MACHINE AND METHOD FOR FORMING, ERECTING, AND LOADING A POUCH WITH A PRODUCT

Abstract

 A transport mechanism for engaging a pouch in an erect configuration at a first station of a packaging machine and transferring the pouch to a second station of the packaging machine includes a carriage and a grip assembly. The carriage is moveable between the first station and the second station. The grip assembly is coupled to the carriage and is at least partially moveable relative to the carriage between an engaged position for clamping the pouch in the erect configuration within the grip assembly, and a released position.

Description

FIELD

[0001] This disclosure relates generally to packaging, and more particularly to a machine for forming, erecting, and loading a package with a product for shipping such as in an e-commerce environment.

BACKGROUND

[0002] Shipping needs for e-commerce and the like include considerable volume of packaging used for shipping products. Multiple items can be grouped in a single order, but in order to economize and ship the products together, they must be packaged together in a single shipping container. In other cases, a single product such as a book may be shipped on its own, but it needs a shipping package or container to protect it during transit. Fulfilment centres 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 centres. The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever-present need for improved packaging systems and methods. This disclosure provides a solution for this need.

SUMMARY

[0003] In one aspect a transport mechanism for engaging a pouch in an erect configuration at a first station of a packaging machine and transferring the pouch to a second station of the packaging machine is provided. The transport mechanism includes a carriage and a grip assembly. The carriage is moveable between the first station and the second station. The grip assembly is coupled to the carriage and is at least partially moveable relative to the carriage between an engaged position for clamping the pouch in the erect configuration within the grip assembly, and a released position.

[0004] In another aspect a packaging machine is provided. The packaging machine includes a first station for receiving a container in an erect configuration and a second station spaced from the first station. The packaging machine further includes a transport mechanism for engaging the container in the erect configuration at the first station and carrying the container to the second station. The transport mechanism includes a carriage that is moveable between the first station and the second station and a grip assembly coupled to the carriage. The grip assembly is at least partially moveable relative to the carriage between an engaged position for clamping the container in the erect configuration within the grip assembly, and a released position.

[0005] In yet another aspect, a method of assembling a pouch is provided. The method includes receiving a pouch in an erected configuration at a first station of a packaging machine and moving a transport mechanism to the first station. The transport mechanism including a carriage and a grip assembly couped to the carriage. The method further includes clamping the pouch within the grip assembly by moving at least a portion of a grip assembly relative to the carriage and carrying, by the transport mechanism, the pouch from the first station to a second station of the packaging machine.

[0006] An aspect of the invention provides a transport mechanism for engaging a pouch in an erect configuration at a first station of a packaging machine and transferring the pouch to a second station of the packaging machine. The transport mechanism comprises a carriage that is moveable between the first station and the second station and a grip assembly coupled to the carriage. The grip assembly is at least partially moveable relative to the carriage between an engaged position for clamping the pouch in the erect configuration within the grip assembly, and a released position.

[0007] Optionally, the grip assembly comprises a first grip for engaging a first side of the pouch and a second grip for engaging a second, opposed side of the pouch, and wherein the first and second grip are each configured to clamp the pouch in the erected configuration at the first station to allow for loading of a product into the pouch through an open end of the pouch.

[0008] Optionally, the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the grip assembly is rotatable about a rotational axis that is perpendicular to the machine transfer direction.

[0009] Optionally, the grip assembly comprises an inner clip for engaging an inner surface of the pouch and an outer clip for engaging an outer surface of the pouch, the outer clip being positioned below the inner clip.

[0010] Optionally, the grip assembly further comprises a first rod rotatably coupled to the carriage and rotatable about a first rotational axis and a second rod rotatably coupled to the carriage and rotatable about a second rotational axis, the inner clip being coupled to the first rod and the outer clip being coupled to the second rod.

[0011] Optionally, when the grip assembly transitions from the released position to the engaged position, the first rod rotates in a first rotational direction and the second rod rotates in a second, opposite, rotational direction.

[0012] Optionally, the transport mechanism further comprises a controller in communication with the transport mechanism and operable to automatically control operation of at least one of the grip assembly and the carriage.

[0013] Optionally, the first station is an erecting station that includes a landing for receiving the pouch and a pulling assembly configured to engage the pouch, the pulling assembly being moveable relative to the landing for erecting the pouch on the landing, and wherein the second station is a sealing station that is configured to close the pouch.

[0014] Optionally, the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the pulling assembly comprises at least one vacuum suction cup operable to selectively engage and erect the pouch, the at least one vacuum suction cup being moveable in a direction perpendicular to the machine transfer direction.

[0015] Optionally, the packaging machine includes a frame at least partially defining the first station and the second station, and wherein the transport mechanism further comprises a track extending along the frame from the first station to the second station, the carriage being moveable along the track.

[0016] Optionally, the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the grip assembly comprises a first grip and second grip each rotatably coupled to the carriage, the first grip being offset from the second grip in a closing direction that is perpendicular to the machine transfer direction, the first and second grip being moveable relative to the carriage in the closing direction between a first configuration in which the first grip is spaced from the second grip and a second configuration in which the first grip contacts the second grip.

[0017] Optionally, the second station comprises an adhesive applicator configured to dispense an adhesive onto an inner surface of the pouch while the grip assembly holds the pouch in the erected configuration.

[0018] Optionally, the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the second station comprises a pair of pressure bars offset from one another in a closing direction that is perpendicular to the machine transfer direction, the pressure bars each being moveable in the closing direction for sealing the pouch.

[0019] Another aspect of the invention provides a packaging machine comprising; a first station for receiving a container in an erect configuration, a second station spaced from the first station, and a transport mechanism for engaging the container in the erect configuration at the first station and carrying the container to the second station. The transport mechanism comprises a carriage that is moveable between the first station and the second station and a grip assembly coupled to the carriage. The grip assembly is at least partially moveable relative to the carriage between an engaged position for clamping the container in the erect configuration within the grip assembly, and a released position.

[0020] Optionally, the grip assembly comprises a first grip for engaging a first side of the container and a second grip for engaging a second, opposed side of the container, wherein, when the first and second grip are each configured to hold the container in the erected configuration at the first station to allow for loading of a product therein through an open end of the container.

[0021] Optionally, the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the grip assembly is rotatable about a rotational axis that is perpendicular to the machine transfer direction.

[0022] Optionally, the grip assembly comprises an inner clip for engaging an inner surface of the container and an outer clip for engaging an outer surface of the container, the outer clip being positioned below the inner clip.

[0023] Optionally, the grip assembly further comprises a first rod rotatably coupled to the carriage and rotatable about a first rotational axis and a second rod rotatably coupled to the carriage and rotatable about a second rotational axis, the inner clip being coupled to the first rod and the outer clip being coupled to the second rod.

[0024] Optionally, when the grip assembly transitions from the released position to the engaged position, the first rod rotates in a first rotational direction and the second rod rotates in a second, opposite, rotational direction.

[0025] Yet another aspect of the invention provides a method of assembling a pouch comprising receiving a pouch in an erected configuration at a first station of a packaging machine and moving a transport mechanism to the first station. The transport mechanism includes a carriage and a grip assembly couped to the carriage. The method comprises clamping the pouch within the grip assembly by moving at least a portion of a grip assembly relative to the carriage and carrying, by the transport mechanism, the pouch from the first station to a second station of the packaging machine.

[0026] Further features and advantages of the present invention will be apparent from the specific embodiments illustrated in the drawings and discussed below.

[0027] Within the scope of this application, it is envisaged or intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be considered or taken independently or in any combination thereof.

[0028] Features or elements described in connection with, or relation to, one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into, or combined with, any of the other embodiments disclosed herein, said features or elements extracted from said one embodiment may be included in addition to, or in replacement of one or more features or elements of said other embodiment.

[0029] A feature, or combination of features, of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment. Alternatively, a feature, or combination of features, of an embodiment may be omitted from that embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a schematic view of an example embodiment of a packaging system according to the present disclosure;

FIG. 2 is a perspective view of an embodiment of a flattened tube of stock packing material for the system of FIG. 1;

FIG. 3 is a perspective view of a portion of the system of FIG. 1, showing a cutting station, a filling station, a sealing station, and an output conveyor;

FIG. 4 is a perspective view of filling station shown in FIG. 3;

FIG. 5 is a perspective view of the filling station and the sealing station shown in FIG. 3;

FIG. 6 is an enlarged view of the filling station shown in FIG. 3;

FIG. 7 is a perspective view of the output conveyor shown in FIG. 3;

FIG. 8 is a schematic view of a grip assembly for use with the system shown in FIG. 3, showing the grip assembly in a released state;

FIG. 9 is another schematic view of the grip assembly shown in FIG. 8, showing the grip assembly in an engaged state;

FIG. 10 is an enlarged view of the filling station shown in FIG. 3, showing a first step of filling a pouch-preform;

FIG. 11 is another view of the filling station shown in FIG. 10, showing a second step of filling the pouch-preform;

FIG. 12 is another view of the filling station shown in FIG. 10, showing a third step of filling the pouch-preform;

FIG. 13 is another view of the filling station shown in FIG. 10, showing a fourth step of filling the pouch-preform;

FIG. 14 is another view of the filling station shown in FIG. 10, showing a fifth step of filling the pouch-preform;

FIG. 15 is another view of the filling station shown in FIG. 10, showing a sixth step of filling the pouch-preform;

FIG. 16 is another view of the filling station shown in FIG. 10, showing a seventh step of filling the pouch-preform;

FIG. 17 is an enlarged view of the sealing station shown in FIG. 3, showing a first step of sealing a filled pouch;

FIG. 18 is another view of the sealing station shown in FIG. 17, showing a second step of sealing the filled pouch;

FIG. 19 is another view of the sealing station shown in FIG. 17, showing a third step of sealing the filled pouch;

FIG. 20 is another view of the sealing station shown in FIG. 17, showing a fourth step of sealing the filled pouch;

FIG. 21 is another view of the sealing station shown in FIG. 17, showing a fifth step of sealing the filled pouch;

FIG. 22 is another view of the sealing station shown in FIG. 17, showing a sixth step of sealing the filled pouch;

FIG. 23 is another view of the sealing station shown in FIG. 17, showing a seventh step of sealing the filled pouch; and

FIG. 24 is a perspective view of the pouch of Fig. 23, showing the pouch closed with product therein, and labelled for shipping.

DETAILED DESCRIPTION

[0031] 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. The systems and methods described herein can be used to package products within bespoke or custom sized mailers for each order being shipped. The system 100 includes a cutting station 102, a product conveyor 104, a filling station 106 (also referred to interchangeably herein as an "erecting station," a sealing station 108, and an output conveyor 110. In other embodiments, the system does not include product conveyor 104.

[0032] In the example embodiment, cutting station 102 includes a tube conveyor 112 for conveying a flattened tube 114 of stock packing material from a supply 107 in the form of a fan-folded bale. The tube conveyor 112 includes an opposed pair of rollers (not shown) that roll the tube 114 therebetween to advance the tube 114 down a slide 116. A separator 118 is operatively connected to the tube conveyor 112 for receiving an end of the flattened tube 114. The tube conveyor 112 is configured to feed a custom length of the tube 114 into the separator 118. An x-y array sensor system 122 is operatively connected to the product conveyor 104 to measure custom orders of product 120 passing through the sensor system 122 on the product conveyor 104, provide measurement input to a controller 125 that is connected to control the tube conveyor 112 and separator 118 to separate the custom length of the tube 114 to fit each custom order of product 120. Those skilled in the art will readily appreciate that the any suitable sensor system can be used in addition to or in lieu of sensor system 122, e.g., an imaging device with an imaging processing module for determining the size of product 120 passing through the field of view, can be placed further upstream than depicted in FIG. 1 without departing from the scope of this disclosure. It is also contemplated that in addition to or in lieu of the sensor system 122, any other suitable type of sensor system can be used, such as devices that measure by physical contact, or that known dimensions for products traveling in order on the product conveyor 104 can be provided from a database (not shown) operatively connected to control the tube conveyor 112 and separator 118 without making measurements.

[0033] The separator 118 is configured to separate the custom length of the tube 114 from the tube 114 for each respective product 120 arriving on the product conveyor 104 to form a custom sized pouch pre-form 132 that can differ for each individual pouch pre-form 132. FIG. 2 shows the end 105 of the tube 114. The two parallel, opposed edges 126, 128 are overlapped and adhered together to form a seam 130 in a first panel 133 of the tube running along the tube 114 in a longitudinal direction L. In its flat state as it arrives at the conveyor 112 from the supply 107, as shown in FIG. 2, the tube 114 includes lines of weakness 138, e.g., score lines, for forming two opposed, pleated side panels 146 each connected to the first panel 133 along a respective fold line 134, 136. A seamless second panel 144 opposite the first panel 133 is connected to the side panels 146 by fold line 140 and a line of weakness 138 for forming a fold line 142. The pleat lines 148 are formed by the remaining lines of weakness 138. In other embodiments, the pouch pre-form 132 may not include the pleat lines 148. For example, in some alternative embodiments the pouch pre-form 132 may be a non-rigid substrate that is provided with two opposed score lines. In further alternative embodiments, any suitable pouch-preform may be used in system 100.

[0034] Referring back to FIG. 1, a first closer 150 is operatively connected to the separator 118 of FIG. 1 to receive the pouch pre-form 132 and close one end 152 of the of the pouch pre-form 132, leaving one end 154 of the pouch pre-form 132 open. In the example embodiment, the first closer 150 includes vacuum suction cups (not shown) that are configured to pull apart the end 152 for applying an adhesive therein and closing the end 152. In other embodiments, the separator 118 and first closer 150 may be substantially the same as the separator 118 and first closer 156 described in U.S. Patent Application Publication No. 2020/0317383 ("the `383 application"), the entire contents of which are hereby incorporated by reference. In particular, separator 118 and first closer 150 receive the tube 114 as an input and cut and seal, respectively, a portion of the tube 114 to output the pouch pre-form 132 in substantially the same manner as described with respect to FIGS. 2-8 of the `383 application. In other embodiments, any suitable separator and/or first closer may be used.

[0035] The filling station 106 is provided downstream from cutting station 102. The filling station receives the pouch 132 (also referred to interchangeably herein as a "container") having an unsealed end 154 (e.g., as shown in FIG. 6) to allow for filling the pouch with a corresponding product 120. In particular, the filling station 106 is operatively connected to the first closer 150 (shown in FIG. 1) to receive the pouch pre-form 132 and to present the unsealed end 154 of the pouch pre-form 132 for receiving orders of product 120.

[0036] Referring to FIGS. 3 and 4, in the example embodiment the system 100 includes a frame 160 that at least partially defines each of the cutting station 102, the filling station 106, the sealing station 108, and the output conveyor 110.

[0037] As shown in FIG. 4, the filling station 106 includes a pivot shuttle 156 configured to receive the closed end of the pouch pre-form (shown in FIG. 1) and flip the open end of the pouch pre-form away from the slide 116, e.g., to face the unsealed end 154 of the pouch pre-form 132 toward a window 158 provided in the frame 160 at the filling station 106. The movement of the pivot shuttle 156 is indicated in FIG. 4 by the large arrow, and is actuated by a linear actuator 211 (shown in FIG. 11), though in other embodiments any suitable actuator may be used.

[0038] The pouch pre-form 132 falls into the pivot shuttle 156 by the force of gravity onto two fingers 162 provided on the shuttle 156. The fingers 162 are attached to a belt driven actuator (not shown). As indicated with the curved arrow in FIG. 4, the pivot shuttle 156 rotates about a pivot under the force of the linear actuator (not shown) and then the fingers 162 move upward, pushing the pouch pre-form 132 upward toward the window 158, as shown in FIG. 11, and described in greater detail below.

[0039] Referring back to FIG. 1, the product conveyor 104 conveys orders of product 120 to the filling station 106. A user, and/or an automated system, takes the product 120 from the product conveyor 104 and places the product 120 into open ends 154 of the pouch pre-forms 132 present at the window 158 (shown in FIG. 4) of the filling station 106. The filled pouch 132 is then conveyed to the sealing station 108 for closing the open end 154 of the filled pouch 132. A user, and/or an automated system, then continuously repeats filling each pouch pre-form 132 one after another, and each custom sized pouch pre-form 132 is presented to the user/system 100 when the corresponding order of product 120 arrives at the user's end of the product conveyor 104. In other embodiments, the system 100 does not include the product conveyor 104. For example, in some such embodiments, the system 100 is configured to provide fixed sized pouch pre-forms 132 to the filling station 106 or a batch of sizes continuously without a demand input from a product conveyor 104.

[0040] The system 100 further includes a clip conveyor 164 (also referred to herein as a "transport mechanism") that carries the filled pouches 132 from the filling station 106 to the sealing station 108. In particular, the clip conveyor 164 grabs the pouch pre-form 132 at the filling station 106 and holds the pouch pre-form 132 in an open, or "erect" configuration for receiving the product 120 therein. In the example embodiment, the product 120 is inserted into the pouch pre-form 132 by a user, though in other embodiments an automated system may be used. The controller 125 is communicatively coupled to the clip conveyor 164 (shown in broken line arrows in FIG. 1) and is configured to control timing and operations of the clip conveyor 164, as described below in greater detail, such that the clip conveyor 164 automatically engages the pre-form pouch 132 at the filling station 106 and holds the pouch 132 at the sealing station 108 while an adhesive is applied. Additionally, the controller 125 may be further configured to control operations and or timing of any of the components/mechanisms described herein with respect to system 100.

[0041] Referring to FIGS. 5 and 6, the clip conveyor 164 is operably coupled to one or more drives (not shown) for moving the clip conveyor 164 relative to the frame 160. In particular, the conveyor 164 includes a track (e.g., as shown partially in FIG. 17) provided on the frame 160 and extending from the filling station 106 to the sealing station 108. A carriage 168 of the conveyor 164 is moveable along the track 166 (shown in FIG. 1) in a machine transfer direction 170, indicated schematically by the large arrow in FIG. 5. The clip conveyor 164 is configured for generally reciprocal movement along the machine transfer direction 170 between the filling station 106 and the sealing station 108. Moreover, in the example embodiment, the machine transfer direction 170 is generally transverse to the direction of movement of the pivot shuttle 156 (shown in FIG. 4) and is also substantially transverse to a feed direction of output conveyor 110 (shown in FIG. 1).

[0042] The clip conveyor 164 then carries the filled packages to the sealing station 108 while a next pouch pre-form 132 is moved by pivot shuttle 156 (shown in FIG. 4) towards the window 158. In the view shown in FIG. 5, the filled pouch 132 is in the open configuration at the sealing station 108, while the carriage 168 is positioned at the filling station 106. However, it should be understood that this view is for illustrative purposes only and that, in normal operation of the example embodiment, a filled pouch 132 would not in the open configuration at the sealing station 108 at the same time the clip conveyor 164 is at the filling station 106 (shown in FIG. 7).

[0043] Referring to FIG. 6, in the example embodiment, the clip conveyor 164 includes the carriage 168 and a grip assembly 172 coupled to the carriage 168. The carriage 168 carries the grip assembly 172 during movement of the clip conveyor 164 to move the filled pouches 132 between the filling station 106 and the sealing station 108 (shown in FIG. 5). The grip assembly 172 includes a plurality of rotatable rods 194, 196 each having at least one clip 198, 200 (shown in FIG. 8) mounted thereon. Rods 194, 196 are each operably coupled to a rotation drive, such as a cam and piston drive (not shown), that is operable to rotate the rods. In other embodiments, any suitable rotation drives may be used to rotate the rods 194, 196.

[0044] Referring back to FIG. 5, the sealing station 108 includes an adhesive assembly 174 slidably coupled to frame 160. The adhesive assembly 174 is moveable relative to the frame 160 in the machine transfer direction 170 and is operable to apply a liquid adhesive to an inner surface 176 of the filled pouch 132. The sealing station 108 also includes a pair of pressure bars 178 for closing the filled pouch 132 after the adhesive has been applied, thereby sealing the product 120 within the filled pouch 132. In particular, the pressure bars 178 are each moveable relative to the frame 160 and are moved toward one another to seal the filled pouch 132. The pressure bars 178 may then be released, thereby dropping the filled pouch 132 onto the output conveyor 110.

[0045] Referring to FIG. 7, in the example embodiment, the output conveyor 110 is positioned underneath sealing station 108, such that the filled pouch 132 may drop from the pressure bars 178 (shown in FIG. 5) and slide onto the output conveyor 110 by an inner ramped surface 180 of the frame 160. In the example embodiment, the output conveyor 110 is a belt conveyor, though in other embodiments, any other suitable conveyor may be used. The output conveyor 110 moves the filled pouches 132 in a feed direction 182 that is generally perpendicular to the machine transfer direction 170 (shown in FIG. 5). In particular, in the example embodiment, the feed direction 182 of the output conveyor 110 is generally opposite to a feed direction 183 of the tube conveyor 112 (shown in FIG. 1). As a result, the pouch pre-forms 132 and filled pouches 132 are carried in a general U-shaped path from the tube conveyor 112 at the cutting station 102 to an end of the output conveyor 110.

[0046] FIGS. 8 and 9 show a schematic sectional view of the grip assembly 172 of the clip conveyor 164 (shown in FIG. 6). The grip assembly 172 is at least partially moveable relative to the carriage 168 between a released state, as shown in FIG. 8, and an engaged state for clamping the pouch 132 within the grip assembly 172, as shown in FIG. 9.

[0047] In the example embodiment, the grip assembly 172 includes a first grip 184 for engaging a first side 186 of the pouch 132 and a second grip 188 for engaging a second, opposed side 190 of the pouch 132. The first and second grips 184, 188 are configured to hold the pouch 132 in an open configuration at the filling station 106 to allow for loading of the product 120 into the pouch through the open end 154. The first grip 184 and second grip 188 are spaced apart from one another in a closing direction 189 to define a gap 192 therebetween, in which the pouch 132 may be received. In the example embodiment, the closing direction 189 is substantially perpendicular to the machine transfer direction 170 (shown in FIG. 5).

[0048] The first grip 184 and second grip 188 each include a pair of rotatable rods 194, 196 which are rotatably coupled to the carriage 168 (shown in FIG. 6). At least one clip 198, 200 is coupled on each of the rotatable rods 194, 196 and is configured to rotate with the respective rod 194, 196. In particular, the grips 184, 188 each include an inner clip 198 coupled to a first rotatable rod 194 and an outer clip 200 coupled on a second rotatable rod 196. The first rods 194 and inner clips 198 are each positioned vertically above the respective the second rods 196 and outer clips 200. In the example embodiment, the first grip 184 and the second grip 188 are substantially identical and are mirrored about the gap 192, such that the clips 198, 200 all extend inward and towards the opposed clips 198, 200 of the opposed grip 184, 188. In other embodiments, at least one of the first grip 184 and second grip 188 may be different from one another. For example, and without limitation, in some embodiments, the first grip 184 includes a different number of clips 198, 200 than the second grip 188.

[0049] The grip assembly 172 is transitionable between the released state and the engaged state by rotating the rods 194, 196 of the first grip 184 and second grip 188. Each of the rods 194, 196 are rotatable about a respective rotational axis R1-R4, extending into the page in FIGS. 8 and 9. In the example embodiment, each of the respective rotational axes R1-R4 of the rods 194, 196 are parallel to one another and are also parallel to the machine transfer direction 170 (extending into the page in FIGS. 8 and 9). To transition from the released state to the engaged state, the first rod 194 of the first grip 184 is rotated in a first direction (clockwise direction as shown in FIGS. 8 and 9) and the second rod 196 of the first grip 184 is rotated in a second direction (counter-clockwise direction as shown in FIGS. 8 and 9) that is opposite of the first direction. Additionally, the first rod 194 of the second grip 188 is rotated in the second direction and the second rod 196 of the second grip 188 is rotated in the first direction. As a result, as the rods 194, 196 are rotated to the engaged state, the clips 198, 200 of the respective grips 184, 188 are brought into close position with one another to pinch the pouch pre-form 132 therebetween. Moreover, the grip assembly 172 is transitionable from the engaged state to the released state in substantially the reverse manner as described above.

[0050] Referring to FIG. 9, when the grip assembly 172 is in the engaged state, the inner clips 198 of the first grip 184 and the second grip 188 each contact an inner surface 176 of the pouch pre-form 132. Likewise, the outer clips 200 of the first grip 184 and the second grip 188 each contact an outer surface 177 of the pouch pre-form. The clips 198, 200 each apply pressure on the pouch pre-form 132 such that pouch pre-form 132 is pinched between the clips 198, 200 of the respective grips 184, 188 and may be held in the open configuration, as shown in FIG. 9. Accordingly, the grip assembly 172 is operable to support and carry the pouch pre-form 132 while holding the pouch pre-form 132 in the open configuration for inserting the product 120 and to allow for adhesive to be applied on the inner surface 176, as described in greater detail below.

[0051] FIGS. 10-23 illustrate steps of the process of filling the pouch pre-form 132 with a product at the filling station 106 and sealing the filled pouch 132 at the sealing station 108.

[0052] Referring to FIG. 10, the pouch pre-form 132 is provided on the fingers 162 of the pivot shuttle 156 at the filling station 106 and the window 158 is closed. The frame 160 includes an interior surface 202 (also referred to interchangeably herein as a "landing") facing the pivot shuttle 156 for receiving the pouch 132. The system 100 further includes a pair of moveable guide paddles 204 (only one shown in FIG. 10) that are selectively moveable relative to the interior surface 202 between a retracted position (as shown in FIG. 10) and an extended position (as shown in FIG. 11). The guide paddles 204 are spaced on the interior surface 202 to contact opposed sides of the pouch pre-form 132 when the pivot shuttle 156 is rotated (as shown in FIG. 11).

[0053] The filling station 106 further includes a plurality of moveable suction cups 206, 208. A first side suction cup 206 is positioned within the frame and at least partially recessed relative to the interior surface 202. The first side suction cup 206 is selectively extendable out through an opening 210 in the interior surface 202. A group of second side suction cups 208 are spaced from the first side suction cup 206 and are oriented facing the first side suction cup 206. In the example embodiment, the system 100 includes one first side suction cup 206 and three second side suction cups 208, though in alternative embodiments, any suitable number of suction cups 206, 208 may be used.

[0054] Referring to FIG. 11, the pivot shuttle 156 is shown extended by the actuator 211 (e.g., along the arc as shown in FIG. 4). During operation, when the pivot shuttle 156 is moved, the guide paddles 204 are also extended outward from the interior surface 202 to guide the pouch pre-form 132 along the interior surface 202. The fingers 162 then raise the pouch pre-form 132 on the interior surface 202 within the paddles 204 until the pouch pre-form 132 is aligned with the opening 210 and the first side suction cup 206 (shown in FIG. 10). The first side suction cup 206 is then actuated to provide a negative pressure on the pouch pre-form 132 and hold the pouch pre-form 132 in position on the interior surface 202 and the guide paddles 204 are retracted back into the interior surface 202. Additionally, the pivot shuttle 156 is moved back to the slide 116 (e.g., as shown in FIG. 4).

[0055] Referring to FIG. 12., the pivot shuttle 156 is shown being retracted back to the slide 116 and the second side suction cups 208 are moved to an extended configuration to contact the second side 190 of the pouch pre-form 132. The second side cups 208 are then actuated to provide a negative pressure on the second side 190 of the pouch pre-form 132. Referring to FIG. 13, the second side suction cups 208 are then moved to a partially retracted position to provide the pouch pre-form 132 in the open configuration.

[0056] Referring to FIG. 14, with the pouch pre-form 132 in the open configuration, the carriage 168 is moved along the machine transfer direction 170 to the filling station 106 with the grip assembly 172 in the released configuration and the clips 198, 200 aligned with the pouch pre-form 132. Referring to FIG. 15, the grip assembly 172 is then rotated to the engaged configuration, pinching the sides 186, 190 of the pouch pre-form 132 between the clips 198, 200 of the first and second grips 184, 188. Once the grip assembly 172 has secured the pouch pre-form 132, the suction cups 206, 208 are turned off and the second side cups 208 are retracted from the second side 190 of the pouch pre-form 132. The window 158 is then opened (as shown in FIG. 16, e.g., by retracting or rotating the window 158), exposing the interior 212 of the pouch pre-form 132. The product 120 (shown in FIG. 1) may then be inserted into the pouch pre-form 132 by a user and/or an automated machine (not shown). After the product 120 is received within the pouch pre-form 132, the window 158 is closed and the carriage 168 is moved to the sealing station 108 (as shown in FIG. 17).

[0057] In some embodiments, system 100 may include one or more sensors (not shown) for determining when a product 120 has been received in the pouch pre-form 132. For example, and without limitation, in some embodiments, the system 100 includes a scale (not shown) for measuring a weight of the pouch pre-form 132. In some such embodiments, the window 158 is closed and the carriage is moved to the sealing station 108 in response to the scale detecting a change in weight of the grip assembly 172 that exceeds a predetermined threshold. In other embodiments, system 100 includes one or more proximity sensors (not shown) that are operable to detect a product 120 entering the pouch pre-form 132.

[0058] Moreover, in some embodiments, system 100 further includes a sensor (not shown) operable to detect a position of the pouch pre-form 132 on the interior surface 202. For example, and without limitation, in one embodiment, system 100 includes a photosensor (not shown) that registers a position of the pouch pre-form 132 on the interior surface 202. In some such embodiments, when the photosensor detects the presence of the pouch pre-form 132 on the interior surface 202 as being aligned with the vacuum cups 206, 208, the pouch pre-form is secured by the first side cup 206 and the pivot shuttle 156 is moved back to the slide 116.

[0059] FIGS. 17-23 illustrate a process of sealing the filled pouch 132 at the sealing station 108. Referring to FIG. 17, in the example embodiment, the carriage 168 is at the filling station 106, the pressure bars 178 are positioned in a first separated position, and the adhesive assembly 174 is in a retracted position. After the product 120 is received in the pouch pre-form 132, the carriage 168 is moved in the machine transfer direction 170 (shown in FIG. 5) to the sealing station 108, as shown in FIG. 18. Referring to FIG. 18, after the carriage 168 is moved to the sealing station 108, the grip assembly 172 and the filled pouch 132 are each positioned laterally between each of the pressure bars 178. The adhesive assembly 174 is then extended to position a nozzle 214 (shown in FIG. 19) of the adhesive assembly 174 within the pouch interior 212. In particular, in the example embodiment, the adhesive assembly 174 includes a telescoping tip portion 216 that is selectively moveable between an extended position, as shown in FIGS. 18 and 19, and a retracted position, as shown in FIGS. 17 and 21-23.

[0060] The adhesive assembly 174 is also moveable along a track (not shown) to move the adhesive assembly 174 in the machine transfer direction 170. For example, with continued reference to FIG. 18, the adhesive assembly 174 is simultaneously moved along the machine transfer direction 170 to a first end 218 of the filled pouch 132 while the tip portion 216 is moved into the extended position. The adhesive assembly 174 then selectively releases a liquid adhesive onto an interior surface 203 of the filled pouch 132 proximate the first end 218. As the adhesive is being released, the adhesive assembly 174 is moved in the machine transfer direction 170 and within the pouch to a second end 220 of the filled pouch 132, as shown in FIG. 19. In the example embodiment, the travel path of the adhesive assembly 174 is predetermined in correspondence with the width of the filled pouches 132. In other embodiments, system 100 may include one or more proximity sensors (not shown), configured to detect a position of the first and second ends 218, 220 of the filled pouch 132 and the adhesive assembly 174 is moved based on the detected positions of the ends 218, 220.

[0061] Referring to FIG. 20, after the adhesive assembly 174 has deposited the adhesive on the interior surface 203 of the filled pouch 132, the tip portion 216 is retracted out of the pouch 132 and the grips 184, 188 are each moved inward. In particular, in the example embodiment, the grips 184, 188 are coupled to respective slidable frames 222, 224 that are each moveable along a closing direction 189. The closing direction 189 is generally perpendicular to the machine transfer direction 170 and to the rotational axes of the rods 194, 196 (shown in FIGS. 5 and 8). Simultaneously and/or subsequent to the grips 184, 188 being moved inward, the pressure bars 178 are also moved inward to apply pressure on the sides 186, 190 of the filled pouch 132 and seal the pouch 132 closed. Additionally, the pressure bars 178 pinch the filled pouch 132 to support the pouch 132 in position at the sealing station 108.

[0062] Referring to FIG. 21, after the pressure bars 178 have engaged the pouch 132, the grips 184, 188 are moved away from one another back along the closing direction 189 and the pressure bars 178 continue to hold the filled pouch 132 in position at the sealing station 108. The grips 184, 188 are then rotated to the released position, as shown in FIG. 21 and the carriage 168 is moved back to the filling station 106 to grab another pouch pre-form 132, as shown in FIG. 22. Referring to FIG. 23, after the carriage 168 has left the sealing station 108, the pressure bars 178 are retracted away from one another in the closing direction 189, thereby releasing the filled pouch 132 onto the output conveyor 110 (shown in FIG. 7). In some embodiments, the sealing station 108 further includes one or more photosensors (not shown) for detecting whether the filled pouch 132 is in position to allow for insertion of the tip portion 216 of the adhesive assembly 174.

[0063] With reference now to FIG. 24, the closed pouch 132 complete with a shipping label 228 on the outside and product inside forms a mailer 226 suitable for shipping in the mail or any suitable courier. The mailer 226 is formed of a single piece of corrugated paperboard 230, or any other suitable type of rigid tube form substrate such as solid fibre cardboard, wrapped around product. Two parallel, opposed edges 126, 128 (labelled in FIG. 2) of the single piece are adhered to one another to form a tube around an interior space for enclosing product. A first end 244 of the tube is adhered to itself to enclose a first end of the product. A second end 246 of the tube opposite the first end of the tube is adhered to itself to enclose a second end of the product.

[0064] The two parallel, opposed edges 126, 128 are adhered together to form a seam 130 in a first panel 133 of the tube along a first side of the product. The tube includes two side panels 146 each connected to the first panel 133 along a respective fold line 136,134. Each side panel 146 extends from the first end 244 of the tube to the second end 246 of the tube. Each side panel 146 includes an inward pleat formed by a fold line or pleat line 148 extending parallel to the seam 130 from the first end 244 of the tube to the second end 246 of the tube. In other embodiments, the pouch 132 does not include the pleat line 148. Those skilled in the art will readily appreciate that the label 228 can be placed on the opposite panel 144 (labelled in FIG. 2), instead of the first panel 133. The corrugation lines 232, only some of which are indicated in FIG. 24, in the tube run lateral to the longitudinal direction L of the seam 130 to facilitate forming the closures on the ends 244 and 246 of the mailer 226.

[0065] Example embodiments of packaging machines are described above in detail. The packaging machines are not limited to the specific embodiments described herein, but rather, components of the machine may be utilized independently and separately from other components described herein.

[0066] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

[0067] This written description uses examples to disclose various embodiments, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

[0068] It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape

[0069] It will be recognised that as used herein, directional references such as "top", "bottom", "base", "front", "back", "end", "side", "inner", "outer", "upper" and "lower" do not necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.

[0070] As used herein, the terms "hinged connection" and "fold line" refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. Any reference to "hinged connection" should not be construed as necessarily referring to a single fold line only; indeed, a hinged connection can be formed from two or more fold lines wherein each of the two or more fold lines may be either straight/linear or curved/curvilinear in shape. When linear fold lines form a hinged connection, they may be disposed parallel with each other or be slightly angled with respect to each other. When curvilinear fold lines form a hinged connection, they may intersect each other to define a shaped panel within the area surrounded by the curvilinear fold lines. A typical example of such a hinged connection may comprise a pair of arched or arcuate fold lines intersecting at two points such that they define an elliptical panel therebetween. A hinged connection may be formed from one or more linear fold lines and one or more curvilinear fold lines. A typical example of such a hinged connection may comprise a combination of a linear fold line and an arched or arcuate fold line which intersect at two points such that they define a half moon-shaped panel therebetween.

[0071] As used herein, the term "fold line" may refer to one of the following: a scored line, an embossed line, a debossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted cutline, a line of aligned slits, a line of scores and any combination of the aforesaid options.

[0072] It should be understood that hinged connections and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cutline, an interrupted cutline, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line or a severance line or both. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort.

[0073] The phrase "in registry with" as used herein refers to the alignment of two or more elements in an erected carton, such as an aperture formed in a first of two overlapping panels and a second aperture formed in a second of two overlapping panels. Those elements in registry with each other may be aligned with each other in the direction of the thickness of the overlapping panels. For example, when an aperture in a first panel is "in registry with" a second aperture in a second panel that is placed in an overlapping arrangement with the first panel, an edge of the aperture may extend along at least a portion of an edge of the second aperture and may be aligned, in the direction of the thickness of the first and second panels, with the second aperture.

Claims

1. A transport mechanism for engaging a pouch in an erect configuration at a first station of a packaging machine and transferring the pouch to a second station of the packaging machine, the transport mechanism comprising:

a carriage that is moveable between the first station and the second station; and

a grip assembly coupled to the carriage, the grip assembly being at least partially moveable relative to the carriage between an engaged position for clamping the pouch in the erect configuration within the grip assembly, and a released position.

2. The transport mechanism of claim 1, wherein the grip assembly comprises a first grip for engaging a first side of the pouch and a second grip for engaging a second, opposed side of the pouch, and wherein the first and second grip are each configured to clamp the pouch in the erected configuration at the first station to allow for loading of a product into the pouch through an open end of the pouch.

3. The transport mechanism of claim 1, wherein the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the grip assembly is rotatable about a rotational axis that is perpendicular to the machine transfer direction.

4. The transport mechanism of claim 1, wherein the grip assembly comprises an inner clip for engaging an inner surface of the pouch and an outer clip for engaging an outer surface of the pouch, the outer clip being positioned below the inner clip.

5. The transport mechanism of claim 4, wherein the grip assembly further comprises a first rod rotatably coupled to the carriage and rotatable about a first rotational axis and a second rod rotatably coupled to the carriage and rotatable about a second rotational axis, the inner clip being coupled to the first rod and the outer clip being coupled to the second rod.

6. The transport mechanism of claim 5, wherein, when the grip assembly transitions from the released position to the engaged position, the first rod rotates in a first rotational direction and the second rod rotates in a second, opposite, rotational direction.

7. The transport mechanism of claim 1, further comprising a controller in communication with the transport mechanism and operable to automatically control operation of at least one of the grip assembly and the carriage.

8. The transport mechanism of claim 1, wherein the first station is an erecting station that includes a landing for receiving the pouch and a pulling assembly configured to engage the pouch, the pulling assembly being moveable relative to the landing for erecting the pouch on the landing, and wherein the second station is a sealing station that is configured to close the pouch.

9. The transport mechanism of claim 8, wherein the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the pulling assembly comprises at least one vacuum suction cup operable to selectively engage and erect the pouch, the at least one vacuum suction cup being moveable in a direction perpendicular to the machine transfer direction.

10. The transport mechanism of claim 1, wherein the packaging machine includes a frame at least partially defining the first station and the second station, and wherein the transport mechanism further comprises a track extending along the frame from the first station to the second station, the carriage being moveable along the track.

11. The transport mechanism of claim 1, wherein the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the grip assembly comprises a first grip and second grip each rotatably coupled to the carriage, the first grip being offset from the second grip in a closing direction that is perpendicular to the machine transfer direction, the first and second grip being moveable relative to the carriage in the closing direction between a first configuration in which the first grip is spaced from the second grip and a second configuration in which the first grip contacts the second grip.

12. The transport mechanism of claim 1, wherein the second station comprises an adhesive applicator configured to dispense an adhesive onto an inner surface of the pouch while the grip assembly holds the pouch in the erected configuration.

13. The transport mechanism of claim 1, wherein the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the second station comprises a pair of pressure bars offset from one another in a closing direction that is perpendicular to the machine transfer direction, the pressure bars each being moveable in the closing direction for sealing the pouch.

14. A packaging machine comprising:

a first station for receiving a container in an erect configuration;

a second station spaced from the first station; and

a transport mechanism for engaging the container in the erect configuration at the first station and carrying the container to the second station, the transport mechanism comprising:

a carriage that is moveable between the first station and the second station; and

a grip assembly coupled to the carriage, the grip assembly being at least partially moveable relative to the carriage between an engaged position for clamping the container in the erect configuration within the grip assembly, and a released position.

15. The packaging machine of claim 14, wherein the grip assembly comprises a first grip for engaging a first side of the container and a second grip for engaging a second, opposed side of the container, wherein, when the first and second grip are each configured to hold the container in the erected configuration at the first station to allow for loading of a product therein through an open end of the container.

16. The packaging machine of claim 14, wherein the carriage is moveable along a machine transfer direction between the first station and the second station, and wherein the grip assembly is rotatable about a rotational axis that is perpendicular to the machine transfer direction.

17. The packaging machine of claim 14, wherein the grip assembly comprises an inner clip for engaging an inner surface of the container and an outer clip for engaging an outer surface of the container, the outer clip being positioned below the inner clip.

18. The packaging machine of claim 17, wherein the grip assembly further comprises a first rod rotatably coupled to the carriage and rotatable about a first rotational axis and a second rod rotatably coupled to the carriage and rotatable about a second rotational axis, the inner clip being coupled to the first rod and the outer clip being coupled to the second rod.

19. The packaging machine of claim 18, wherein, when the grip assembly transitions from the released position to the engaged position, the first rod rotates in a first rotational direction and the second rod rotates in a second, opposite, rotational direction.

20. A method of assembling a pouch comprising:

receiving a pouch in an erected configuration at a first station of a packaging machine;

moving a transport mechanism to the first station, the transport mechanism including a carriage and a grip assembly couped to the carriage;

clamping the pouch within the grip assembly by moving at least a portion of a grip assembly relative to the carriage; and

carrying, by the transport mechanism, the pouch from the first station to a second station of the packaging machine.

Drawing