Note: Descriptions are shown in the official language in which they were submitted.
MACHINE AND METHODS FOR FORMING, ERECTING,
AND LOADING A POUCH WITH A PRODUCT
BACKGROUND
[0001] This disclosure relates generally to packaging, and more particularly
to a
machine for forming, erecting, and loading a package with a product for
shipping such as in an e-
commerce environment.
[0002] Shipping needs for e-commerce and the like include considerable volume
of packaging used for shipping products. Multiple items can be grouped in a
single order, but in
order to economize and ship the products together, they must be packaged
together in a single
sipping container. In other cases, a single product such as a book may be
shipped on its own, but
it needs a shipping package or container to protect it during transit.
Fulfilment centers where
products are placed in shipping containers match orders with one or more
products by size to an
appropriate shipping container. Given the large variation in order and
products sizes, there must
be a large variety of shipping containers in stock. Systems that provide
custom-sized shipping
packages on an order by order basis can considerably reduce the complications
in fulfilment
centers. The conventional techniques have been considered satisfactory for
their intended purpose.
However, there is an ever-present need for improved packaging systems and
methods. This
disclosure provides a solution for this need.
BRIEF DESCRIPTION
[0003] In one aspect a transport mechanism for engaging a pouch in an erect
configuration at a first station of a packaging machine and transferring the
pouch to a second
station of the packaging machine is provided. The transport mechanism includes
a carriage and a
grip assembly. The carriage is moveable between the first station and the
second station. The grip
assembly is coupled to the carriage and is at least partially moveable
relative to the carriage
between an engaged position for clamping the pouch in the erect configuration
within the grip
assembly, and a released position.
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Date Recue/Date Received 2023-01-30
[0004] In another aspect a packaging machine is provided. The packaging
machine includes a first station for receiving a container in an erect
configuration and a second
station spaced from the first station. The packaging machine further includes
a transport
mechanism for engaging the container in the erect configuration at the first
station and carrying
the container to the second station. The transport mechanism includes a
carriage that is moveable
between the first station and the second station and a grip assembly coupled
to the carriage. The
grip assembly is at least partially moveable relative to the carriage between
an engaged position
for clamping the container in the erect configuration within the grip
assembly, and a released
position.
[0005] In yet another aspect, a method of assembling a pouch is provided. The
method includes receiving a pouch in an erected configuration at a first
station of a packaging
machine and moving a transport mechanism to the first station. The transport
mechanism
including a carriage and a grip assembly couped to the carriage. The method
further includes
clamping the pouch within the grip assembly by moving at least a portion of a
grip assembly
relative to the carriage and carrying, by the transport mechanism, the pouch
from the first station
to a second station of the packaging machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic view of an example embodiment of a packaging
system according to the present disclosure.
[0007] FIG. 2 is a perspective view of an embodiment of a flattened tube of
stock
packing material for the system of FIG. 1.
[0008] FIG. 3 is a perspective view of a portion of the system of FIG. 1,
showing
a cutting station, a filling station, a sealing station, and an output
conveyor.
[0009] FIG. 4 is a perspective view of filling station shown in FIG. 3.
[0010] FIG. 5 is a perspective view of the filling station and the sealing
station
shown in FIG. 3.
[0011] FIG. 6 is an enlarged view of the filling station shown in FIG. 3.
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Date Recue/Date Received 2023-01-30
[0012] FIG. 7 is a perspective view of the output conveyor shown in FIG. 3.
[0013] FIG. 8 is a schematic view of a grip assembly for use with the system
shown in FIG. 3, showing the grip assembly in a released state.
[0014] FIG. 9 is another schematic view of the grip assembly shown in FIG. 8,
showing the grip assembly in an engaged state.
[0015] FIG. 10 is an enlarged view of the filling station shown in FIG. 3,
showing
a first step of filling a pouch-preform.
[0016] FIG. 11 is another view of the filling station shown in FIG. 10,
showing a
second step of filling the pouch-preform.
[0017] FIG. 12 is another view of the filling station shown in FIG. 10,
showing a
third step of filling the pouch-preform.
[0018] FIG. 13 is another view of the filling station shown in FIG. 10,
showing a
fourth step of filling the pouch-preform.
[0019] FIG. 14 is another view of the filling station shown in FIG. 10,
showing a
fifth step of filling the pouch-preform.
[0020] FIG. 15 is another view of the filling station shown in FIG. 10,
showing a
sixth step of filling the pouch-preform.
[0021] FIG. 16 is another view of the filling station shown in FIG. 10,
showing a
seventh step of filling the pouch-preform.
[0022] FIG. 17 is an enlarged view of the sealing station shown in FIG. 3,
showing a first step of sealing a filled pouch.
[0023] FIG. 18 is another view of the sealing station shown in FIG. 17,
showing
a second step of sealing the filled pouch.
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Date Recue/Date Received 2023-01-30
[0024] FIG. 19 is another view of the sealing station shown in FIG. 17,
showing
a third step of sealing the filled pouch.
[0025] FIG. 20 is another view of the sealing station shown in FIG. 17,
showing
a fourth step of sealing the filled pouch.
[0026] FIG. 21 is another view of the sealing station shown in FIG. 17,
showing
a fifth step of sealing the filled pouch.
[0027] FIG. 22 is another view of the sealing station shown in FIG. 17,
showing
a sixth step of sealing the filled pouch.
[0028] FIG. 23 is another view of the sealing station shown in FIG. 17,
showing
a seventh step of sealing the filled pouch.
[0029] FIG. 24 is a perspective view of the pouch of Fig. 23, showing the
pouch
closed with product therein, and labeled for shipping.
DETAILED DESCRIPTION
[0030] Reference will now be made to the drawings wherein like reference
numerals identify similar structural features or aspects of the subject
disclosure. For purposes of
explanation and illustration, and not limitation, a partial view of an
embodiment of a system in
accordance with the disclosure is shown in FIG. 1 and is designated generally
by reference
character 100. The systems and methods described herein can be used to package
products within
bespoke or custom sized mailers for each order being shipped. The system 100
includes a cutting
station 102, a product conveyor 104, a filling station 106 (also referred to
interchangeably herein
as an "erecting station," a sealing station 108, and an output conveyor 110.
In other embodiments,
the system does not include product conveyor 104.
[0031] In the example embodiment, cutting station 102 includes a tube conveyor
112 for conveying a flattened tube 114 of stock packing material from a supply
107 in the form of
a fan-folded bale. The tube conveyor 112 includes an opposed pair of rollers
(not shown) that roll
the tube 114 therebetween to advance the tube 114 down a slide 116. A
separator 118 is
operatively connected to the tube conveyor 112 for receiving an end of the
flattened tube 114. The
4
Date Recue/Date Received 2023-01-30
tube conveyor 112 is configured to feed a custom length of the tube 114 into
the separator 118. A
an x-y array sensor system 122 is operatively connected to the product
conveyor 104 to measure
custom orders of product 120 passing through the sensor system 122 on the
product conveyor 104,
provide measurement input to a controller 125 that is connected to control the
tube conveyor 112
and separator 118 to separate the custom length of the tube 114 to fit each
custom order of product
120. Those skilled in the art will readily appreciate that the any suitable
sensor system can be used
in addition to or in lieu of sensor system 122, e.g. an imaging device with an
imaging processing
module for determining the size of product 120 passing through the field of
view, can be placed
further upstream than depicted in FIG. 1 without departing from the scope of
this disclosure. It is
also contemplated that in addition to or in lieu of the sensor system 122, any
other suitable type of
sensor system can be used, such as devices that measure by physical contact,
or that known
dimensions for products traveling in order on the product conveyor 104 can be
provided from a
database (not shown) operatively connected to control the tube conveyor 112
and separator 118
without making measurements.
[0032] The separator 118 is configured to separate the custom length of the
tube
114 from the tube 114 for each respective product 120 arriving on the product
conveyor 104 to
form a custom sized pouch pre-form 132 that can differ for each individual
pouch pre-form 132.
FIG. 2 shows the end 105 of the tube 114. The two parallel, opposed edges 126,
128 are overlapped
and adhered together to form a seam 130 in a first panel 133 of the tube
running along the tube
114 in a longitudinal direction L. In its flat state as it arrives at the
conveyor 112 from the supply
107, as shown in FIG. 2, the tube 114 includes lines of weakness 138, e.g.,
score lines, for forming
two opposed, pleated side panels 146 each connected to the first panel 133
along a respective fold
line 134, 136. A seamless second panel 144 opposite the first panel 133 is
connected to the side
panels 146 by fold line 140 and a line of weakness 138 for forming a fold line
142. The pleat lines
148 are formed by the remaining lines of weakness 138. In other embodiments,
the pouch pre-
form 132 may not include the pleat lines 148. For example, in some alternative
embodiments the
pouch pre-form 132 may be a non-rigid substrate that is provided with two
opposed score lines.
In further alternative embodiments, any suitable pouch-preform may be used in
system 100.
[0033] Referring back to FIG. 1, a first closer 150 is operatively connected
to the
separator 118 of FIG. 1 to receive the pouch pre-form 132 and close one end
152 of the of the
Date Recue/Date Received 2023-01-30
pouch pre-form 132, leaving one end 154 of the pouch pre-form 132 open. In the
example
embodiment, the first closer 150 includes vacuum suction cups (not shown) that
are configured to
pull apart the end 152 for applying an adhesive therein and closing the end
152. In other
embodiments, the separator 118 and first closer 150 may be substantially the
same as the separator
118 and first closer 156 described in U.S. Patent Application Publication No.
2020/0317383 ("the
'383 application"), the entire contents of which are hereby incorporated by
reference. In particular,
separator 118 and first closer 150 receive the tube 114 as an input and cut
and seal, respectively, a
portion of the tube 114 to output the pouch pre-form 132 in substantially the
same manner as
described with respect to FIGS. 2-8 of the '383 application. In other
embodiments, any suitable
separator and/or first closer may be used.
[0034] The filling station 106 is provided downstream from cutting station
102.
The filling station receives the pouch 132 (also referred to interchangeably
herein as a "container")
having an unsealed end 154 (e.g., as shown in FIG. 6) to allow for filling the
pouch with a
corresponding product 120. In particular, the filling station 106 is
operatively connected to the
first closer 150 (shown in FIG. 1) to receive the pouch pre-form 132 and to
present the unsealed
end 154 of the pouch pre-form 132 for receiving orders of product 120.
[0035] Referring to FIGS. 3 and 4, in the example embodiment the system 100
includes a frame 160 that at least partially defines each of the cutting
station 102, the filling station
106, the sealing station 108, and the output conveyor 110.
[0036] As shown in FIG. 4, the filling station 106 includes a pivot shuttle
156
configured to receive the closed end of the pouch pre-form (shown in FIG. 1)
and flip the open
end of the pouch pre-form away from the slide 116, e.g. to face the unsealed
end 154 of the pouch
pre-form 132 toward a window 158 provided in the frame 160 at the filling
station 106. The
movement of the pivot shuttle 156 is indicated in FIG. 4 by the large arrow,
and is actuated by a
linear actuator 211 (shown in FIG. 11), though in other embodiments any
suitable actuator may be
used.
[0037] The pouch pre-form 132 falls into the pivot shuttle 156 by the force of
gravity onto two fingers 162 provided on the shuttle 156. The fingers 162 are
attached to a belt
driven actuator (not shown). As indicated with the curved arrow in FIG. 4, the
pivot shuttle 156
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Date Recue/Date Received 2023-01-30
rotates about a pivot under the force of the linear actuator (not shown) and
then the fingers 162
move upward, pushing the pouch pre-form 132 upward toward the window 158, as
shown in FIG.
11, and described in greater detail below.
[0038] Referring back to FIG. 1, the product conveyor 104 conveys orders of
product 120 to the filling station 106. A user, and/or an automated system,
takes the product 120
from the product conveyor 104 and places the product 120 into open ends 154 of
the pouch pre-
forms 132 present at the window 158 (shown in FIG. 4) of the filling station
106. The filled pouch
132 is then conveyed to the sealing station 108 for closing the open end 154
of the filled pouch
132. A user, and/or an automated system, then continuously repeats filling
each pouch pre-form
132 one after another, and each custom sized pouch pre-form 132 is presented
to the user/system
100 when the corresponding order of product 120 arrives at the user's end of
the product conveyor
104. In other embodiments, the system 100 does not include the product
conveyor 104. For
example, in some such embodiments, the system 100 is configured to provide
fixed sized pouch
pre-forms 132 to the filling station 106 or a batch of sizes continuously
without a demand input
from a product conveyor 104.
[0039] The system 100 further includes a clip conveyor 164 (also referred to
herein as a "transport mechanism") that carries the filled pouches 132 from
the filling station 106
to the sealing station 108. In particular, the clip conveyor 164 grabs the
pouch pre-form 132 at the
filling station 106 and holds the pouch pre-form 132 in an open, or "erect"
configuration for
receiving the product 120 therein. In the example embodiment, the product 120
is inserted into
the pouch pre-form 132 by a user, though in other embodiments an automated
system may be used.
The controller 125 is communicatively coupled to the clip conveyor 164 (shown
in broken line
arrows in FIG. 1) and is configured to control timing and operations of the
clip conveyor 164, as
described below in greater detail, such that the clip conveyor 164
automatically engages the pre-
form pouch 132 at the filling station 106 and holds the pouch 132 at the
sealing station 108 while
an adhesive is applied. Additionally, the controller 125 may be further
configured to control
operations and or timing of any of the components/mechanisms described herein
with respect to
system 100.
7
Date Recue/Date Received 2023-01-30
[0040] Referring to FIGS. 5 and 6, the clip conveyor 164 is operably coupled
to
one or more drives (not shown) for moving the clip conveyor 164 relative to
the frame 160. In
particular, the conveyor 164 includes a track (e.g., as shown partially in
FIG. 17) provided on the
frame 160 and extending from the filling station 106 to the sealing station
108. A carriage 168 of
the conveyor 164 is moveable along the track 166 (shown in FIG. 1) in a
machine transfer direction
170, indicated schematically by the large arrow in FIG. 5. The clip conveyor
164 is configured
for generally reciprocal movement along the machine transfer direction 170
between the filling
station 106 and the sealing station 108. Moreover, in the example embodiment,
the machine
transfer direction is generally transverse to the direction of movement of the
pivot shuttle 156
(shown in FIG. 4) and is also substantially transverse to a feed direction of
output conveyor 110
(shown in FIG. 1).
[0041] The clip conveyor 164 then carries the filled packages to the sealing
station 108 while a next pouch pre-form 132 is moved by pivot shuttle 156
(shown in FIG. 4)
towards the window 158. In the view shown in FIG. 5, the filled pouch 132 is
in the open
configuration at the sealing station 108, while the carriage 168 is positioned
at the filling station
106. However, it should be understood that this view is for illustrative
purposes only and that, in
normal operation of the example embodiment, a filled pouch 132 would not in
the open
configuration at the sealing station 108 at the same time the clip conveyor
164 is at the filling
station 106 (shown in FIG. 7).
[0042] Referring to FIG. 6, in the example embodiment, the clip conveyor 164
includes the carriage 168 and a grip assembly 172 coupled to the carriage 168.
The carriage 168
carries the grip assembly 172 during movement of the clip conveyor 164 to move
the filled pouches
132 between the filling station 106 and the sealing station 108 (shown in FIG.
5). The grip
assembly 172 includes a plurality of rotatable rods 194, 196 each having at
least one clip 198, 200
(shown in FIG. 8) mounted thereon. Rods 194, 196 are each operably coupled to
a rotation drive,
such as a cam and piston drive (not shown), that is operable to rotate the
rods. In other
embodiments, any suitable rotation drives may be used to rotate the rods 194,
196.
[0043] Referring back to FIG. 5, the sealing station 108 includes an adhesive
assembly 174 slidably coupled to frame 160. The adhesive assembly 174 is
moveable relative to
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Date Recue/Date Received 2023-01-30
the frame 160 in the machine transfer direction 170 and is operable to apply a
liquid adhesive to
an inner surface 176 of the filled pouch 132. The sealing station 108 also
includes a pair of pressure
bars 178 for closing the filled pouch 132 after the adhesive has been applied,
thereby sealing the
product 120 within the filled pouch 132. In particular, the pressure bars 178
are each moveable
relative to the frame 160 and are moved toward one another to seal the filled
pouch 132. The
pressure bars 178 may then be released, thereby dropping the filled pouch 132
onto the output
conveyor 110.
[0044] Referring to FIG. 7, in the example embodiment, the output conveyor 110
is positioned underneath sealing station 108, such that the filled pouch 132
may drop from the
pressure bars 178 (shown in FIG. 5) and slide onto the output conveyor 110 by
an inner ramped
surface 180 of the frame 160. In the example embodiment, the output conveyor
110 is a belt
conveyor, though in other embodiments, any other suitable conveyor may be
used. The output
conveyor 110 moves the filled pouches 132 in a feed direction 182 that is
generally perpendicular
to the machine transfer direction 170 (shown in FIG. 5). In particular, in the
example embodiment,
the feed direction 182 of the output conveyor 110 is generally opposite to a
feed direction 183 of
the tube conveyor 112 (shown in FIG. 1). As a result, the pouch pre-forms 132
and filled pouches
132 are carried in a general U-shaped path from the tube conveyor 112 at the
cutting station 102
to an end of the output conveyor 110.
[0045] FIGS. 8 and 9 show a schematic sectional view of the grip assembly 172
of the clip conveyor 164 (shown in FIG. 6). The grip assembly 172 is at least
partially moveable
relative to the carriage 168 between a released state, as shown in FIG. 8, and
an engaged state for
clamping the pouch 132 within the grip assembly 172, as shown in FIG. 9.
[0046] In the example embodiment, the grip assembly 172 includes a first grip
184 for engaging a first side 186 of the pouch 132 and a second grip 188 for
engaging a second,
opposed side 190 of the pouch 132. The first and second grips 184, 188 are
configured to hold
the pouch 132 in an open configuration at the filling station 106 to allow for
loading of the product
120 into the pouch through the open end 154. The first grip 184 and second
grip 188 are spaced
apart from one another in a closing direction 189 to define a gap 192
therebetween, in which the
9
Date Recue/Date Received 2023-01-30
pouch 132 may received. In the example embodiment, the closing direction 189
is substantially
perpendicular to the machine transfer direction 170 (shown in FIG. 5).
[0047] The first grip 184 and second grip 188 each include a pair of rotatable
rods
194, 196 which are rotatably coupled to the carriage 168 (shown in FIG. 6). At
least one clip 198,
200 is coupled on each of the rotatable rods 194, 196 and is configured to
rotate with the respective
rod 194, 196. In particular, the grips 184, 188 each include an inner clip 198
coupled to a first
rotatable rod 194 and an outer clip 200 coupled on a second rotatable rod 196.
The first rods 194
and inner clips 198 are each positioned vertically above the respective the
second rods 196 an outer
clips 200. In the example embodiment, the first grip 184 and the second grip
188 are substantially
identical and are mirrored about the gap 192, such that the clips 198, 200 all
extend inward and
towards the opposed clips 198, 200 of the opposed grip 184, 188. In other
embodiments, at least
one of the first grip 184 and second grip 188 may be different from one
another. For example, and
without limitation, in some embodiments, the first grip 184 includes a
different number of clips
198, 200 than the second grip 188.
[0048] The grip assembly 172 is transitionable between the released state and
the
engaged state by rotating the rods 194, 196 of the first grip 184 and second
grip 188. Each of the
rods 194, 196 are rotatable about a respective rotational axis Ri-R4,
extending into the page in
FIGS. 8 and 9. In the example embodiment, each of the respective rotational
axes Ri-R4 of the
rods 194, 196 are parallel to one another and are also parallel to the machine
transfer direction 170
(extending into the page in FIGS. 8 and 9). To transition from the released
state to the engaged
state, the first rod 194 of the first grip 184 is rotated in a first direction
(clockwise direction as
shown in FIGS. 8 and 9) and the second rod 196 of the first grip 184 is
rotated in a second direction
(counter-clockwise direction as shown in FIGS. 8 and 9) that is opposite of
the first direction.
Additionally, the first rod 194 of the second grip 188 is rotated in the
second direction and the
second rod 196 of the second grip 188 is rotated in the first direction. As a
result, as the rods 194,
196 are rotated to the engaged state, the clips 198, 200 of the respective
grips 184, 188 are brought
into close position with one another to pinch the pouch pre-form 132
therebetween. Moreover,
the grip assembly 172 is transitionable from the engaged state to the released
state in substantially
the reverse manner as described above.
Date Recue/Date Received 2023-01-30
[0049] Referring to FIG. 9, when the grip assembly 172 is in the engaged
state,
the inner clips 198 of the first grip 184 and the second grip 188 each contact
an inner surface 176
of the pouch pre-form 132. Likewise, the outer clips 200 of the first grip 184
and the second grip
188 each contact an outer surface 177 of the pouch pre-form. The clips 198,
200 each apply
pressure on the pouch pre-form 132 such that pouch pre-form 132 is pinched
between the clips
198, 200 of the respective grips 184, 188 and may be held in the open
configuration, as shown in
FIG. 9. Accordingly, the grip assembly 172 is operable to support and carry
the pouch pre-form
132 while holding the pouch pre-form 132 in the open configuration for
inserting the product 120
and to allow for adhesive to be applied on the inner surface 176, as described
in greater detail
below.
[0050] FIGS. 10-23 illustrate steps of the process of filling the pouch pre-
form
132 with a product at the filling station 106 and sealing the filled pouch 132
at the sealing station
108.
[0051] Referring to FIG. 10, the pouch pre-form 132 is provided on the fingers
162 of the pivot shuttle 156 at the filling station 106 and the window 158 is
closed. The frame 160
includes an interior surface 202 (also referred to interchangeably herein as a
"landing") facing the
pivot shuttle 156 for receiving the pouch 132. The system 100 further includes
a pair of moveable
guide paddles 204 (only one shown in FIG. 10) that are selectively moveable
relative to the interior
surface 202 between a retracted position (as shown in FIG. 10) and an extended
position (as shown
in FIG. 11). The guide paddles 204 are spaced on the interior surface 202 to
contact opposed sides
of the pouch pre-form 132 when the pivot shuttle 156 is rotated (as shown in
FIG. 11).
[0052] The filling station 106 further includes a plurality of moveable
suction
cups 206, 208. A first side suction cup 206 is positioned within the frame and
at least partially
recessed relative to the interior surface 202. The first side suction cup 206
is selectively extendable
out through an opening 210 in the interior surface 202. A group of second side
suction cups 208
are spaced from the first side suction cup 206 and are oriented facing the
first side suction cup 206.
In the example embodiment, the system 100 includes one first side suction cup
206 and three
second side suction cups 208, though in alternative embodiments, any suitable
number of suction
cups 206, 208 may be used.
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Date Recue/Date Received 2023-01-30
[0053] Referring to FIG. 11, the pivot shuttle 156 is shown extended by the
actuator 211 (e.g., along the arc as shown in FIG. 4). During operation, when
the pivot shuttle 156
is moved, the guide paddles 204 are also extended outward from the interior
surface 202 to guide
the pouch pre-form 132 along the interior surface 202. The fingers 162 then
raise the pouch pre-
form 132 on the interior surface 202 within the paddles 204 until the pouch
pre-form 132 is aligned
with the opening 210 and the first side suction cup 206 (shown in FIG. 10).
The first side suction
cup 206 is then actuated to provide a negative pressure on the pouch pre-form
132 and hold the
pouch pre-form 132 in position on the interior surface 202 and the guide
paddles 204 are retracted
back into the interior surface 202. Additionally, the pivot shuttle 156 is
moved back to the slide
116 (e.g., as shown in FIG. 4).
[0054] Referring to FIG. 12., the pivot shuttle 156 is shown being retracted
back
to the slide 116 and the second side suction cups 208 are moved to an extended
configuration to
contact the second side 190 of the pouch pre-form 132. The second side cups
208 are then actuated
to provide a negative pressure on the second side 190 of the pouch pre-form
132. Referring to FIG.
13, the second side suction cups 208 are then moved to a partially retracted
position to provide the
pouch pre-form 132 in the open configuration.
[0055] Referring to FIG. 14, with the pouch pre-form 132 in the open
configuration, the carriage 168 is moved along the machine transfer direction
170 to the filling
station 106 with the grip assembly 172 in the released configuration and the
clips 198, 200 aligned
with the pouch pre-form 132. Referring to FIG. 15, the grip assembly 172 is
then rotated to the
engaged configuration, pinching the sides 186, 190 of the pouch pre-form 132
between the clips
198, 200 of the first and second grips 184, 188. Once the grip assembly 172
has secured the pouch
pre-form 132, the suction cups 206, 208 are turned off and the second side
cups 208 are retracted
from the second side 190 of the pouch pre-form 132. The window 158 is then
opened (as shown
in FIG. 16, e.g., by retracting or rotating the window 158), exposing the
interior 212 of the pouch
pre-form 132. The product 120 (shown in FIG. 1) may then be inserted into the
pouch pre-form
132 by a user and/or an automated machine (not shown). After the product 120
is received within
the pouch pre-form 132, the window 158 is closed and the carriage 168 is moved
to the sealing
station 108 (as shown in FIG. 17).
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Date Recue/Date Received 2023-01-30
[0056] In some embodiments, system 100 may include one or more sensors (not
shown) for determining when a product 120 has been received in the pouch pre-
form 132. For
example, and without limitation, in some embodiments, the system 100 includes
a scale (not
shown) for measuring a weight of the pouch pre-form 132. In some such
embodiments, the
window 158 is closed and the carriage is moved to the sealing station 108 in
response to the scale
detecting a change in weight of the grip assembly 172 that exceeds a
predetermined threshold. In
other embodiments, system 100 includes one or more proximity sensors (not
shown) that are
operable to detect a product 120 entering the pouch pre-form 132.
[0057] Moreover, in some embodiments, system 100 further includes a sensor
(not shown) operable to detect a position of the pouch pre-form 132 on the
interior surface 202.
For example, and without limitation, in one embodiment, system 100 includes a
photosensor (not
shown) that registers a position of the pouch pre-form 132 on the interior
surface 202. In some
such embodiment, when the photosensor detects the presence of the pouch pre-
form 132 on the
interior surface 202 as being aligned with the vacuum cups 206, 208, the pouch
pre-form is secured
by the first side cup 206 and the pivot shuttle 156 is moved back to the slide
116.
[0058] FIGS. 17-23 illustrate a process of sealing the filled pouch 132 at the
sealing station 108. Referring to FIG. 17, in the example embodiment, the
carriage 168 is at the
filling station 106, the pressure bars 178 are positioned in a first separated
position, and the
adhesive assembly 174 is in a retracted position. After the product 120 is
received in the pouch
pre-form 132, the carriage 168 is moved in the machine transfer direction 170
(shown in FIG. 5)
to the sealing station 108, as shown in FIG. 18. Referring to FIG. 18, after
the carriage 168 is
moved to the sealing station 108, the grip assembly 172 and the filled pouch
132 are each
positioned laterally between each of the pressure bars 178. The adhesive
assembly 174 is then
extended to position a nozzle 214 (shown in FIG. 19) of the adhesive assembly
174 within the
pouch interior 212. In particular, in the example embodiment, the adhesive
assembly 174 includes
a telescoping tip portion 216 that is selectively moveable between an extended
position, as shown
in FIGS. 18 and 19, and a retracted position, as shown in FIGS. 17 and 21-23.
[0059] The adhesive assembly 174 is also moveable along a track (not shown) to
move the adhesive assembly 174 in the machine transfer direction 170. For
example, with
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Date Recue/Date Received 2023-01-30
continued reference to FIG. 18, the adhesive assembly 174 is simultaneously
moved along the
machine transfer direction 170 to a first end 218 of the filled pouch 132
while the tip portion 216
is moved into the extended position. The adhesive assembly 174 then
selectively releases a liquid
adhesive onto an interior surface 203 of the filled pouch 132 proximate the
first end 218. As the
adhesive is being released, the adhesive assembly 174 is moved in the machine
transfer direction
170 and within the pouch to a second end 220 of the filled pouch 132, as shown
in FIG. 19. In the
example embodiment, the travel path of the adhesive assembly 174 is
predetermined in
correspondence with the width of the filled pouches 132. In other embodiments,
system 100 may
include one or more proximity sensors (not shown), configured to detect a
position of the first and
second ends 218, 220 of the filled pouch 132 and the adhesive assembly 174 is
moved based on
the detected positions of the ends 218, 220.
[0060] Referring to FIG. 20, after the adhesive assembly 174 has deposited the
adhesive on the interior surface 203 of the filled pouch 132, the tip portion
216 is retracted out of
the pouch 132 and the grips 184, 188 are each moved inward. In particular, in
the example
embodiment, the grips 184, 188 are coupled to respective slidable frames 222,
224 that are each
moveable along a closing direction 189. The closing direction 189 is generally
perpendicular to
the machine transfer direction 170 and to the rotational axes of the rods 194,
196 (shown in FIGS.
and 8). Simultaneously and/or subsequent to the grips 184, 188 being moved
inward, the
pressure bars 178 are also moved inward to apply pressure on the sides 186,
190 of the filled pouch
132 and seal the pouch 132 closed. Additionally, the pressure bars 178 pinch
the filled pouch 132
to support the pouch 132 in position at the sealing station 108.
[0061] Referring to FIG. 21, after the pressure bars 178 have engaged the
pouch
132, the grips 184, 188 are moved away from one another back along the closing
direction 189
and the pressure bars 178 continue to hold the filled pouch 132 in position at
the sealing station
108. The grips 184, 188 are then rotated to the released position, as shown in
FIG. 21 and the
carriage 168 is moved back to the filling station 106 to grab another pouch
pre-form 132, as shown
in FIG. 22. Referring to FIG. 23, after the carriage 168 has left the sealing
station 108, the pressure
bars 178 are retracted away from one another in the closing direction 189,
thereby releasing the
filled pouch 132 onto the output conveyor 110 (shown in FIG. 7). In some
embodiments, the
sealing station 108 further includes one or more photosensors (not shown) for
detecting whether
14
Date Recue/Date Received 2023-01-30
the filled pouch 132 is in position to allow for insertion of the tip portion
216 of the adhesive
assembly 174.
[0062] With reference now to FIG. 24, the closed pouch 132 complete with a
shipping label 228 on the outside and product inside forms a mailer 226
suitable for shipping in
the mail or any suitable courier. The mailer 226 is formed of a single piece
of corrugated
paperboard 230, or any other suitable type of rigid tube form substrate such
as solid fiber
cardboard, wrapped around product. Two parallel, opposed edges 126, 128
(labeled in FIG. 2) of
the single piece are adhered to one another to form a tube around an interior
space for enclosing
product. A first end 244 of the tube is adhered to itself to enclose a first
end of the product. A
second end 246 of the tube opposite the first end of the tube is adhered to
itself to enclose a second
end of the product.
[0063] The two parallel, opposed edges 126, 128 are adhered together to form a
seam 130 in a first panel 133 of the tube along a first side of the product.
The tube includes two
side panels 146 each connected to the first panel 133 along a respective fold
line 136,134. Each
side panel 146 extends from the first end 244 of the tube to the second end
246 of the tube. Each
side panel 146 includes an inward pleat formed by a fold line or pleat line
148 extending parallel
to the seam 130 from the first end 244 of the tube to the second end 246 of
the tube. In other
embodiments, the pouch 132 does not include the pleat line 148. Those skilled
in the art will
readily appreciate that the label 228 can be placed on the opposite panel 144
(labeled in FIG. 2),
instead of the first panel 133. The corrugation lines 232, only some of which
are indicated in FIG.
24, in the tube run lateral to the longitudinal direction L of the seam 130 to
facilitate forming the
closures on the ends 244 and 246 of the mailer 226.
[0064] Example embodiments of packaging machines are described above in
detail. The packaging machines are not limited to the specific embodiments
described herein, but
rather, components of the machine may be utilized independently and separately
from other
components described herein.
[0065] Although specific features of various embodiments of the disclosure may
be shown in some drawings and not in others, this is for convenience only. In
accordance with the
Date Recue/Date Received 2023-01-30
principles of the disclosure any feature of a drawing may be referenced and/or
claimed in
combination with any feature of any other drawing.
[0066] This written description uses examples to disclose various embodiments,
including the best mode, and also to enable any person skilled in the art to
practice the disclosure,
including making and using any devices or systems and performing any
incorporated methods.
The patentable scope of the disclosure is defined by the claims, and may
include other examples
that occur to those skilled in the art. Such other examples are intended to be
within the scope of
the claims if they have structural elements that do not differ from the
literal language of the claims,
or if they include equivalent structural elements with insubstantial
differences from the literal
language of the claims.
16
Date Recue/Date Received 2023-01-30
