Product packaging system and method

Abstract

A method of packaging a product for shipment includes advancing a base layer in a downstream direction and placing a product to be packaged on the base layer. After the product is placed on the base layer, adhesive is applied onto the base layer adjacent the product. A cover layer is then placed over the product and base layer. The cover layer is secured to the base layer via the adhesive, and the product is secured to the base layer by securing the cover layer to the base layer on both the upstream and downstream sides of the product. The base layer is then folded transversely over both the cover layer and the product to securely package the product for shipment.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to product packaging systems, and more particularly to machines and methods for packaging products in protective packaging for shipping. [Background technology]

[0002] When a product is shipped from one location to another, it is typically shipped in a container with protective packaging. The container may be a cardboard box or a protective envelope. Alternatively, the product may be wrapped in protective packaging such as plastic bubble wrap, cardboard, paper, or expanded slit sheet material, or the product may be placed in a pre-made envelope and the envelope may be closed to enclose the product.

[0003] Alternatively, the product may be placed on a continuous sheet, which may enclose the product on both sides to form a tube into which the product can be enclosed. The tube is then cut to separate the wrapped product from the continuous sheet, and both ends of the tube are sealed. If the sheet is a plastic material, heat may be applied to "shrink" the material, causing it to conform more closely to the shape of the product and prevent the product from moving relative to the material during shipping. Summary of the Invention

[0004] The present disclosure relates to a system and method for encasing different sized products in layers of protective sheet material. A product scanner scans the product to identify the product size and adjusts the system and method for different sized products. Rather than wrapping both side edges of a continuous sheet around the product, the product is placed on a continuous base layer, and a continuous cover layer is stretched over both the product and the base layer. The cover layer is secured to the base layer and cut. The first layer is cut and folded around the product to complete the package. In this way, the product is secured within the layers of material to prevent movement of the product relative to the sheet material during shipping. The sheet material is preferably paper, which is a recyclable, reusable, and renewable resource.

[0005] A method for packaging a product for shipment includes placing the product for packaging on a base layer. After the product is placed on the base layer, adhesive is applied to the base layer at a location upstream of the product. A cover layer is extended over the product and base layer. The cover layer is secured to the base layer at both the upstream and downstream sides of the product, thereby securing the product to the base layer via the cover layer. The base layer is then folded over both the cover layer and the product.

[0006] An exemplary method for packaging a product for shipping includes the steps of placing the product on a base layer, extending a cover layer lengthwise over the product, securing the cover layer to the base layer such that the product is secured to the base layer by the cover layer, and after the securing step, folding both sides of the base layer widthwise of the product and gluing the two sides of the base layer together.

[0007] An exemplary embodiment of the method further includes one or more of the following steps. cutting the base layer and the cover layer after the fixing step; cutting the base layer and the cover layer simultaneously as the cover layer is secured to the base layer; providing a base layer from a continuous sheet material and a cover layer from a continuous sheet material; and Detecting the upstream edge of the product on the base layer.

[0008] The cutting step may include cutting both the base layer and the cover layer in the same cutting motion, cutting the base layer and the cover layer at a location upstream of the product, cutting the base layer and the cover layer along a cut line, the cut line being located on the base layer with adhesive on upstream and downstream sides of the cut line such that portions of the base layer and the cover layer are secured together on either side of the cut line, and cutting the base layer and the cover layer at the upstream side of the product.

[0009] The step of securing may include applying an adhesive to the base layer on the upstream side of the product. The securing step may include applying an adhesive to the base layer and then pressing the cover layer against the adhesive on the base layer. The applying step may include identifying an upstream end of the product and applying adhesive to the base layer at a location upstream of the product. The detecting step includes detecting a linear dimension of the product. The method may include repeating the method steps for a series of products having at least one different dimension.

[0010] An exemplary packaging system for packaging a product for shipment includes a product delivery assembly configured to place the product on a base layer; a sensor for detecting an upstream end of the product on the base layer; an adhesive application device configured to apply adhesive to the base layer at a location upstream of the product based on a signal from the sensor; a stock material supply assembly configured to place a cover layer over the product and the base layer; and a pressing member configured to press the cover layer against the base layer such that the adhesive secures the cover layer to the base layer in a manner such that the cover layer secures the product to the base layer.

[0011] An exemplary embodiment of the system further includes one or more of the following elements: a source of sheet stock material for the base layer and the cover layer; a cutting assembly configured to cut across a width dimension of the base layer and the cover layer; a folding assembly disposed downstream of the pressing member and configured to widthwise fold opposite sides of the base layer around the product and the cover layer; an adhesive applicator positioned to apply adhesive to the base layer to secure the folded sides together; and A conveyor for advancing the base layer and the product disposed on the base layer downstream past a pressing member.

[0012] Another exemplary method for packaging a product includes the steps of: (1) supplying sheet-form stock material for the base layer and cover layer; (2) advancing the base layer and cover layer in a downstream direction; (3) placing the product on the base layer; (4) extending the cover layer longitudinally over the product and base layer; (5) securing the cover layer to the base layer on upstream and downstream sides of the product such that the product is secured to the base layer by the cover layer; (6) cutting the cover layer and base layer to separate the cover layer secured to the base layer from the supply; (7) cross-folding the base layer widthwise over the cover layer and product; and (8) securing the cross-folded base layer over the cover layer and product. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a schematic diagram of a product packaging system for packaging products for shipping. [Figure 2] 1 is a schematic perspective view of an exemplary product packaging system for packaging products for shipping according to a first embodiment. FIG. [Figure 3] FIG. 1 is a perspective view of a package having a partially folded base layer. [Figure 4] FIG. 3 is a schematic side view of the machine of FIG. 2 illustrating the operation of the packaging process. [Figure 5] FIG. 3 is a schematic side view of the machine of FIG. 2 illustrating the operation of the packaging process. [Figure 6] FIG. 3 is a schematic side view of the machine of FIG. 2 illustrating the operation of the packaging process. [Figure 7] FIG. 3 is a schematic side view of the machine of FIG. 2 illustrating the operation of the packaging process. [Figure 8A] 1 is a schematic plan view of a product of one size disposed on a base layer under a cover layer. FIG. [Figure 8B] 8B is a schematic cross-sectional side view of the product of FIG. 8A. [Figure 8C] FIG. 8B is a schematic front view of the product of FIG. 8A. [Figure 9A]10 is a schematic plan view of another size of product placed on a base layer under a cover layer. FIG. [Figure 9B] 9B is a schematic cross-sectional side view of the product of FIG. 9A. [Figure 9C] FIG. 9B is a schematic front view of the product of FIG. 9A. [Figure 10A] 10 is a schematic plan view of another size of product placed on a base layer under a cover layer. FIG. [Figure 10B] FIG. 10B is a schematic cross-sectional side view of the product of FIG. 10A. [Figure 10C] FIG. 10B is a schematic front view of the product of FIG. 10A. [Figure 11] FIG. 10 is a schematic plan view of another embodiment of a product packaging system. [Figure 12] FIG. 12 is a schematic diagram showing how the system of FIG. 11 accommodates different product sizes. DETAILED DESCRIPTION OF THE INVENTION

[0014] 1 and 2, a packaging system 20 for packaging one or more products 22 for shipment includes a supply 24 of sheet-form stock material, a stock material supply assembly 30, a product delivery assembly 32, a cutting and fastening assembly 34, a folding assembly 36, and a system controller 40. The system controller 40 includes a processor, such as a programmable logic controller (PLC), a memory, one or more inputs, and one or more outputs, and is configured to control various operations of the packaging system 20. The packaging system 20 moves the sheet-form stock material from the supply 24 in an upstream-to-downstream direction, also referred to as the downstream direction 42. The upstream direction is opposite the downstream direction 42.

[0015] The sheet stock material source 24 may comprise a support for a roll 44 of sheet stock material, a support for a folded stack 46 of sheet stock material, or a combination thereof, as shown in FIG. 2 . The source may include a single material or multiple materials. In the illustrated embodiment, the sheet stock material source 24 comprises a source of base material for the base layer 50 and a source of cover material for the cover layer 52. An exemplary sheet material for the base layer 50 or the cover layer 52, or both, is made of paper, such as kraft paper. Paper is an environmentally friendly choice for sheet stock material because it is biodegradable, recyclable, and composed of renewable resources.

[0016] The base layer 50 and the cover layer 52 may each be provided from a continuous sheet of material. Both the base layer 50 and the cover layer 52 may be any sheet-like stock material used to cover and protect the product 22 during transport. In an exemplary embodiment, the base layer 50 is corrugated cardboard, a multi-layered paper product that provides some cushioning and puncture resistance, and the cover layer 52 is a single sheet of paper that is flexible enough to conform to the shape of the product 22 being shipped and strong enough to hold the product 22 to the base layer 50. In other embodiments, both the base layer and the cover layer are corrugated cardboard, with a heavier cardboard used for the base layer and a lighter cardboard used for the cover layer. In yet other embodiments, the base layer and the cover layer are discontinuous sheets of paper of the same or different basis weights. Alternatively, the base layer and the cover layer may be any other material that protects the product during transport, including, but not limited to, corrugated cardboard, paper, polyurethane, polymer foam, cork, etc. The base layer, the cover layer, or both may have a non-perforated configuration. Alternatively, the base layer, the cover layer, or both may have a perforated configuration. In yet other embodiments, the base layer, the cover layer, or both may be formed from a mesh or web-like material.

[0017] The stock material feed assembly 30 feeds the sheet of stock material in a downstream direction 42 from the supply source 24 to the product delivery assembly 32. As shown in FIG. 2 , the illustrated stock material feed assembly 30 includes at least one pair of driven feed rollers 54 and one or more non-driven guide members 56 that define respective paths for the sheet of stock material of the base layer 50 and the cover layer 52. The feed rollers 54 and guide members 56 of the stock material feed assembly 30 advance both the base layer 50 and the cover layer 52 in the downstream direction 42 from the supply source 24 toward the product delivery assembly 32.

[0018] As the stock material supply assembly 30 advances the base layer in the downstream direction 42, the product delivery assembly 32 places the products to be shipped on the base layer 50, and the products 22 then advance in the downstream direction 42 on the base layer 50 through the packaging system 20. The product delivery assembly 32 typically includes a conveyor 60 for supporting and advancing the products 22 and base layer 50.

[0019] 3 , the product has a length dimension L parallel to the downstream direction 42, a width dimension W1 perpendicular to the length dimension L and parallel to the width dimension W2 of the base layer 50, and a height dimension H extending in a direction perpendicular to the width dimension W1 and the length dimension L. The corresponding length and height dimensions of the packaged product are equivalent to the corresponding length and height dimensions of the product. However, the width dimension W2 of the base layer 50 is generally greater than the corresponding width dimension W1 of the product 22 such that the base layer 50 extends beyond at least one edge of the product 22 to provide stand-off protection for the product 22. The difference between the width dimension W1 of the product 22 and the width dimension W2 of the base layer 50, and therefore the amount of width dimension W2 of the base layer 50 that provides such stand-off protection, varies depending on the width dimension W1 of the product 22.

[0020] 11 , the product delivery assembly 32 may optionally include a product scanner 62 configured to identify the size of the product 22. The product scanner 62 includes at least one sensor for determining the length dimension L of the product 22. The product scanner 62 identifies or measures the length dimension L of the product 22. The sensor may include a barcode scanner, a laser, a camera, or other device for determining one or more dimensions of the product, including at least the length dimension. Additionally or alternatively, a sensor may be provided for detecting the upstream edge of the product 22 after it has been placed on the base layer 50.

[0021] The system controller 40 processes the sensor signals and outputs signals to the cutting and fastening assembly 34 and the folding assembly 36 to adjust to the determined size of the product 22. This adjustment allows the packaging system 20 to accommodate and package products of various sizes and shapes. Thus, as will become apparent from this disclosure, the same operation of the packaging system 20 can be used to package a wide range of sizes and shapes of products for shipment.

[0022] 4-7 and returning to the product delivery assembly 32, the conveyor 60 includes a first conveyor section 64 and a second conveyor section 66 located downstream of the first conveyor section 64. The products 22 are placed on the base layer 50 on the first conveyor section 64, and the first conveyor section 64 advances the base layer 50 and the products 22 in the downstream direction 42 toward the second conveyor section 66. As shown in FIG. 4, the cover layer 52 is secured to the base layer 50, and the products 22 are positioned on the base layer 50 between the base layer 50 and the cover layer 52 at a location upstream of where the cover layer 52 is secured to the base layer 50. As the products 22 and base layer 50 advance in the downstream direction 42 on the first conveyor section 64, the stock material supply assembly 30 guides the cover layer 52 to extend over the products 22.

[0023] The cutting and fastening assembly 34 includes an adhesive applicator 70 that applies adhesive, such as, but not limited to, liquid glue, hot glue, or adhesive tape, to the base layer 50 adjacent the upstream end of the product 22, as shown in FIG. 5 . In the illustrated embodiment, the adhesive applicator 70 moves downstream until a positioning device 72 engages the upstream end of the product 22 and applies adhesive to the base layer 50 upstream adjacent the product 22. The positioning device 72 can also assist in advancing the product 22 downstream faster than the base layer 50 to press the product 22 against the cover layer 52, the cover layer already secured to the base layer 50 downstream of the product 22. Alternatively, an electronic sensor can be provided to detect the upstream end of the product 22, and the system controller 40 can control the adhesive applicator 70 to apply adhesive after the upstream end of the product 22 has passed the adhesive applicator 70.

[0024] As shown in FIG. 6 , the cutting and fastening assembly 34 further includes a press member 74 and a cutting assembly 76. The press member vertically moves the cover layer 52 to engage the adhesive on the base layer 50, capturing the product 22 between the cover layer 52 and the base layer 50. The press member 74 also cooperates with the cutting assembly 76 to cut through both the base layer 50 and the cover layer 52, separating the captured product 22 from the continuous base layer 50 and continuous cover layer 52 extending from the supply 24. In the illustrated embodiment, the press member 74 has a generally rectangular shape and is shaped with a recess 90 located on its bottom surface. The press member 74 extends widthwise across the base layer 50 and is movable between a waiting position ( FIG. 7 ) vertically spaced from the path of the cover layer 52 and the product 22 and a pressing position ( FIG. 6 ) adjacent to the base layer 50. The park position is generally based on the height dimension of the largest product, which is predetermined and also determines the path of the cover layer 52.

[0025] As the product 22 advances in the downstream direction 42, the pressure member 74 engages the cover layer 52 and presses it against the base layer 50, where adhesive is applied below the pressure member 74 between the cover layer 52 and the base layer 50. As a result, the cover layer 52 is pressed against the top surface of the product 22 and secured to the base layer 50 at the upstream end of the product 22, capturing the product 22 between the cover layer 52 and the base layer 50. This secures the cover layer 52 to the base layer 50 on both the upstream and downstream sides of the product 22, and the product 22 is held to the base layer 50 by the cover layer 52.

[0026] The illustrated cutting assembly 76 cooperates with the press member 74 to cut the cover layer 52 and the base layer 50. The cutting assembly 76 includes a cutting member 92, such as a sharp wedge or blade. The cutting member 92 is positioned below the gap between the first conveyor section 64 and the second conveyor section 66 and is movable between a waiting position (FIG. 4) below the path of the base layer 50 and a cutting position (FIG. 6) in which the cutting member 92 cuts the base layer 50 and the cover layer 52 and extends into the recess 90 of the press member 74. Both the base layer 50 and the cover layer 52 are cut simultaneously by the cutting member 92 during the same cutting step.

[0027] The cutting assembly 76 cuts both the base layer 50 and the cover layer 52 along a cut line bounded on an upstream side and a downstream side by adhesive. A first portion of the adhesive is disposed upstream of the cut line, and a second portion of the adhesive is disposed downstream of the cut line. Because a portion of the adhesive is disposed on both the upstream and downstream sides of the cut line, portions of the base layer 50 and the cover layer 52 are secured together on either side of the cut line. Thus, when cutting the base layer 50 and the cover layer 52 on the upstream side of the product 22, the cutting assembly 76 leaves the base layer 50 and the cover layer 52 secured together on the downstream side of the subsequently packaged product.

[0028] In the illustrated embodiment, the base layer 50 and cover layer 52 are simultaneously cut while the press member 74 secures the cover layer 52 to the base layer 50 via an adhesive, as shown. Alternatively, the cutting assembly 76 may operate independently of the press member 74. Once the cover layer 52 is secured to the base layer 50 and both the base layer 50 and cover layer 52 are cut, the press member 74 and cutting member 92 return to their respective standby positions, as shown in FIG.

[0029] After the base layer 50 and cover layer 52 are cut, the product 22 continues to advance in the downstream direction 42 on the second conveyor section 66 toward the folding assembly 36. As shown in FIG. 2 , the folding assembly 36 folds both sides of the base layer 50 widthwise over both the cover layer 52 and the product 22. First, the sides of the base layer 50 are folded upright at crease lines spaced approximately the same width dimension W1 of the product 22, and then the first side of the base layer 50 is folded over the top of the product 22. Adhesive is applied to the base layer 50, and the second side of the base layer 50 is folded over the product 22 and secured to the first side of the base layer 50 to complete the packaging process. The folding assembly 36 may include a mechanism for applying shipping labels or a printer for printing labels, and the packaged product is ready for shipment.

[0030] As mentioned above, an advantage of this packaging system 20 is its ability to be adjusted to accommodate different product sizes and shapes. This is illustrated in Figures 8A through 10C. Referring now to Figures 8A, 9A, and 10A, three different sized products 22, 26, and 28 are shown in plan view positioned on a base layer 50 with a cover layer 52 overlapping the products 22, 26, and 28 and the base layer 50 and secured to the base layer 50 on the upstream and downstream sides of the products 22, 26, and 28. In these examples, the base layer 50 and cover layer 52 have the same width dimension, and the packaged products 22, 26, and 28 each have a different length dimension L and width dimension W1. Side cross-sectional views illustrating how products 22, 26, and 28 having different length dimensions L and height dimensions H are held by the base layer 50 are shown in corresponding Figures 8B, 9B, and 10B. 8C, 9C and 10C show front views of the packaged products showing different sizes corresponding approximately to the width dimension W1 and height dimension H of each product 22, 26, 28.

[0031] A corresponding method for packaging product 22 for shipment will be described with reference to packaging system 20 depicted in Figure 1. However, the method for packaging product 22 for shipment can be accomplished using a product packaging system that is structurally different from the product packaging system depicted in Figure 1.

[0032] A method of packaging products 22 for shipment includes advancing a base layer 50 in a downstream direction 42 on a product delivery assembly 32, such as a conveyor 60, from a pair of driven feed rollers 54 of a stock material supply assembly 30. The method includes placing at least one product 22 on the base layer 50 and advancing the product 22 in the downstream direction 42 over the base layer 50 on a first conveyor section 64. The method includes identifying or detecting a length dimension L or an upstream end of the at least one product 22. The method includes applying adhesive to the base layer 50 on the upstream side of the product 22, such as with an adhesive applicator 70. The method further includes placing a cover layer 52 over the product 22 and base layer 50, and, after applying the adhesive to the base layer 50, pressing the cover layer 52 against the adhesive on the base layer 50 to secure the cover layer 52 and product 22 to the base layer 50.

[0033] The method also includes cutting the base layer 50 and the cover layer 52 along the cutting lines with adhesive on the upstream and downstream sides. The cutting step can be performed simultaneously with the pressing step. Alternatively, the pressing step can occur before the cutting step. Finally, the method also includes folding opposite sides of the base layer 50 widthwise around the product 22 and the cover layer 52 and securing the opposite sides together. The folding step may include folding a first side of the base layer 50 around the product 22 and applying adhesive, and then folding a second side of the base layer 50 around the opposite side of the product 22 and securing the second side to the first side. At this point, the product 22 is packaged and ready for shipment.

[0034] An alternative embodiment of a packaging system 100 is shown in Figure 11. In this packaging system 100, the base layer 50 and cover layer 52 are cut to a desired length, and the cover layer 52 is secured to the base layer 50. In other words, the cutting and securing assembly 34 is upstream of the product delivery assembly 32. The product delivery assembly 32 places the product 22 on both the cover layer 52 and the base layer 50. The previously described product scanner 62 then detects the product dimensions, which the system controller 40 uses to control the cutting assembly 76.

[0035] Next, the folding assembly 36 folds the upstream and downstream ends of the cover layer 52 longitudinally over the product 22 and secures the upstream and downstream ends of the cover layer 52 over the product 22. Next, the folding assembly 36 folds the opposite sides of the base layer 50 widthwise around the product 22 and the cover layer 52, similar to the folding assembly 36 in the previous embodiment.

[0036] The manner in which this packaging system 100 accommodates different product sizes is shown in Figure 12. The lengths of the base layer 50 and cover layer 52 vary depending on the corresponding length dimension L of the products 22, 25, 27.

[0037] Thus, in summary, the packaging method described herein for packaging a product 22 for shipment includes advancing a base layer 50 in the downstream direction 42 and placing the product 22 for packaging on the base layer 50. After the product 22 is placed on the base layer 50, adhesive is applied to the base layer 50 adjacent the upstream end of the product 22. A cover layer 52 is then stretched over the top surfaces of the product 22 and the base layer 50. The method includes securing the cover layer 52 to the base layer 50, thereby securing the product 22 to the base layer 50 by securing the cover layer 52 to the base layer 50 on both the upstream and downstream sides of the product 22. The base layer 50 is then folded transversely across its width over both the cover layer 52 and the product 22 to securely package the product 22 for shipment.

Claims

1. 1. A method of packaging a product for shipping, comprising: placing the product on a base layer; extending a cover layer longitudinally over a top surface of the article; securing the cover layer to the base layer such that the cover layer secures the product to the base layer; after the securing step, cutting the base layer and the cover layer; after the securing step, folding opposite sides of the base layer widthwise around the product and securing the opposite sides of the base layer together.

2. The method of claim 1 , wherein the cutting step includes cutting both the base layer and the cover layer with the same cutting operation.

3. The method of claim 1 , wherein the cutting step includes cutting the base layer and the cover layer at a location upstream of the product.

4. 2. The method of claim 1, wherein the securing step includes applying adhesive to the base layer upstream of the product, and the cutting step includes cutting the base layer and the cover layer along a cut line disposed on the base layer with adhesive on both sides of the cut line such that portions of the base layer and the cover layer are secured together.

5. The method of claim 1 , further comprising cutting the base layer and the cover layer simultaneously as the cover layer is secured to the base layer.

6. The method of claim 1 , including providing the base layer from a continuous sheet material and providing the cover layer from a continuous sheet material.

7. The method of claim 1 , wherein the securing step comprises applying an adhesive to the base layer and then pressing the cover layer against the adhesive on the base layer.

8. The method of claim 7 , wherein the applying step includes identifying an upstream end of the product and applying adhesive to the base layer at a location upstream of the product.

9. The method of claim 1 , wherein the cutting step includes cutting the base layer and the cover layer upstream of the product.

10. The method of claim 1 further comprising detecting an upstream end of the product on the base layer.

11. The method of claim 10 , wherein the detecting step includes detecting a linear dimension of the product.

12. 12. The method of any one of claims 1 to 11, repeated for a series of products having at least one different dimension.

13. 1. A packaging system for packaging a product for shipment, comprising: a product delivery assembly configured to place the product on the base layer; a sensor for detecting an upstream end of the product on the base layer; an adhesive applicator configured to apply adhesive to the base layer at a location upstream of the product based on a signal from the sensor; a stock material supply assembly configured to place a cover layer on top of the product and the base layer; a pressing member configured to press the cover layer against the base layer such that the adhesive secures the cover layer to the base layer in such a way that the product is secured to the base layer by the cover layer; a cutting assembly configured to cut across a width dimension of the base layer and the cover layer; a folding assembly disposed downstream of the pressing member and configured to fold opposite sides of the base layer widthwise around the product and the cover layer.

14. The packaging system of claim 13 including a supply of sheet-form stock material for the base layer and the cover layer.

15. 14. The packaging system of claim 13, further comprising an adhesive applicator positioned to apply adhesive to the base layer to secure the folded sides together.

16. 14. The packaging system of claim 13, further comprising a conveyor for advancing the base layer and the products disposed on the base layer downstream past the pressure member.

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