Paper shipping packages and methods of forming the same

Abstract

In accordance with at least one aspect of this disclosure, a method of forming a paper shipping package comprises the steps of feeding a paper substrate to printing machine, printing a coating on an area that is less than an entire surface area of the paper substrate and in a pattern that is configured to create an open pathway between an interior of the paper shipping package and ambient atmosphere, cutting the paper substate to a predetermined length, folding the cut paper substrate to form an enclosure defining an interior of the paper shipping package, and applying heat to the peripheral surface area to seal the paper shipping package only at the defined peripheral surface area to enclose the interior space, where the interior space communicates with the ambient atmosphere through the open pathway.

Description

FIELD OF THE DISCLOSURE

[0001] This disclosure relates to paper shipping packages, and more particularly, to paper mailers, and methods of forming the same.BACKGROUND OF THE RELATED ART

[0002] Conventional paper shipping packages are sealed by applying heat to the edges of the package having a sealing medium applied to the entire surface area of an interior of the paper shipping package. However, flood coating the entire paper sheet with the sealing medium leaves the paper shipping package impervious to air. Accordingly, conventional methods require holes to be made through the main body of the paper shipping package to allow airflow to pass from inside the package to the atmosphere without bursting the fully sealed edges of the package.

[0003] Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improvements. The present disclosure provides a solution for this need.SUMMARY OF THE DISCLOSURE

[0004] In accordance with at least one aspect of this disclosure, a method of forming a paper shipping package comprises the steps of feeding a paper substrate to printing machine, printing a coating on an area of the paper substrate that is less than an entire surface area of the paper substrate and in a pattern that is configured to create an open pathway between an interior of the paper shipping package and ambient atmosphere, cutting the paper substate to a predetermined length, folding the cut paper substrate to form an enclosure defining an interior of the paper shipping package, and applying heat to the peripheral surface area to seal the paper shipping package only at the defined peripheral surface area to enclose the interior space, where the interior space communicates with the ambient atmosphere through the open pathway.

[0005] The peripheral surface area is configured to form sealed edges of the paper shipping package, wherein the sealed edges are configured to retain the product within the interior space of the package while allowing air within the interior space of the package to escape through the open pathway in response to an increase in pressure within the interior space of the package to avoid bursting the sealed edges of the package.

[0006] In certain embodiments, the pattern can be or include a width-wise stripe pattern and the open pathway can include a plurality of airflow channels formed between adjacent widthwise stripes. In certain embodiments, the pattern can include a plurality of spaced apart linear bands extending across a width of the paper substrate (e.g., perpendicular to a direction of travel through the printing machine), and the open pathway can include a plurality of airflow channels formed between the spaced apart linear bands.

[0007] Applying the coating further comprises, generating a flexographic print plate having the pattern defined thereon, attaching the print plate to a roller, and applying the coating to the print plate via a second roller in fluidly connected to a coating reservoir for transfer to the paper substrate.

[0008] In certain embodiments, the coating can be or include a heat activated adhesive coating. Accordingly, the method further includes, applying heat to the peripheral surface area at a predefined temperature configured to melt the coating to seal the paper substrate to itself. In certain embodiments, is based on the material of the coating. For example, in certain embodiments, the predefined temperature can be between about 120°C (about 250°F) to about 150°C (about 300°F). In certain embodiments, the coating can be or include a heat seal coating. In certain embodiments, the heat seal coating can be a poly-based heat seal coating.

[0009] In accordance with at least on aspect of this disclosure, a package formed by the process of described herein is disclosed. The package comprises, a single layer of continuous paper substrate folded to form an enclosure defining an interior space of the package having a first panel and a second panel connected at a fold. Each of the first panel and the second panel include a first edge, a second edge, and a third edge having the coating printed thereon, wherein the coating is applied to an area that is less than an entire surface area of the continuous paper substrate and in a pattern forming an open pathway allowing airflow to permeate from the interior space to ambient environment via the open pathway, wherein the first, second, and third edges are sealed to one another to form first, second, and third outer seams defining the interior space of the enclosure therein.

[0010] The open pathway is configured to allow airflow to permeate from the interior space to ambient environment in response to an increase in pressure within the interior space of the package to avoid bursting the outer seams of the package.

[0011] In accordance with at least one aspect of this disclosure, a method of forming a blank of a paper shipping package, comprises the steps of feeding a continuous paper substrate to a printing machine; and printing a heat activated adhesive coating onto an area that is less than an entire surface area of the paper substrate and in a defined pattern that is configured to create an open pathway between an interior of the package and ambient atmosphere with the paper substrate folded and sealed into a paper shipping package.

[0012] In accordance with at least one aspect of this disclosure, an apparatus for forming a blank of a paper shipping package, comprises a first roller configured to feed a continuous paper substrate from a feed roll into a printing area of a printing machine and a second roller positioned proximate the first roller and having a printing medium disposed thereon configured to print a heat activated adhesive coating onto an area that is less than an entire surface area of the continuous paper substrate and in a defined pattern, where the first roller and second roller sandwich the continuous paper substrate therebetween during printing. A third roller is positioned proximate the second roller configured to transfer the heat activated adhesive coating from a reservoir to the second roller. The defined pattern printed onto the continuous paper substrate by the second roller is configured to create an open pathway between an interior of the package and ambient atmosphere with the continuous paper substrate folded and sealed into a paper shipping package.

[0013] These and other features of the embodiments of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein: Fig. 1 is a flow chart illustrating the steps in a method of forming a paper shipping package in accordance with this disclosure; Fig. 2 is a schematic diagram of an embodiment of an apparatus in accordance with this disclosure for performing a method of forming a paper shipping package, specifically showing application of a coating to a paper substrate; Fig. 3 is a perspective view of a portion of the apparatus of Fig. 2, showing application of the coating to a paper substrate in a pattern of spaced apart linear bands, where an application pattern of the coating is shown in greater detail; Fig. 4 is an enlarged localized view of the paper substrate taken from Fig. 3, where an application pattern of the coating is shown in greater detail; Fig. 5 is a perspective view of a blank of a paper shipping package formed by the apparatus shown in Figs. 2 through 4 using the method of the subject invention, before it is formed into a paper shipping package; Fig. 6 illustrates the step of forming the paper shipping package, where the blank is folded to enclose a product therein; Fig. 7 is a perspective view of the paper shipping package formed by the method of the subject invention, where heat is applied to the blank to seal the product within the paper shipping package; Fig. 8 is an enlarged localized view taken from Fig. 6 of the blank being folded into the paper shipping package, showing the coating in greater detail; Fig. 9 is an enlarged localized view taken from Fig. 7 of the paper shipping package after heat is applied, showing the sealed coating and air passages formed therethrough in greater detail; and Fig. 10 is a perspective view of the assembled paper shipping package with a product sealed therein. DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE DISCLSOURE

[0015] 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, an illustrative view of a method of coating and forming a paper shipping package in accordance with the subject disclosure is shown in Fig. 1 and is designated generally by reference character 10. Other views, embodiments, and / or aspects of this disclosure are illustrated in Figs. 2-10. Certain embodiments described herein can be used to form a paper substrate which can then be folded and sealed into a shipping package.

[0016] Fig. 1 shows a flowchart describing a method 10 of forming a blank 200 and a paper shipping package 300 from the blank 200 (e.g., as shown in Figs. 2-10) in accordance with the subject disclosure. The method 10 includes generating a print plate having a printing pattern defined thereon and attaching the print plate to a roller at step 12 and feeding a paper substrate to a printing machine at step 14. The method 10 further includes printing a coating in a defined pattern onto the paper substrate by way of a roller at step 16 and at step 18, the method 10 further includes cutting the paper substrate to length and folding the cut paper substrate to form an enclosure of a paper shipping package. At step 20, the method 10 further includes applying heat to a peripheral surface of the paper shipping package to seal the package around a product. These steps will be discussed in further detail below with reference to Figs. 2 through 10.

[0017] Referring now to Figs. 2 and 3, there is shown an apparatus 100 for performing the method shown and described in Fig. 1. With reference to Fig. 2, the apparatus 100 includes a printing machine 102 configured to receive a paper substrate 104 for printing thereon. The apparatus 100 includes a paper roll 106, which the paper substrate 104 is wound upon for feeding into the printing machine 102. The printing machine 102 includes a printing area 108 at which a coating 116 is printed onto the paper substrate 104, for example by way of a roller (e.g., roller 112). A first roller 110 is provided to draw the paper substrate 104 from the roll 106 into the printing area 108. A second roller 112 is located above the first roller 110 and has a printing medium 114 thereon. The printing medium 114 applies the coating 116 to a surface area of the paper substrate 104. As shown, the paper substrate 104 is sandwiched between the first roller 110 and second roller 112. A third roller 118 (e.g., an anilox roller) is included and located above the second roller 112 for transferring the coating 116 from a coating reservoir 120 to the printing medium 114 disposed on the second roller 112. Those skilled in the art would readily appreciate that other mechanisms for transferring the coating 116 to the second roller 112 can be used, for example, in certain embodiments, the second roller 112 can receive the coating 116 directly from the reservoir 120, or the coating 116 may be extruded out through the second roller 112.

[0018] Upstream or downstream of the first roller 110 and second roller 112, the paper substrate 104 may pass through several additional print stations. For example, the printing machine 102 can have a plurality of printing "stations" or printing areas 108 configured to print various graphics and / or coatings onto the paper substrate 104, in addition to the coating 116. At the end of the printing line, and after receiving the coating 116 and all other print, the paper substrate 104 is wound onto a final roll 124, which is then provided to a customer (e.g., a packing warehouse or a packaging / distribution center). In Figs. 2 and 3, only a single printing area 108 is shown for ease of explanation.

[0019] In certain embodiments, the printing medium 114 can be a print plate installed on the second roller 112. For example, the print plate can be a flexographic print plate. Referring to Figs. 2 through 4, the coating 116 is applied to the paper substrate 104 in a pattern defined by a plurality of linear, spaced apart bands, extending across a width of the paper substrate 104, perpendicular to the axis of travel of the paper substrate 104 through the printing machine 102, parallel to the axis of the roller 112. The particular pattern in which the coating 116 is printed onto the paper substrate 104 is configured to create a multiplicity of open pathways 323 between an interior 328 of the package 300 and ambient atmosphere when the blank 200 is folded and sealed into the paper shipping package 300 (such as shown in Figs. 5 through 10, for example).

[0020] An embodiment of the pattern is more closely shown in Figs. 3 and 4, where the pattern defined on the print plate 114 is a plurality of spaced apart bands extending along a rotational axis of the roller 112. This in turn applies the coating 116 to the paper substate 104 in linear, spaced apart bands 116a-116n extending across a width of the paper substrate 104, perpendicular to the axis of travel of the paper substrate 104 through the printing machine 102, and parallel to the axis of the roller 112. Accordingly, the coating 116 is applied to the paper substrate 104 on an area that is less than an entirety of the surface area of the paper substrate 104, for example as best seen in Figs. 3 and 4. The empty space 122a-122n between coating strips 116a-116n are what will become the open pathways 323 in the formed and sealed paper shipping package 300 as will discussed further below with reference to Figs. 8 and 9. Fig. 4 shows a localized view of the pattern applied to the paper substrate 104, where the bands 116a-116n of the coating 116 are shown enlarged for clarity and ease of explanation.

[0021] It should be appreciated by those having ordinary skill in the art that the while the bands 116a-116n and spaces therebetween 122a-122n are shown applied in a uniform manner, in certain embodiments, the width of the bands 116a-116n and / or the spaces therebetween 122a-122n can be varied along a length of the paper substrate 104. Additionally, in certain embodiments, one or more of the bands 116a-116n within the pattern may be non-linear or can have a non-linear portion.

[0022] In certain embodiments, the coating 116 can be or include a heat activated adhesive coating configured to melt the coating 116 to seal the paper substrate 104 to itself upon application of a predetermined temperature to the coating. In certain embodiments, the applied temperature is based on the material of the coating 116. For example, in certain embodiments, the predefined application temperature can be between about 120°C (about 250°F) to about 150°C (about 300°F). In certain embodiments, the coating 116 can be or include a heat seal coating. In certain embodiments, the heat seal coating can be a polymer-based heat seal coating.

[0023] Referring back to Fig. 1, in conjunction with Figs. 2 through 4, the operations at steps 12, 14, and 16 occur at the apparatus 100 as they relate to the printing of the coating 116 on the paper substrate 104 by way of the printing machine 102. At step 12, the coating pattern is designed and defined on the printing medium 114, which can be the flexographic print plate. The print plate printing medium 114 is then attached to the second roller 112, which is the printing roller. At step 14, the paper substrate wound on roll 106 is fed into the printing area 108 of the printing machine 102 by way of the first roller 110. At step 16, as the paper substrate 104 is pulled through the first and second rollers 110, 112, the coating 116 is transferred from the second roller 112 onto the paper substrate 104 in the defined pattern, e.g., the widthwise, linear spaced apart bands 116a-116n as shown. The coating 116 can be provided to the second roller 112 by way of the anilox roller 118, which receives the coating 116 from the reservoir 120. As the paper substrate 104 moves through the printing machine 102, additional graphics, coatings, or indicia can be printed onto the paper substrate 104, before it is ultimately wound around roll 124. The roll 124 is then provided to a customer, such as a packaging facility, to form the blank 200 and the paper shipping package 300, which are described below with reference to the method shown and described in steps 18 and 20.

[0024] Referring now to Figs. 5 through 7, once the paper substrate 104 has received the coating 116, the coated paper substrate 104 wound on roll 124 is loaded onto an automated machine, such as an automated packaging machine. The automated packing machine is configured to cut the paper substrate 104 to size into the blank 200 and fold the blank 200 across a fold line 226 to form an enclosure defining an interior space 228 of the paper shipping package 300, as described in step 18 of the method 10. The automated packing machine can be configured to cut the paper substrate 104 into any suitable sized blank, for example to fit the size of a desired product.

[0025] Shown in Fig. 7, to seal the product within the paper shipping package, as in step 20 of the method 10, heat is applied to a peripheral surface area 232 (indicated by the dot-dot-dash line in Fig. 7). This activates the coating 116 to seal the blank 200 around the product 230. Sealing the paper substrate 104 at the peripheral edges generates the paper shipping package 300. Heat is only applied at a defined heat application area 232 to enclose product 230 within the interior space 228 and seal it within the package 300. Because the coating 116 is applied in the defined pattern, even after sealing the paper shipping package 300, the interior space 228 communicates with the ambient atmosphere through the open pathways 323 formed by the spaces 122a-122n between coating bands 116a-116n in the sealed edges. This can be is more easily seen in the enlarged localized views of Figs. 8 and 9.

[0026] A number and size of the coating bands 116a-116n can be selected such that the sealed edges are configured to retain the product 230 within the interior space 228 of the package 300, for example during movement or jostling experienced during loading or transport of the package. Even with the sealed edges securely retaining the product 230 within the package 300, the open pathways 323 still allow air within the interior space 328 of the package 300 to escape through the open pathways 323 in the sealed edges. The open pathways 323 are important for allowing air to quickly pass from the interior space 328 of the package 300 in response to an increase in pressure within the interior space 328 of the package 300, to avoid bursting the sealed edges of the package 300. The open pathways 323 also eliminate the need for pin holes to be formed in the main body of the package 300, which eliminates a step conventionally required in typical methods of forming paper shipping packages.

[0027] The paper shipping package 300, e.g., as shown in Figs. 7 through 10, comprises, a single layer of continuous paper substrate 104 folded to form an enclosure defining an interior space 328 of the package 300 having a first panel 350 and a second panel 352 connected at a fold 326. Each of the first panel 350 and the second panel 352 include a first edge 354, a second edge 356, and a third edge 358. As described above, the coating 116 is printed on an interior surface of the paper substrate 104 and the first panel 350 and second panel 352 are sealed to one another by activating the coating on the first edge 354, the second edge 356, and the third edge 358 to form first, second, and third outer seams. The interior space 328 of the enclosure is thus within the outer seams.

[0028] Figs. 8 and 9, show an enlarged elevational view of the coating 116 applied to the paper substrate 104 before and after folding, respectively, where the first panel 350 is shown on top and the second panel 352 is shown on the bottom. The height of the coating 116 as shown in the Figures is enlarged for illustrative purposes only and for clarity and ease of explanation. However, in practice, the coating 116 may not be visible to the eye in an elevational view. As shown, the coating pattern on the first panel 350 is configured to be offset from the coating pattern on the second panel 352, such that when the blank 200 is folded to form the first 350 and second panels 352, the coating pattern on the first panel (e.g., 116c, 116d) lands between the coating pattern of the second panel 352 (e.g., between 116a and 116b). This way the open pathway 323 is configured to allow airflow to permeate from the interior space 328 to ambient environment in response to an increase in pressure within the interior space of the package to avoid bursting the outer seams of the package. In certain embodiments, however, the coating pattern of the first panel 350 can align with the coating pattern of the second panel 352 when folded.

[0029] The paper shipping package as shown in Fig. 10 and made by the process 10 shown in Fig. 1, can be a rectangular shipping package, having four edges. The first 354, second 356, and third 358 edges are sealed formed by applying heat to the first and second panels, fusing them together with the heat activated coating 116 applied thereon. The fourth edge 360 is a fold (e.g., fold 326) and no heat is applied to the fourth edge. Due to the nature of the coating pattern, in certain embodiments, all open pathways 323 and airflow channels are in the same direction, e.g., widthwise, regardless of which edge they are defined in. For example, the open pathways 323 defined in a "top" edge 358 of the package as shown in Fig. 10 still extend along the widthwise direction, and not in a length wise direction. In certain embodiments, there are no open pathways 323 defined in the lengthwise direction.

[0030] Referring again to Fig. 1, as shown at step 12, the method 10 for forming the paper shipping package 300 includes generating the print plate 114 having a specific pattern defined thereon and applying the print plate 114 to the second roller 112 of the printing machine 102. At step 14, the method 10 includes providing the continuous paper substate 104 into the printing machine 102 via the first roller 110. At step 16, the method 10 includes printing the coating 116 onto the continuous paper substrate 104 via the print plate 114 attached to the second roller 114, in the pattern defined on the print plate 114. As discussed above, the pattern in which the coating is applied to the substrate is configured to create an open pathway between an interior of the paper shipping package and ambient atmosphere.

[0031] The steps 12, 14, and 16 of the method 10 can be performed at a first facility, e.g., a paper manufacturing facility. Certain steps of the method 10, e.g., steps 18 and 20, can be performed at a second facility, e.g., a packaging facility. The packaging facility can receive the paper substrate 104 having the coating applied thereto on the roll 124. Once received, the packaging facility can load the roll 124 onto an automated packaging machine for ultimately forming the blank 200 and the paper shipping package 300 from the coated paper substrate 104.

[0032] At step 18, once the roll 124 is loaded onto the automated packaging machine, the method 10 can further include, cutting the paper substrate 104 to a desired length (e.g., to fit a particular product 230 to be placed within the paper shipping package 300) and folding the paper substrate 104 around the product 230 to form an enclosure surrounding the product 230. At step 20, the method includes applying heat to the peripheral surface 232 of the paper shipping package 300 to seal the product 230 within the paper shipping package 300. Because the coating 116 applied to the paper substrate 104 is applied only in the defined pattern, a plurality of airflow passages 323 are defined in the sealed edges 354, 356, 358 of the paper shipping package 300, allowing air to pass from the interior space 228 of the paper shipping package 300 to the ambient environment.

[0033] Embodiments of a method of forming a paper envelope (e.g., a paper mailer) includes applying a heat seal coating in a linear spaced apart band pattern (e.g., a stripe pattern) to seal a package within the envelope with forced gaps in the seal to remove the need for pin-holes defined in the paper envelope itself. Embodiments of the method described herein allow for the removal of a step in the conventional mailer manufacturing process. By applying the coating on in a pattern allowing airflow between the interior of the package and ambient, the step of pin-hole formation is removed. Embodiments apply the heat seal coating using a flexographic print plate in the defined pattern to an extensible paper that then seals on itself in an automated packing machine to envelope the product within the paper mailer. The patterned heat seal coating provides a pathway for air to easily escape though the vented seal so there would no longer be a need for additional pin holes, e.g., in the main body of the envelope. The side vents provided in embodiments of the paper mailer provide strength to the seal to contain the product inside the mailer but still allow air to escape during a bursting scenario (e.g., if a heavy object falls directly on top of the sealed paper mailer, air leaves the package through the airflow pathway instead of bursting the seal). Embodiments of the method apply the seal coating in a purposeful, predefined patter, instead of flood coating the entire paper substrate, for example as is done in conventional methods.

[0034] Any suitable combination(s) of any disclosed embodiments and / or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure.

[0035] The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the subject disclosure includes reference to certain embodiments, those skilled in the art will readily appreciate that changes and / or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.

Claims

1. A method of forming a paper shipping package, comprising the steps of: feeding a continuous paper substrate to a printing machine; printing a coating on an area that is less than an entire surface area of the paper substrate and in a defined pattern that is configured to create an open pathway between an interior of the paper shipping package and ambient atmosphere; cutting the paper substate to a predetermined length; folding the cut paper substrate along a fold line to form an enclosure defining an interior of the paper shipping package having a peripheral surface area; and applying heat to the peripheral surface area to seal the paper shipping package only at the peripheral surface area to enclose the interior space, wherein the interior space communicates with the ambient atmosphere through the open pathway.

2. The method of claim 1, wherein the peripheral surface area is configured to form sealed edges of the paper shipping package, wherein the sealed edges are configured to retain the product within the interior space of the package while allowing air within the interior space of the package to escape through the open pathway in response to an increase in pressure within the interior space of the package to avoid bursting the sealed edges of the package.

3. The method of claim 2, wherein the pattern includes a plurality of spaced apart linear bands extending across a width of the paper substrate and perpendicular to a direction of movement of the paper substrate through the printing machine.

4. The method of claim 3, wherein the open pathway includes a plurality of airflow channels formed between the spaced apart linear bands.

5. The method of claim 1, wherein applying the coating further comprises; generating a print plate having the pattern defined thereon; attaching the print plate to a roller; and applying the coating to the print plate via a second roller in fluidly connected to a coating reservoir for transfer to the paper substrate.

6. The method of claim 1, wherein the coating is a heat activated adhesive coating.

7. The method of claim 6, wherein applying heat to the peripheral surface area further comprises: applying heat to the peripheral surface area at a predefined temperature configured to melt the coating to seal the paper substrate to itself, and preferably wherein the predefined temperature is between about 120°C to about 150°C.

8. The method of claim 1, wherein the coating is a heat seal coating, and preferably wherein the heat seal coating is a poly-based heat seal coating.

9. A paper shipping package formed by the process of claim 1, comprising: a single layer of continuous paper substrate folded to form an enclosure defining an interior space of the paper shipping package having a first panel and a second panel connected at a fold; wherein each of the first panel and the second panel include a first edge, a second edge, and a third edge having the coating printed thereon, wherein the coating is applied to an area that is less than an entire surface area of the continuous paper substrate and in a pattern forming an open pathway allowing airflow to permeate from the interior space to ambient environment via the open pathway, wherein the first, second, and third edges are sealed to one another to form first, second, and third outer seams defining the interior space of the enclosure therein.

10. The paper shipping package of claim 9, wherein the open pathway is configured to allow airflow to permeate from the interior space to ambient environment in response to an increase in pressure within the interior space of the paper shipping package to avoid bursting the outer seams of the paper shipping package.

11. The paper shipping package of claim 10, wherein the pattern includes a plurality of spaced apart linear bands extending across a width of the paper substrate, wherein the open pathway includes a plurality of airflow channels formed between the spaced apart linear bands.

12. The paper shipping package of claim 9 to 11, wherein the coating is a heat activated adhesive coating and preferably wherein the heat activated adhesive coating is configured to activate at a temperature between about 120°C to about 150°C.

13. The paper shipping package of claim 9, wherein the coating is a heat seal coating and preferably. wherein the heat seal coating is a poly-based heat seal coating.

14. A method of forming a blank of a paper shipping package, comprising the steps of: feeding a continuous paper substrate to a printing machine; and printing a heat activated adhesive coating onto an area that is less than an entire surface area of the paper substrate and in a defined pattern that is configured to create an open pathway between an interior of the package and ambient atmosphere with the paper substrate folded and sealed into a paper shipping package.

15. An apparatus for forming a blank of a paper shipping package, comprising: a first roller configured to feed a continuous paper substrate from a feed roll into a printing area of a printing machine; a second roller positioned proximate the first roller and having a printing medium disposed thereon configured to print a heat activated adhesive coating onto an area that is less than an entire surface area of the continuous paper substrate and in a defined pattern; and a third roller positioned proximate the second roller configured to transfer the heat activated adhesive coating from a reservoir to the second roller, wherein the defined pattern is configured to create an open pathway between an interior of the package and ambient atmosphere with the continuous paper substrate folded and sealed into a paper shipping package.

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