Machine-openable paper mailers and associated machines

Abstract

A mailer includes a web that is arranged to form two panels. The panels are bordered by two sides, a bottom, and a top of the mailer. The web includes a paper skin layer and a paper cushioning layer. The paper skin layer is on an outer side of each of the two panels and the paper cushioning layer is on an inner side of each of the two panels. The paper skin layer of one panel extends a first distance from the bottom and the paper skin layer of the other panel extends a second distance from the bottom. The first distance is greater than the second distance such that an offset exists between the tops of the paper skin layers of the two panels.

Description

MACHINE-OPENABLE PAPER MAILERS AND ASSOCIATED MACHINESSPECIFICATIONBACKGROUND

[0001] The present disclosure is in the technical field of paper mailers and machines for handling paper mailers. More particularly, the present disclosure is directed to paper mailers that can be reliably opened by an automated machine and to automated machines for opening such paper mailers.

[0002] A wide variety of products — including documents, books, consumer products, fragile items, and other items — are transported in various t pes of cushioned mailing envelopes generally called ‘"mailers”.

[0003] One type of a commercial mailer is an envelope with a front and rear wall, sealed at its two lateral and bottom edges, with a flap integrally formed from and extending from the rear wall. The flap extends beyond the upper end of the front wall when the envelope is open. The flap includes on one side a pressure sensitive adhesive that is covered by a release tape. After the envelope is filled with an article to be mailed, the release tape is removed from the flap, and the flap is folded over and adhered to the exterior surface of the front wall, thus sealing the envelope.

[0004] The walls of this type of commercial envelope comprise a multilayer outer ply, and an air cellular material forming an inner ply. The air cellular material is typically a material such as BUBBLE WRAP™ air cellular material sold by Sealed Air Corporation. Over many years, all-plastic mailers became more popular. These all plastic mailers typically have an outer ply that comprises an outer layer of a high density polyethylene (HDPE). and an inner layer comprising a low density' polyethylene (LDPE). The outer layer thus forms the outermost layer of the envelope. The inner layer is in adhering contact with the air cellular material of the inner ply.

[0005] However, all-plastic mailers nevertheless have some disadvantages. In particular, all-plastic are typically very difficult for consumers to recycle. All-plastic mailers typically include types of films that are not accepted in the most convenient recycling locations. In particular, all-plastic mailers are not accepted in most curbside recycling bins. It may be possible for consumers find drop-off recycling locations that will accept all-plastic mailers. However, it is typically inconvenient for consumers to take used all-plastic mailers to such drop-off recycling locations and many all-plastic mailers end up being thrown away and ending up in landfill or other solid waste disposal facilities (e.g., landfills).SUMMARY

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] In a first embodiment, a mailer incudes a web arranged to form first and second panels of the mailer. The first and second panels are bordered by two sides, a bottom, and a top. The web includes a paper skin layer and a paper cushioning layer. The web is arranged such that the paper skin layer is on an outer side of each of the first and second panels of the mailer and the paper cushioning layer is on an inner side of each of the first and second panels of the mailer. The paper skin layer of the first panel extends a first distance from the bottom and the paper skin layer of the second panel extends a second distance from the bottom. The first distance is greater than the second distance such that an offset exists between a top of the paper skin layer of the first panel and a top of the paper skin layer of the second panel.

[0008] In a second embodiment, the offset of the first embodiment between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is in a range between 0.039 in (1.0 mm) and 0.197 in (5.0 mm).

[0009] In a third embodiment, the offset of the first embodiment between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is in a range between 0.079 in (2.0 mm) and 0.157 in (4.0 mm).

[0010] In a fourth embodiment, the offset of the first embodiment between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is about 0. 1 18 in (3.0 mm).

[0011] In a fifth embodiment, the offset of the first embodiment between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is less than or equal to about 0.25 in (6.35 mm).

[0012] In a sixth embodiment, the paper cushioning layer of the first and second panels of any of the preceding embodiments extends a third distance from the bottom. The third distance is less than each of the first and second distances such that tops of the paper cushioning layer of the first and second panels are closer to the bottom than each of the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel.

[0013] In a seventh embodiment, the mailer of the sixth embodiment further includes a seal area on an inner side of the paper skin layer either or both of the first and second panels. The seal area is located between the tops of the paper cushioning layer of the first and second panels and the tops of the paper skin layer of the first and second panels.

[0014] In an eighth embodiment, the top of the mailer of the seventh embodiment is open and the seal area is configured to be sealed to close the top of the mailer.

[0015] In a ninth embodiment, the paper skin layer of any of the preceding embodiments is formed from kraft paper.

[0016] In a tenth embodiment, the paper cushioning layer of any of the preceding embodiments is formed from extensible paper that is formed into a nonplanar form.

[0017] In an eleventh embodiment, the two sides of the mailer of any of the preceding embodiments are formed by seams that seal the first panel to the second panel.

[0018] In a twelfth embodiment, the web of any of the preceding embodiments includes one piece of the paper skin layer and one piece of the paper cushion layer, and wherein the web is folded to form the bottom of the mailer.

[0019] In a thirteenth embodiment, the web of any of the preceding embodiments includes two pieces of the paper skin layer and two pieces of the paper cushion layer, and wherein the two pieces of the web are connected together to form the bottom of the mailer.

[0020] In a fourteenth embodiment, a system includes a mailer conveyance device, mailer engagement devices, and a blower. The mailer conveyance device is configured to individually advance discrete mailers, where each of the discrete mailers is the mailer of any of the preceding claims. The system is configured to advance, by the mailer conveyance device, a first discrete mailer to a filling and sealing position. The system is further configured to hold, by the mailer engagement devices, the first discrete mailer at the filling and sealing position, where the mailer engagement devices is configured to grip the sides of the first discrete mailer. The system is further configured to open the top of the first discrete mailer by directing, by the blower, a stream of gas toward the top of the first discrete mailer, and exerting, by the mailer engagement devices, an inward force of the sides of the mailer. The system is further configured to, in response to receiving an indication that the first discrete mailer has been filled, flatten the top of the first discrete mailer by pulling, by the mailer engagement devices, the sides of the first discrete mailer away from each other. The system is further configured to, after the top of the first discrete mailer has been flattened, close the top of the first discrete mailer.

[0021] In a fifteenth embodiment, the system of the fourteenth embodiment further includes a suction device configured to engage the paper skin layer of the first panel of the first discrete mailer when the first discrete mailer is in the filling and sealing position.

[0022] In a sixteenth embodiment, the system of the fifteenth embodiment is further configured to open the top of the first discrete mailer by engaging, by the suction device, the paper skin layer of the first panel of the first discrete mailer.

[0023] In a seventeenth embodiment, the system of any of the fourteenth to sixteenth embodiments further includes a heat sealer configured to apply heat to the heat seal area of the first discrete mailer.

[0024] In an eighteenth embodiment, the sy stem of the seventeenth embodiment is further configured to close the top of the first discrete mailer by sealing, by the heat sealer, the heat seal area of the first discrete mailer.

[0025] In a nineteenth embodiment, the mailer engagement devices of any of the seventeenth and eighteenth embodiments are programmable to be positioned at a plurality of differentdistances away from the heat sealer when the first discrete mailer is in the filling and loading position.

[0026] In a twentieth embodiment, the discrete mailers of any of the fourteenth to nineteenth embodiments are held in a supply in the machine. The discrete mailers in the supply are arranged substantially horizontally. The first discrete mailer is arranged substantially vertically when in the filling and loading position. The mailer conveyance device is configured to change an orientation of the first discrete mailer from substantially horizonal in the supply to substantially vertical in the filling and sealing position.

[0027] In a twenty -first embodiment, the mailer engagement devices of any of the fourteenth to twentieth embodiments are programmable to grip the sides of the first discrete mailer at different positions based on a size of the first discrete mailer, to exert one of a plurality of different inward distances based on the size of the first discrete mailer, and pull to one of a number of different outward distances based on the size of the first discrete mailer.BRIEF DESCRIPTION OF THE DRAWING

[0028] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0029] Figs. 1A and IB depict front and cross-sectional views, respectively, of an embodiment of a mailer, in accordance with the embodiments disclosed herein;

[0030] Fig. 1C depicts a detail view of a portion of the mailer shown in Fig. 1 A that shows an offset in the tops of the first and second panels, in accordance with the embodiments disclosed herein;

[0031] Fig. 2 depicts an example of a machine aiding in the opening of the mailer shown in Figs. 1 A to 1C, in accordance with the embodiments disclosed herein;

[0032] Fig. 3 depicts a perspective view of the machine shown in Fig. 2, in accordance with the embodiments disclosed herein;

[0033] Figs. 4A to 4F each depict an instance of an embodiment of a process of the machine shown in Figs. 2 and 3 being used to aid in opening, loading, and sealing the mailer shown in Figs. 1 A to 1C, in accordance with the embodiments disclosed herein;

[0034] Fig. 5 depicts an example embodiment of a system that may be used to implement some or all of the embodiments described herein; and

[0035] Fig. 6 depicts a block diagram of an embodiment of a computing device, in accordance with the embodiments described herein.DETAILED DESCRIPTION

[0036] The present disclosure describes embodiments of mailers formed from a web. The web is arranged to form two panels. The panels are bordered by two sides, a bottom, and a top of the mailer. The web includes a paper skin layer and a paper cushioning layer. The paper skin layer is on an outer side of each of the two panels and the paper cushioning layer is on an inner side of each of the two panels. The paper skin layer of one panel extends a first distance from the bottom and the paper skin layer of the other panel extends a second distance from the bottom. The first distance is greater than the second distance such that an offset exists between the tops of the paper skin layers of the two panels. The embodiment of mailers with offset tops disclosed herein can be opened reliably by a machine that blows a stream of gas at the top to cause the offset top to open.

[0037] Figs. 1A and IB depict front and cross-sectional views, respectively, of an embodiment of a mailer 100. The mailer 100 is formed from a w eb that includes a paper skin layer 102 and a paper cushioning layer 104. In some embodiments, the paper skin layer 102 is formed from kraft paper, such as 50# kraft paper. In some embodiments, the paper skin layer 102 can be uncoated paper. In some embodiments, the paper skin layer 102 can be paper coated — either fully coated or partially coated — in a polymer to enable the paper skin layer 102 to be connected to the paper cushioning layer 104 and / or to itself. In some embodiments, it may be desirable to minimize the amount of any coating on the paper of the paper skin layer 102 so that the mailer 100 is recyclable and / or repulpable.

[0038] The paper cushioning layer 104 is a paper layer having a nonplanar form. In some embodiments, the paper cushioning layer 104 is formed into a nonplanar layer by pressing orembossing the paper of the paper cushioning layer 104. In some embodiments, the paper of the paper cushioning layer is an extensible paper having a stretch to failure of at least 4% in any direction. In the depicted embodiment, the paper cushioning layer 104 has embossed protrusions in the form of hemispheres (or “bubbles”). In other embodiment, the paper cushioning layer 104 can have any shape of protrusions or any other pattern or design that causes the paper cushioning layer 104 to be nonplanar. Other examples of paper cushioning layers are shown in International Application No. PCT / US2023 / 013616, in U.S. Patent Application No. 63 / 533,927, and in U.S. Patent Application No. 63 / 536,732, the contents of each of which are hereby incorporated by reference in their entirety.

[0039] The web can be formed by connecting the paper skin layer 102 to the paper cushioning layer 104. In some embodiments, one or both of the paper skin layer 102 and the paper cushioning layer 104 is coated with a polymer that can be heated to cause the polymer coating to bond the paper skin layer 102 to the paper cushioning layer 104. In other embodiments, an adhesive is applied to one or both of the paper skin layer 102 and the paper cushioning layer 104 and then the paper skin layer 102 and the paper cushioning layer 104 are pressed together to adhere the layers together.

[0040] The web of the paper skin layer 102 and the paper cushioning layer 104 are arranged to form two panels of the mailer 100. For example, in the depicted embodiment, the web of the paper skin layer 102 and the paper cushioning layer 104 are arranged to form a first panel 106 and a second panel 108 of the mailer. When the mailer 100 is viewed as shown in Fig. 1A, the first panel 106 forms a back of the mailer 100 and the second panel 108 forms a front of the mailer 100. The web is arranged such that the paper skin layer 102 is on an outer side of each of the first and second panels 106 and 108 of the mailer 100 and the paper cushioning layer 104 is on an inner side of each of the first and second panels 106 and 108 of the mailer 100.

[0041] The mailer 100 has a bottom 1 10 and a top 112. The first and second panels 106 and 108 extend from the bottom 110 of the mailer 100 to the top 112 of the mailer 100. In the depicted embodiment, the web is one piece of the web material that has been folded such that the fold forms the bottom 110 of the mailer 100. In other embodiments, the web can be two pieces of the web material that are connected together (e.g.. adhered, sealed, etc.) to form thebottom 110 of the mailer 100. The first and second panels 106 and 108 extend upward from the bottom 110 toward the top 112. The mailer 100 also has sides 114 and 116. In some embodiments, the sides 114 and 116 are formed by connected the sides of the first and second panels 106 and 1 8 together. In some embodiments, the sides 1 14 and 1 16 can be formed by sealing, adhering, or gluing the sides of the first and second panels 106 and 108 together. In other embodiments, the sides 114 and 116 can be formed by connecting the first and second panels 106 and 108 together in any other manner.

[0042] The first panel 106 has a top 118 and the second panel 108 has a top 120. Fig. 1C depicts a detail view of a portion of the mailer 100 that includes the tops 118 and 120 of the first and second panels 106 and 108. As can be seen in Figs. 1 A and 1 C, the first panel 106 extends a first distance from the bottom 110 and the second panel 108 extends a first distance from the bottom 110, where the first distance is greater than the second distance. As can be seen in Fig. 1C, this difference in the distances that the first and second panels 106 and 108 extend upward from the bottom 110 of the mailer 100 results in an offset 122 between the tops 118 and 120 of the first and second panels 106 and 108. In some embodiments, the offset 122 between the tops 118 and 120 of the first and second panels 106 and 108 is in a range between 0.039 in (1.0 mm) and 0.197 in (5.0 mm). In some embodiments, the offset 122 between the tops 118 and 120 of the first and second panels 106 and 108 is in a range between 0.079 in (2.0 mm) and 0.157 in (4.0 mm). In some embodiments, the offset 122 between the tops 118 and 120 of the first and second panels 106 and 108 is about 0.118 in (3.0 mm). In some embodiments, the offset 122 between the tops 118 and 120 of the first and second panels 106 and 108 is less than or equal to about 0.25 in (6.35 mm). This offset between the tops 1 18 and 120 of the first and second panels 106 and 108 aid in opening the mailer 100, as discussed in greater detail below.

[0043] As can be seen in Figs. 1 A and IB, the paper skin layer 102 of the first and second panels 106 and 108 extend from the bottom 110 of the mailer 100 to the tops 118 and 120 at the top 112 of the mailer 100. However, the paper cushioning layer 104 does not extend to the tops 118 and 120. In the depicted embodiment, the paper cushioning layer 104 in each of the first and second panels 106 and 108 extends from the bottom 110 of the mailer 100 to tops 124 of the paper cushioning layer 104. The tops 124 of the paper cushioning layer 104 are closer to the bottom 110 of the mailer 100 than the tops 118 and 120 of the paper skinlayer 102. In the depicted embodiment, the tops 124 of the paper cushioning layer 104 each extend to the same distance from the bottom 110 of the mailer 100. In other embodiments, the tops 124 of the paper cushioning layer 104 extend different distances from the bottom 110 of the mailer 100. Because the tops 124 of the paper cushioning layer 104 are closer to the bottom 110 of the mailer 100 than the tops 118 and 120 of the paper skin layer 102, a gap 126 exists between the tops 124 of the paper cushioning layer 104 and the tops 118 and 120 of the paper skin layer 102.

[0044] The opening of the mailer 100 at the top 112 of the mailer 100 can be closed using the area in the gap 126 between the tops 124 of the paper cushioning layer 104 and the tops 118 and 120 of the paper skin layer 102. In the depicted embodiment, the mailer 100 includes a seal area 128 that can be sealed to close the top 112 of the mailer 100. In some embodiments, the inner sides of the paper skin layer 102 in each of the first and second panels 106 and 108 includes a sealing material. In one example, the inner sides of the paper skin layer 102 in each of the first and second panels 106 and 108 can have a polymer coating in the seal area 128, where the polymer coating will be sealed together upon application of heat to the seal area. In another example, the inner side of the paper skin layer 102 in the first panel 106 can have a first coating and the inner side of the paper skin layer 102 in the second panel 108 can have a second coating, where the first and second coatings will be adhered together upon application of pressure to the seal area. In another example, the inner side of the paper skin layer 102 of one of the first and second panels 106 and 108 can have a pressure sensitive adhesive which will adhere the first and second panels 106 and 108 together upon application of pressure to the seal area. In the depicted embodiment, the seal area 128 has a height 130 that is entirely within the gap 126. In some embodiments, the sealing material is located entirely within the gap 126. In other embodiments, the sealing material can be applied to the seal area 128 and to areas of the first and second panels 106 and 108 outside of the seal area 128. For example, where the sealing material is a polymer coating, the entirety of the inner sides of the paper skin layer of both of the first and second panels 106 and 108 can be coated with the polymer coating.

[0045] It will be noted that the offset 122 is sufficiently small that the mailer 100 does not have a typical closure flap. Typical mailers and envelopes have closure flaps that are sized to be manually folded over to close the mailer. For example, typical mailers and envelopeshave closure flaps that are at least 0.25 in (6.35 mm) wide. These closure flaps can have pressure sensitive adhesives, a wetting adhesive (e.g., gum arabic adhesive), or other adhesives that can be activated to close the envelope. The mailer 100 in the depicted embodiment does not have a closure flap because the offset 122 betw een the tops 118 and 120 of the first and second panels 106 and 108 is too small (e.g., less than or equal to about 0.25 in (6.35 mm)) for the top of the first panel 106 to be considered a closure flap.

[0046] In practice, the mailer 100 can be used to package and ship an item. The opening at the top of the mailer 100 can be opened sufficiently for a person to place the item inside of the mailer 100 and then the mailer 100 can be closed by sealing the top 112 of the mailer 100 in the seal area 128. If this process can be done entirely manually. However, performing the process completely manually can limit the number of mailers that a single person can fill in any given time period. In some instances, it w ould be advantageous for a machine to automate at least some of the process of opening, filling, and closing the mailer 100 in order to increase the throughput of a single operator.

[0047] Fig. 2 depicts an example of a machine 200 aiding in the opening of the mailer 100. In particular, the machine 200 is holding the sides 1 14 and 116 of the mailer 100 such that the top 112 of the mailer 100 is held open. The machine 200 can hold the mailer 100 in this orientation while a user inserts one or more objects into the mailer 100 through the top 112. Once all of the one or more objects to be shipped are located in the mailer 100. the machine 200 can hold the mailer 100 so that the top 112 is closed and then seal the top 112 of the mailer 100 so that the one or more objects cannot be removed from the mailer 100 without destroying some aspect of the mailer 100. These functions of the machine 200 are discussed in greater detail below.

[0048] Fig. 3 depicts a perspective view of the machine 200. The machine 200 includes a mailer conveyance device 202. In the depicted embodiment, the mailer conveyance device 202 is configured to advance discrete mailers, such as the mailer 100 described above. In some embodiments, the machine 200 holds a supply of discrete mailers, such as a supply of multiple discrete mailers that are similar to the mailer 100 described above, and the mailer conveyance device 202 is arranged to advance the discrete mailers individually from that supply. In the depicted embodiment, the mailer conveyance device 202 includes a pluralityof conveyor belts. In other embodiments, the mailer conveyance device 202 can include a single conveyor belt, driven rollers, or any other conveyance devices. In the depicted embodiment, the machine 200 further includes a mailer guide 204 that is configured to direct the mailers to a filling and sealing position. As described in greater detail below, the mailer guide 204 is configured to direct the discrete mailers from a substantially horizontal orientation, such as when the mailers are stored substantially horizontally in a supply in the machine 200, to a substantially vertical orientation for filling and sealing.

[0049] In the depicted embodiment, the machine 200 further includes a heat sealer 206. The machine 200 is capable of sealing closed mailers that can be sealed by heating the opening of the mailers. The heat sealer 206 can be a heating wire or any other heating element that extends across the width of the mailer when the mailer is held in the filling and sealing position. In the depicted embodiment, the machine 200 further includes a seal backing bar 210. At the instance shown in Fig. 3, the seal backing bar 210 is spaced apart from the heat sealer 206. When the opening of a mailer is located between the heat sealer 206 and the seal backing bar 210, the seal backing bar 210 can be moved toward the heat sealer 206 so that the seal backing bar 210 applies pressure to the opening of the mailer as the heat sealer 206 heats the opening of the mailer.

[0050] The machine 200 further includes a blower 212 that is arranged to direct a stream of gas toward the top of the mailer when it is held in the filling and sealing position. As discussed in greater detail below, the combination of the stream of gas directed to the mailer by the blower 212 and the offset in the heights of the first and second panels of the mailer causes the first and second panels of the mailer to diverge and open the opening of the mailer. This results in a simple and reliable way for the machine 200 to automatically open mailers for filling by a user. In the depicted embodiment, the machine 200 further includes a suction device 218. In the depicted embodiment, the suction device 218 is a vacuum suction cup. The suction device 218 may optionally be included in the machine 200 to engage and hold one panel of the mailer when the mailer is opened by the stream of gas from the blower 212. Engaging and holding one panel of the mailer in this manner will help to hold the mailer open until is filled by a user.

[0051] The machine 200 further includes mailer engagement devices 214 and 216. The mailer engagement devices 214 and 216 are configured to engage the sides of the mailer, such as to hold the mailer, assist in opening the mailer, close the mailer, hold the mailer closed while the opening is sealed, and the like. In the depicted embodiment, the engagement devices 214 and 216 are in the form of grippers. The engagement devices 214 and 216 can take any number of forms, such as clamps, vices, pinchers, and the like. The engagement devices 214 and 216 are configured to selectively engage and hold the sides of the mailer.

[0052] Figs. 4A to 4F each depict an instance of an embodiment of a process of the machine 200 being used to aid in opening, loading, and sealing the mailer 100. In Fig. 4A, the mailer conveyance device 202 is advancing the mailer 100. In the depicted embodiment, the mailer 100 is advanced with the bottom 110 in the front of the direction of advancement. In the depicted embodiment, the mailer 100 is advanced in a substantially horizontal direction by the mailer conveyance device 202. In the depicted embodiment, the mailer guide 204 causes the mailer 100 to transition from the substantially horizontal direction advanced by the mailer conveyance device 202 to a substantially vertical direction with the bottom 110 of the mailer 100 facing downward. The mailer conveyance device 202 is in the proceed of advancing the mailer 100 to a filling and sealing position.

[0053] From the instance shown in Fig. 4A to the instance shown in Fig. 4B, the mailer conveyance device 202 has advanced the mailer 100 until the mailer 100 is in the filling and sealing position. At the instance shown in Fig. 4B, the engagement devices 214 and 216 are gripping the sides 114 and 116 of the mailer 100 to hold the mailer 100 at the filling and sealing position. In the depicted embodiment, when the mailer 100 is in the filling and sealing position, the mailer 100 is held with the seal area 128 of the mailer vertically aligned with the heat sealer 206 of the machine 200. When the engagement devices 214 and 216 initially grip the sides 114 and 116 of the mailer 100 in Fig. 4B, the top 112 of the mailer 100 remains flat and closed (though not sealed). In that position, the top 112 is not ready for a user to insert an object into the mailer 100.

[0054] At the instance shown in Fig. 4C, the blower 212 is directing a stream of gas downward toward the top 112 of the mailer 100. In some embodiments, the stream of gas can be described as a curtain of gas. a jet of gas. a puff of gas, or any other shape and / orduration of a stream of gas. The stream of gas directed at the top 112 has caused the first and second panels 106 and 108 of the mailer 100 at the top 112 to diverge. The offset 122 between the top 118 of the first panel 106 and the top 120 of the second panel 108 causes the divergence of the first and second panels 106 and 108 of the mailer 1 0 at the top 112 when the stream of gas is directed at the top 112. When the machine 200 was attempted to be used mailers that did not have an offset (i.e., with mailers where the tops of the two panels were the same distance from the bottom of the mailer), the tops of the two panels did not reliably diverge; in many instances, the panels would be directed in the same direction resulting in the top of the mailer remaining closed. However, in the case of the mailer 100 having the offset 122 between the tops 118 and 120 of the first and second panels 106 and 108, the first and second panels 106 and 108 reliably diverge from each other when the stream of gas is directed at the top 112 of the mailer 100 by the blower 212. In this way, directing the stream of gas from the blower 212 toward the top 112 of the mailer 100 opens the top 112 of the mailer 100.

[0055] From the instance shown in Fig. 4C to the instance shown in Fig. 4D, the engagement devices 214 and 216 have been moved toward each other to exert an inward force on the sides 114 and 116 of the mailer 100. In the depicted embodiment, the movement of the engagement devices 214 and 216 includes a movement of the each of the engagement devices 214 and 216 with respect to the rest of the machine 200. In this way, the mailer 100 can remain substantially centered with respect to the machine 200 while the engagement devices 214 and 216 move with respect to each other to exert the inward force. In other embodiments, the respective movement of the engagement devices 214 and 216 can include the engagement device 214 remaining fixed with respect to the rest of the machine 200 while the engagement device 216 moves toward the engagement device 214 (or vice versa). The respective inward movement of the engagement devices 214 and 216 to exert the inward force on the sides 114 and 116 of the mailer 100 causes the top 112 of the mailer 100 to open even further.

[0056] At either or both of the instances shown in Figs. 4C and 4D, the suction device 218 may optionally be operated to engage the first panel 106. For example, the suction device 218 can be a vacuum suction cup which can be activated to selectively apply a vacuum to thepaper skin layer 102 of the first panel 106. The engagement of the first panel 106 by the suction device 218 can further assist in holding the top 112 of the mailer 100 open.

[0057] With the top 112 of the mailer 100 open as shown in Fig. 4D, the mailer 100 has been automatically prepared for filling by a user. A user can insert one or more objects to be shipping in the mailer 100 through the top 112 of the mailer 100. The engagement device 214 and 216 are configured to grip the sides 1 14 and 116 of the mailer 100 sufficiently to prevent the mailer 100 from falling due to the force of the object(s) being inserted into the mailer 100 by the user and due to the force of the weight of the object(s) after being inserted into the mailer 100. Once the user fills the mailer 100 with the object(s). an indication can be sent to the machine 200 that the machine has been filled. The indication can come in the form of a signal from a button that is pushed by the user after the mailer 100 is filled, a foot pedal stepped on by the user after the mailer 100 is filled, an optical tracking system that senses when the user fills the mailer 100, a proximity sensor that detects the number of the object(s) inserted into the mailer, and the like.

[0058] In response to the system receiving the indication that the mailer 100 has been filled, the mailer engagement devices 214 and 216 can flatten the top 112 of the mailer 100. From the instance show n in Fig. 4D to the instance shown in Fig. 4E, the mailer engagement devices 214 and 216 have flattened the top 112 of the mailer 100. In the depicted embodiment, the mailer engagement devices 214 and 216 have flattened the top 112 of the mailer 100 by pulling the sides 114 and 116 of the mailer 100 away from each other. In some embodiments, the mailer engagement devices 214 and 216 flatten the top 112 of the mailer 100 by returning the locations where the mailer engagement devices 214 and 216 initially gripped the sides 114 and 116 of the mailer 100 (e.g., at the locations of the mailer engagement devices 214 and 216 in Fig. 4B) in order to flatten the top 112 of the mailer 100.

[0059] After the top 112 of the mailer 100 has been flattened, the machine 200 can close the top 1 12 of the mailer 100. In the depicted embodiment, the inner sides of the seal area 128 of the mailer 100 are coated with a material (e.g., a polymer coating) that will seal the top 112 of the mailer 100 when subjected to heat and pressure. As shown in Fig. 4F, the seal backing bar 210 has been moved toward the heat sealer 206 so that the top 112 of the mailer 100 with the seal area 128 is pinched between the heat sealer 206 and the seal backing bar 210. Theheat sealer 206 applies heat to the top 112 of the mailer 100 while the seal backing bar 210 applied pressure to the top 112 of the mailer 100 to cause the top 112 of the mailer to be sealed closed.

[0060] One of the benefits of the machine 200 is that the machine 200 is capable of being used with mailers of different widths. For example, because the mailer engagement devices 214 and 216 are capable of moving inward and outward, the mailer engagement devices 214 and 216 can be programed to grip the sides of mailers at different positions based on a size of the mailer. In another example, the mailer engagement devices 214 and 216 can be programed to exert a different inward force one the sides of the mailer based on the size of the mailer. In another example, the mailer engagement devices 214 and 216 can be programed to pull to any of a number of different outward distances based on the size of the mailer. In another example, the mailer engagement devices 214 and 216 can be programed to be positioned at certain distances away from the heat sealer 206 (e.g.. in the horizontal direction) when holding the sides 114 and 1 16 of the mailer 100 so that the machine 200 can accommodate mailers with a number of different sizes of openings.

[0061] Fig. 5 depicts an example embodiment of a system 310 that may be used to implement some or all of the embodiments described herein. In the depicted embodiment, the system 310 includes computing devices 320i, 3202, 3203. and 3204 (collectively computing devices 320). In the depicted embodiment, the computing device 320i is a tablet, the computing device 3202 is a mobile phone, the computing device 320s is a desktop computer, and the computing device 3204 is a laptop computer. In other embodiments, the computing devices 320 include one or more of a desktop computer, a mobile phone, a tablet, a phablet, a notebook computer, a laptop computer, a distributed system, a gaming console (e.g., Xbox, Play Station. Wii). a watch, a pair of glasses, a key fob. a radio frequency identification (RFID) tag, an ear piece, a scanner, a television, a dongle, a camera, a wristband, a wearable item, a kiosk, an input terminal, a server, a server network, a blade, a gateway, a switch, a processing device, a processing entity, a set-top box, a relay, a router, a network access point, a base station, any other device configured to perform the functions, operations, and / or processes described herein, or any combination thereof.

[0062] The computing devices 320 are communicatively coupled to each other via one or more networks 330 and 332. Each of the networks 330 and 332 may include one or more wired or wireless networks (e.g.. a 3G network, the Internet, an internal network, a proprietary network, a secured network). The computing devices 320 are capable of communicating with each other and / or any other computing devices via one or more wired or wireless netw orks. While the particular system 310 in Fig. 5 depicts that the computing devices 320 communicatively coupled via the network 330 include four computing devices, any number of computing devices may be communicatively coupled via the netw ork 330.

[0063] In the depicted embodiment, the computing device 320? is communicatively coupled with a peripheral device 340 via the network 332. In the depicted embodiment, the peripheral device 340 is a scanner, such as a barcode scanner, an optical scanner, a computer vision device, and the like. In some embodiments, the network 332 is a wired network (e g., a direct wired connection between the peripheral device 340 and the computing device 320s), a wireless network (e.g., a Bluetooth connection or a WiFi connection), or a combination of wired and wireless networks (e.g., a Bluetooth connection between the peripheral device 340 and a cradle of the peripheral device 340 and a wired connection betw een the peripheral device 340 and the computing device 320s). In some embodiments, the peripheral device 340 is itself a computing device (sometimes called a “smart” device). In other embodiments, the peripheral device 340 is not a computing device (sometimes called a “dumb” device).

[0064] Depicted in Fig. 6 is a block diagram of an embodiment of a computing device 400. Any of the computing devices 320 and / or any other computing device described herein may include some or all of the components and features of the computing device 400. In some embodiments, the computing device 400 is one or more of a desktop computer, a mobile phone, a tablet, a phablet, a notebook computer, a laptop computer, a distributed system, a gaming console (e.g., an Xbox, a Play Station, a Wii), a watch, a pair of glasses, a key fob, a radio frequency identification (RFID) tag, an ear piece, a scanner, a television, a dongle, a camera, a wristband, a wearable item, a kiosk, an input terminal, a server, a server network, a blade, a gateway, a switch, a processing device, a processing entity, a set-top box, a relay, a router, a network access point, a base station, any other device configured to perform the functions, operations, and / or processes described herein, or any combination thereof. Such functions, operations, and / or processes may include, for example, transmitting, receiving,operating on, processing, displaying, storing, determining, creating / generating, monitoring, evaluating, comparing, and / or similar terms used herein. In one embodiment, these functions, operations, and / or processes can be performed on data, content, information, and / or similar terms used herein.

[0065] In the depicted embodiment, the computing device 400 includes a processing element 405, memory 410, a user interface 415, and a communications interface 420. The processing element 405, memory 410, a user interface 415, and a communications interface 420 are capable of communicating via a communication bus 425 by reading data from and / or writing data to the communication bus 425. The computing device 400 may include other components that are capable of communicating via the communication bus 425. In other embodiments, the computing device does not include the communication bus 425 and the components of the computing device 400 are capable of communicating with each other in some other way.

[0066] The processing element 405 (also referred to as one or more processors, processing circuitry, and / or similar terms used herein) is capable of performing operations on some external data source. For example, the processing element may' perform operations on data in the memory' 410, data receives via the user interface 415, and / or data received via the communications interface 420. As will be understood, the processing element 405 may be embodied in a number of different ways. In some embodiments, the processing element 405 includes one or more complex programmable logic devices (CPLDs), microprocessors, multicore processors, co processing entities, application-specific instruction-set processors (ASIPs), microcontrollers, controllers, integrated circuits, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), programmable logic arrays (PLAs), hardware accelerators, any other circuitry, or any combination thereof. The term circuitry may refer to an entirely' hardware embodiment or a combination of hardware and computer program products. In some embodiments, the processing element 405 is configured for a particular use or configured to execute instructions stored in volatile or nonvolatile media or otherwise accessible to the processing element 405. As such, whether configured by hardware or computer program products, or by a combination thereof, the processing element 405 may be capable of performing steps or operations when configured accordingly.

[0067] The memory 410 in the computing device 400 is configured to store data, computerexecutable instructions, and / or any other information. In some embodiments, the memory 410 includes volatile memory (also referred to as volatile storage, volatile media, volatile memory circuitry, and the like), non-volatile memory (also referred to as non-volatile storage, non-volatile media, non-volatile memory circuitry', and the like), or some combination thereof.

[0068] In some embodiments, volatile memory' includes one or more of random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), fast page mode dynamic random access memory (FPM DRAM), extended data-out dynamic random access memory' (EDO DRAM), synchronous dynamic random access memory' (SDRAM), double data rate synchronous dynamic random access memory' (DDR SDRAM), double data rate ty pe two synchronous dynamic random access memory (DDR2 SDRAM), double data rate type three synchronous dynamic random access memory (DDR3 SDRAM), Rambus dynamic random access memory (RDRAM), Twin Transistor RAM (TTRAM), Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM), Rambus in-line memory module (RIMM), dual in-line memory module (DIMM), single in-line memory module (SIMM), video random access memory (VRAM), cache memory (including various levels), flash memory, any other memory that requires power to store information, or any combination thereof.

[0069] In some embodiments, non-volatile memory includes one or more of hard disks, floppy disks, flexible disks, solid-state storage (SSS) (e.g., a solid state drive (SSD)), solid state cards (SSC), solid state modules (SSM), enterprise flash drives, magnetic tapes, any other non-transitory magnetic media, compact disc read only memory’ (CD ROM), compact disc-rewritable (CD-RW), digital versatile disc (DVD). Blu-ray disc (BD). any other non- transitory optical media, read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory' (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory (e.g., Serial, NAND, NOR, and / or the like), multimedia memory’ cards (MMC). secure digital (SD) memory cards. Memory Sticks, conductive-bridging random access memory (CBRAM), phase-change random access memory (PRAM), ferroelectric random-access memory' (FeRAM), nonvolatile random access memory’ (NVRAM), magneto-resistive random access memory(MRAM), resistive random-access memory (RRAM), Silicon Oxide-Nitride-Oxide-Silicon memory (SONOS), floating j unction gate random access memory (FJG RAM). Millipede memory, racetrack memory, any other memory that does not require power to store information, or any combination thereof.

[0070] In some embodiments, memory 410 is capable of storing one or more of databases, database instances, database management systems, data, applications, programs, program modules, scripts, source code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, or any other information. The term database, database instance, database management system, and / or similar terms used herein may refer to a collection of records or data that is stored in a computer-readable storage medium using one or more database models, such as a hierarchical database model, network model, relational model, entity relationship model, object model, document model, semantic model, graph model, or any other model.

[0071] The user interface 415 of the computing device 400 is in communication with one or more input or output devices that are capable of receiving inputs into and / or outputting any outputs from the computing device 400. Embodiments of input devices include a keyboard, a mouse, a touchscreen display, a touch sensitive pad, a motion input device, movement input device, an audio input, a pointing device input, a joystick input, a keypad input, peripheral device 340, foot switch, and the like. Embodiments of output devices include an audio output device, a video output, a display device, a motion output device, a movement output device, a printing device, and the like. In some embodiments, the user interface 415 includes hardware that is configured to communicate with one or more input devices and / or output devices via wired and / or wireless connections.

[0072] The communications interface 420 is capable of communicating with various computing devices and / or networks. In some embodiments, the communications interface 420 is capable of communicating data, content, and / or any other information, that can be transmitted, received, operated on, processed, displayed, stored, and the like.Communication via the communications interface 420 may be executed using a wired data transmission protocol, such as fiber distributed data interface (FDDI), digital subscriber line (DSL). Ethernet, asynchronous transfer mode (ATM), frame relay, data over cable serviceinterface specification (DOCSIS), or any other wired transmission protocol. Similarly, communication via the communications interface 420 may be executed using a wireless data transmission protocol, such as general packet radio service (GPRS), Universal Mobile Telecommunications System (UMTS), Code Division Multiple Access 2000 (CDMA2000), CDMA2000 IX (IxRTT), Wideband Code Division Multiple Access (WCDMA), Global System for Mobile Communications (GSM), Enhanced Data rates for GSM Evolution (EDGE), Time Division-Synchronous Code Division Multiple Access (TD-SCDMA), Long Term Evolution (LTE), Evolved Universal Terrestrial Radio Access Network (E-UTRAN), Evolution-Data Optimized (EVDO), High Speed Packet Access (HSPA), High-Speed Downlink Packet Access (HSDPA), IEEE 802.11 (WiFi), WiFi Direct, 802.16 (WiMAX), ultra wideband (UWB), infrared (IR) protocols, near field communication (NFC) protocols, Wibree, Bluetooth protocols, wireless universal serial bus (USB) protocols, or any other wireless protocol.

[0073] As will be appreciated by those skilled in the art, one or more components of the computing device 400 may be located remotely from other components of the computing device 400 components, such as in a distributed system. Furthermore, one or more of the components may be combined and additional components performing functions described herein may be included in the computing device 400. Thus, the computing device 400 can be adapted to accommodate a variety of needs and circumstances. The depicted and described architectures and descriptions are provided for exemplary purposes only and are not limiting to the various embodiments described herein.

[0074] Embodiments described herein may be implemented in various ways, including as computer program products that comprise articles of manufacture. A computer program product may include a non-transitory computer-readable storage medium storing applications, programs, program modules, scripts, source code, program code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, and / or the like (also referred to herein as executable instructions, instructions for execution, computer program products, program code, and / or similar terms used herein interchangeably). Such non- transitory computer-readable storage media include all computer-readable media (including volatile and non-volatile media).

[0075] As should be appreciated, various embodiments of the embodiments described herein may also be implemented as methods, apparatus, systems, computing devices, and the like. As such, embodiments described herein may take the form of an apparatus, system, computing device, and the like executing instructions stored on a computer readable storage medium to perform certain steps or operations. Thus, embodiments described herein may be implemented entirely in hardware, entirely in a computer program product, or in an embodiment that comprises a combination of computer program products and hardware performing certain steps or operations.

[0076] Embodiments described herein may be made with reference to block diagrams and flowchart illustrations. Thus, it should be understood that blocks of a block diagram and flowchart illustrations may be implemented in the form of a computer program product, in an entirely hardware embodiment, in a combination of hardware and computer program products, or in apparatus, systems, computing devices, and the like carrying out instructions, operations, or steps. Such instructions, operations, or steps may be stored on a computer readable storage medium for execution buy a processing element in a computing device. For example, retrieval, loading, and execution of code may be performed sequentially such that one instruction is retrieved, loaded, and executed at a time. In some exemplary embodiments, retrieval, loading, and / or execution may be performed in parallel such that multiple instructions are retrieved, loaded, and / or executed together. Thus, such embodiments can produce specifically configured machines performing the steps or operations specified in the block diagrams and flowchart illustrations. Accordingly, the block diagrams and flowchart illustrations support various combinations of embodiments for performing the specified instructions, operations, or steps.

[0077] For purposes of this disclosure, terminology such as “upper,” “lower.” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings,and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value.

[0078] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure, as claimed.

Claims

CLAIMSWhat is claimed is:1 . A mailer, comprising: a web arranged to form first and second panels of the mailer, wherein the first and second panels are bordered by two sides, a bottom, and a top; wherein the web includes: a paper skin layer, and a paper cushioning layer; wherein the web is arranged such that the paper skin layer is on an outer side of each of the first and second panels of the mailer and the paper cushioning layer is on an inner side of each of the first and second panels of the mailer; wherein the paper skin layer of the first panel extends a first distance from the bottom and the paper skin layer of the second panel extends a second distance from the bottom, and wherein the first distance is greater than the second distance such that an offset exists between a top of the paper skin layer of the first panel and a top of the paper skin layer of the second panel.

2. The mailer of claim 1, wherein the offset between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is in a range between 0.039 in (1.0 mm) and 0.197 in (5.0 mm).

3. The mailer of claim 1, wherein the offset between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is in a range between 0.079 in (2.0 mm) and 0. 157 in (4.0 mm).

4. The mailer of claim 1, wherein the offset between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is about 0. 118 in (3.0 mm).

5. The mailer of claim 1, wherein the offset between the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel is less than or equal to about 0.25 in (6.35 mm).

6. The mailer of claim 1, wherein the paper cushioning layer of the first and second panels extends a third distance from the bottom, and wherein the third distance is less than each of the first and second distances such that tops of the paper cushioning layer of the first and second panels are closer to the bottom than each of the top of the paper skin layer of the first panel and the top of the paper skin layer of the second panel.

7. The mailer of claim 6, further comprising a seal area on an inner side of the paper skin layer either or both of the first and second panels, and wherein the seal area is located between the tops of the paper cushioning layer of the first and second panels and the tops of the paper skin layer of the first and second panels.

8. The mailer of claim 7, wherein the top of the mailer is open and the seal area is configured to be sealed to close the top of the mailer.

9. The mailer of claim 1, wherein the paper skin layer is formed from kraft paper.

10. The mailer of claim 1, wherein the paper cushioning layer is formed from extensible paper that is formed into a nonplanar form.

11. The mailer of claim 1, wherein the two sides of the mailer are formed by seams that seal the first panel to the second panel.

12. The mailer of claim 1, wherein the web includes one piece of the paper skin layer and one piece of the paper cushion layer, and wherein the web is folded to form the bottom of the mailer.

13. The mailer of claim 1, wherein the web includes two pieces of the paper skin layer and two pieces of the paper cushion layer, and w herein the two pieces of the web are connected together to form the bottom of the mailer.

14. A system, comprising: a mailer conveyance device configured to individually advance discrete mailers, wherein each of the discrete mailers is the mailer of any of the preceding claims; mailer engagement devices; and a blower; wherein the system is configured to: advance, by the mailer conveyance device, a first discrete mailer to a filling and sealing position, hold, by the mailer engagement devices, the first discrete mailer at the filling and sealing position, wherein the mailer engagement devices is configured to grip the sides of the first discrete mailer, open the top of the first discrete mailer by directing, by the blow er, a stream of gas toward the top of the first discrete mailer, and exerting, by the mailer engagement devices, an inw ard force of the sides of the mailer, in response to receiving an indication that the first discrete mailer has been filled, flatten the top of the first discrete mailer by pulling, by the mailer engagement devices, the sides of the first discrete mailer aw ay from each other, and after the top of the first discrete mailer has been flattened, close the top of the first discrete mailer.

15. The system of claim 14, further comprising: a suction device configured to engage the paper skin layer of the first panel of the first discrete mailer when the first discrete mailer is in the filling and sealing position.

16. The system of claim 15, wherein the system is further configured to open the top of the first discrete mailer by engaging, by the suction device, the paper skin layer of the first panel of the first discrete mailer.

17. The system of claim 14, further comprising: a heat sealer configured to apply heat to the heat seal area of the first discrete mailer.

18. The system of claim 17, wherein the system is further configured to close the top of the first discrete mailer by sealing, by the heat sealer, the heat seal area of the first discrete mailer.

19. The system of claim 17, wherein the mailer engagement devices are programmable to be positioned at a plurality of different distances away from the heat sealer when the first discrete mailer is in the filling and loading position.

20. The system of claim 14, wherein the discrete mailers are held in a supply in the machine, wherein the discrete mailers in the supply are arranged substantially horizontally, wherein the first discrete mailer is arranged substantially vertically when in the filling and loading position, and wherein the mailer conveyance device is configured to change an orientation of the first discrete mailer from substantially horizonal in the supply to substantially vertical in the filling and sealing position.

21. The system of claim 14, wherein the mailer engagement devices are programmable to grip the sides of the first discrete mailer at different positions based on a size of the first discrete mailer, to exert one of a plurality of different inward distances based on the size of the first discrete mailer, and pull to one of a number of different outward distances based on the size of the first discrete mailer.

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