Patent Publication Number: US-2022212432-A1

Title: Continuous fanfolded joined corrugated

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 16/374,491, filed Apr. 3, 2021, the entire contents of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     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 sipping 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 OF THE INVENTION 
     A bale of stock packaging material includes a continuous tube of paperboard material, the continuous tube of paperboard material being flattened and folded back and forth on itself into a fan-folded bale. The continuous tube of paperboard can be a single piece of paperboard with two opposed edges that are folded to overlap with each other. The paperboard material can include a corrugated layer. The opposed edges can be adhered together to form a single seam that runs lengthwise along the continuous tube of paperboard. The adhesive can be applied between the two edges which can join to form the single seam. 
     The continuous tube of paperboard can have a first and a second set of parallel scores imparted on it such that they extend along the continuous tube parallel to the single seam in a longitudinal direction. The continuous tube of paperboard can include a first panel that includes the joined opposed edges and the single seam, and an opposed second panel connected to the opposite side of the tube from the first panel. The first panel can include the first set of parallel scores, and the opposed second panel can include a second set of parallel scores that can be located on the opposite side of the tube from the first set of parallel scores. Corrugation in the paperboard can be aligned perpendicular to the single seam. 
     The first end of the continuous tube of paperboard can be open and located on the top of the fan-folded bale, and the second end of the continuous tube of paperboard can be open and can be located on the bottom of the bale. 
     A system includes a ramp. The system includes two or more rails operatively connected to the ramp. The rails are configured to guide a pair of opposed edges of a web to fold in towards each other and overlap, with a first opposed edge folding underneath a second opposite second edge. The system includes an adhesive applicator is operatively connected to the rails to receive a folded over continuous web. A conveyor can be operatively connected to the adhesive applicator to receive the continuous tube of web. The conveyor can be configured to drive a stock of continuous paperboard, including corrugated paperboard. The system can include a folder operatively connected to the adhesive applicator to receive a continuous 
     One or more skis can be operatively connected between the ramp and the rails. The skis can be configured to create a pair of fold lines running the length of the continuous paperboard. A scoring unit can be operatively connected between the ramp and the rails. The scoring unit can be configured to create scores running down the length of the continuous paperboard. The scoring unit can be a set of rotary slitter scorers. 
     A method includes folding a flat continuous paperboard stock material into a continuous tube and then folding the continuous tube back and forth on itself to form a fan-folded bale. Folding a flat continuous paperboard stock material can include folding a pair of opposed edges of the continuous paperboard stock material inwards to form a single seam so that the first opposed edge overlaps the second opposed edge. An adhesive can be applied to the second opposed edge so that a single seam is permanently formed when the first opposed edge is pressed into the second opposed edge. The method can include scoring the flat continuous paperboard stock material prior to the folding of the pair of opposed edges. The scoring can be performed by one or more rotary slitter scorer units. 
     Folding the opposed edges of the flat continuous paperboard stock material can include driving the stock material beneath two or more rails. Each rail can be designated to fold one of the opposed edges inwards. The folding of the opposed edges can be partially completed with one or more ski devices and two or more anvils. 
     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 of the preferred embodiments 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, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein: 
         FIG. 1  is a schematic top plan view of a system, showing the elements of the system used to fold and adhere the web substrate into a continuous tube of material; 
         FIG. 2  is a schematic side elevation view of the system constructed in accordance with the present disclosure, showing the elements for folding and adhering a web substrate into a fan-folded bale of a continuous tube of material; 
         FIG. 3  is a schematic top plan view of the web being treated by the system of  FIG. 1 , showing the change in width of the web as it is folded by the system; 
         FIG. 4  is a perspective view of an embodiment of a continuous tube of material before it is folded into a bale, showing scoring lines, the opening of the tube, a seam and a place for applying adhesive; and 
         FIG. 5  is a perspective view of an embodiment of a fan-folded bale of a continuous tube of material. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     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 schematic 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. 2-5 , as will be described. The systems and methods described herein can be used to prepare a bale of continuous stock packaging material. 
     The system  100  includes a ramp  102  for smoothing and centering the continuous web material  101  as it is introduced to the system  100  to be scored and folded downstream. A scoring unit  103  is operatively connected between the ramp  102  and the pair of rails  114 ,  116 . The scoring unit  103  is configured to create lines of weakness or scores  412 ,  413  (labeled in  FIG. 4 ) running down the length of the continuous web  101 . The scoring unit  103  is optionally a set of rotary slitter scorers. The scores  412 ,  413  inlaid on the continuous web  101  may be in different orientations than those depicted herein. The continuous web  101  may be pre-scored before use in the system  100 . The continuous web  101  may be scored in any number of ways to enable the tube to be folded, assembled, or erected into a general rectangular shape or a simple envelope type shape for packaging and mailing items. 
     One or more skis  104  are operatively connected to the scoring unit  103 . The skis  104  are configured to create fold lines  404 ,  406  (labeled in  FIG. 4 ) running the length of the continuous web  101 . The fold lines  404 ,  406  are created on scores made by the scoring unit  103  or that were pre-existing in the stock material  128  of continuous web  101 . One or more anvils  106 ,  108  are operatively connected to the skis  104  to aid in the creation of the pair of fold lines  404 ,  406  running the length of the continuous web  101 . One or more wheels  110 ,  112  are operatively connected to the anvils  106 ,  108 . The wheels  110 ,  112  are configured to both guide the continuous web  101  to fold inward and position the continuous web  101  for interaction with a set of two or more rails  114 ,  116 . The wheels  110 ,  112  may be angled in such a manner as to encourage inward folding. 
     Two or more of rails  114 ,  116  are operatively connected to the wheels  110 ,  112 . The rails  114 ,  116  are configured to guide a pair of opposed edges  105 ,  107  of the web to fold in towards each other and overlap, with the first edge  105  folding underneath the opposite second edge  107 . The rails  114 ,  116  are parabolic or arcuate in shape. The rails may be optionally replaced with plows, belts, channel guides, or any device capable of folding the opposed edges  105 ,  107  of the web. The rail  114  responsible for folding the first edge  105  begins contact with the continuous web  101  at a point a small distance ahead (e.g., rail  114  is further to the left of the second rail  116  as depicted in  FIG. 1 ). of the point at which the second rail  116  contacts the second edge  107  of the continuous web  101 . The arrangement with the first rail  114  contacting the web  101  before the second rail  116  ensures folding of the opposed edges  105 ,  107 , such that the first opposed edge  105  folds down first, followed by the second edge  107 , so that they overlap. When viewed in  FIG. 2 , a schematic side view of the system  100 , it can be appreciated that the rails  114 ,  116  rise a distance off the surface  130  to interface with the continuous web  101 . The rails  114 ,  116  then descend smoothly in order to gently guide the inward folding of the opposed edges  105 ,  107  to a flattened state. 
     The system  100  also includes a flattener  118  operatively connected to the rails which applies pressure to one or more of the first edge  105  and the second edge  107  to flatten, smooth and position the folded continuous web prior to its interaction with the adhesive applicator  120 . The flattened tube can also be referred to as being in a knock-down format. 
     An adhesive applicator  120  is operatively connected to receive the flattened continuous web from the flattener  118 . The adhesive applicator  120  applies a layer of adhesive  416  (labeled in  FIG. 4 ) to first edge  105  and applies a downward force onto the opposite second edge  107  in order to bond the opposed edges  105 ,  107  together along a seam  410  to create a continuous flattened tube of web  101 ,  400  (labeled in  FIG. 4 ). The adhesive applicator includes an adhesive nozzle  122  which is positioned such that it is tucked between the folded first edge  105  and second edge  107  while applying the layer of adhesive  416 . A conveyor  124  is operatively connected to the adhesive applier  120 . The conveyor  124  is configured to draw the continuous flattened tube of web  101 ,  400  through the folding and adhesive applications in the direction D. A folder  136  (labeled in  FIG. 2 ) is operatively connected to the conveyor  124 . The folder  136  is configured to fold the continuous flattened tube of web  101 ,  400  (labeled in  FIG. 4 ) back and forth on itself to create a fan-folded bale  136 . The folder  136  may be optionally an automated machine, or a station for manual folding. 
     With reference now to  FIG. 2 , a schematic side view of the system  100  is presented. It should be noted that the scale of the system  100  in  FIG. 2  is not necessarily the same as the scale of the system  100  in  FIG. 1 . The system includes a stock  128  of continuous web  101  material. The stock  128  may be a roll, a bale, or in another format. The system includes a common base  130  on which the system  100  is assembled. The base  130  can be any of length and of any material suitable (e.g., a factory floor, or a platform) for assembling the elements of the present system  100 . The schematic depiction of the system  100  of  FIG. 2  shows a folder  136  which is configured to fold the continuous flattened tube of web  400  back and forth on itself to create a fan-folded bale  136 . 
     The continuous web  101  can be manually threaded through each of the elements of the system  100  described herein as part of initiating the operation of the system  100 . 
     Now with reference to  FIG. 3 , the continuous web  101  is depicted being distributed from the stock  128  at a width W 1 . The continuous web  101  is folded to create the folded continuous web  400  which is width W 2 , which is a reduced width from W 1 . The system  100  is not depicted in  FIG. 3  so as to schematically illustrate the transformation of the continuous web  101  as it proceeds through the system  100 . 
     Now with reference to  FIG. 4 , the continuous flattened tube of web  400  is depicted after its assembly, prior to being folded into a bale  136 . The continuous flattened tube of web  400  includes first and second fold lines  404 ,  406 . The end  411  of the continuous flattened tube of web  400  is shown. The leading end  411  of the tube is not adhered closed prior to forming a bale  136 . A first and a second panel  402 ,  408  of the continuous flattened tube of web  400  is shown. The first panel  402  includes the seam  410  formed when the fist edge  105  is folded underneath the second edge  107 . The continuous flattened tube of web  400  includes the layer of adhesive  416  for keeping the seam adhered. Lines of weakness  412 ,  413  or scoring marks run parallel to the seam  410  down the length of the continuous flattened tube of web  400 . One pair of lines of weakness  412  are included on the first panel  402  of the continuous flattened tube of web  400 , and a second pair of lines of weakness  413  are included on the second panel  408 , on the opposite side of the tube  400  from the lines of weakness  412  on the first panel  402  (e.g., as oriented in  FIG. 4 , the lines of weakness  412  on the first panel  402  are on the left, and the lines of weakness  413  on the second panel  408  are on the right). Among the lines of weakness  412 ,  413 , some are included for use as erectable fold lines,  420 ,  421 , and others are included as pleats,  420 ,  421 . The specific number of lines of weakness  412 ,  413  that may be included is not limited to the depiction of  FIG. 4 . The lines of weakness included as pleats,  420 ,  421  may optionally be omitted so that the continuous flattened tube of web  400  may be used in a downstream process to form envelop type packages with no pleats. 
     Alternatively, there may be two or more lines of weakness included as pleats  420 ,  421  to form packages that have rectangular or accordion-like folds along the sides. 
     Now with reference to  FIG. 5 , the fan-folded bale  136  of a continuous flattened tube of web  101 ,  400  is shown, with the continuous flattened tube of web  400  being folded back and forth on itself. The entire bale  136  is comprised of one unbroken, continuous tube of web  400 . A second end  502  is depicted in the bale, with the leading end  411  included on the bottom of the bale  136 . The bale  136  is folded at fan-fold lines  504  into a length L in the direction D. The fan-fold lines  504  may optionally match those fold lines established in the stock material  128 , and may also follow transverse scores made to the stock material  128  of continuous web  101  before introduction to the system  100 . The length L of the bale can be any length that is practicable for a bale  136  of stock material. The seam  410 , lines of weakness  412 ,  413 , first fold line  404  and second fold line  406  are shown as they are positioned in the folded bale  136 . 
     The web  101  used in the present invention can be paperboard, solid fiberboard, a corrugated paperboard, or any suitable type of web material used for packaging thereof Corrugations  506  present in the web material are aligned so as to be perpendicular to the seam  410 . 
     The web  101  may be optionally pre-scored prior to introduction to the system  100  to obviate the need for further scoring. 
     The methods and systems of the present disclosure, as described above and shown in the drawings, provide for a continuous tube of web with superior properties including reproducibility, transportability, durability and reduced cost of production. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, 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.