Packaging system and method for expandable padded mailers

Abstract

A packaging system for packaging an item in an envelope having a front sheet and a rear sheet connected together along respective side edges to form a pouch, includes a supply configured to provide one or more envelopes, and a sled assembly configured to accept an envelope from the supply. The sled assembly includes a sled belt, a retractable sled body, and a plurality of top and bottom suction cups. The sled belt positions the envelope between the plurality of top and bottom suction cups. The top suction cups are disposed on the retractable sled body to engage the front sheet and the bottom suction cups are disposed below the conveyor to engage the rear sheet. The sled body is configured to move between a closed position to an open position to open the envelope, and from the open position to the closed position to close the envelope.

Description

[0001] PACKAGING SYSTEM AND METHOD FOR EXPANDABLE PADDED MAILERS

[0002] Field of the Invention

[0003] The present invention relates generally to the field of packaging, and more particularly to a system and method for packing a padded packaging envelope for shipping an article.

[0004] Background

[0005] Padded mailers, such as padded envelopes, are often used to ship items, particularly fragile items. Padded mailers are typically made with plastic air-bubble material lining the inside of the mailer, however, alternatives such as foam, recycled fiber fluff, and paper-based cushioning material may be used. Padded mailers are provided to packers in a ready-to-use state. The packer typically retrieves a mailer from a supply, opens the mailer and inserts a product to be shipped without any assistance. The envelope is then closed before being ready for shipment.

[0006] Summary

[0007] Traditional methods of manually packaging products into mailers for shipment is a slow and inefficient process. The present disclosure allows packaging of products in mailers to be faster and more efficient by automating steps in the packaging process that would otherwise be manually completed by an operator. The automated packaging system automatically opens a mailer and presents the opened mailer to an operator for the operator to subsequently insert a product into the mailer. Then the automated packaging system closes and seals the mailer with the product inside of the mailer.

[0008] This automated packaging system can include a supply of mailers, either mailers made on demand as needed or one or more magazines of a plurality of mailers. In the case of multiple magazines, the magazines can contain a supply of mailers of varying sizes. An exemplary packaging system for supplying packaging envelopes for packaging an item for shipment uses envelopes having a front sheet and a rear sheet, and each of the front sheet and the rear sheet include a bottom edge, a top edge, and opposing side edges; and the front sheet and the rear sheet are connected together along the bottom edge and along respective side edges to form a pouch. The top edge of the rear sheet can extend beyond the front sheet to form a flap.

[0009] The packaging system includes at least one conveyor; supply of envelopes configured to provide one or more envelopes; and a sled assembly configured to accept an envelope from the supply. The sled assembly includes a sled belt, a retractable sled body, a plurality of top and bottom suction cups configured to engage the envelope. The sled belt positions the envelope between the plurality of top and bottom suction cups. The plurality of top suction cups is disposed on the retractable sled body to engage the front sheet of the envelope and the plurality of bottom suction cups is disposed below the envelope to engage the rear sheet of the envelope. The sled body is configured to move between an open position and a closed position. Specifically, the sled body is configured to move the top suction cups away from the bottom suction cups from the closed position to the open position to open the envelope, and the sled body is configured to move the top suction cups toward the bottom suction cups from the open position to the closed position to close the envelope. The packaging system further includes a controller in communication with the envelope feeding assembly and the sled assembly that is configured to control operations of the sled body, the sled belt, and the suction cups.

[0010] The packaging system can be configured wherein the at least one conveyor comprises one or more of a staging conveyor, a packaging conveyor, a sealing conveyor, a shipping conveyor, and combinations thereof.

[0011] The packaging system can include a conveyor configured to convey envelopes from the supply to the sled assembly. The packaging system can include a backstop configured to receive the envelope and support the bottom edge of the envelope, and a justifier configured to align the envelope on the backstop.

[0012] The packaging system can include a retractable shutter door disposed between the sled assembly and an operator. The shutter door can be configured to be in a closed position when the sled body is in the closed position prior to opening the envelope, and configured to be in an open position when the sled body is in the open position. When the shutter door is in the open position, the open door defines an opening.

[0013] The packaging system can include a sensor that detects when an item passes though the opening.

[0014] The packaging system can be configured wherein the sensor is disposed between the retractable shutter door and the operator.

[0015] The packaging system can include an operator-actuated input adjacent the opening. The controller can be configured to close the shutter door upon receipt of both a signal from the sensor and a signal from the operator-actuated input.

[0016] The packaging system can be configured wherein the operator-actuated input can include one or more of a button, a foot pedal, a touchscreen, a switch, an optical sensor a lever, and combinations thereof.

[0017] The packaging system can be configured wherein the controller is configured to open and close the door, move the sled body toward the bottom suction cups and move the sled body away from the conveyor, and engage and release the suction cups to engage and release the envelope.

[0018] The packaging system sensor can include a light curtain.

[0019] The packaging system can include a packaging station disposed in a downstream direction from the supply configured to house an operator and provide one or more items to the operator.

[0020] The packaging system can include a sealing assembly that includes an adhesive applicator disposed in a downstream direction from the packaging station configured to apply an adhesive to an envelope flap as the envelope is fed through the sealing assembly. The packaging system can include a hinge member configured to fold the flap to contact the flap with the front sheet of the envelope. The packaging system can include a sealing roller configured to press the flap to the envelope and compress the adhesive therebetween.

[0021] The packaging system can be configured wherein the sled body includes an actuator having an adjustable stroke to vary a distance between the top suction cups and the bottom suction cups in the open position.

[0022] The packaging system can include a controller configured to send a reset signal if the sled body does not return to the closed position when closing a mailer. Upon receipt of the reset signal, the sled body can be configured to return to the open position to reopen the mailer.

[0023] The packaging system can include a diverting conveyor disposed downstream from the supply and upstream of the sled assembly. The diverting conveyor can be configured to accept a mailer from the supply and advance the mailer downstream onto one or more staging conveyors.

[0024] The packaging system can include an adjustable diverting backstop. The adjustable diverting backstop can be configured to be adjustable independent from the adjustable staging backstop.

[0025] The packaging system can include an adjustable packaging backstop. The adjustable packaging backstop can be configured to be adjustable independent from the adjustable staging backstop.

[0026] The packaging system can include an adjustable sealing backstop. The adjustable sealing backstop can be configured to be adjustable independent from the adjustable staging backstop.

[0027] The packaging system can be configured wherein the operator includes a human, a robot arm, and a robot. The packaging system can be configured wherein the adhesive applicator can apply adhesive in a pattern selected from a single line of adhesive, two parallel lines of adhesive, a wave pattern, a series of circular spots, and combinations thereof.

[0028] An exemplary method for supplying packaging envelopes for packaging an item for shipment, includes the step of (i) supplying one or more envelopes, with each envelope having a front sheet and a rear sheet, and each of the front sheet and the rear sheet include a bottom edge, a top edge, and opposing side edges; and the front sheet and the rear sheet are connected together along the bottom edge and along respective side edges to form a pouch, and the top edge of the rear sheet extending beyond the front sheet to form a flap. The method further includes the steps of: (ii) providing a plurality of top and bottom suction cups; (iii) positioning the envelope between the suction cups; (iv) controlling the plurality of top suction cups to engage the front sheet of the envelope, controlling the plurality of bottom suction cups to engage the rear sheet of the envelope, and (v) moving the top suction cups away from the bottom suction cups to open the envelope.

[0029] The method can include inserting one or more packages into the open envelope.

[0030] The method can include controlling the plurality of top suction cups to release the front sheet of the envelope, and controlling the plurality of bottom suction cups to release the rear sheet of the envelope.

[0031] The method can include moving the top suction cups toward the bottom suction cups to close the envelope.

[0032] The method can include sealing the envelope.

[0033] In one or more embodiments, the packaging method may include the steps of folding the top edge of the rear sheet over the top edge of the front sheet and securing the rear sheet to an outer surface of the front sheet.

[0034] Brief Description of the Drawings

[0035] FIG. 1 is a schematic view of an exemplary method of packaging an envelope. FIG. 2 is a perspective view of an open packaging envelope, as known in the prior art.

[0036] FIG. 3 is a perspective view of an exemplary packaging system.

[0037] FIG. 4 is an alternate embodiment of an exemplary packaging system.

[0038] FIG. 5 is a front view of an exemplary packaging system.

[0039] FIG. 6 is a top, front perspective view of the packaging system of FIG. 5.

[0040] FIG. 7 is a front, side perspective view of the packaging system of FIG. 5.

[0041] FIG. 8 is a bottom, front perspective view of the packaging system of FIG. 6.

[0042] FIG. 9 is a side view of an exemplary sled assembly.

[0043] FIG. 10 is a front view of the sled assembly of FIG. 9.

[0044] FIG. 11 is a perspective view of the sled assembly of FIG. 9 in the envelope- closed position.

[0045] FIG. 12 is a perspective view of the sled assembly of FIG. 9 in the envelopeopen position.

[0046] FIG. 13 is a perspective view of an exemplary sealing assembly.

[0047] Detailed Description

[0048] The present disclosure allows packaging of products in mailers to be faster and more efficient by automating steps in the packaging process that would otherwise be manually completed by an operator. The automated packaging system automatically opens a mailer or envelope and presents the opened mailer to an operator for the operator to subsequently insert a product into the open mailer. Then the automated packaging system closes and seals the mailer with the product inside of the mailer.

[0049] This automated packaging system accepts mailers fed by a magazine of mailers, or accepts mailers made on demand as needed. An example of mailers made on demand is disclosed in International Patent Application No. PCT / US22 / 48281 (published under International Patent Application Publication No. WO2023 / 076628), the disclosure of which is hereby incorporated by reference in its entirety. An exemplary automated pouch package-making apparatus includes a dunnage conversion apparatus that converts sheet material into a longitudinal strip of expanded dunnage, and an enveloping apparatus that makes the expanded dunnage into a pouch package mailer.

[0050] An exemplary method is shown schematically in FIG. 1 . The method 20 starts by supplying envelopes 26, either fed by a magazine 22 or made on demand as needed 24. Next, the method can include providing suction cups 28, and controlling the suctions cups to apply a suction to the envelope 30. Next, the method can include moving the suction cups apart to open an envelope 32, and inserting an item into the envelope 34. Next, the method can include moving 36 and releasing 38 the suction cups to close the envelope. Finally, the method can include sealing the envelope 40.

[0051] An exemplary packaging envelope or mailer 50 is shown in FIG. 2 and includes a pouch 52 formed by at least a front sheet 54 and a rear sheet 56. The envelope 50 can be a pre-made mailer or a mailer made on demand. Each of the front sheet 54 and the rear sheet 56 can be formed of a laminated construction, with at least two cover sheets sandwiching at least one cushioning liner between the cover sheets. Each of the front sheet 54 and the rear sheet 56 include a bottom edge 58, a top edge 60, 61 , and opposing side edges 62. A direction from the bottom edges to the top edges is referred to herein as a bottom-to-top direction 64 relative to the pouch 52 and a direction from a face of the front sheet to a face of the rear sheet is referred to herein as a thickness direction.

[0052] Each envelope 50 has a front sheet 54 and a rear sheet 56, and each of the front sheet and the rear sheet include a bottom edge 58, a top edge 60, 61 , and opposing side edges 62. The front sheet 54 and the rear sheet 56 are connected together along the bottom edge 58 and along respective side edges 62 to form the pouch 52. Each of the front sheet 54 and the rear sheet 56 may have multiple layers, which may include a liner formed of cushioning materials. In an exemplary embodiment of an envelope 50, the bottom edge 58 and the opposing side edges 62 of the front sheet 54 are affixed to the bottom edge 58 and the opposing side edges 62 of the rear sheet 56, respectively, to form an interior space of the assembled pouch 52. The bottom edges 58 and opposing side edges 62 may be affixed to each other with, for example, an adhesive, a mechanical fastener, or a fold line. The pouch 52 optionally may include at least one gusset where the front sheet 54 is affixed to the rear sheet 56 along their respective bottom edges 58 and each of their respective opposing side edges 62 for reinforcing the pouch 52 or providing for expansion to a greater internal volume when opened. The top edge 60 of the front sheet 54 and the top edge 61 of the rear sheet 56 remain unconnected from each other to form an opening into the interior space of the pouch for inserting an item to be packaged therein.

[0053] In an alternative exemplary embodiment of an envelope 50, the envelope 50 is constructed of a single sheet of material, or formed of a laminated construction, with at least two cover sheets sandwiching at least one cushioning liner between the cover sheets, that is folded over itself and joined along the edges 62. The front sheet 54 and rear sheet 56 are formed as a single unit and folded along the bottom edge 58. The opposing side edges 62 of the front sheet 54 are affixed to the opposing side edges 62 of the rear sheet 56, respectively, to form an interior space of the assembled pouch 52. The opposing side edges 62 may be affixed to each other with, for example, an adhesive, a mechanical fastener, or a fold line. The pouch 52 optionally may include at least one gusset where the front sheet 54 is affixed to the rear sheet 56 along each of their respective opposing side edges 62 for reinforcing the pouch 52 or providing for expansion to a greater internal volume when opened. The top edge 60 of the front sheet 54 and the top edge 61 of the rear sheet 56 remain unconnected from each other to form an opening into the interior space of the pouch for inserting an item to be packaged therein.

[0054] Each of the front sheet 54 and the rear sheet 56 may have a multi-layer composition with a cushioning liner and one or more planar sheets facing or bounding the cushioning liner. One or more layers may be coated with materials that improve properties for the desired application, including insulation, cushioning, moisture resistance, etc. To facilitate description, references to the front sheet or the rear sheet are used to mean a single sheet, a multi-sheet, or a multi-layer construction with one or more layers of cushioning materials.

[0055] As shown in FIG. 2, the rear sheet 56 of the mailer 50 may have a greater length in the bottom-to-top direction 64 than the front sheet 54 such that when the bottom edges 58 of the front sheet 54 and rear sheet 56 are aligned with each other and affixed, the top edge 61 of the rear sheet 56 extends beyond the top edge 60 of the front sheet 54 in the bottom-to-top direction 64 to form an envelope flap 66. The envelope flap 66 may be folded over the top edge 60 of the front sheet 54 to close the opening of the pouch 52. The envelope flap 66 may be secured to the front sheet 54 to seal the mailer 50 for shipment. The rear sheet 56 may include a crease or fold line adjacent the top edge 60 of the front sheet 54, on the envelope flap 66, to facilitate folding the envelope flap 66 over the top edge 60 of the front sheet 54 to close the opening after an item to be shipped has been inserted into the pouch 52.

[0056] The envelope flap 66 may include an envelope flap adhesive layer 68 adjacent the top edge 61 of the rear sheet 56 on an inner surface of the rear sheet 56 (the inner surface of the top sheet facing the interior space of the pouch 52) for sealing the padded mailer 50 for shipment. Alternatively, the adhesive 68 may be omitted from the initial mailer 50, and an adhesive may be applied as part of the packaging process in a later sealing step. When the envelope flap 66 is folded over the top edge 60 of the front sheet 54, the envelope flap 66 can adhere to the exterior (outside face) of the front sheet 54, thereby closing the opening and sealing the padded mailer 50. The envelope flap 66 adhesive layer 68 may be covered by a removable release liner 70 to prevent adherence of the envelope flap 66 to anything prior to removal of the release liner 70, whereupon the envelope flap 66 may be folded over and adhered to the front sheet 54. The adhesive layer 68 may be pre-applied or may be applied just prior to closure of the mailer and may be applied to either of an inwardly-facing face of the envelope flap 66 or the outside face of the front sheet 54.

[0057] In addition to or in place of the adhesive layer 68, the envelope 50 may include a mechanical fastener adjacent the respective top edges 60, 61 of the front sheet 54 and the rear sheet 56, for example on the envelope flap 66, for closing the opening. The envelope 50 may also or alternatively include a gum seal adjacent the respective top edges 60, 61 of the front sheet 54 and the rear sheet 56, for example, on the envelope flap 66, for closing the opening of the envelope 50.

[0058] The front sheet 54 and rear sheet 56 are made of mailer material, which preferably is recyclable, and more preferably the entire mailer 50 is made of recyclable material, preferably curbside-recyclable such that no disassembly and separation of materials is necessary for recycling. Paper, such as kraft paper, is an exemplary mailer material. The mailer material may be any type and grade of paper, depending on the particular application or environment in which the mailer is to be used. The mailer material may have any of various basis weights and may be made of zero to 100% recycled material. In some embodiments, the mailer material may be laminated or may include any other suitable material such as another paper, plastic sheets, metal foil, or any other combination thereof. The mailer 50 may include insulation or padding to protect items during shipment. Wax or other coatings and chemical treatments may be added to the mailer material to add or improve desired properties such as moisture resistance or thermal resistance for cold chain applications. The mailer 50 used in the systems and methods discussed herein is not limited to a mailer having a particular material, the described mailer 50 is just one example of a mailer that could be used in the following systems and methods.

[0059] Turning now to FIGs. 3-8, the disclosed automated packaging system 80 is shown. Various structural supporting members non-vital elements are omitted from the drawings for purposes of clarity. The automated packaging system 80 includes one or a series of angled conveyors 82, 136 that move mailers 50 sequentially along a series of stations to prepare, pack, and ship a mailer 50. The system 80 starts with a staging station 84 and moving to a packaging station 86, then to a sealing station 88, then to an optional labeling conveyor or station, and finally to an exit, such as a shipping conveyor or station. This sequence order of stations is referred to as a downstream direction 90, and the opposite direction is the upstream direction. In other words, the packaging station 86 is downstream 90 from the staging station 84 and upstream from the sealing station 88.

[0060] In an alternative exemplary embodiment, one or more staging conveyors 82 can be positioned in parallel operation and a diverting conveyor can be disposed upstream of the staging conveyors, and downstream of the supply of mailers 50. The diverting conveyor accepts mailers fed by one or more magazines of mailers, or accepts mailers made on demand as needed and diverts the mailers in two or more directions to feed multiple staging conveyors positioned downstream from the supply of mailers. In an exemplary embodiment, the diverter conveyor is a T-shaped system where the supply feeds the diverting conveyor, which feeds two packaging stations, as opposed to an L-shaped system, where only one packaging station 86 is fed. In a further exemplary embodiment, the divertor conveyor can include a plus (+)-shaped or star-shaped system that can feed three or more packaging stations, can feed into further diverting conveyors for multiple packaging stations, or can include one or more additional supply streams from magazines or mailers made on demand as needed. The diverting conveyor has its own individual backstop (discussed in more detail below) that is adjusted to a position separate from that of the backstop(s) 100 of the packaging station(s). This allows the multiple packaging stations to accept different sized mailers from the supply of mailers at the same time.

[0061] One or more of the conveyors 82, 136 may be angled or tilted which causes one edge of the conveyor 82 to be raised higher relative to the other parallel edge. The higher or raised edge 92 may be disposed closer to an operator 96 and the lower edge 94 may be disposed nearer to the ground and farther from the operator 96. The higher raised edge 92 can be referred to as the operator edge 92 of the conveyor 82. At a supplying station, a feeding assembly draws mailers 50 from a supply, such as a magazine, a stack, a hopper, or other storage container or storage area of pre-made mailers 22, or receives mailers from the supply in the form of a machine 81 configured to create the mailers on demand as needed 24. The feeding assembly then feeds or otherwise supplies the mailer 50 in a downstream direction 90 to the staging station 84.

[0062] When the supply includes a mailer-on-demand machine 81 configured to make mailers on an as-needed basis 24 and the feeding assembly sends a mailer 50 downstream 90, as soon as the feeding assembly advances the mailer 50 from the staging conveyor, the feeding assembly may draw a new mailer 50 from the mailer- on-demand machine 81 .

[0063] When the supply includes pre-made mailers in a storage container 22, the feeding assembly draws a mailer 50 from the storage container (e.g. magazine of stacked mailers) and sends the mailer 50 to the staging conveyor 82 of the staging station 84. As soon as the feeding assembly advances the mailer 50 from the staging conveyor 82, the feeding assembly draws a new mailer 50 from the container to keep the staging conveyor 84 stocked with a mailer 50. When the storage container is depleted, an operator 96 inserts a new container (e.g. a fresh magazine) of mailers, then the feeding assembly resumes drawing and feeding mailers.

[0064] The feeding assembly advances the mailer 50 to a staging conveyor 82, where a justifier assembly 98 aligns the mailer with a backstop 100. The backstop 100 is an adjustable surface positioned above the conveyors 82 and supports the bottom edge 58 of the mailers 50 when the mailers are on the conveyor 82. The justifier assembly 98 positions the mailer 50 so that the mailer 50 is fully flush or square to the backstop 100 using multidirectional wheels to move and / or adjust the mailer without skewing the mailer 50 in relation to the backstop 100. In an exemplary embodiment, a label applicator can apply a barcode or license plate label to the top of the mailer 50 after it has been justified to the backstop 100. The backstop 100 can be in contact with the conveyor 82 or positioned just above the conveyor 82 such that the backstop 100 does not contact the conveyor 82 but still supports the bottom edge 58 of the mailers 50. The backstop 100 can be single unit that extends downstream 90 the length of the automated packaging system 80, or can be made up of a series of backstops 100. Each section of the packaging system (diverting, staging 84, packaging 86, sealing 88) can have its own independent backstop 100. The backstop 100 can adjust along the width dimension 102 of the conveyors 82. That is, the backstop 100 can move closer to the lower edge 94 or closer to the operator edge 92 of the conveyor 82. Thus, the backstop 100 can reposition to adjust the top edge 60 of the mailer 50 to account for different lengths of mailers 50 to maintain the top edge 60 of the mailer 50 at a desired distance relative to the operator edge 92 of the conveyors 82. The backstop 100 can be adjusted by the controller 124 or by the operator 96 via a human-machine interface (HMI) 125. Because each station or section can have its own backstop, this allows each backstop 100 to be adjusted to different positions relative to one another to allow multiple size (length) mailers to advance through the packaging system one after another to accommodate random product packing.

[0065] As noted above, a diverting conveyor can be disposed upstream of the staging conveyor 82. Such a diverting conveyor can have its own independent, adjustable position backstop 100 to which the mailer 50 can be justified. The diverting conveyor then advances the mailer 50 in one or more directions to supply the staging conveyor 82 of one or more packaging stations 86.

[0066] As a mailer 50 advances along the staging conveyor 82, conveyor guide wheels or rods 104 can provide pressure to the front sheet 54 of the mailer 50 to ensure the staging conveyor 82 has sufficient grip to transport the mailer 50 downstream 90. An optional inkjet printer may be positioned downstream 90 of the feeding assembly to print logos, graphics, barcodes, QR codes, and / or other package identification or messages on the mailer 50. By printing directly on the mailer 50, a separate label may not be necessary. In addition, printing on the mailer 50 before the item to be shipped is placed in the mailer 50 facilitates the printing process, which is able to produce a higher quality print when the mailer 50 is flat.

[0067] Continuing to follow the mailers 50 downstream 90 from the staging station 84 brings the mailers 50 to a packaging station 86, which includes a packaging deck 108 and a packaging sled assembly 110 (See FIGs. 9 - 12). The sled assembly 1 10 includes a sled belt 112 and a retractable sled body 1 14. The sled belt 112 is oriented parallel to the staging conveyor 82 and packaging deck 108 and is configured to cooperate with the staging conveyor 82 to draw the mailer 50 in a downstream direction onto the packaging deck 108. The sled belt 112 is configured to engage the front sheet 54 of the mailer 50 while the rear sheet 56 of the mailer 50 slides along the packaging deck 108 to move the mailer 50 in a downstream direction. If there is no mailer present in the packaging station 86, the staging station 84 advances the staged mailer 50 to the packaging station 86 by way of advancing the conveyor 82 and sled belt 112 simultaneously until the mailer 50 is centered on the packaging deck 108 in the packaging area 86. Once the mailer 50 is centered, the belt 1 12 stops moving and the mailer 50 is held in place on the packaging deck 108 by the belt 1 12. In an exemplary embodiment, the packaging deck 108 is a sheet metal plate.

[0068] The retractable sled body 114 is positioned at the packaging station 86. At the packaging station 86, two or more suction cups 116, 118, at least one above the mailer 50 and at least one below the mailer 50, extend and activate suction to engage or grab respective opposing faces of the mailer 50. The top suction cups 116 are attached to and are supported by the retractable sled body 114. The top suction cups 116 engage the front sheet 54 of the mailer 50, and the bottom suction cups 118 engage the rear sheet 56 of the mailer 50. In an exemplary embodiment, two suction cups 116 are disposed above the mailer 50 and two suction cups 1 18 are disposed below the mailer 50. The top suction cups 1 16 are mounted to the sled body 1 14 and the bottom suction cups 1 18 are mounted below the packaging deck 108. The bottom suction cups 1 18 extend through holes 109 in the packaging deck 108. The sled body 114 is then retracted or moved away from the bottom suction cups 118 and packaging deck 108 which, because of the suction cups 1 16, 118 engaging the front 54 and back 56 sheets of the mailer 50, opens the mailer 50 to a create or expose a uniform open pouch 52 area inside the mailer 50 to allow a product or multiple products to be placed inside the mailer 50. The retractable sled body 1 14 in the closed position is shown in FIG. 1 1 , and the retractable sled body 114 in the open position is shown in FIG. 12.

[0069] The suction cups 1 16, 118 can include a flow sensor connected to the vacuum generators that monitors suction pressure and / or flow patterns. The controller 124 can be configured to detect if any of the suction cups 116, 1 18 fail to grab the mailer 50 via the flow sensor of the vacuum generators. If the flow sensors indicate improper suction, indicating a failure to grab the mailer, the controller can send a reset signal to the sled body 1 14 and suction cups 116, 1 18 to automatically retry the mailer opening sequence.

[0070] The sled body 114 is actuated by a piston or other actuating device known in the art. The stroke of the actuating device that retracts the sled body 1 14 can be adjusted automatically to determine the size of the mailer 50 opening that is presented to the operator 96. This can be used to "right size" the mailer opening to accommodate or limit the size of product that can be inserted into the mailer 50, or accommodate different mailer sizes.

[0071] The packaging station 86 includes an area for an operator 96 to be placed or housed, such as an operator workstation. The operator 96 is provided with items or products to insert into the mailers 50. The items can be provided to the operator 96 by any known means, such as a conveyor, a refillable hopper, a series of boxes, etc. The operator 96 can be a human or a robot, such as a robot arm.

[0072] The packaging station 86 can optionally include a shutter door 122 (See FIGs. 5-8). The shutter door 122 is operated by a controller 124, which controls the door 122 to open or close. The shutter door 122 can be any door that opens and closes to allow and prevent access to the envelope. An exemplary shutter door 122 can be a single door that slides in an up-down direction, or slides in a side-to-side direction. An exemplary shutter door 122 can be a single door that swings open on a hinge. An exemplary shutter door 122 can be composed of two or more doors the slide apart to open, or that swing open on one or more hinges. An exemplary shutter door 122 can include several movable members that cooperate to open and close like an iris or a camera shutter.

[0073] The shutter door 122 can be operated by any known means, such as electrically driven servo motors, hydraulicly or pneumatically driven pistons, electromagnetic motors, etc. The shutter door 122 is positioned between the sled assembly 110 and the operator 96. When the sled body 114 opens the mailer 50, the controller 124 opens the shutter door 122 to indicate to the operator 96 that the mailer 50 is ready to accept one or more products or items. The operator 96 then inserts the product(s) into the mailer 50. In an alternative exemplary embodiment, the operator 96 first scans a code on the product(s) using a code reader 126 and then inserts the product(s) into the mailer 50.

[0074] The shutter door 122 in the open position defines an opening 128. A sensor 130 can be mounted in front of the shutter door 122, i.e., between the door 122 and the operator 96, which detects that an item has passed though the opening 128 and been inserted into the mailer 50. The sensor 130, in concert with the controller 124, can function as a safety device, by preventing further operation of the machinery or system if the sensor 130 detects any body part or object passing though or remaining in the opening 128. The sensor 130 can be any known sensor, for example, light curtains.

[0075] The system 80 can include an operator-actuated input 132. In an exemplary embodiment, the operator 96 then presses one or more button(s) or other operator- actuated input 132 to confirm the mailer 50 is ready to be sealed. The operator- actuated input 132 is positioned within reach of the operator 96 at the packaging station 86. The operator-actuated input 132 can include one or more of a button, a foot pedal, a touchscreen, a switch, an optical sensor, and / or a lever. After receiving the operator-actuated input, the controller 124 closes the shutter door 122, moves the sled body 1 14 back down toward the packaging deck 108, and switches off the vacuum so that the suction cups 116, 118 release the mailer 50. When the sled body 114 has returned to its starting position, the sled belt 112 and sealing conveyor 136 advance simultaneously to advance the product-filled mailer 50 downstream 90 to the sealing section or station 88.

[0076] The sled body 114 can be configured such that if the sled body 1 14 does not return to its starting position, for example, if it is physically blocked by a product that is too large or not oriented correctly in the mailer, the controller 124 will send a reset signal to maintain or reestablish vacuum to the suction cups 1 16, 1 18 and move the sled body 114 and suction cups 116, 1 18 to reopen the mailer 50. The controller 124 can also provide a message to the operator 96 to either reorient the object such that it does not block the sled body 1 14 from reaching its starting position and retry the closing of the mailer 50, or to stop the process and discard the mailer 50. The message to the operator 96 can be conveyed via display screen, a human-machine interface (HMI) 125, a speaker, a display panel, or other communication means known in the art.

[0077] In an alternate embodiment, when the sensor 130 detects that an item(s) has passed through the opening 128, the sensor 130 can send a signal to the controller 124. In addition, when the operator 96 actuates the operator-actuated input 132, the operator-actuated input 132 sends a signal to the controller 124. Once the controller receives both the signal from the sensor and the signal from the operator-actuated input 132, the controller 124 closes the shutter door 122.

[0078] Next, in an exemplary embodiment shown in FIG. 13, the mailer 50 enters the sealing station 88. The sealing station 88 includes a sealing conveyor 136 configured so that the flap 66 of the mailer 50 extends past the operator edge 92 of the conveyor 136, and a top hold down assembly 138 configured to apply downward pressure onto the top side of the mailer 50 near the top edge 60 of the mailer 50 to hold the mailer 50 in place during the sealing process. The top hold down assembly 138 can include a row of spring loaded rollers and / or a static guide rail (See FIGs. 6 and 7). The sealing station 88 also optionally includes an adhesive dispensing head 140. If the mailer 50 does not have a pre-applied adhesive, shortly after the mailer 50 enters the sealing station 88 the adhesive dispensing head 140 applies a pattern of adhesive to the flap 66 as the mailer 50 moves along the sealing conveyor 136. The mailer passes underneath a flap hold down plate. The flap hold down plate is positioned near the flap crease of the mailer to help force the mailer to be folded by the flap fold plate at the flap crease. The flap 66 then contacts a flap fold plate 142 that partially folds the mailer 50 at a flap 66 crease. The partially folded flap 66 then enters a hinge section 144. When the full width of the mailer 50 has entered the hinge section 144, the hinge section 144 then actuates down to uniformly fold over the flap 66 of the mailer 50 such that the flap 66 contacts the front sheet 54 of the mailer 50, closing the mailer 50 as the mailer 50 moves through the sealing station 88. Immediately following the hinge section 144 is a sealing roller 146 downstream of the hinge section 144. The sealing roller 146 applies pressure to the folded-over flap 66, which presses the pattern of adhesive on the inside of the folded flap 66, sealing the mailer 50 closed with the product inside. The mailer 50 advances through the sealing sequence in one continuous motion without stopping. After the mailer 50 has been sealed, the product-filled mailer 50 continues downstream along the sealing conveyor to the remaining stations. An optional print-and-apply labeling unit may be integrated at the end portion of the sealing section to apply a shipping label to the mailer before it exits the sealing conveyor.

[0079] The pattern of adhesive is configured to allow the flap 66 to be securely sealed, and also allows easy manual opening by the end user. The pattern can be any desired pattern, such as, for example, a single bead of adhesive, one or more parallel lines of adhesive, a wave pattern, and / or a series of circular or oval drops or spots of adhesive. A preferred exemplary pattern of adhesive on the flap can include two thin beads of adhesive. Two thin beads in combination with the pressure from the sealing roller creates a sealed construction between the flap and top sheet of the mailer that allow two important properties of the mailer: a strong flap seal, yet still allow an end user to open the mailer without damaging the mailer. The seal strength of the flap is weak enough to allow an end user to manually open the flap without tearing or damaging the construction of the mailer. This allows easy access to the product inside the mailer, and also allows the mailer to be reused and resealed by the end user of the product. Even though the flap can be easily opened by the end user, the seal strength of the flap is strong enough to resist delamination or bursting caused by movement of product inside the mailer or other outside forces caused during normal shipping conditions.

[0080] After the mailer 50 exits the sealing station 88, the product is fully sealed inside the mailer 50 with optional shipping or other labels on the outside of the mailer 50. The finished package may be transferred from the sealing conveyor 136 to a subsequent conveyor, such as a shipping conveyor, or to a collection point, such as a bin, cart, hopper, etc.

[0081] The controller 124 in the packaging system 80 includes a microprocessor, a memory, and software that controls the packaging system 80 and accessories, typically at least the feeding assembly, conveyors 82, 136 , justifier assembly 98, backstop(s) 100, retractable sled 114, sled belt 1 12, suction cups 116, 118, shutter door 122, adhesive head(s) 140, flap hinge 144, and sealing roller 146, to produce the sealed mailers.

[0082] An exemplary packaging method includes the following steps: (i) providing a plurality of packaging envelopes, (ii) positioning one of the packaging envelopes in front of an operator, (iii) capturing the front and rear sheets of the packaging envelope, (iv) expanding the packaging envelope to expose a pouch opening, (v) inserting the item(s) to be shipped into the pouch, (vi) closing the pouch, and (vii) sealing the packaging envelope with the item to shipped inside the packaging envelope.

[0083] Although the invention has been shown and described with respect to certain embodiments, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment of the invention.

Claims

ClaimsWhat is claimed is:1 . A packaging system (80) for supplying packaging envelopes (50) for packaging an item for shipment, each envelope (50) having a front sheet (54) and a rear sheet (56), and each of the front sheet (54) and the rear sheet (56) include a bottom edge (58), a top edge (60, 61 ), and opposing side edges (62); and the front sheet (54) and the rear sheet (56) are connected together along the bottom edge (58) and along respective side edges (62) to form a pouch (52); the packaging system (80) comprising: a supply configured to provide one or more envelopes (50); a sled assembly (1 10) configured to accept an envelope (50) from the supply, the sled assembly (1 10) including: a retractable sled body (114), a sled belt (112) disposed on the sled body (114), a plurality of top and bottom suction cups (116, 118) configured to engage the envelope (50), wherein the sled belt (1 12) positions the envelope (50) between the plurality of top and bottom suction cups (116, 118); wherein the plurality of top suction cups (116) is disposed on the retractable sled body (114) to engage the front sheet (54) of the envelope (50) and the plurality of bottom suction cups (1 18) engage the rear sheet (56) of the envelope (50); wherein the sled body (114) is configured to move between an open position and a closed position, wherein the sled body (1 14) is configured to move the top suction cups (116) away from the bottom suction cups (1 18) from the closed position to the open position to open the envelope (50), and the sled body (1 14) is configured to move the top suction cups (116) toward the bottom suction cups (118) from the open position to the closed position to close the envelope (50); and a controller (124) in communication with the supply and the sled assembly(1 10);wherein the controller (124) is configured to control operations of the sled body (1 14), sled belt (112), and the suction cups (1 16, 1 18).

2. The packaging system of claim 1 , further including a staging conveyor (82) configured to convey envelopes (50) from the supply to the sled assembly (1 10).

3. The packaging system of claim 1 or any of claims 1 to 2, further comprising: an adjustable staging backstop (100) configured to receive the envelope (50) and support the bottom edge (58) of the envelope (50), and a justifier assembly (98) configured to align the envelope (50) on the backstop (100).

4. The packaging system of claim 1 or any of claims 1 to 3, further comprising a packaging station (86) disposed in a downstream direction (90) from the supply configured to house an operator (96) and provide one or more items to the operator (96), wherein the packaging station (86) includes the sled assembly (1 10).

5. The packaging system of claim 4, further comprising a retractable shutter door (122) disposed between the sled assembly (110) and the operator (96), wherein the shutter door (122) is configured to be in a closed position when the sled body (114) is in the closed position prior to opening the envelope (50), and configured to be in the open position when the sled body (114) is in the open position, wherein the shutter door (122) in the open position defines an opening (128).

6. The packaging system of claim 5, further comprising a sensor (130) that detects when an item passes though the opening (128).

7. The packaging system of claim 6, wherein the sensor (130) is disposed between the retractable shutter door (122) and the operator (96).

8. The packaging system of claim 6 or any of claims 6 to 7, further comprising an operator-actuated input (132) disposed in the packaging station (86) within reach of the operator (96), wherein the controller (124) is configured to close the shutter door (122) upon receipt of both a signal from the sensor (130) and a signal from the operator-actuated input (132).

9. The packaging system of claim 8, wherein the operator- actuated input (132) includes one or more of a button, a foot pedal, a touchscreen, a switch, an optical sensor, a lever, and combinations thereof.

10. The packaging system of claim 5, wherein the controller (124) is configured to open and close the shutter door (122), move the sled body (1 14) toward the bottom suction cups (118) and move the sled body (114) away from the bottom suction cups (1 18), and engage and release the suction cups (116, 118) to engage and release the envelope (50).11 . The packaging system of claim 6, wherein the sensor (130) includes a light curtain.

12. The packaging system of claim 11 , further comprising a sealing assembly (88) including: an adhesive applicator (140) disposed in a downstream direction (90) from the packaging station (86) configured to apply an adhesive to an envelope flap (66) as the envelope (50) is fed through the sealing assembly (88), a hinge member (144) configured to fold the flap (66) to contact the flap (66) with the front sheet (54) of the envelope (50), a sealing roller (146) configured to press the flap (66) to the envelope (50) and compress the adhesive therebetween.

13. The packaging system of claim 1 , wherein the sled body (114) includes an actuator having an adjustable stroke to vary a distance between the top suction cups (1 16) and the bottom suction cups (118) in the open position.

14. The packaging system of claim 1 , wherein the controller (124) is configured to send a reset signal if the sled body (114) does not return to the closed position when closing a mailer (50), wherein, upon receipt of the reset signal, the sled body (114) is configured to return to the open position to reopen the mailer (50).

15. The packaging system of claim 1 , further comprising a diverting conveyor disposed downstream from the supply and upstream of the sled assembly (1 10), wherein the diverting conveyor is configured to accept a mailer (50) from the supply and advance the mailer (50) downstream (90) onto one or more staging conveyors (86).

16. The packaging system of claim 15, further comprising an adjustable diverting backstop, wherein the adjustable diverting backstop is configured to be adjustable independent from the adjustable staging backstop (100).

17. The packaging system of claim 4, further comprising an adjustable packaging backstop, wherein the adjustable packaging backstop is configured to be adjustable independent from the adjustable staging backstop (100).

18. The packaging system of claim 12, further comprising an adjustable sealing backstop, wherein the adjustable sealing backstop is configured to be adjustable independent from the adjustable staging backstop (100).

19. The packaging system of claim 4, wherein the operator (96) includes a human, a robot arm, and a robot.

20. The packaging system of claim 12, wherein the adhesive applicator (140) is configured to apply adhesive in a pattern selected from a single line of adhesive, two parallel lines of adhesive, a wave pattern, a series of circular spots, and combinations thereof.21 . A method for supplying packaging envelopes for packaging an item for shipment, each envelope having a front sheet and a rear sheet, and each of the front sheet and the rear sheet include a bottom edge, a top edge, and opposing side edges; and the front sheet and the rear sheet are connected together along the bottom edge and along respective side edges to form a pouch; the packaging method comprising the following steps: supplying one or more envelopes; providing a plurality of top and bottom suction cups; positioning the envelope between the suction cups; controlling the plurality of top suction cups to engage the front sheet of the envelope, controlling the plurality of bottom suction cups to engage the rear sheet of the envelope, and moving the top suction cups away from the bottom suction cups to open the envelope.

22. The method of claim 21 , further comprising: inserting one or more items into the envelope; controlling the plurality of top suction cups to release the front sheet of the envelope;controlling the plurality of bottom suction cups to release the rear sheet of the envelope, and sealing the envelope.

23. The method of claim 22, further comprising after inserting the one or more items in the envelope, moving the top suction cups toward the bottom suction cups to close the envelope.

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