Abstract:
A package for the delivery of products of various sizes and shapes to customers, and apparatus and a method of producing the package are disclosed, wherein a sealing and a cutting process is employed to produce a customized shipping package from a first and a second web of material. The package is readily adaptable to be reused by the customer to return the product to the original source.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/853,596 filed on Oct. 23, 2006. 
     
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to packaging and more particularly to a package for the delivery of products of various sizes and shapes to customers for approval and use and readily adaptable to be reused by the customer to return the product to the original source. 
       BACKGROUND OF THE INVENTION 
       [0003]    Sheets of plastic materials are utilized in forming finished packages, such as pouches, for example, by various methods. In one such method, a heat formed seal or adhesive seal is formed to define the periphery of the final package. In the event that a rectangular package or pouch is desired, a rectangular film twice the desired length of the package is folded upon itself and the two parallel side edges perpendicular to the fold, are heat or adhesive sealed. Then the product to be packaged is inserted therein, and the remaining open side of the periphery is heat or adhesive sealed. 
         [0004]    Another method for making a package or pouch is achieved by sealing on three sides the face-to-face film material; filling the formed open package with the product to be packaged therein; and then sealing the fourth side. 
         [0005]    The problem encountered by the end user of the product within the pouch or package involves the reuse of the package to return the product due to size, color, style, etc. The packaging of the prior art has provided zipper-type closures, adhesive flap extensions, and hook and loop fasteners which have generally dealt with the reusable resealable feature of the package. However, the structures of the prior art have been expensive and time consuming to manufacture. 
         [0006]    The typical pouch or package is produced in one of a number standard sizes. The sender of the product chooses a standard sized package that is large enough to contain the product to be shipped. The selected standard sized package is often larger than required to contain the product, increases the cost of packaging and shipping the product. 
         [0007]    It would be desirable to produce a package of flexible sheet material which may be readily and economically produced in customized sizes and may be resealed to facilitate the reshipping of the package. 
       SUMMARY OF THE INVENTION 
       [0008]    Compatible and attuned with the present invention, a package of flexible sheet material which may be readily and economically produced in customized sizes and may be resealed to facilitate the reshipping of the package, has surprisingly been discovered. 
         [0009]    In one embodiment, the package comprises a first sheet of flexible sheet material having parallel spaced apart side edges and parallel spaced apart end edges; a second sheet of flexible sheet material superposed on the first sheet having parallel spaced apart side edges and parallel spaced apart end edges, the respective side edges of the first and second sheets sealed together and the respective end edges of the first and second sheets sealed together to form a pouch having interior facing surfaces of sheet material; a line of perforations formed along at least one of the side edges and end edges of the first and second sheets to facilitate the separation of one of the sealed edges; and a selectably useable adhesive disposed on at least one of the facing surfaces of sheet material adjacent the line of perforations. 
         [0010]    The apparatus for producing packages for differing sized objects comprises a first web of flexible material having spaced apart side edges for delivery along a path; a second web of flexible material having spaced apart side edges for delivery along the path in superposed relation with the first web; and sealing mechanism adapted to seal an object between facing surfaces of the first web and the second web forming a sealed package containing the object. 
         [0011]    The invention also contemplates a method of producing the package that comprises the steps of providing a first web of flexible sheet material having parallel spaced apart side edges and a longitudinal axis; providing a second web of flexible sheet material in superposed relation with the first web having parallel spaced apart side edges in alignment with the respective side edges of the first web and a longitudinal axis; applying a selectably useable adhesive strip on at least one of the facing surfaces of the first and second webs; sealing the respective spaced apart side edges of the first and second webs; providing a weakening line extending generally parallel and adjacent to at least one of the sealed side edges; providing a control system having an electronic processor and at least one sensor in communication with the processor; detecting the critical dimensions of an object to be packaged with the at least one sensor; transmitting a signal representative of the critical dimensions from the sensor to the electronic processor effective to cause a sealing member to form a pair of spaced apart sealed ends in the first and second webs to form the sealed package containing the object. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The above, as well as other advantages of the invention, will become readily apparent to those skilled in the art from the following detailed description of an embodiment of the invention when considered in the light of the accompanying drawings, in which: 
           [0013]      FIG. 1  is a schematic side elevational illustration of the apparatus for producing the package of the invention; 
           [0014]      FIG. 2  is a schematic fragmentary top plan view of the apparatus shown in  FIG. 1 ; 
           [0015]      FIG. 3  is a schematic illustration of a control system in communication with selected components of the apparatus shown in  FIGS. 1 and 2 ; 
           [0016]      FIG. 4  is an enlarged schematic fragmentary perspective view of the apparatus shown in  FIGS. 1 and 2  showing an object to be packaged entering a sealing mechanism of the apparatus; 
           [0017]      FIG. 5  is an enlarged schematic fragmentary perspective view of the apparatus shown in  FIGS. 1 and 2  showing a completed package containing the object exiting the sealing mechanism; and 
           [0018]      FIG. 6  is a top plan view of the package produced by the apparatus shown in  FIGS. 1 and 2 , with a portion cut-away to more clearly illustrate the structure of the package. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0019]    The following detailed description and appended drawings describe and illustrate an exemplary embodiment of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and the order of the steps is not regarded as necessary or critical. 
         [0020]    Referring to the drawings and in particular to  FIGS. 1 and 2 , there is illustrated an apparatus incorporating the features of the invention. The apparatus is adapted to produce a custom sized reusable and resealable package formed of flexible sheet material. 
         [0021]    The apparatus includes a conveyor  10  for transporting an object to be packaged. A scanner  12  is attached to the conveyer  10  adapted to read a bar code disposed on the object identifying the object. Favorable results have been obtained employing such scanners as supplied by Accu-Sort of Telford, Pa. 
         [0022]    A conveyor  14  is provided that is in longitudinal alignment with the conveyer  10 . At least a portion of the conveyor  14  is disposed beneath the conveyer  10  having one end extending outwardly therefrom. At least one material dispensing apparatus  16  is attached to the conveyor  14 . The material dispensing apparatus  16  is adapted to dispense selected pre-printed materials, such as a brochure or a return label, for example, to the conveyor  14 . Favorable results have been obtained employing ST Series Droppers supplied by Thiele Tecnologies, Inc. (Streamfeader) of Minneapolis, Minn. A printer  18  is provided adjacent the conveyor  14 . The printer  18  is adapted to print customized materials, such as an invoice, for example, and dispose the customized materials on the conveyor  14 . The pre-printed materials and the customized materials are disposed on the conveyor  14  to form a single stack of printed materials desired to be included in the final sealed package. 
         [0023]    The conveyor  10  includes an inclined member  20  disposed at the one end adjacent the conveyer  14 . The inclined member  20  is adapted to place the object to be packaged on the conveyor  10  onto the conveyer  14  substantially centered on the stack of printed materials previously disposed on the conveyor  14 . 
         [0024]    An ultrasonic sensor  22  is provided adjacent the inclined member  20  and conveyor  14  to measure the combined height of the object and printed materials. It should be understood that other types of sensors can be used to measure the combined height of the object and printed materials. Additionally, it should be understood that the sensor  22  can be adapted to measure other critical dimensions of the object such as a width, for example. 
         [0025]    The conveyor  14  terminates adjacent a receiving end of a sealing mechanism  24  adapted to enclose the object and the printed materials within a custom sized package. A photo electric sensor  26  is provided adjacent the receiving end of the sealing mechanism  24  to measure the length of the object along the longitudinal axis of the conveyor  14  as the object enters the sealing mechanism  24 . It should be understood that other types of sensors can be used to measure the length of the object. Additionally, it should be understood that the sensor  26  can be adapted to measure other critical dimensions of the object such as a width, for example. 
         [0026]    The sealing mechanism  24  includes a dispensing member  28  and a dispensing member  28 ′ adapted to supply a web of flexible sheet material  30  and a web of flexible sheet material  32 , respectively, to form the final sealed package. The webs  30 ,  32  each have parallel spaced apart side edges  34 ,  36  and  34 ′,  36 ′ respectively. The dispensing member  28 ′ is adapted to dispense the web  32  in superposed relation to the web  30  having the parallel spaced apart side edges  34 ,  36  of the web  30  in alignment with the respective parallel spaced apart side edges  34 ′,  36 ′ of the web  32 . The webs  30 ,  32  include surfaces  38 ,  38 ′, respectively, forming the inner facing surfaces in the sealed package. 
         [0027]    The dispensing members  28 ,  28 ′ include support frames  40 ,  42  having shafts  44 ,  44 ′, respectively, suitably supported in journal bearings  46  disposed thereon. The shafts  44 ,  44 ′ are adapted to receive a roll of the webs  30 ,  32  of material, respectively, and rotatably dispense the material therefrom. 
         [0028]    In the illustrated embodiment, the webs  30 ,  32  of material are a polyethylene laminate film. The material is a thermoplastic material to facilitate the formation of welded or heat sealed seams or edges between the webs  30 ,  32 . The material includes a cohesive latex coating  48  disposed adjacent the side edges  34 ,  36  and  34 ′,  36 ′ to cold seal the respective side edges  34 ,  36  and  34 ′,  36 ′ of the and webs  30 ,  32  to form respective sealed side edges  37 ,  37 ′. Favorable results have been obtained using polyethylene films from Single Face Supply Co. of Aurora, Ill. It should be understood that other polymeric films could be employed, as well as other materials. Such other materials include bubble wrap, polyethylene, polyester, nylon, and laminates thereof, paper, foil, and foil laminates. The preferred laminate is comprised of a high density polyethylene layer and a low density polyethylene layer. 
         [0029]    Perforators  50 ,  50 ′ are provided adjacent each dispensing member  28 ,  28 ′. The perforators  50 ,  50 ′ are adapted to form perforated lines  52 ,  52 ′, shown in  FIGS. 4 and 5 , in the webs  30 ,  32 , respectively, parallel and adjacent to the side edges  34 ,  34 ′. It should be understood that the perforators  50 ,  50 ′ can be adapted to form the perforated lines  52 ,  52 ′ adjacent the side edges  36 ,  36 ′. The perforated lines  52 ,  52 ′ facilitate the removal of the sealed side edge  37  to form an opening for the package and provide access to the packaged object. 
         [0030]    A dispensing member  54  is provided adjacent the dispensing member  28 ′. The dispensing member  54  includes a support shaft  56  suitably journaled in bearings  58  disposed on the support frame  42 . The dispensing member  50  is adapted to dispense an adhesive  60  to the inner surface  38 ′ of the web  32  inboard of the perforated line  52 ′, and adjacent and parallel to the perforated line  52 ′. The adhesive  60  is adapted to facilitate the closing of the opening formed in the package upon removal of the sealed edge  37  at the perforated lines  52 ,  52 ′. In the illustrated embodiment, the adhesive  60  is a double sided pressure sensitive adhesive tape having one side covered with a readily removable protective strip and the opposite side adhered to the inner surface  38 ′ of the web  32 . It should be understood that the dispensing member  50  can be adapted to apply the adhesive  60  to the inner surface  38  of the web  30  inboard of the perforated line  52 . In the illustrated embodiment, the perforated lines  52 ,  52 ′ are in substantial alignment. It should be understood that line  52  can be offset from line  52 ′ and inboard of the adhesive  60  to facilitate the removal of a wider portion of the web  30  in respect of web  32  to form a flap in web  32  including the adhesive  60 . The flap is adapted to facilitate access to the adhesive  60  and facilitate the closing of the opening formed in the package by folding the flap to place the adhesive  60  in contact with the outer surface of the web  30 . 
         [0031]    A side sealing member is provided to seal together the parallel spaced apart side edges  34 ,  36  of the web  30  with the respective parallel spaced apart side edges  34 ′,  36 ′ of the web  32  to form the respective sealed side edges  37 ,  37 ′. The side sealing member includes a pair of driven spaced apart resilient pinch rolls  62 ,  62 ′. Each pinch roll  62 ,  62 ′ is adapted to receive the side edges  34 ,  34 ′ and  36 ,  36 ′, respectively, of the webs  32 ,  34  causing the cohesive latex coating  48  to seal the respective side edges  34 ,  34 ′ and  36 ,  36 ′ of the webs  32 ,  34  to form the respective sealed side edges  37 ,  37 ′. Additionally, the pinch rolls  62 ,  62 ′ cooperate to pull the webs  30 ,  32  of material from the dispensing members  28 ,  28 ′ through the sealing mechanism  24 . In the illustrated embodiment, the pinch rolls  62 ,  62 ′ are a pair of pneumatic tubes which frictionally engage the formed sealed side edges  37 ,  37 ′. It should be understood that the respective side edges  34 ,  34 ′ and  36 ,  36 ′ of the webs  30 ,  32  can be joined together by heat sealing or with an adhesive such as a double sided pressure sensitive adhesive tape, for example. 
         [0032]    The sealing mechanism  24  includes an end sealing member disposed adjacent the side sealing member. The end sealing member includes an upper jaw  64  and a cooperating lower jaw  64 ′. The jaws  64 ,  64 ′ cooperate to press the facing inner surfaces  38 ,  38 ′ of the respective webs  30 ,  32  and form sealed end edges  66 ,  66 ′ in the final sealed package shown in  FIG. 6 . The jaws  64 ,  64 ′ provide heat energy to form a pair of spaced apart seals joining the web  30  to the web  32 . The jaws  64 ,  64 ′ include a cutting blade (not shown) to sever the webs  30 ,  32  between the two heat seals to form the trailing sealed edge  66 ′ in one package and the leading sealed edge  66  in a following package. The sealed edges  66 ,  66 ′ can also be formed using a hot wire sealer which simultaneously joins the web  30  to the web  32  and severs the web  30  and the web  32  to form the trailing sealed edge  66 ′ in the one package and the leading sealed edge  66  in the following package. It should be understood that the sealed edges  66 ,  66 ′ can be formed using an adhesive such as a double sided pressure sensitive adhesive tape, for example. A sensor  68  is provided adjacent the jaws  64 ,  64 ′ and is adapted to detect the completed package as it exits the sealing mechanism  24 . 
         [0033]    A conveyor  70  is provided adjacent the jaws  64 ,  64 ′ to receive the completed package from the sealing mechanism  24  and transport the sealed package away from the sealing mechanism  24 . 
         [0034]    A conveyor  72  is provided to receive the completed package form the conveyor  70  and transport the package to a final accept-reject conveyor  74 . The conveyor  72  may include a scale or weighing section (not shown) adapted to detect the weight of the completed package. Favorable results have been obtained employing the in-motion weighing conveyor 9481 Expresscheck® supplied by Mettler-Toledo, Inc. of Columbus, Ohio. 
         [0035]    A labeling station  76  is provided adjacent the conveyor  72 . The labeling station includes a printer adapted to print a shipping label for the completed package. An applicator attaches the shipping label to the completed package. The downstream end of the labeling station includes a scanner adapted to read the label to verify the attachment thereof. Favorable results have been obtained using label printer-applicator Model 5200 supplied by Webber Marking Systems, Inc. of Arlington Heights, Ill. 
         [0036]    The apparatus includes a control system  78 . A schematic drawing of the control system is shown in  FIG. 3 . The control system has an electronic processor adapted to control the operation of the apparatus. The control system  78  is in electrical communication with selected components of the apparatus. The control system  78  receives input signals  82  from selected components, namely; the scanner  12 , ultrasonic sensor  22 , photo electric sensor  26 , the weigh station  77  (if included), and the scanner for the labeling station  76 . The input signals are effective for the control system  78  to determine and send selected output signals  84  to control the operation of the conveyors  10 ,  14 ,  70 ,  72 ,  74 ; the material dispensing apparatus  16 ; the printer  18 ; the pinch rolls  62 ,  62 ′; the seal jaws  64 ,  64 ′; and the labeling station  76 . Additionally, the control system  78  is in communication with an electronic data base  80  containing information related to each object to be packaged, such as the shipping address for each object, for example. 
         [0037]    To form the sealed package containing the object and the printed materials, an operator places the object to be packaged on the conveyor  10 . The object includes a bar code thereon having a unique identification reference associated with the object. The scanner  12  reads the bar code identification and transmits the bar code identification to the control system  78 . The control system  78  then employs the bar code identification to obtain specific order and customer information for the object from the data base  80 . The control system employs the obtained information from the data base  80  to dispense the required pre-printed materials from the material dispensing apparatus  16  to the conveyor. Selected information is also transmitted to the printer  18  effective for the printer  18  to print an invoice for the object. The control system  78  controls the placement of the printed materials on the conveyor  14  to coordinate the object and the printed materials coming together on the conveyor  14  in a single stack  100 , as shown in  FIG. 4 . 
         [0038]    The conveyor  14  transports the stack  100  to the sealing mechanism  24 . The ultrasonic sensor  22  measures the height of the stack  100  as it is passes thereby. The sensor  22  transmits a signal representative of the measured stack height to the control system  78 . The photo electric sensor  26  then measures the length of the stack  100  as it passes thereby and enters the sealing mechanism  24 . The sensor  26  transmits a signal representative of the measured stack length to the control system  78 . The control system  78  employs the height and length signals to determine the length of the webs  30 ,  32  required to form a package large enough to contain the stack  100 . It should be understood that other critical dimensions can be measured and transmitted to the control system  78  as desired. 
         [0039]    The webs  30 ,  32  are supplied to the sealing mechanism  24  from the respective rolls of web material received on the respective dispensing members  28 ,  28 ′. The dispensing members  28 ,  28 ′ direct the respective webs  30 ,  32  to a series of rollers to guide the webs  30 ,  32  to the pinch rolls  62 ,  62 ′ of the sealing mechanism  24 . The stack  100  is received from the conveyor  14  between the webs  30 ,  32 , as shown in  FIG. 4 . 
         [0040]    As the webs  30 ,  32  are supplied to the sealing mechanism  26 , the webs  30 ,  32  are caused to contact the respective perforators  50 ,  50 ′ forming the perforated lines  52 ,  52 ′ in the respective webs  30 ,  32 . The perforated lines  52 ,  52 ′ are formed adjacent and substantially parallel to the side edge  34  of each web  30 ,  32 . Additionally, the adhesive  60  is dispensed from the dispensing member  54  and disposed on the inner surface  38 ′ of the web  32 . In the illustrated embodiment, the adhesive  60  is a double sided pressure sensitive adhesive tape having one side covered with a readily removable protective strip. The opposite side of the tape containing the exposed adhesive is pressed against the inner surface  38 ′ of the web  32 . 
         [0041]    The webs  30 ,  32  are then directed to the pinch rolls  62 ,  62 ′ in superposed relation having the respective inner surfaces  38 ,  38 ′ thereof facing each other. The respective side edges  34 ,  34 ′ and  36 ,  36 ′ of webs  30 ,  32  are received in the pinch rolls  62 ,  62 ′, respectively. The pinch rolls  62 ,  62 ′ cause the cohesive latex  48  disposed on the inner surfaces  38 ,  38 ′ adjacent the side edges  34 ,  34 ′ and  36 ,  36 ′ to contact and form the respective sealed side edges  37 ,  37 ′ of the completed package. The conveyor  12  causes the stack  100  to be received between the inner facing surfaces  38 ,  38 ′ of the and webs  30 ,  32  as the side edges  34 ,  34 ′ and  36 ,  36 ′ are received by the pinch rolls  62 , 62 ′. The stack  100  passes between the spaced apart pinch rolls  62 ,  62 ′ as the sealed side edges  37 ,  37 ′ are formed on each side of the stack  100 . The control system causes the pinch rollers  62 ,  62 ′ to advance the webs  30 ,  32  with the stack  100  disposed therebetween through the sealing mechanism  24 . The webs  30 ,  32  are advanced a length determined by the control system  78  employing the height and length measurements of the stack  100  provided by the ultrasonic sensor  22  and the photo electric sensor  26 , respectively. 
         [0042]    The webs  30 ,  32  then pass between the jaws  64 ,  64 ′. The control system  78  causes the forward motion of the webs  30 ,  32  to cease while the jaws  64 ,  64 ′ are closed, as shown in  FIG. 5 , to form a pair of parallel spaced apart sealed seams extending from the sealed side edge  37  to the sealed side edge  37 ′ substantially perpendicular thereto. The jaws  64 ,  64 ′ then sever the webs  32 ,  34  parallel to and between the pair of parallel spaced apart seems to form the trailing end edge  66 ′ in one package and the leading end edge  66  in a second package. The one package is then received on the conveyor  70  and transported away from the sealing mechanism  24 . The control system then causes the jaws  64 ,  64  to open and the pinch rolls  62 ,  62 ′ to advance the webs  30 ,  32  substantially equivalent to the length detected by the control system  78  required to form the second package. The control system then causes the jaws  64 ,  64 ′ to close once again to form the trailing sealed end edge  66 ′ in the second package and the leading sealed end  66  in the next package. The process described is repeated on a substantially continuous basis to form custom sized packages for varying sized stacks  100  of objects and printed materials passing through the sealing mechanism  24 . 
         [0043]    The sealed package is then received on the conveyor  70  and transported to the conveyor  72 . The conveyor  72  may include a scale (not shown) adapted to detect the weight of the package. The scale transmits a signal representative of the measured weight to the control system  78 . The control system  78  can employ the weight signal to calculate the required postage or shipping cost to deliver the package to the customer. The package is then transported to the label station  76  where the control system  78  causes the shipping label to be printed and applied to the upward facing outer surface of the sealed package to form the completed shipping package  102  shown in  FIG. 6 . The label station  76  can employ the dimensional data of the package from the control system  78  to substantially center the shipping label on the completed package. The sensor of the label station  76  senses if the shipping label has been properly printed and attached to the package and sends a representative signal to the control system  78  that either indicates the label is or is not correctly printed and attached. 
         [0044]    The conveyor  72  then transports the completed package  102  to the accept-reject conveyor  74 . The control system  78  either causes the accept-reject conveyor  74  to pass the package  102  onward to be shipped to the customer or reject the package as a result of the sensor of the labeling station  76  detecting that the label is not correctly printed or attached. 
         [0045]    The completed package  102 , illustrated in  FIG. 6 , includes the webs  30 ,  32  joined together in superposed relation having the object and selected printed materials to be shipped sealed therebetween. The package  102  has the sealed side edges  37 ,  37 ′ and the sealed end edges  66 ,  66 ′. The customer tears the webs  30 ,  32  along the perforated lines  52 ,  52 ′ which removes the sealed edge  37  forming an opening into the interior of the package. The opening provides ready access to both the object enclosed in the package  104  and the adhesive  60 . 
         [0046]    However, it is a phenomenon of the present merchandising and sales of products over the internet, for example, that nearly sixty (60%) percent of the ordered products are returned to the sender for a myriad of reasons. In the event the product is to be returned, the product is replaced into the opened package, the protective strip is removed exposing the heretofore protected adhesive  60 , and the inner surface  38  of the opened edge is pressed against the adhesive  60  to seal closed the opening. Alternatively, when the perforated lines  52 ,  52 ′ are offset to form the flap (not shown) in the web  32 , the flap is folded and the adhesive  60  is pressed against the outer surface of the web  30  to seal closed the opening. The package is then ready to be returned. 
         [0047]    The completed package  102  is produced at a minimized cost compared to the packages of the prior art. The size of the package  102  is customized to the object to be contained therein, which reduces the consumption of the material employed to form the package  102 . Additionally, the apparatus and method disclosed herein, substantially automates the process of packaging the object. The automated process reduces the time required to package the object for shipping which reduces shipping costs and provides for a reduced delivery time. 
         [0048]    From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.