Patent Publication Number: US-2022219421-A1

Title: Single face tube die-cut and sheet process

Description:
BACKGROUND 
     1. Field 
     The present disclosure relates to packaging, and more particularly to packaging for shipping such as in e-commerce. 
     2. Description of Related Art 
     Shipping needs for e-commerce include considerable volume of packaging used for shipping products. Multiple items can be grouped in a single order, where each individual product is already packaged or does not need its own package. However, in order to economize and ship the products together, they must be packaged together in a single shipping container. In other cases, a product such as a book may be shipped on its own, but it needs a shipping container to protect it during transit. 
     Fulfilment centers where products are placed in shipping containers match orders with one or more products by size to an appropriate shipping container. Given the large variation in order and products sizes, there must be a large variety of shipping containers in stock. Systems that provide custom-sized shipping packages on an order by order basis can considerably reduce the complications in fulfilment centers. 
     The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved packaging materials, systems, and methods. This disclosure provides a solution for this need. 
     SUMMARY 
     A system comprises a corrugator single facer configured to receive a first web and a second web, to corrugate the first web and adhere the first web in a corrugated state to the second web in an uncorrugated state to form a single face corrugated web as output. The system also includes a folder gluer operatively connected to receive the single face corrugated web from the corrugated single facer. The folder gluer is configured to fold and adhere the single-face corrugated web into a tube. 
     The system can include a rotary die cutting machine operatively connected between the corrugated single facer and the folder gluer to receive the single-face web from the corrugator single facer, and to cut a pattern in the single-face web upstream from the single face web entering the folder gluer. The rotary die cutting machine can include a plurality of tandem rotary dies for cutting the pattern into tandem portions of the single-face web. The system can be configured to form the single-face corrugated web into a tube without any break in the single-face corrugated web or tube formed therefrom. More specifically, the single-face web  101  can remain one continuous web from formation until it is finally cut into sheets. 
     The system can also include a rotary creaser/slitter machine operatively connected between the rotary die cutting machine and the folder gluer. The rotary creaser/slitter machine can be configured to receive the single-face web with the pattern from the rotary die cutting machine, to crease and/or slit the single-face web lengthwise, feeding the single face web into the folder gluer. The creaser/slitter can include a plurality of rotary creasers configured to form fold lines to facilitate folding the single-face web into a tube in the folder gluer and at least one rotary slitter configured to slit the single-face corrugated web into tandem portions. 
     The system can further include a rotary cut-off knife machine configured to cut one or more tandem tubes received from the folder gluer into sheets. The corrugator single-facer can include a first splicer for roll-to-roll splicing to make the first web continuous from multiple rolls of stock paper and a second splicer for roll-to-roll splicing to make the second web continuous from multiple rolls of stock paper. 
     The folder gluer can include a pair of contoured rails configured to roll lateral edges of the single-face web into overlapping position to form a tube. The pair of contoured rails can be a first pair of contoured rails for folding a first portion of the single-face web into a first tube. The folder gluer can also include a second pair of contoured rails for folding a second portion of the single face web into a second tube. The folder gluer can include an adhesive applicator configured to apply adhesive longitudinally along the web to join lateral edges of the single face web into a tube. 
     A method includes producing a continuous single-face corrugated web, and forming the continuous single-face corrugated web into a tube without any break in the single-face corrugated web or tube formed therefrom. 
     The method can also include at least one of the following, cutting a pattern in the single-face web upstream from the tube, cutting the pattern into tandem portions of the single-face web, creasing and/or slitting the single-face web lengthwise, folding the single-face web into a tube along the creases and/or slits, cutting one or more tandem tubes into sheets, applying adhesive longitudinally along the web and join lateral edges of the single face web into a tube, and/or performing the method for each of the tandem portions of the single-face web simultaneously. 
     These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein: 
         FIG. 1  is a schematic side view of an embodiment of a system constructed in accordance with the present disclosure, showing production of a single-face tube and sheet; 
         FIG. 2  is a schematic top down view of the system of  FIG. 1 , showing the tube production; 
         FIG. 3  is a schematic perspective view of the system of sheet of  FIG. 1 , showing a completed sheet; and 
         FIG. 4  is a schematic box diagram of a method in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a system in accordance with the disclosure is shown in  FIG. 1  and is designated generally by reference character  100 . Other embodiments of systems in accordance with the disclosure, or aspects thereof, are provided in  FIGS. 2-3 , as will be described. The systems and methods described herein can be used to continuously produce a single-face tube. 
     A system  1  can comprises a corrugator single facer  10  configured to receive a first web  101 ′ and a second web  101 ″, to corrugate the first web  101 ′ and adhere the first web  101 ′ in a corrugated state to the second web  101 ″ in an uncorrugated state to form a single face corrugated web  101  as output. The system  1  can be configured to form the single-face corrugated web  101  into the tube  400  without any break in the single-face corrugated web  101  or tube  400  formed therefrom. For example, the system can continuously form tube  400  from the single face-corrugated web  101  from the initial rolls exiting the single facer  10  without any breaks or cuts in the paper until the final cutting process. As shown in  FIG. 1 , the corrugated first web  101 ′ can be laminated on a bottom face of the uncorrugated web  101 ″ so that when the single-face corrugated web  101  is flipped prior to entering the processing machinery described below, the corrugated side of the single-face corrugated web  101  will be face up and the resulting tube  400 ,  500  will have internal corrugation. However, it is also possible that the single-face corrugated web  101  can be formed so that when flipped, the uncorrugated portion of the single-face corrugated web  101  can be face up such that the resulting tube  400 ,  500  will have external corrugation. 
     The corrugator single-facer  10  can include a first splicer  124  for roll-to-roll splicing to make the first web  101 ′ continuous from multiple rolls of stock paper (e.g. rolls  126 ,  128  stocked in line with first web  101 ′) and a second splicer  130  for roll-to-roll splicing to make the second web  101 ″ continuous from multiple rolls of stock paper (e.g. rolls  132 ,  134  similar to that of first web  101 ′.). While  FIG. 1  shows two rolls of stock paper for each of the first and second webs  101 ′,  101 ″, it should be appreciated by those skilled in the art that any number of rolls of stock paper can be included, and stock rolls may be added to the line during operation for continuous splicing and facing. 
     The system  1  can include a rotary die cutting machine  103  operatively connected between the corrugated single facer  10  and the folder gluer  20  to receive the single-face web  101  from the corrugator single facer  10 . After receiving the single-face web  101 , the rotary die cutting machine  103  can cut a pattern  102  (e.g. an elongated hexagon as shown) in the single-face web  101 , where the rotary die cutting machine  103  is placed upstream from the single-face web  101  entering the folder gluer  20 . The rotary die cutting machine  103  can include a plurality of tandem rotary dies (e.g.  103 ,  203 ) for cutting the pattern  102  into tandem portions  100 ,  200  of the single-face web  101 . 
     The system  1  can also include a rotary creaser/slitter machine  104  operatively connected between the rotary die cutting machine  103  and the folder gluer  20  and mounted transversal to the flow of the single-face web  101  (e.g. direction D). The rotary creaser/slitter machine  104  can be configured to receive the single-face web  101  with the pattern  105  from the rotary die cutting machine  103 , to crease and/or slit the single-face web  101  lengthwise, before feeding the single-face web  101  into the folder gluer  20 . The rotary creaser/slitter  104 ,  204  can include a plurality of rotary creasers configured to form fold lines  150 ,  170 ,  250 ,  270  to facilitate folding the single-face web  101  into a tube in the folder gluer  20 , and at least one rotary slitter to slit the single-face corrugated web  101  into tandem portions  100 ,  200 . The rotary creaser/slitter machine  104  may be geared together with the rolls driving the movement of the single-face web  101 , and the rolls of the rotary die cutting machine  103 , however it is also possible each element may be driven independently. 
     The folder gluer  20  can include at least one pair of contoured rails (e.g. helical skis  114 ,  116 ) to guide each of the lateral edges  105 ,  107 ,  205 ,  207  upwards to roll fold the edges near  180  degrees about corresponding fold lines  150 ,  170 ,  250 ,  270  into an overlapping position to form the single-face web  101  into a non-glued partially flat tube. The lateral edges  105 ,  107 ,  205 ,  207  are not initially folded to a full  180  but the contoured rails so that there is space for adhesive  140  to be applied to the respective lateral edge receiving the adhesive  140 . The pair of contoured rails can be a first pair (e.g.  114 ,  116 ) of contoured rails for folding a first portion  100  of the single-face web  101  into a first tube  400 . 
     The folder gluer  20  can also include a second pair of contoured rails (e.g.  214 ,  216 ) for folding a second portion  200  of the single-face web  101  into a second tube  500  at the same time the first portion  100  is formed. The folder gluer  20  can include an adhesive applicator  120  configured to apply adhesive  140  longitudinally along the web  101  to join lateral edges  105 ,  107 ,  205 ,  207  of the single-face web  101  into a glued tube  400 ,  500 . Because the folder gluer  20  can operate simultaneously for each of the tandem tubes, the system  1  can include a second adhesive applicator  220  for applying adhesive  140  to the second tube  500 . To secure the adhesive  140 , the system  1  can include a set of pressure rollers  121  to apply pressure to a top and bottom surfaces of the tube  400 ,  500  after application of adhesive  140 , as shown in  FIG. 1 . 
     The system  1  can further include a rotary cut-off knife machine  122  configured to cut one or more tandem tubes  400 ,  500  received from the folder gluer  20  into sheets (e.g. sheet  402 / 502  as shown in  FIG. 3 ). Like the rotary creaser/slitter machine  104 , the rotary cut-off knife machine  122  may be geared together with the rolls driving the movement of the single-face web  101 , and the rolls of the rotary die cutting machine  103 , and the rolls driving the rotary creaser/slitter machine  104 , however it is also possible each element, including the rotary cut-off knife machine  122 , may be driven independently. The drive for the rotary cut-off knife machine  122  allows for a cut to be at a desired, predetermined, repeated interval, for example, every 20 inches, or any suitable interval. 
     Further, the rotary cut-off knife machine  122  can include a registration system (not shown, but it should be appreciated that the registration system may be within the rotary cut-off knife machine  122 ) that includes a photosensor and/or a vision camera that can detect the pattern  102 ,  202  that has been cut into the single-face web  101 . The detection of this pattern  102 ,  202  can be used to time the operation of rotary cut-off knife machine  122 . For example, the registration of the die-cut pattern  102 ,  202  allows rotary cut-off knife machine  122  drive to time and place a transversal cut at the same location as the die cut pattern  102 ,  202 , or a specified offset from the die cut pattern, e.g. to allow for overhang or flaps such as shown in the sheeted tubes  402 ,  502  in  FIG. 3 . 
     A method includes producing  1000  a continuous single-face corrugated web  101 , and forming  1002  the continuous single-face corrugated web  101  into a tube  400 ,  500  without any break in the single-face corrugated web  101  or tube  400 ,  500  formed therefrom until the tube  400 ,  500  is finally cut. 
     When forming  1002 , the method can include cutting  1004  a pattern  102 ,  202  in the single-face web  101  upstream from the tube  400 ,  500 . Cutting  1004  can include cutting the pattern  202 , into tandem portions of the single-face web (e.g. for portions  100 ,  200 ). The method  1000  can include creasing and/or slitting  1006  the single-face web  101  lengthwise prior to feeding  1008  the single-face web into the folder gluer. Further, the method  1000  can include folding  1008  the single-face web  101  into a tube  400 ,  500  along the creases and/or slits (e.g. fold lines  150 ,  170 ,  250 ,  270 ). The method  1000  can also include cutting  1010  one or more tandem tubes  400 ,  500  into sheets. Applying adhesive  1012  longitudinally along the web  101  and joining  1014  lateral edges of the single-face web  101  into a tube  400 ,  500 . Performing the method  1000  can include repeating  1016  the method  1000  for each of the tandem portions  100 ,  200  of the single-face web  101 , or repeating  1016  the method  1000  simultaneously for each tandem portion  100 ,  200 . 
     The methods and systems of the present disclosure, as described above and shown in the drawings, allow for improved packaging through continuously producing a single-face tube with an integrated die-cut feature. While the apparatus and methods of the subject disclosure have been shown and described, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.