20130101; B65B 65/00 20130101; B65B
51/303 20130101; B65B 2210/04 20130101; B65B 59/00 20130101; B65B
11/50 20130101; B65B 61/06 20130101; B65B 51/30 20130101 |
International
Class: |
B65B 11/50 20060101
B65B011/50; B65B 51/30 20060101 B65B051/30; B65B 41/16 20060101
B65B041/16; B65B 35/24 20060101 B65B035/24; B65B 9/02 20060101
B65B009/02; B65B 57/00 20060101 B65B057/00; B65B 61/06 20060101
B65B061/06; B65B 45/00 20060101 B65B045/00; B65B 25/14 20060101
B65B025/14; B65B 59/02 20060101 B65B059/02; B65B 59/00 20060101
B65B059/00; B65B 65/00 20060101 B65B065/00 |
Claims
1. A method of forming a package around a product to be shipped in
a packaging forming system, the method comprising: placing a
product to be packaged on a pathway of a packaging forming system
supported by an adjustable table of the packaging forming system;
determining a distance that the adjustable table is to be moved in
an upwardly or downwardly direction to align a centerline of the
product to be packaged with nip rollers of the packaging forming
system with a controller of the packaging forming system; moving
the adjustable table the determined distance in an upwardly or
downwardly direction to align the centerline of the product to be
packaged with nip rollers of the packaging forming system based
with the controller of the packaging forming system; running side
edges of the bottom sheet material and side edges of a top sheet
material through the nip rollers to form sides of a package on
either side of the product; and engaging a cross seal device to
engage the bottom sheet material and the top sheet material in a
direction transverse to the direction that the bottom sheet
material and the top sheet material are traveling in the packaging
forming system to form a leading end and trailing end of the
package.
2. The method according to claim 1, wherein the step of placing a
product to be packaged on the pathway of the packaging forming
system comprises using laser lines and a placement gate to
determine where to place the product on the pathway.
3. The method according to claim 1, wherein the step of determining
a distance that the adjustable table is to be moved comprises
taking a measurement of a distance between a measuring point and a
leading edge of the product as the product travels along the
pathway with a sensor, communicating the measurement to the
controller and the controller calculating the distance to move the
adjustable table.
4. The method according to claim 1, wherein the step of determining
a distance that the adjustable table is to be moved comprises
taking at least one of a height measurement or a length measurement
with one or more sensors and communicating the at least one of a
height measurement or a length measurement to the controller and
the controller calculating the distance to move the adjustable
table.
Description
RELATED APPLICATION
[0001] The presently disclosed subject matter claims the benefit of
U.S. patent application Ser. No. 15/684,887, filed Aug. 23, 201,
which in turn claimed the benefit of U.S. Provisional Patent
Application Ser. No. 62/378,432, filed Aug. 23, 2016, the
disclosures of both patent applications are incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] The present subject matter relates to shipping package
forming apparatuses, systems, and related methods. In particular,
the present subject matter relates to apparatuses and systems that
form and aid in forming packages, such as envelopes, around
physical items that are being shipped in the packages.
BACKGROUND
[0003] The advent of online purchasing, through such e-commerce
website as Amazon or online box stores, such as Walmart online,
have created a need for packaging items that are bought by a
customer online and then shipped from a distribution center to the
customer. These distribution centers must process thousands of
items of various sizes.
[0004] These items include all of the various that are sold in mass
on these e-commerce websites. Such items can include, but are not
limited to: jewelry, such as rings, bracelets, necklaces, key
rings, etc.; utility items, such as knives of various sizes, tools,
etc.; electronics, such as cellular phones, tablet devices,
televisions, computers, flash drives or other fobs, etc.; personal
care items, such as make-up items, moisturizers and creams, razors,
brushes, combs, hair dryers, etc.; apparel, such as dresses, pants,
skirts, shorts, shirts, belts, shoes, socks, etc.; home
furnishings, such as pillows, sheets, fabric coverings, etc.; toys
of various sizes; and books of various sizes.
[0005] Due to the varied sizes of the items being processed in
these distribution centers, packaging these items can be
problematic. Having to separately package items can be labor
intensive and time-consuming. Such problems can be partially
addressed by separately items to be shipped from a fulfillment
center by size. For smaller items, known as "smalls," such as
books, jewelry, apparel, etc., envelope forming machines can be
used to form envelope packages around the smaller items. These
envelope forming machines allow placement of the smaller items
between two sheets of material that for the envelope that will form
the packing around the smaller item. The envelope forming machine
can press and seal the sides and press, seal, and cut the ends to
form the package around the smaller item.
[0006] While these envelope forming machines can speed up the
packaging and shipping process, the current envelope forming
machines still have many drawbacks that cost processing time, can
raise labor costs, and can hurt the quality of the packages being
formed. For example, with current envelope forming machines, even
slight variations in height of the items can misalign the sheets of
material that can in turn cause weak seals along the sides of the
package, and depending on the product used to form the sealed
sides, can expose adhesives, sealants, or other tacky substances to
exterior of the package. Additionally, due to the mechanisms used
to cut and seal the ends of the package, weakened seals are often
formed leading to a tendency for one or both ends of the package to
open unintentionally, for example, during shipping.
[0007] As such, a need exists, for example, for shipping package
forming apparatuses and systems that can more effectively form
packaging around a wider range of sizes of items to be shipped,
while also providing sturdier packages that will not
unintentionally open during shipping.
SUMMARY
[0008] The present subject matter provides package forming
apparatuses, systems, and related methods. In particular, the
present subject matter relates to apparatuses and systems that form
and aid in forming packages, such as envelopes, around physical
items that are being shipped in the packages. Methods related to
the manufacture and use of the shipping package forming apparatuses
and systems as disclosed herein are also provided.
[0009] Thus, it is an object of the presently disclosed subject
matter to provide package forming apparatuses and systems as well
as methods related thereto. While one or more objects of the
presently disclosed subject matter having been stated hereinabove,
and which is achieved in whole or in part by the presently
disclosed subject matter, other objects will become evident as the
description proceeds when taken in connection with the accompanying
drawings as best described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A full and enabling disclosure of the present subject matter
including the best mode thereof to one of ordinary skill in the art
is set forth more particularly in the remainder of the
specification, including reference to the accompanying figures, in
which:
[0011] FIG. 1A illustrates a schematic view looking in a machine
direction down a travel path of a product being packaged in an
embodiment of a package forming system according to the present
subject matter as a package is being formed around the product;
[0012] FIG. 1 B illustrates a schematic view looking in a
cross-machine direction perpendicular to a travel path of a product
being packaged in an embodiment of a package forming system
according to the present subject matter as a package is being
formed around the product;
[0013] FIG. 2 illustrates a schematic view of an embodiment of a
package forming system according to the present subject matter;
[0014] FIG. 3A illustrates a front top perspective view of another
embodiment of a package forming system according to the present
subject matter;
[0015] FIG. 3B illustrates a side top perspective view of the
embodiment of the package forming system according to FIG. 3A;
[0016] FIG. 3C illustrates a rear top perspective view of the
embodiment of the package forming system according to FIG. 3A;
[0017] FIG. 3D illustrates a side view of the embodiment of the
package forming system according to FIG. 3A;
[0018] FIG. 3E illustrates an opposing side view of the embodiment
of the package forming system according to FIG. 3A to the view in
FIG. 3D;
[0019] FIG. 3F illustrates a side bottom perspective view of the
embodiment of the package forming system according to FIG. 3A;
[0020] FIG. 3G illustrates a side view of the embodiment of the
package forming system according to FIG. 3A with an embodiment of
top rolling positioning arms for holding a roll of sheet material
in an upper run position;
[0021] FIG. 3H illustrates a side view of the embodiment of the
package forming system according to FIG. 3A with the top rolling
positioning arms for holding a roll of sheet material show in FIG.
3G in a lowered loading position;
[0022] FIG. 4A illustrates a top perspective view of an embodiment
of an adjustable table that can be used in the embodiment of the
package forming system according to FIG. 3A;
[0023] FIG. 4B illustrates a front view of the embodiment of the
adjustable table according to FIG. 4A;
[0024] FIG. 4C illustrates a front side perspective view of the
embodiment of the adjustable table according to FIG. 4A;
[0025] FIG. 4D illustrates a front side perspective view of the
embodiment of the adjustable table according to FIG. 4A;
[0026] FIG. 4E illustrates a side bottom perspective view of the
embodiment of the adjustable table according to FIG. 4A;
[0027] FIG. 4F illustrates an exploded view of the embodiment of
the adjustable table according to FIG. 4A;
[0028] FIG. 5A illustrates a schematic view of an embodiment of a
package forming system according to the present subject matter with
an embodiment of a guide tension roller secured to an adjustable
table (not shown) in a lower position;
[0029] FIG. 5B illustrates a schematic view of the embodiment of
the package forming system according to FIG. 5A with the guide
tension roller secured to the adjustable table (not shown) in an
upper position;
[0030] FIG. 6 illustrates a front perspective view of an embodiment
of a controller that can be used in the embodiment of the package
forming system according to FIG. 3A;
[0031] FIG. 7A illustrates a front view of an embodiment of a weigh
station that can be used in the embodiment of the package forming
system according to FIG. 3A;
[0032] FIG. 7B illustrates a side view of an embodiment of the
weigh station according to FIG. 8A;
[0033] FIG. 8A illustrates a side view of an embodiment of a
printer station that can be used in the embodiment of the package
forming system according to FIG. 3A;
[0034] FIG. 8B illustrates a side rear perspective view of an
embodiment of the printer station according to FIG. 9A;
[0035] FIG. 9A illustrates a top front perspective view of an
embodiment of a package forming system according to FIG. 3A with an
embodiment of a laser guide thereon and an embodiment of a product
on a product pathway of the package forming system;
[0036] FIG. 9B illustrates a close-up view taken about the circled
portion A1 in FIG. 9A showing the laser lines projected from the
laser guide;
[0037] FIG. 9C illustrates a top view of the entry way of the
product pathway of the package forming system according to FIG.
9A;
[0038] FIG. 10A illustrates a top side perspective view of an
embodiment of a height sensor that can be used in the embodiment of
the package forming system according to FIG. 3A;
[0039] FIG. 10B illustrates a side view of the embodiment of the
height sensor according to FIG. 9A; and
[0040] FIG. 11 illustrates a rear side perspective view of an
embodiment of a roll axle that can be used in the embodiment of the
package forming system according to FIG. 3A.
[0041] Repeat use of reference characters in the present
specification and drawings is intended to represent the seam or
analogous features or elements of the present subject matter.
DETAILED DESCRIPTION
[0042] Reference now will be made to the embodiments of the present
subject matter, one or more examples of which are set forth below.
Each example is provided by way of an explanation of the present
subject matter, not as a limitation. In fact, it will be apparent
to those skilled in the art that various modifications and
variations can be made in the present subject matter without
departing from the scope or spirit of the present subject matter.
For instance, features illustrated or described as one embodiment
can be used on another embodiment to yield still a further
embodiment. It is to be understood by one of ordinary skill in the
art that the present discussion is a description of exemplary
embodiments only, and is not intended as limiting the broader
aspects of the present subject matter, which broader aspects are
embodied in exemplary constructions.
[0043] Although the terms first, second, right, left, front, back,
top, bottom, etc. may be used herein to describe various features,
elements, components, regions, layers and/or sections, these
features, elements, components, regions, layers and/or sections
should not be limited by these terms. These terms are only used to
distinguish one feature, element, component, region, layer or
section from another feature, element, component, region, layer or
section. Thus, a first feature, element, component, region, layer
or section discussed below could be termed a second feature,
element, component, region, layer or section without departing from
the teachings of the disclosure herein.
[0044] Similarly, when a feature or element is being described in
the present disclosure as "on" or "over" another feature or
element, it is to be understood that the features or elements can
either be directly contacting each other or have another feature or
element between them, unless expressly stated to the contrary.
Thus, these terms are simply describing the relative position of
the features or elements to each other and do not necessarily mean
"on top of" since the relative position above or below depends upon
the orientation of the device to the viewer.
[0045] Embodiments of the subject matter of the disclosure are
described herein with reference to schematic illustrations of
embodiments that may be idealized. As such, variations from the
shapes and/or positions of features, elements or components within
the illustrations as a result of, for example but not limited to,
user preferences, manufacturing techniques and/or tolerances are
expected. Shapes, sizes and/or positions of features, elements or
components illustrated in the figures may also be magnified,
minimized, exaggerated, shifted or simplified to facilitate
explanation of the subject matter disclosed herein. Thus, the
features, elements or components illustrated in the figures are
schematic in nature and their shapes and/or positions are not
intended to illustrate the precise configuration of the subject
matter and are not necessarily intended to limit the scope of the
subject matter disclosed herein unless it specifically stated
otherwise herein.
[0046] It is to be understood that the ranges and limits mentioned
herein include all ranges located within the prescribed limits
(i.e., subranges). For instance, a range from about 100 to about
200 also includes ranges from 110 to 150, 170 to 190, 153 to 162,
and 145.3 to 149.6. Further, a limit of up to about 7 also includes
a limit of up to about 5, up to 3, and up to about 4.5, as well as
ranges within the limit, such as from about 1 to about 5, and from
about 3.2 to about 6.5.
[0047] The term "thermoplastic" is used herein to mean any material
formed from a polymer which softens and flows when heated; such a
polymer may be heated and softened a number of times without
suffering any basic alteration in characteristics, provided heating
is below the decomposition temperature of the polymer. Examples of
thermoplastic polymers include, by way of illustration only,
polyolefins, polyesters, polyamides, polyurethanes, acrylic ester
polymers and copolymers, polyvinyl chloride, polyvinyl acetate,
etc. and copolymers thereof.
[0048] "Cohesive" or "cohesives" as used herein means substances
that can be applied to a substrate and once cured generally only
bond or adhere to itself and not to other non-adhesive materials or
substances. Thus, cohesives are substances that, once applied and
cured, generally only adhere or bond together to form a seal when a
portion of the cohesive come in contact with another portion of the
cohesive and generally does not form a seal with other non-adhesive
materials or substances with which the cohesive comes into contact.
Cohesives, as used herein, are often referred to in the industry as
self-seal, cold seal, or cold seal adhesives.
[0049] "Adhesive" or "adhesives" as used herein means substances
that are used to secure materials, such as substrates, together by
binding or adhering to the materials with which they come in
contact and resist separation of the materials even under
force.
[0050] Thus, adhesives are substances that have the ability to
secure together non-similar materials or substances by binding
and/or adhering to the non-similar materials or substances.
[0051] "Pressure-sensitive adhesives" as used herein means
adhesives that can have binding or adhesion or enhanced binding or
adhesion to non-similar materials or substances when placed under
some level of pressure.
[0052] "Product" as used herein means one or more physical items
that are being packaged on the package forming systems and
apparatuses disclosed herein. The term "product" can include, but
are not limited to such items as: jewelry, such as rings,
bracelets, necklaces, key rings, etc.; utility items, such as
knives of various sizes, tools, etc.; electronics, such as cellular
phones, tablet devices, televisions, computers, flash drives or
other fobs, etc.; personal care items, such as make-up items,
moisturizers and creams, razors, brushes, combs, hair dryers, etc.;
apparel, such as dresses, pants, skirts, shorts, shirts, belts,
shoes, socks, etc.; home furnishings, such as pillows, sheets,
fabric coverings, etc.; toys of various sizes; automobile and
machinery parts, such as nuts, bolts, bushings, filters, bearings,
etc.; tools and hardware, such as screws, nails, screwdrivers,
wrenches, pliers, hammers, etc.; and books of various sizes. Thus,
the term "product" as used herein can be synonymous and can be used
interchangeably with the phrase "one or more products."
[0053] "Sheet material" as used herein means one or more items or
materials are used to create packages and that can be packed or
bundled together or processed in some manner to form a unit for
transport.
[0054] The present subject matter discloses shipping package
forming apparatuses, systems, and related methods. In particular,
the present subject matter discloses apparatuses and systems that
form and aid in forming packages, such as envelopes, around
physical items that are being shipped in the packages. The
presently disclosed shipping package forming apparatuses and
systems have features that improve the forming of the package
around items to be shipped. For example, in some embodiments, the
shipping package forming apparatuses can ensure proper placement of
the item relative to the sides of the package and can ensure proper
alignment of the sides of the sheet material that form the sides of
the package so that the sides of the package form a stronger seal.
In some embodiments, the shipping package forming apparatuses can
ensure proper sealing of packages across the ends of the packages
that for stronger seals at the ends of the formed packages. In some
embodiments, a more efficient manner of cutting the sheet material
to form the ends of the package can be provided.
[0055] Referring to FIGS. 1A and 1B, schematics of packages E.sub.1
and/or E.sub.2 are shown being formed around products P.sub.1
and/or P.sub.2. The packages E.sub.1 and/or E.sub.2 are being
formed by two sheets being pressed together along the sides as
shown in FIG. 1A with packages E.sub.1 and E.sub.2 being pressed
together at either end as shown in FIG. 1B. In particular, each of
the packages E.sub.1 and/or E.sub.2 can be formed by a top sheet
material TS and a bottom sheet material BS that can be pressed
together by nip rollers as explained further below.
[0056] The top and bottom sheet materials TS, BS can be a variety
of sheeting materials depending on the desired parameters of
packaging. For example, in some embodiments, the top and bottom
sheet materials TS, BS can comprise a suitable paper or other wood
pulp product. In some embodiments, the top and bottom sheet
materials TS, BS can comprise a paper with a cushioned backing
secured thereto to for a cushioned interior of the packaging when
the top and bottom sheet materials TS, BS are joined together. In
some embodiments, the top and bottom sheet materials TS, BS can
comprise a nonwoven fabric such as a spunbonded fabric, a meltblown
fabric, or the like. In some embodiments, the top and bottom sheet
materials TS, BS can comprise a polymeric film. For example, the
top and bottom sheet materials TS, BS can comprise a thermoplastic
film in some embodiments. The thermoplastic film can comprise a
polyolefin film such as a polypropylene film, for instance.
Alternatively, the thermoplastic film can comprise at least one of
a polyethylene film, a nylon film, or a polyester film. In some
embodiments, the top and bottom sheet materials TS, BS can comprise
tri-layered films or other multi-layered films, such as
nine-layered films.
[0057] In some embodiments, to join the top and bottom sheet
materials TS, BS together, one or both of the top and bottom sheet
materials TS, BS can have an adhesive on an interior side, such as
pressure sensitive adhesives. In some embodiments, to join the top
and bottom sheet materials TS, BS together, each of the top and
bottom sheet materials TS, BS can have an interior side that
includes cohesive layer. The cohesives that can be used to form the
cohesive layer can have different bond strength depending on the
desired parameters of the respective packaging sheet.
[0058] For many applications, the cohesives that can be used to
form the cohesive layer can have a high bond strength. While,
depending on the bond strength, cohesives can slightly tack or
stick to other non-adhesive material, cohesives generally only
provide a strong seal to themselves. When the cohesive layer coated
on the top and bottom sheet materials TS, BS comes into contact
with itself or the other sheet material coated with the same
cohesive, the bond can result by applying appropriate pressure to
the sheet materials with the contacted cohesives. Thus, through the
use of the cohesive layer, the top and bottom sheet materials TS,
BS can be bonded to itself or to the other sheet material. In some
embodiments, the cohesive can comprise a water-based cohesive. In
some embodiments, the cohesive can comprise a solvent-based
cohesive. Examples of cohesives that can be used to more or less
affect include COSEAL.TM. and certain ROBOND.TM. CS, which are
supplied by the Dow Chemical Company, and the cohesives used in
CRO-NEL.RTM. and NYVEL.RTM. products, which are produced and sold
by Automated Solutions, LLC, to name a few.
[0059] FIG. 1B is cross-sectional view taken in a cross-machine
direction CD of the package E.sub.1 being formed around the product
P.sub.1 showing the joining of the sides of the package E.sub.1
being formed. Once a product P.sub.1, which can include one or more
items, is to be shipped, the product P.sub.1 can be placed on the
bottom sheet material BS within a package forming system or
apparatus (not shown in FIGS. 1A and 1B). The bottom sheet material
BS can act as a conveyor through the package forming system or
apparatus. The top sheet material TS and the bottom sheet material
BS can converge between the nips of two sets of rollers SR.sub.1
and SR.sub.2 on either side. The sets of rollers SR.sub.1 and
SR.sub.2 can comprise pressurized or weighted rollers that can
create a great enough pressure to bond the cohesives on the top and
bottom sheet materials TS, BS that are facing each other. The first
set of rollers SR.sub.1 can include a top roller SRT.sub.1 and a
bottom roller SRB.sub.1 on a first side. The second set of rollers
SR.sub.2 can include a top roller SRT.sub.2 and a bottom roller
SRB.sub.2 on a second side. A first side of the top sheet material
TS and a first side of the bottom sheet material BS converge
together and run between the nip of the top roller SRT.sub.1, and
bottom roller SRB.sub.1 to join the top sheet material TS and the
bottom sheet material BS together on the first side. Similarly, a
second side of the top sheet material TS and a second side of the
bottom sheet material BS converge together and run between the nip
of the top roller SRT.sub.2 and bottom roller SRB.sub.2 to join the
top sheet material TS and the bottom sheet material BS together on
the second side.
[0060] Ideally, it is desirable to have the product P.sub.1 align
with the sets of rollers SR.sub.1 and SR.sub.2 with the product
P.sub.1 so that a center line CL (shown in dashed lines) of the
product P.sub.1 can pass through, or proximal to the aligned nips
of the sets of rollers SR1 and SR2. In this manner, the sides of
the top and bottom sheet materials TS, BS can more closely align
with each other to provide a better seal on the sides of the
package. For example, it can be desirable to have the angles formed
between the top sheet material TS and the centerline CL and between
the bottom sheet material BS and the centerline CL to be the same
or substantially similar.
[0061] Similarly, a cross seal device, such as a set of rollers CR
can be used to seal the ends of the packages E.sub.1 and E.sub.2 as
the respective package is being formed as shown in FIG. 1B. The set
of rollers CR can comprise pressurized or weighted rollers that can
create a great enough pressure to bond the cohesives on the top and
bottom sheet materials TS, BS that are facing each other to form
the ends of the respective packages E.sub.1 and E.sub.2. The set of
rollers CR can run back and forward in the cross-machine direction
as the product being packaged passes through the package forming
system to form a first end and a second end of each package E.sub.1
and E.sub.2. The first set of rollers CR can include a top roller
CRT and bottom roller CRB that run back and forth from one side of
the forming apparatus to other across the pathway of the top and
bottom sheet materials TS, BS. As shown in the schematic drawing of
FIG. 1B, as the second package E.sub.2 passes through the side
rollers SR.sub.1 such that an end of the product P.sub.2 passes the
side rollers SR.sub.1 and enough of the top and bottom sheet
materials TS, BS have passed through to allow a back end of the
second package E.sub.2 to be closed, the first set of rollers CR
which can operate on a track can run across the package pathway
with the top and bottom sheet materials TS, BS passing between the
nip of set of rollers CR such that a seal is made between the top
and bottom sheet materials TS, BS. This sealed portion between the
top and bottom sheet materials TS, BS can form a second end of the
second package E.sub.2 as well as a first end of the first package
E.sub.1 being formed. In particular, the cross sealed portion can
be cut or perforated by a cutting device to form the second end of
the second package E.sub.2 and the first end of the first package
E.sub.1 being formed. Such cuts or perforations can be performed
after the end sealed portion is formed or during the formation of
the end sealed portion. Similarly, instead of a set of rollers CR,
a singular pressurized roller can form a nip with a portion of the
shipping package forming system, such as an anvil bar or a portion
of the frame, between which the top and bottom sheet materials TS,
BS can pass.
[0062] As with the formation of the sides of the packages E.sub.1
and E.sub.2, the length of the top and bottom sheet materials TS,
BS between the respective ends of the products P.sub.1 and P.sub.2
and the respective front end and the back end of the respective
sides of the packages E.sub.1 and E.sub.2 is such that the front
end and the back end of the respective sides of the packages
E.sub.1 and E.sub.2 can at least proximately align with center
lines CL.sub.1 and CL.sub.2 of the respective packages E.sub.1 and
E.sub.2. In some embodiments, each of the ends of the packages
E.sub.1 and E.sub.2 can be about an inch thick. With the alignment
with the center lines CL.sub.1 and CL.sub.2 of the respective
packages E.sub.1 and E.sub.2, the closure angles between the
centerline and the top and bottom sheet materials TS, BS can be
approximately the same. For example, the closure angle .beta.
between the top sheet material TS and the centerline CL.sub.1 on an
end of the package E.sub.1 being formed can be equal to or
substantially similar to the closure angle .beta. between the
bottom sheet material BS and the centerline CL.sub.1 on the end of
the package E.sub.1 being formed. Similarly, the closure angle
.epsilon. between the top sheet material TS and the centerline
CL.sub.1 on either end of the second package E.sub.2 can be equal
to or substantially the same as the closure angle E between the
bottom sheet material BS and the centerline CL.sub.1 on either end
of the second package E.sub.2. As shown in FIGS. 1A and 1B,
variations in the height of the product being shipped will likely
often occur. As shown, product P.sub.2 has a greater height than a
height of the product P.sub.1. Thus, to accommodate the alignment
of the sealed side and end portions of the package with the
centerline of the products, a portion of the shipping package
forming system can be adjustable. For example, the shipping package
forming system can have an adjustable table portion over which the
bottom sheet material BS can run and on which the product (on top
of the bottom sheet material BS) can be placed. Such a table
portion can allow for the alignment of the nips between the various
rollers (and, in some embodiments, between rollers and frame
portion) to be aligned with a centerline line of each product to
improve the sealing of the ends and sides of the respective
packages.
[0063] For example, referring to FIG. 2, a schematic of an
embodiment of a shipping package forming system, also known as a
former, generally designated 10, is provided. The package forming
system 10 can comprise a top sheet material guide system 12 and a
bottom sheet material guide system 14. Each of the top and bottom
sheet material guide systems 12 and 14 can each comprise one or
more tension rollers and/or drive rollers for providing top and
bottom sheet materials TS, BS under tension. For example, a roll
TS.sub.1 of the top sheet material TS can be installed into the top
sheet material guide system 12 and the top sheet material TS can be
properly placed around the tension rollers and/or between the
driver rollers. Similarly, a roll BS.sub.1 of the bottom sheet
material BS can be installed into the bottom sheet material guide
system 14 and the bottom sheet material BS can be properly placed
around the tension rollers and/or between the driver rollers. The
sides of the top and bottom sheet materials TS, BS can be secured
between the nips of two sets of rollers 18 (of which only one set
is shown in FIG. 2, but similar to the sets of rollers SR.sub.1 and
SR.sub.2 shown in FIG. 1A) on either side of the pathway of the top
and bottom sheet materials TS, BS. The sets of nip rollers 18 can
be pressurized or weighted to create a pressure high enough to seal
the sides of the package being formed by the top and bottom sheet
materials TS, BS. In some embodiments, the nip rollers 18 can
operate as driver rollers for the top and bottom sheet material
guide systems 12 and 14 and can pull the top and bottom sheet
materials TS, BS along the product pathway.
[0064] The package forming system 10 can also comprise a cross seal
device 20 for forming ends of the package being formed. The cross
seal device 20 can be a variety of devices that can form ends of
packages being formed. In some embodiments, the cross seal device
20 can comprise sealing bar and knife which extends across the
product pathway. The knife can pushed straight downward against the
sealing bar under pressure so that the end of the package is both
sealed and cut. In some embodiments, as the embodiment shown in
FIG. 2, the cross seal device 20 can comprise an anvil 22 that can
be engaged by one or more rollers 24 carried by a carriage 26. The
carriage 26 can be operated along a track (not shown) transverse to
the product pathway of the top and bottom sheet materials TS, BS.
The rollers 24 can be placed under pressure so as to create a
pressured engagement with anvil 22 as the rollers 24 roll across
the top and bottom sheet materials TS, BS transverse to the pathway
of the top and bottom sheet materials TS, BS. Due to cohesive on
the interior side of the top and bottom sheet materials TS, BS, the
top and bottom sheet materials TS, BS can be sealed together to
form an end of package for the product as the rollers 24 roll over
the top and bottom sheet materials TS, BS. When engaged with the
anvil 22, the transverse movement of the rollers 24 can form a
first end of a package being formed and a second end of the package
being finished as the rollers 24 roll across the top and bottom
sheet materials TS, BS. The carriage 26 can include one or more
blades 28 that can cut the joined top and bottom sheet materials
TS, BS to form the ends of the respective adjacent packages being
formed in the system 10.
[0065] The package forming system 10 can also comprise a support
table 30 that can be used to support a portion of the bottom sheet
material BS and the product P that is placed upon the bottom sheet
material BS and is being conveyed by the bottom sheet material BS.
The support table 30 can include some of the guide system 14 of the
bottom sheet material BS. The support table 30 can be positioned
along the pathway to provide support to the product to be packaged
such that the height of the table is movable to adjust a position
of each individual product to be packaged in a transverse direction
to the pathway relative to the nip rollers. For example, in some
embodiments, the height of the table is movable to adjust a
position of each individual product to be packaged upwardly or
downwardly relative to the nip rollers. For instance, the table is
movable to adjust a position of each product to align a centerline
of the product with the nip rollers. The support table 30 can be
automatically or semi-automatically adjusted upwardly or downwardly
based on the centerline of the product P being packaged to align
the centerline of the product P with the nips of the sets of
rollers 18 as well as the nip created by the roller 24 and anvil 22
when the rollers are put under pressure.
[0066] In some embodiments, the package forming system 10 can
comprise a height sensor 40 that can measure the height of the
product P being processed. Additionally, the package forming system
10 can comprise, in some embodiments, a weight sensor 42, such as a
scale to measure the weight of the product or the package that is
formed around the product and contains the product. For example, in
some embodiments, a weight sensor can be positioned after the
packaged is formed. Alternatively, the package that is formed
around and that contains the product can be weighted in a later
process. Further, in some embodiments, the package forming system
10 can include one or more sensors 44 that can measure distances
related to the product P. In some embodiments, the sensors 44 can
comprise length sensors that are used to measure the length of a
product. In some embodiments, instead of measuring the length of
the product, one or more sensors 44, such as photo eyes, can be
used to measure the presence of a product on the pathway and can
also measure the distance from a start position once the product is
placed on the pathway to a lead edge of the product once the bottom
sheet material and product are moved forward. This measurement by
sensors 44 can be sent to the controller 50 and can be used to
determine the amount of top and bottom sheet materials TS, BS
needed to form the rear portion of the package and the amount of
adjustment for the table 30 in some embodiments.
[0067] As another example, in some embodiments, a weigh station 45
can be provided on which a product P.sub.3 to be packaged can be
placed before being placed on the conveying bottom sheet material
BS on the support table 30. The weigh station 45 can include the
scale 42 for measuring the weight of the product to be shipped.
Above the scale 42, the height sensor 40 can be placed to measure
the height of the product P.sub.3 as the product P.sub.3 is being
weighed.
[0068] In embodiments that include a sensor 44, the sensor 44 can
operate as a length sensor and can be placed along the pathway of
product within the package forming system 10 as the bottom sheet
material BS moves the product P along the pathway. In some
embodiments, the sensor 44 can be used to measure other distances
beside the length of the product P. For example, in some
embodiments, the sensor 44 can be secured to the support table 30
with guide rollers/tensioning rollers secured to the table 30 that
guide the bottom sheet material BS around the sensor 44 in such a
manner that the sensor 44 has an unobstructed view of the product P
as it passes above the length sensor 44 while, at the same time,
not interfering with the ability of the bottom sheet material BS to
convey the product P within the package forming system 10.
[0069] The package forming system 10 can further comprise a
controller 50 that can be in communication with drive system (not
shown) that can power the package forming system 10 to control the
operation of the package forming system 10. Further, for
embodiments that employ one or more height, weight, and/or length
sensors, such as sensors 40, 42, and 44, the controller 50 can be
in communication with one or more of such sensors 40, 42, 44. The
controller 50 can also be in communication with the driver system
(not shown) that can be used to adjust the support table 30
upwardly or downwardly. The controller 50 can comprise any capable
processing unit, such as a programmable logic controller ("PLC"), a
desktop computer, a laptop computer, a mini computer, or the like,
including combinations thereof. The controller 50 can process the
information provided by the sensors mentioned above as well as
other sensors and information that the controller 50 can use to
effectively operate the package forming system 10. For example, in
some embodiments, one or more sensors 44, such as photo eyes, can
be provided that can be used measure the presence of a product on
the pathway and can also measure the distance from a start position
once the product is placed on the pathway to lead edge of the
product once the bottom sheet material and product are moved
forward. This measurement by sensor 44 can be sent to the
controller 50 and can be used to determine the amount of adjustment
for the table 30 in some embodiments.
[0070] Regarding the adjustment of the table 30, the controller 50
can obtain and process information from the sensors, such as height
sensor 40 or distance measurements from sensor 44, to determine
whether the table 30 should be moved upward or downward to position
the table 30 such that the centerline of the product aligns
properly with the nips of the set of side rollers 18 and the roller
24 and the anvil 22. The controller 50 can then communicate with a
drive system (not shown) that moves the table 30 up and down to
move the table 30 to the desired position at the appropriate time
once the product that was measured is placed on the bottom sheet
material BS and the table 30.
[0071] Instead of using a height sensor and/or a length sensor,
some embodiments can employ one or more sensors 44, such as photo
eyes, that measure the distance the product moves after placement
of the product by an operator on the bottom sheet material BS along
the pathway of the package forming system 10. The controller 50 can
use this measured distance to determine the length of top and
bottom sheet materials TS and BS at the rear of the package and to
determine the amount of adjustment that is needed for the table 30
for formation of the package.
[0072] As described above, when packaging a product with the
package forming system 10, it is desirable to have the seal on the
side of the package in the center of the package top to bottom.
This makes the top and bottom sheet materials TS and BS the same
width with both side edges equal. One method for determining the
height or thickness of the product to be packaged is for an
operator to examine the package and estimate its thickness. The
adjustable table 30 can have a placement gate attached, as
explained in more detail below, and one or more laser guides LS can
project one or more laser lines onto the bottom sheet material BS
on the table 30. For example, the laser guide LS can project three
(3) laser lines in front of the placement gate. The distance
between the laser lines and the distance between the forward most
laser line and the placement gate can comprise the same distance or
different distances. In some embodiments, these distances can be
permanently set. In some embodiments, these distances can be varied
depending on the types of products being packaged. For example, in
some embodiments, these three lines can each be about one (1) inch
apart and the first line closest to the placement gate can be about
one (1) inch from the placement gate. The operator places the
material to be packaged so that its front edge is located at the
approximate thickness from the gate. The laser lines being about 1
inch apart gives the operator an opportunity to place the products
to be packaged in the appropriate place where the operator judges
enough room is available to provide an adequate seal at the ends of
the package. Additionally, there can be a laser line projected down
the center of the table 30 to assist the operator in placing the
material in the middle of the table 30.
[0073] The operator can then press a start button in communication
with the controller 50 and the product is advanced on the bottom
sheet material BS along the pathway of the package forming system
10. The distance that the conveying bottom sheet material BS moves
before the product to be packaged encounters a viewing path of the
sensor 44, such as the view path of photo eyes, determines the
height or thickness of the package estimated by the operator and
the table can be automatically adjusted so that the center of the
package is on the center of the nip rollers 18 that seal the side
of the package based on a simple calculation using that
measurement. For instance, a measurement of a distance between a
measuring point and a leading edge of the product as the product
travels along the pathway can be taken with a sensor. The measuring
point, for example, can be where the viewing path of the sensor
intersects the product pathway before the product is moved along
the travel path. This measurement can be communicated to the
controller and the controller can calculate the distance to move
the adjustable table.
[0074] The distance between the sensor 44 and the cross seal device
20 that separate one package from the next package is a fixed
distance that tells the controller 50 when to stop and cut the
package in question. As the product continues to advance through
the package forming system 10, the sensor 44 can identify the back
edge of the package. To get the correct amount of top and bottom
sheet materials TS, BS for the package to be formed, the controller
50 adds to the back of the package the same length of bottom sheet
material BS as measured from the front of the product after the
operator places it on the bottom sheet material BS along the
pathway of the package forming system 10 to the position where the
sensor 44 takes the reading of the front of the product. This
represents the cut line for the back of the package and the front
of the next product being packaged.
[0075] Also based on the measurement of the table 30 moves up and
down to the center line of each of the products being packaged just
before each package is about to advance through the side seal nip
rollers. Using this method, the controller 50 does not need the
length of the product to determine the length of material needed
for the package but only the leading and trailing edges of the
package.
[0076] The package forming system 10 can also comprise one or more
perforation rollers 60 within the respective top and bottom sheet
material guide systems 12 and 14 to perforate the respective top
and bottom sheet materials TS and BS. IN embodiments that use them,
the perforation rollers create perforations in the top and bottom
sheet materials TS and BS so that when the package is formed, the
perforations create a tear away access to open the formed package.
Additionally, the top sheet material guide system 12 of the package
forming system 10 can further comprise a sheet material switch, or
sensor, 62 that can monitor the presence of top sheet material TS
to notify an operator when the roll TS.sub.1 of top sheet material
TS has run out. Similarly, the bottom sheet material guide system
14 of the package forming system 10 can further comprise a sheet
material switch, or sensor, 64 that can monitor the presence of top
sheet material BS to notify an operator when the roll BS.sub.1 of
bottom sheet material BS has run out.
[0077] For example, in some embodiments, the sheet material sensors
62 and 64 can be contact switches that are positioned along the
path of the top sheet material TS and the bottom sheet material BS.
The top sheet material TS can be run between the upper switch 62
and the frame of the package forming system 10 and the bottom sheet
material BS can run between the lower switch and the frame of the
former. In such embodiments, when either the rolls of the top or
bottom sheet materials TS and BS runs out, the respective contact
switch will make contact with the frame and thereby stop operation
of the package forming system 10 until a new roll of sheet material
is loaded into the package forming system 10 and the sheet material
is again placed between the respective contact switch and the
frame. The controller 50 can be in communication with the sensors
62 and 64 to stop the package forming system 10 when a roll runs
out until a new roll of sheet material can be installed. To make it
easier to install a new roll of sheet material on either the top or
bottom sheet material guide systems 12 and 14, in some embodiments,
one or both top and bottom sheet material guide systems 12 and 14
can include splicer devices 66. In some embodiments, each splicer
device 66 that can include a cutting slot 67 to allow for even cuts
of the ends of the old roll and a new roll of sheet material being
installed and a tape dispenser 68 for taping the ends of rolls of
sheet material together.
[0078] In some embodiments, a scanner can also be in operable
communication with the controller 50 to allow information related
to the product being packaged and shipped to be scanned into system
operated by the controller. For example, mailing information can be
tied to a bar code that may be on a sticker on the product or on a
printout with the product.
[0079] Further, in some embodiments, the package forming system 10
can comprise a printer 70 that can print a label to be placed on
the package during formation of the package. In some such
embodiments, the printer 70 can include a movable frame 72 and an
application device 74 to aid in the application of a printed label
to the package being formed. For example, the application device
can be a label holding applicator arm 74. As the printer prints a
label to be attached, the printer 70 can be configured to remove
the release backing of the label. At the same time, the label
holding applicator arm 74 can be made of a metal and can be
positioned above the mouth of the printer 70 where the label exits
the printer 70 and in close proximity so that the printed label
contacts and is held to the label holding applicator arm 74 by
static electricity. The label, once printed and ejected from the
printer 70, can extend slightly outward from the end of the label
holding applicator arm 74 with the tacky side of the label facing
outward away from the label holding applicator arm 74. When the
controller 50 indicates to the system that the label should be
applied to the top sheet material TS that is to form a top portion
of the package associated with the label, the movable frame can
move toward the top sheet material TS so that the tacky side of the
label firmly contacts the top sheet material TS and the end of the
label holding applicator arm 74 helps to apply the label to the top
sheet material TS.
[0080] Referring to FIGS. 3A-10, a more detailed embodiment of a
package forming system, also known as a former, generally
designated 100, is provided. As shown in FIGS. 3A-3F, the package
forming system 100 can comprise a top sheet material guide system
102 and a bottom sheet material guide system 104 that feed top and
bottom sheet materials TS, BS into the package forming system 100
to form packaging around a product. The package forming system 100
can also comprise two sets of nip rollers 108 on either side of a
pathway PA to seal the sides of a package being formed and a cross
seal device 130 that can be used to seal the ends of the packages
being formed in the system 100. Additionally, the package forming
system 100 can comprise an adjustable table 110 that can
automatically adjust a position of each individual product to be
packaged upwardly or downwardly to the sets of nip rollers 108 and
the cross seal device 130 so that the top and bottom sheet
materials TS, BS being fed into the package forming system 100 by
the top and bottom sheet material guide systems 102 and 104 can
form stronger and better seals along the sides and ends of a
package around a product being packaged in the package forming
system 100. The package forming system 100 can further comprise a
controller 150 that can be used to control the operation of the
package forming system 100 and the different systems, components,
and devices that comprise the package forming system 100, including
the adjustment of the adjustable table 110 and the nip rollers 108.
The package forming system 100 and its different systems,
components and devices will be explained in more detail below.
[0081] The package forming system 100 can also comprise a frame 106
for supporting the sheet material guide systems 102, 104 and other
components of the package forming system 100, including the
adjustable support table 110. The frame 106 can comprise outer
frame side panels 106A, 106B as well as a plurality of legs 106C
that can be directly or indirectly secured to the side panels 106A,
106B. In some embodiments, the frame 106 can also comprise one or
more safety guards 106D that can cover components of the package
forming system 100 to protect the respective components of the
package forming system 100 and reduce the possibility of injury to
an operator of the package forming system 100.
[0082] The top and bottom sheet material guide systems 102 and 104
can each comprise one or more tension rollers and/or drive rollers
for providing the top and bottom sheet materials TS, BS under
tension. For example, a roll TS.sub.1 of the top sheet material TS
can be installed into the top sheet material guide system 102 and
the top sheet material TS can be properly placed around the tension
rollers and/or between the driver rollers. Similarly, a roll
BS.sub.1 of the bottom sheet material BS can be installed into the
bottom sheet material guide system 104 and the bottom sheet
material BS can be properly placed around the tension rollers
and/or between the driver rollers as described further below. In
some embodiments, the nip rollers 108 can operate as driver rollers
for the top and bottom sheet material guide systems 102 and 104 and
can pull the top and bottom sheet materials TS, BS along the
product pathway as explained further below. Other drive rollers
(not shown) may be used in additionally or alternatively.
[0083] In particular in some embodiments as shown in FIGS. 3G and
3H, the top sheet material guide system 102 can comprise a roll
holding member that can include roll positioning arms 182 secured
to the frame 106 that can have an axle lock 184A for engaging an
axle 184 on which the roll TS.sub.1 of the top sheet material TS
can be placed. Similarly, the bottom sheet material guide system
104 can comprise a roll holding member that can include roll
positioning arms 186 secured to the frame 106 that can engage an
axle 188 on which the roll BS.sub.1 of the bottom sheet material BS
can be placed. The axles 184 and 188 can aid in maintaining a
proper tension in the top and bottom sheet materials TS, BS as the
top and bottom sheet materials TS, BS travel within the package
forming system 100 and can prevent over-rotation of the rolls
TS.sub.1, BS.sub.1.
[0084] For example, as shown in FIG. 10, the axle 188 can have
grooves or recesses 188A, 188B that can be aligned with each other
on one or both ends of the axle 188 that can be configured to
engage a portion, such as a protrusion or a detent, formed on one
or both of the roll positioning arms 186 that can prevent the axle
188 from rotating. The fit between the roll BS.sub.1 of the bottom
sheet material BS and the axle 188 can be snug so that the roll
BS.sub.1 can rotate as the bottom sheet material BS is pulled
through the package forming system 100 but prevents over-rotation
of the roll BS.sub.1 of the bottom sheet material BS. Similarly,
the axle 184 and roll positioning arms 182 can be similarly
configured to add tension and prevent over-rotation of the roll
TS.sub.1 of the top sheet material TS. Additionally or
alternatively, the lock 184A can be used to aid in preventing
rotation of the axle 184.
[0085] To load the roll TS.sub.1 of the top sheet material TS on
the axle 184 and into the roll positioning arms 182, the roll
positioning arms 182 can be pivotally secured on the end opposite
from where the axle 184 is secured to allow the roll positioning
arms 182 to be lowered once the roll TS.sub.1 runs low or runs out
of the top sheet material TS. The lock 184A can be used to secure
the axle 184 and the roll TS.sub.1 of the top sheet material TS to
the roll positioning arms 182 during operation of the package
forming system 100 and during roll changing procedures. The roll
positioning arms 182 can be secured in an operating position as
shown in FIG. 3G during operation of the package forming system
100. Once it is time to change the roll TS.sub.1, the roll
positioning arms 182 can be lowered to a loading position as shown
in FIG. 3H and the lock 184A unlocked to allow removal of the axle
184 for an easier exchange of the roll TS.sub.1. Once a new roll IS
of the top sheet material TS is placed on the axle 184 and the axle
184 installed and locked in the roll positioning arms 182, the roll
positioning arms 182 can be rotated and secured back in an
operating position as shown in FIG. 3G. While the embodiment of the
roll positioning arms 182 as shown in FIGS. 3G and 3H are moveable
between a loading position and an operating position, it is noted
that, in some embodiments, the roll positioning arms 182 can be
stationary or fixed similar to the roll positioning arms 186 for
the bottom roll BS.sub.1. For example, in some embodiments, the
roll positioning arms 182 and/or the roll positioning arms 186 can
be integral to the outer frame side panels 106A, 106B of the frame
106.
[0086] The sides of the top and bottom sheet materials TS, BS can
be secured between the nips of the two sets of rollers 108 (of
which only one set is shown in FIGS. 3A, 5A and 5B, but similar to
the sets of rollers SR.sub.1 and SR.sub.2 shown in FIG. 1A) on
either side of the pathway PA of the top and bottom sheet materials
TS, BS. The two sets of rollers 108 can comprise drive rollers that
move the top and bottom sheet materials TS, BS as well as the
product to be packaged along the pathway PA and through the package
forming system 100. A plurality of tension rollers 116 can also be
provided to aid in holding the top and bottom sheet materials TS,
BS under proper tension for forming the packages around the
different sized products that are process through the package
forming system 100. The sets of rollers 108 can be pressurized or
weighted to create a pressure high enough to seal the sides of the
package being formed by the top and bottom sheet materials TS, BS.
To adjust the package forming system 100 to package different sized
products, the adjustable support table 110 can be provided that can
be automatically adjusted up and down depending on a measured
height of the product to be package, which can include one or more
items.
[0087] The adjustable support table 110 can be movably secured to
the frame 106 to allow the adjustable support table 110 to be moved
upwardly and downwardly to facilitate accommodation of a wide
variety of different sized products that can vary in height and
length. The adjustable support table 110 can be secured to the
frame 106 in a variety of difference manners and can have
difference adjustment mechanisms to allow for movement of the
adjustable support table 110 upwardly and downwardly. In some
embodiments, as shown in FIGS. 3A-3F and 4A-4F, the adjustable
support table 110 can comprise a table top 114 that are secured to
moveable inner side panels 118A, 118B. The table top 114 and inner
side panels 118A, 118B can be moved upwardly or downwardly relative
to the nip rollers 108, or side forming rollers to allow for
automatic accommodation of products with different heights based on
measurements taken of the heights of products. As shown in FIG. 4A,
the adjustable support table 110 can comprise outer side panels
120A, 120B that can be secured to the outer frame side panels 106A,
106B and can be considered generally stationary in that the outer
side panels 120A, 120B do not move with the table top 114 and inner
side panels 118A, 118B when these components are being adjusted
upwardly or downwardly.
[0088] In the embodiment shown in FIGS. 3A-3F and 4A-4F, the table
110 supporting the bottom sheet material BS for the pathway PA that
the products to packaged travel. In particular, the table top 114
supports the bottom sheet material BS, which acts a conveyor of the
product being, package to carry the product through the package
forming system 100. The table 100 can also comprise a placement
gate 112 that can aid in centering products to be packaged based on
the height of the products and prevent products, which can contain
multiple items, that are too tall to be properly packaged in the
system 100 from travelling down the pathway PA to where the nip
rollers 108 and the cross seal device 130 form the sides and ends
of packages. The bottom sheet material BS travels along the table
top 114 beneath the placement gate 112. The placement gate 112 can
have angled inner side walls that slant toward an inner top wall to
form an aperture through which the pathway PA and the bottom sheet
material BS passes. The inner top wall of the gate 112 can be
centered on the pathway PA and can be about parallel to the table
top 114 so that the inner top wall is about centered with and about
parallel to the bottom sheet material BS. The inner side walls of
the placement gate 112 are angled such that these side walls can
help guide the placement of taller products to be packaged toward
the center of the bottom sheet material BS to aid in proper align
of the side edges of the top and bottom sheet materials TS, BS and
can prevent products that are too wide for a given height from
traveling further down the pathway PA. The size of the aperture
formed between the placement gate 112 and the table top 114 and the
angle of the inner side walls of the placement gate 112 can be
dependent upon the width of the respective top and bottom sheet
materials TS, BS being fed into the package forming system 100.
Thereby the placement gate 112 can be used to help prevent weak
seals on the sides of packages being formed.
[0089] The placement gate 112 can have one or more laser guides
(not shown) attached thereto. The laser guides can project a laser
liner downward on the bottom sheet material BS in the pathway PA to
identify where to place the product to be packaged. For example,
placement gate 112 can have laser guides attached thereto that
provide lateral and longitudinal laser guide lines that provide a
centerline and a forward placement lateral line for placement of
the product on the bottom sheet material BS.
[0090] The table top 114 and inner side panels 118A, 118B can be
moved upwardly or downwardly in different manners and by different
configurations and mechanisms. In some embodiments, as shown in
FIGS. 3F and 4A-4F, the adjustable support table 110 can further
comprise cam plates 126A, 126B in addition to the inner side panels
118A, 118B and the outer side panels 120A, 120B. The cam plates
126A, 126B, inner side panels 118A, 118B, and the outer side panels
120A, 120B can be configured to interact with each other so that
linear horizontal movements of the cam plates 126A, 126B can
translate to generally upward and downward movement of the table
top 114.
[0091] In particular, in some embodiments, the cam plates 126A,
126B, inner side panels 118A, 118B, and the outer side panels 120A,
120B, for example, can have respective cam slots and cam members,
such as cam rollers, that interact with each other so that linear
horizontal movements of the cam plates 126A, 126B, can translate to
generally upward and downward movement of the table top 114.
[0092] In some embodiments, the cam plates 126A, 126B, for example,
can have one or more cam slots 128A, 128B therein and one or more
cam members, such as cam rollers 121, that extend outward from an
outer side of the cam plates 126A, 126B. Similarly, the inner side
panels 118A, 118B can have one or more cam members, such as cam
rollers 123B, that extend inwardly from an inners side of the inner
side panels 118A, 118B and one or more cam members, such as cam
rollers 123A that extend outwardly from an outer side of the inner
side panels 118A, 118B. Additionally, the outer side panels 120A,
120B can have one or more cam slots 127A, 127B and 129A, 129B
therein.
[0093] In particular in the embodiment shown in FIGS. 3F and 4A-4F,
each of the cam plates 126A, 126B can have two angled slots 128A,
128B therein in which one of the two respective cam rollers 123B
that extend inwardly from the respective inner side panels 118A,
118B can reside. Additionally, each of the cam plates 126A, 126B
can have two cam rollers 121 protruding outward from a portion
positioned below the inner side panels 118A, 118B that engage
horizontal slots 127A, 127B in the respective outer side panels
120A, 120B. Each of the inner side panels 118A, 118B can
additionally comprise two cam rollers 123A, 123B that extend
outwardly toward the respective outer side panels 120A, 120B. These
outward extending cam members can extend into cam slots 129A, 129B
in outer side panels 120A, 120B in a generally vertical
direction.
[0094] The cam rollers 121 extending outward from each of the cam
plates 126A, 126B extend into the horizontal cam slots 127A, 127B
so that as the cam plates 126A, 126B are moved, the horizontal cam
slots 127A, 127B ensure this movement is a horizontal movement. As
the cam plates 126A, 126B move back and forth in a linear
horizontal movement, the cam members 123B extending inward from the
inner side panels 118A, 118B ride up and down the angled slots
128A, 128B in the cam plates 126A, 126B. Further, as the cam
members 123B extending inward from the inner side panels 118A, 118B
ride up and down the angled slots 128A, 128B in the cam plates
126A, 126B, the cam members 123A extending outward from the inner
side panels 118A, 118B that engage the generally vertical slots in
the outer side panels 120A, 120B direct the movement of the table
top 114 and inner side panels 118A, 118B in a generally upward
direction or downward direction.
[0095] To move the cam plates 126A, 126B, for example, as shown in
FIGS. 3F and 4A-4F, the table 110 can be constructed so that the
cam plates 126A, 126B can be operated by one or more air cylinders
125. In some embodiments, an adjustable air cylinder can be
directly or indirectly secured to the cam plates 126A, 126B and can
adjustably move the cam plates 126A, 126B by a desired amount in a
horizontal direction causing the cam plates to ride up or down on
respective cam members to move the table 110 up or down depending
on the direction of movement of the adjustable air cylinder. In
some embodiments as shown, multiple air cylinders 125 can work in
conjunction to move the cam plates 126A, 126B by a desired amount
in a horizontal direction causing the cam plates to ride up or down
on respective cam members to move the table 110 up or down. The
different cylinders 125 can raise and lower the table using the cam
plate by varying amounts of distance as desired and designed. For
example, a first air cylinder can raise the table about an eighth
(1/8) of an inch, a second can raise the conveyor about a quarter
(1/4) of an inch, the third cylinder can move the table up about a
half (1/2) of an inch, while a fourth cylinder will can raise the
table up about one (1) inch. By using these cylinders, the table
can move up or down from 0 inches to about 17/8 inches. By using
these cylinders, the table can be moved up or down from 0 inches to
about 17/8 inches of eighth (1/8) of an inch increments.
[0096] In particular, the cylinders 125 can be secured to a cross
bar 122 that is secured to the cam plates 126A, 126B on a first end
and to a cross bar 124 that is secured to the outer side panels
120A, 120B or the outer frame side panels 106A, 106B on a second
end. By the cross bar 124 being attached to the outer frame side
panels 106A, 106B or to the outer side panels 120A, 120B, which are
held stationary by being secured to the outer frame side panels
106A, 106B, the second end of the cylinders 125 are held stationary
while the first end of the cylinders 125 secured to the cross bar
122 attached to the cam plates 126A, 1268 moves with the cam plates
126A, 126B as the cylinders 125 are activated. The cam plates 126A,
1268 can have cross bar grooves, or slots, 124A in which the cross
bar 124, which is attached to the outer side panels 120A, 120B of
the table 110, can reside. As the cylinders 125 move the cam plates
126A, 126B, the cam plates 126A, 126B can slide over the cross bar
124 within the cross bar grooves 124A.
[0097] Thus, as the cylinders 125 push the cross bar 122 and the
cam plates 126A, 126B attached thereto in one direction and as the
cam plates 126A, 126B slide over the cross bar 124 within the cross
bar grooves 124A, the cam rollers 121 extending outward from the
cam plates 126A, 126B slide horizontally within the horizontal
slots 127A, 127B in the outer side panels 120A, 120B while the cam
rollers 123B extending inward from the inner side panels 118A, 118B
slide downward in the angled slots 128A, 128B and the cam rollers
123A extending outward from the inner side panels 118A, 118B move
downwardly within the generally vertical slots in the outer side
panels 120A, 120B with the table top 114 and inner side panels
118A, 118B moving downward. Conversely, as the cylinders 125 pull
the cross bar 122 and the cam plates 126A, 126B in the opposite
direction, the cam rollers 121 extending outward from the cam
plates 126A, 126B slide horizontally within the horizontal slots
127A, 127B in the outer side panels 120A, 120B while the cam
rollers 123B extending inward from the inner side panels 118A, 118B
slide upward in the angled slots 128A, 128B and the cam rollers
123A extending outward from the inner side panels 118A, 118B move
upwardly within the generally vertical slots in the outer side
panels 120A, 120B with the table top 114 and inner side panels
118A, 118B moving upward.
[0098] As the table top 114 and inner side panels 118A, 118B move
upward and downward, the tension rollers 116 attached to the inner
side panels 118A, 118B can move upward and downward with the inner
side panels 118A, 118B. To maintain the tension in the bottom sheet
material BS without causing a pulling displacement of the sheet
material when the table 110 moves upward and a bunching of excess
sheet material as the table 110 moves downward, the translation of
the lateral movements of the cam plates 126A, 126B to the upward
and downward movement of the table 110 can be such that the upward
and downward movement of the table 110 is at a slight angle off
perpendicular. Thus, the cam slots in the outer side panels 120A,
120B can extend vertically at a slight angle off perpendicular. For
example, in some embodiments, the cam slots in the outer side
panels 120A, 120B can extend vertically at an angle of between
about 1.degree. and about 5.degree. off perpendicular. In some
embodiments, the cam slots in the outer side panels 120A, 120B can
extend vertically at an angle of between about 2.degree. off
perpendicular. Thus, in some embodiments, the upward and downward
movement of the table 110 can be at an angle of between about
1.degree. and about 5.degree. off perpendicular. In some
embodiments, the upward and downward movement of the table 110 can
be at an angle of between about 2.degree. off perpendicular.
Additionally, some of the tension rollers proximate to the location
where the top and bottom sheet materials TS, BS enter between the
nip rollers 108 on either side of the top and bottom sheet
materials TS, BS can be stationary relative to the table to
maintain the proper tensioning in the bottom sheet material BS. The
inner side panels 118A, 118B can have angle slots formed therein to
accommodate these stationary tension rollers.
[0099] Additionally, horizontal slots can be provided in the outer
side panels 120A, 120B of the table 110 that can be engaged by
outward extending members of the cam plates 126A, 126B. As the cam
plates 126A, 126B are moved back and forth, the outward extending
members on the cam plates 126A, 126B move within the horizontal
slots in the outer side panels 120A, 120B of the table 110 to keep
the movement of the cam plates 126A, 126B in a horizontal
directional. Thereby, the movement of the cam plates 126A, 126B can
be limited to horizontal movement.
[0100] For example, as shown in FIGS. 5A and 58, schematic views
are provided of the travel paths for the top and bottom sheet
material guide systems 102 and 104, including associated tension
rollers for the top and bottom sheet materials TS, BS leading into
the two sets nip rollers 108 with the table moved in a direction
M.sub.1 to an upward position in FIG. 5B and moved in a direction.
M.sub.2 to a downward position in FIG. 5A. As the top and bottom
sheet materials TS, BS are pulled off the respective top sheet
material roll TS.sub.1 and bottom sheet material roll BS.sub.1 by
the drive the two sets of nip rollers 108, top and bottom sheet
material TS, BS travel around the various tension rollers 116 of
which at least some are secured to and move upwardly and downwardly
with the adjustable table 110 (shown in FIGS. 4A-4F). A controller
150 can be used to start and stop the two sets of nip rollers 108
that start and stop the travel of the top and bottom sheet
materials TS, BS and can be used to automatically raise and lower
the height of the adjustable table 110 (shown in FIGS. 4A-4F), for
example, based on measurements taken of the height of the product
to be packaged or based on placement of the package on the product
pathway by an operator. The controller, as explained further below
can be a variety of computing devices, such as various types of
computers, programmable logic controllers, smart tablet or cellular
devices, or the like, or combinations of such computing devices
that can operate the package forming system 100. Based on
measurements of the length of the products to be packaged provided
to the controller 150, the controller 150 can also operate the
cross seal device 130 to form and seal the ends of the packages
around the respective products being packaged as explained in more
detail below.
[0101] To aid in ensuring that the bottom sheet material BS does
not improperly pull a product being packaged forward or create
undesirable slack in the bottom sheet material BS, the package
forming system 100 and bottom sheet material guide system 104 can
include tension rollers 117A, 117B that are rotatably secured to,
for example, the outer side panels 120A, 120B or the outer frame
side panels 106A, 106B. In some embodiments as some in FIG. 4F,
generally vertical slots 118S can be provided in the inner side
panels 118A, 118B that travel upwardly and downwardly with the
table top 114 and apertures 120S can be provided in the outer side
panels 120A, 120B to accommodate the tension rollers 117A, 117B
that can be secured to the outer frame side panels 106A, 106B.
These stationary tension rollers 117A, 117B, while rotatable, are
stationary in their position relative to the adjustable table 110
as it is moved up and down. These stationary tension rollers 117A,
1178 can be positioned far enough below the table top 114 so as to
not interfere with the movement of the table top 114 or the
movement of the bottom sheet material 85. By having a guide tension
roller 116C that is secured to the table 110 and farthest inward
along the pathway PA and closest to the sets of nip rollers 108 and
the cross seal device 130, the bottom sheet material BS can act as
conveyor before the package begins to be formed. The bottom sheet
material BS can wrap around the guide tension roller 116C and then
move back and downward around the stationary tension rollers 117A,
117B before extending upward from the stationary tension roller
1178 to the sets of nip rollers 108 that engage the side edges of
the top and bottom sheet materials TS, BS. The slight angle off
perpendicular of the movement of the table top 114 (shown in FIGS.
4A-4F) and the position of the stationary tension rollers 117A,
117B relative to the guide tension roller 116C as well as the fact
that these stationary tension rollers 117A, 117B stay in the same
position relative to the movement of the table top 114 and guide
tension roller 116C can help prevent improper alignment of the
bottom sheet material BS as it conveys products toward the sets of
nip rollers 108 and the cross seal device 130. Additionally, as
shown in FIGS. 5A and 5B, the package forming system 100 and bottom
sheet material guide system 104 can include stationary rotatable
tension rollers 111A, 111B on the front end of the guide system 104
proximal to the bottom sheet material roller BS.sub.1 and a fixed
tube 113 that creates a drag on the sheet material BS that also aid
in ensuring that the bottom sheet material BS does not improperly
pull a product being packaged forward or create undesirable slack
in the bottom sheet material BS. The stationary rotatable tension
rollers 111A, 111B stay in the same position relative to the
movement of the table top 114 and front tension rollers 116 to help
prevent improper alignment of the bottom sheet material BS as it
conveys products toward the sets of nip rollers 108 and the cross
seal device 130 in a similar manner as the stationary rotatable
tension rollers 117A, 117B described above. As stated, the fixed
tube 113 that creates a drag on the sheet material BS that also can
help prevent improper alignment of the bottom sheet material BS as
it conveys products toward the sets of nip rollers 108 and the
cross seal device 130. The set of tensioning rollers 116 shown in
FIGS. 5A and 58 near the roll BS.sub.1 of bottom sheet material can
also be used to help track the bottom sheet material BS in a
similar manner to the guide tension roller 116C and the stationary
tension rollers 117A, 117B described above. Two of the tensioning
rollers 116 near the roll BS.sub.1 can be stationary while a third
roller 116 attached to the adjustable table at the bottom of the
front end can move with the table as the table is adjusted. Thus,
in a similar manner as described above, the set of tensioning
rollers 116 near the roll BS.sub.1 of bottom sheet material can be
used to aid in ensuring that the bottom sheet material BS does not
improperly pull a product being packaged forward or create
undesirable slack in the bottom sheet material BS.
[0102] To aid in preventing the top sheet material TS from causing
a misalignment of the product being packaged as the side edges of
the top and bottom sheet materials TS, BS enter the nips of the
sets of rollers 108, the package forming system 100 can comprise a
holding arm 119. The holding arm 119 can have the top sheet
material TS extend around one end and can move up or down so as to
push the top sheet material TS against a top portion of a product
to be packaged as the begins to enter the side forming and end
forming area of the package forming system 100 where the sets of
nip rollers 108 and the cross seal device 130 reside. The holding
arm 119 can be useful in stabilizing products that comprise more
than one item, such as plurality of books or compact discs, as the
items enter the side forming and end forming area of the package
forming system 100. The holding arm 119 can be pivotally secured to
the package forming system 100 on one end and can have a tension
roller on the other end around which the top sheet material TS can
extend. The controller 150 can move the holding arm 119 into
position based on the height of the product being packaged and the
position of the table top 114 so that the top sheet material TS
firmly contacts the top side of the product being packaged, but
allows the product and top and bottom sheet materials TS, BS to
move forward in the package forming system 100.
[0103] In some embodiments, the package forming system 100 can also
comprise one or more perforation rollers 180 as shown in FIGS. 5A
and 58 within the top sheet material guide system 102 to perforate
the respective top sheet material TS. The perforation rollers 180
can create perforations in the top sheet material TS so that when
the package is formed, the perforations create a tear away access
to open the formed package. In some embodiments, one or more
perforation rollers 180 can additionally or alternatively, be
positioned within the bottom sheet material guide system 104 to
perforate the respective bottom sheet material BS. Additionally,
the top sheet material guide system 102 of the package forming
system 100 can further comprise a sheet material switch, or sensor,
(not shown) that can monitor the presence of top sheet material TS
to notify an operator when the roll TS.sub.1 of top sheet material
TS has run out.
[0104] Similarly, the bottom sheet material guide system 104 of the
package forming system 100 can further comprise a sheet material
switch, or sensor, (not shown) that can monitor the presence of
bottom sheet material BS to notify an operator when the roll
BS.sub.1 of bottom sheet material BS has run out.
[0105] As shown in FIGS. 3A-3F, to accomplish the adjustment of the
support table 110 in some embodiments, the package forming system
100 can comprise a height sensor 162 that can measure the height of
the product being processed. Additionally, in some embodiments, the
package forming system 100 can comprise a weight sensor 166, such
as a scale, and a length sensor 164, as shown in that can measure
the length of the product. For example, a weigh station 160 can be
provided on which a product to be packaged can be placed before
being placed on the conveying bottom sheet material BS on the
support table 110. The weigh station 160 can include the scale 166
for measuring the weight of the product to be shipped.
[0106] In some embodiments as shown in FIGS. 3A, 3B, 3D, 9A and 9B,
the height sensor 162 can comprise an attachment arm 162A for
attaching the height sensor 162 to the package forming system 110
and a measurement arm 1628 that can be rotatably secured to the
attachment arm 162A along an axle 162C. The measurement arm, for
example, can rotate upward toward the attachment arm 162A and
downward toward the frame 106. The height sensor 162 can also
include a rotary resistor 162D that engages the measurement arm
162B. The height sensor 162 can use the rotary resistor 162D to
measure the rotational movement and position of the measurement arm
1628 relative to the frame 106 to determine the height of product,
which may include one or more items, to be packaged. Using the
rotary resistor 162D, a computer, such as the controller 150, can
calculate the height of the product being packaged based on the
angle of the measurement arm 162D when the product is placed under
the measurement arm 162B, The height sensor 162 can also include an
abutment 162E (see FIG. 30) which the product to be packaged can
abut when the product is placed on the frame 106 under the
measurement arm 162B and the height measurement is to be taken.
[0107] The height sensor 162 can be off to the side of pathway PA
to allow movement of the bottom sheet material BS to compensate for
the height of the product before placement of the product on the
bottom sheet material BS. For example, the height sensor 162 can be
configured so that the measurement for height can be taken on the
frame 106 off to the side of the pathway PA. In this manner, once
the height of the product to be packaged is measured, the bottom
sheet material BS can be moved forward to compensate for the height
of the product before placement of the product on the bottom sheet
material BS to ensure that angle of closure of the ends of the
package being formed are correct.
[0108] In some embodiments as shown in FIGS. 8A and 88, the weigh
station 160 can be provided on which a product to be packaged can
be placed before being placed on the conveying bottom sheet
material 85 on the support table 110. The weigh station 160 can
include the scale 166 with a display for measuring the weight of
the product to be packaged positioned on a platform 168. As an
alternative to the height sensor 162 explained above, the height
sensor 163 can be secured to the platform 168 above the scale 166
to measure the height of the product as the product is being
weighed.
[0109] A sensor 164 can be placed along the pathway PA of product
within the package forming system 100 as the bottom sheet material
85 moves the product along the pathway PA. For example, in some
embodiments, the sensor 164 can be secured to the support table 110
with guide rollers/tensioning rollers 116 and 116A secured to the
table 110 that guide the bottom sheet material BS around the sensor
164 in such a manner that the sensor 164 has an unobstructed view
of the product as it passes above the sensor 164 while, at the same
time, not interfering with the ability of the bottom sheet material
BS to convey the product within the package forming system 100. To
help protect the bottom sheet material BS and aid in the feeding of
the bottom sheet material BS around the tensioning roller 116A, a
half-moon guard 116B can be secured in relatively close proximity
to the tensioning roller 116A to deflect and direct the sheet
material around the tensioning roller 116A. In some embodiments,
the sensor 164 can be used to measure the length of the product to
be packaged.
[0110] Referring to FIGS. 9A-9B, instead of using a height sensor
and/or a length sensor, some embodiments can employ one or more
sensors 164, such as photo eyes, that measure the distance the
product moves after placement of the product by an operator on the
bottom sheet material BS along the pathway of the package forming
system 100. The controller 150 can use this measured distance to
determine the length of top and bottom sheet materials TS and BS at
the rear of the package and to determine the amount of adjustment
that is needed for the table 110 for formation of the package.
[0111] As described above, it is desirable to have the seal on the
side of the package in the center of the package top to bottom when
packaging a product with the package forming system 100. This makes
the top and bottom sheet materials TS and BS the same width with
both side edges equal. One method for determining the height or
thickness of the product to be packaged is for an operator to
examine the package and estimate its thickness. The adjustable
table 110 can have the placement gate 112 attached, as explained
above, and a laser guide, or projector, LS.sub.1 can project one or
more laser lines onto the bottom sheet material BS on the table
110.
[0112] For example, Referring to FIGS. 9A-9C, one or more laser
guides, or laser projectors, LS.sub.1 can project three (3) laser
lines LL1, LL2, LL3 in front of the placement gate 112. The
distance between the laser lines LL1, LL2, LL3 and between the
forward most laser line LL1 and the placement gate 112 can comprise
the same distance or different distances. In some embodiments,
these distances can be permanently set. In some embodiments, these
distances can be varied depending on the types of products being
packaged. For example, in some embodiments, these three lines LL1,
LL2, LL3 can each be about one (1) inch apart and the first line
LL1 closest to the placement gate 112 can be about one (1) inch
from the placement gate 112. The operator can place the one or more
products to be packaged so that the front edge of the one or more
products is located at the approximate thickness of the one or more
products from the gate 112. The laser lines LL1, LL2, LL3 being
about 1 inch apart gives the operator an opportunity to place the
products to be packaged in the appropriate place based on the
operator's assessment of the thickness of the product or one or
more products.
[0113] Additionally, there can be a laser line CLL projected down
the center of the table 110 to assist the operator in placing the
one or more products in the middle of the table 110. In some
embodiments, the center laser line CLL can be projected by a second
laser guide, or projector, LS.sub.2. In the embodiment shown, the
center laser line CLL can be projected from the second laser
projector LS.sub.2 that can be secured to the gate 112. The
operator can then press a start button in communication with the
controller 150 and the product can be advanced on the bottom sheet
material BS along the pathway of the package forming system
100.
[0114] The distance the conveying bottom sheet material BS moves
before the product to be packaged encounters the sensor 164, such
as the view path of photo eyes, determines the thickness of the
package estimated by the operator and the table can be
automatically adjusted so that the center of the package is
generally aligned with the center of the nip rollers 18 that seal
the side of the package. For instance, a measurement of a distance
between a measuring point and a leading edge of the product as the
product travels along the pathway can be taken with a sensor. The
measuring point, for example, can be where the viewing path of the
sensor intersects the product pathway before the product is moved
along the travel path. This measurement between the measuring point
and the leading edge of the product can be communicated to the
controller and the controller can calculate the distance to move
the adjustable table.
[0115] The distance between the sensor 44 and the cross seal device
130 that separate one package from the next package is a fixed
distance that tells the controller 150 when to stop and cut the
package in question. As the product continues to advance through
the package forming system 100, the sensor 164 can identify the
back edge of the package. To get the correct amount of top and
bottom sheet materials TS, BS for the package to be formed, the
controller 150 adds to the back of the package the same length of
bottom sheet material BS as measured from the front of the product
after the operator places it on the bottom sheet material BS along
the pathway of the package forming system 10 to the position where
the sensor 164 takes the reading of the front of the product. This
represents the cut line for the back of the package and the front
of the next product being packaged.
[0116] Also based on the measurement of the table 110 moves up and
down to the center line of each of the products being packaged just
before each package is about to advance through the side seal nip
rollers. Thus, by using this method, the controller 150 does not
need the height or the length of the product to determine the
length of material needed for the package but only the leading and
trailing edges of the package.
[0117] As shown in FIGS. 3A-3F and 7, the package forming system
100 can further comprise a controller 150 that can be in
communication with the sensors 160, 162, 164 and in communication
with a drive system (not shown) that can power the package forming
system 100 to control the operation of the package forming system
100. The controller 150 can also be in communication with the
driver system (not shown) that can be used to adjust the support
table 110 upwardly or downwardly. The controller 160 can comprise
any capable processing unit, such as a programmable logic
controller ("PLC"), a desktop computer, a laptop computer, a mini
computer, or the like, including combinations thereof. The
controller 150 can process the information provided the sensors
mentioned above as well as other sensors and information that the
controller 150 can use to effectively operate the package forming
system 100.
[0118] Regarding the adjustment of the table 110, the controller
150 can obtain and process information from the sensors, such as a
height sensor 162 in some embodiments or one or more sensors 164
that can be used to measurement s distance representative of the
length of a bottom sheet material on which the product is placed
from a measuring point where the package being formed is to begin
to a leading edge LE of the product P, to determine whether the
table 110 should be moved upward or downward as described above to
position the table 110 such that the centerline of the product
aligns properly with the nips of the set of side rollers 108 and
the cross seal device 130. The controller 150 can then communicate
with a drive system (not shown) that moves the table 110 up and
down to move the table 110 to the desired position at the
appropriate time once the product that was measured is placed on
the bottom sheet material BS and the table 110.
[0119] In some embodiments as shown in FIG. 7, the controller 150
can be encased by a housing 106E. The controller 150 can include an
on-off switch 152 for turning on the package forming system 100 and
an emergency stop, or E-stop button 154. The controller 150 can
also include a display 156 that can be used to display pertinent
information to operator as needed. The controller 150 can further
include a switch 158 can be used to drive the bottom sheet
materials TS, BS within the package forming system 100 by
activating the nip rollers 108. The controller 150 can also
comprise an operation button and can be pushed to advance the
products being packaged within the package forming system 100 as
certain criteria are met. For example, the operation button can be
able to be lit green to indicate to the operator that the product
can be advanced within package forming system 100.
[0120] A scanner can also be in operable communication with the
controller to allow information related to the product being
packaged and shipped to be scanned into system operated by the
controller. For example, mailing information can be tied to a bar
code that may be on a sticker on the product or on a printout with
the product. Further, the package forming system 100 can comprise
one or more printer devices 170 that can each comprise one or more
printers. The printers on the printer device 170 can print a label
to be placed on the package during formation of the package. The
printer device 170 can include a movable frame 172 and an
application device 174 to aid in the application of a printed label
to the package being formed. For example, the application device
can be a label holding applicator arm 174. As the printer prints a
label to be attached, the printer device 170 can be configured to
remove the release backing of the label. At the same time, the
label holding applicator arm 174 can be made of a metal and can be
positioned above the mouth of the printer where the label exits the
printer and in close proximity so that the printed label contacts
and is held to the label holding applicator arm 174 by static
electricity. The label, once printed and ejected from the printer
can extend slightly outward from the end of the label holding
applicator arm 174 with the tacky side of the label facing outward
away from the label holding applicator arm 174. When the controller
150 indicates to the system that the label should be applied to the
top sheet material TS that is to form a top portion of the package
associated with the label, the movable frame 172 of the printer
device 170 can move toward the top sheet material TS so that the
tacky side of the label firmly contacts the top sheet material TS
and the end of the label holding applicator arm 174 helps to apply
the label to the top sheet material TS. For example, the movable
frame 172 can rotate the printer device 170 downward toward the top
sheet material TS to apply the label. In some embodiments, the
label applied to the top sheet material TS can run under a nip
roller 176 shown in FIG. 5A and 58 to facilitate the sealing of the
label to the top sheet material TS to a portion that forms the
outer side of the package being formed.
[0121] As outlined above, the packaging forming system can operate
under a variety of different methods as outlined above. For
example, a method of forming a package around a product to be
shipped in a packaging forming system can be provided that includes
various steps. For instance, the method can comprise placing a
product to be packaged on a pathway of a packaging forming system
supported by an adjustable table of the packaging forming system.
The method can comprise determining a distance that the adjustable
table is to be moved in an upwardly or downwardly direction to
align a centerline of the product to be packaged with nip rollers
of the packaging forming system with a controller of the packaging
forming, system. Additionally the method can include moving the
adjustable table the determined distance in an upwardly or
downwardly direction to align the centerline of the product to be
packaged with nip rollers of the packaging forming system based
with the controller of the packaging forming system. Further, the
method can comprise running side edges of the bottom sheet material
and side edges of a top sheet material through the nip rollers to
form sides of a package on either side of the product and engaging
a cross seal device to engage the bottom sheet material and the top
sheet material in a direction transverse to the direction that the
bottom sheet material and the top sheet material are traveling in
the packaging forming system to form a leading end and trailing end
of the package.
[0122] In some embodiments of the method, the step of placing a
product to be packaged on the pathway of the packaging forming
system can comprise using laser lines and a placement gate to
determine where to place the product on the pathway. In some
embodiments, the step of determining a distance that the adjustable
table is to be moved can comprise taking a measurement of a
distance between a measuring point and a leading edge of the
product as the product travels along the pathway with a sensor,
communicating the measurement to the controller and the controller
calculating the distance to move the adjustable table. In some
embodiments, the step of determining a distance that the adjustable
table is to be moved comprises taking at least one of a height
measurement or a length measurement with one or more sensors and
communicating the at least one of a height measurement or a length
measurement to the controller and the controller calculating the
distance to move the adjustable table.
[0123] Further example embodiments of methods of using the package
forming system are now described in more detail. One or more
shipping package forming apparatuses and systems as described
herein can be operated in a fulfillment center. In general for a
use in a fulfillment center, the order can be entered to begin. For
example, an order number, also known as a "license plate, number
can be assigned to an incoming order. The shipper name and address
can be collected as well as the ship to address, the items ordered,
the order number. Further the packaging method can be assigned. A
pick list with the License Plate number attached can then be
generated. The product ordered can be delivered with the pick list
to a shipping packaging forming station.
[0124] In some embodiments, the operator can place the picked
product along with the pick list with the license plate number on a
former weigh scale. In some embodiments, the operator can place the
picked product a on a pathway of former, or package forming system
or apparatus in front of a placement gate. For example, the
operator can estimate the thickness of the picked product or
products and place it on the pathway on top of a bottom sheet
material based on a laser lines projected onto the bottom sheet
material. One or more sensors can be used to measure the distance
between a measuring point on the product pathway to a leading edge
of the product as the product travels along the pathway. The
information gathered from these sensors can be sent to the
controller of the former. The controller can comprise any capable
processing unit, such as a programmable logic controller ("PLC), a
desktop computer, a laptop computer, a mini computer, or the like,
including combinations thereof. A scanner can also be in operable
communication with the controller and can be used to obtain
information from the license plate number. This gathered
information about the distance between the measuring point on the
product pathway to the leading edge of the product as the product
travels along the pathway can later be used to determine the length
of top and bottom sheet materials needed and the amount an
adjustable table is to be adjustable to align the picked product
with nip rollers and/or a cross seal device in the former with the
picked product, such as along a centerline of the picked product,
to form a package around the picked product. For example, the
distance between the measuring point on the product pathway to the
leading edge of the product as the product travels along the
pathway can be used to set the amount of top and bottom sheet
materials to form the trailing end of the package and can be used
to align the centerline of picked product with the nip rollers
and/or a cross seal device.
[0125] Additionally or alternatively, in some embodiments, one or
more sensors of the former can be used to measure such things as
the height, weight and/or length of the product and the information
gathered from these sensors can be sent to the controller of the
former. In such embodiments, the controller can process the weight
and scanned license plate number information. For example, the
controller is connected to another computer, such as a desk top
computer or a main computer system of the fulfillment center to
which it can send the weight and scanned license plate number
information.
[0126] Once the picked product is placed in the appropriate place
on the bottom sheet material along pathway, the controller can set
the start push button to a blinking mode (on\off on\off). The
controller, or a computer in operable communication with the
controller, can send the license plate number to the main computer
system and can provide such information as the packing list, the
shipper name and address, the ship to address, the product weight
and/or the shipping company. In some embodiments, after receiving
the required information, the controller, or a computer in operable
communication with the controller, can request a label from the
shipping vendor via an internet connection. This shipping label
with the requisite information on it can be placed in a printer que
and a packing slip can be sent to a laser printer located on that
is in operable communication with the controller and in close
proximity to the former. In some embodiments, the label can be
requested and printed after the package is formed.
[0127] In some embodiments, the controller of the former can
calculate the movement of the former paper and can move the table
supporting the paper to the desired position based on the distance
between the measuring point on the product pathway to the leading
edge of the product. Alternatively, in some embodiments, the
controller of the former can calculate the movement of the former
paper and can move the table supporting the paper to the desired
position based on the measurements taking by a height sensor or
length sensor. As the sheet material is run over through the former
machine, the bottom sheet material acts as a conveyor that moves
the product through the former machine over the sensor that
measures the length of the product as it passes.
[0128] In some embodiments where the distance between the measuring
point on the product pathway to the leading edge of the product is
measured, the measured distance can be used by the controller to
calculate amount to move the table top to align the height position
of the product with the side nip rollers and/or the cross seal
device of the former. For example, in some embodiments, the
controller can calculate an distance to move the table top upward
based on a simply calculations that calculates a movement distance
that is a portion the distance measured between the measuring point
on the product pathway to the leading edge of the product so that
the centerline of the picked product aligned with the side nip
rollers and/or the cross seal device of the former.
[0129] In some embodiments where the height and length measurements
of the product are taken, the controller of the former can use a
lookup table to find the length of sheet material required to move
from the top of the product to the middle of the product at a
specified angle. In some embodiments, the total length of the
package along with the weight of the packaging material can also be
used by the controller to order a label for the shipment.
[0130] To form the packages around the product, each product to be
packaged can have three (3) to four (4) unique points of interest
as it moves through the former. The first point of interest is
where to stop the conveyor to place the package on the conveyor.
The second point of interest is where to stop the product to adjust
the height of the conveyer table so as to have the seal around the
package in the middle of the package. The third point of interest
is where to stop the conveyor to seal the front of this package and
the back of the previous package. In some embodiments, the fourth
point of interest is where to stop the conveyor to place the label
on the top sheet material so as to have the label positioned on the
middle of the package. As each product is placed on the conveyor,
these three to four locations can be placed in a database que in
the controller with the action to be taken at that stop point.
[0131] The former can also include features to help manage the
production of the packaging around the products to be shipped. For
example, the former can include on the control panel a jog sheet
material button to move the sheet material forward. Such a button
can be useful during the loading of one or more rolls of new sheet
material. The jog button can also be useful for moving the sheet
material forward during maintenance or the like.
[0132] The former can also include sheet material switches or
sensors that can monitor the presence of sheet material to notify
the operator when a roll of sheet material has run out. For
example, the sheet material switches can be contact switches that
positioned along the path of the upper sheet material and the-lower
sheet material. The upper sheet material can be run between the
upper switch and the frame of the former and the lower sheet
material can run between the lower switch and the frame of the
former. When either the upper or lower sheet material runs out, the
respective contact switch will make contact with the frame and
thereby stop operation of the former until new sheet material is
loaded into the former and sheet material is again placed between
the respective contact switch and the frame.
[0133] Additionally, the former can include an emergency stop
switch and a finish package button to allow the last package of
each day or shift to be sealed and finished when no other product
is in line behind the last package. The cross sealer that seals the
ends of the package can also be opened and closed to allow for
maintenance of the transverse pressure rollers and the blades used
to cut the end of each package.
[0134] When the machine is empty, the top and bottom sheet material
can be loaded. This can be done by an operator or by some loading
mechanism.
[0135] Once the operator places the product to be packaged in front
of the gate and press the lighted start button, the bottom sheet
material, acting as a conveyor, then moves the picked product
forward within the former.
[0136] The controller will stop the bottom sheet material when the
front of the product being packaged reaches the front of the table
on which the product is to be conveyed. The controller will move
the table height up or down to position the center line of the
product being packaged to the nip roll height. The conveying bottom
sheet material will move the front of the package to the cross seal
cut line. The controller can then call the horizontal seal/cut
routine. New products to be packaged and shipped will follow
through the former as required.
[0137] The table can be constructed with cam plates operated by 4
air cylinders. The different cylinders can raise and lower the
table using the cam plate by varying amounts of distance as desired
and designed. For example, a first air cylinder can raise the table
about an eighth (1/8) of an inch, a second can raise the conveyor
about a quarter (1/4) of an inch, the third cylinder can move the
table up about a half (1/2) of an inch, while a fourth cylinder
will can raise the table up about one (1) inch. By using these
cylinders, the table can move up or down from 0 inches to about
17/8 inches.
[0138] The cross cut-seal cylinder is equipped with two vertical
air cylinders in addition to a cross rod-less cylinder. The two
vertical cylinders can raise and lower the cross cut-seal cylinder
in different manners. For example, one vertical cylinder can raise
the seal anvil up and down. The other vertical cylinder can raise
and lower a safety bar to be sure that there is nothing in the way
of the cross cylinder. This cylinder can have a switch that is made
if the safety bar is completely down on both ends of the seal bar.
The cross rod-less cylinder has switches on both ends of its stroke
and can be operated by a double solenoid air valve.
[0139] The cross cut/seal routine can operate as follows. The PLC
can look at both the left and right end of stroke of the rod-less
cylinder to see where the carriage of the cylinder is parked. The
seal anvil can be raised and the safety bar is lowered. The
solenoid can be energized to move the cut/seal carriage away from
the end where it is parked if both sides of the safety bar are
down. If both ends are not down, the system stops notifies the
operator via operator panel. This solenoid can remain on until the
end of stroke switch on the opposite of the rod-less cylinder
closes. This solenoid can be turned off, the safety bar can be
raised and the seal anvil can then be lowered.
[0140] These and other modifications and variations to the present
subject matter may be practiced by those of ordinary skill in the
art, without departing from the spirit and scope of the present
subject matter, which is more particularly set forth herein above
and any appending claims. In addition, it should be understood the
aspects of the various embodiments may be interchanged either in
whole or in part. Furthermore, those of ordinary skill in the art
will appreciate that the foregoing description is by way of example
only, and is not intended to limit the present subject matter.
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