US20070011993A1 - Method and system for manufacturing adhesive packets - Google Patents

Method and system for manufacturing adhesive packets Download PDF

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Publication number
US20070011993A1
US20070011993A1 US11/183,597 US18359705A US2007011993A1 US 20070011993 A1 US20070011993 A1 US 20070011993A1 US 18359705 A US18359705 A US 18359705A US 2007011993 A1 US2007011993 A1 US 2007011993A1
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liner
label
attached
unattached
roll
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Abandoned
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US11/183,597
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Jack Salvatore Mannoia
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Individual
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Individual
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Priority to US11/183,597 priority Critical patent/US20070011993A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65BMACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B61/00Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
    • B65B61/20Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for adding cards, coupons or other inserts to package contents

Definitions

  • the present invention relates generally to a method and system for manufacturing material-filled packets and more particularly to a method and system for manufacturing a roll of material-filled packets adhesively bonded to a substrate and enabling easily dispensing of the packets from the substrate upon rotation of the roll.
  • the present invention also relates to a roll of material-filled packets which can be adhesively attached to objects upon removal from the roll.
  • packets of granular or liquid material are often dispensed with products being sold.
  • packets or sugar or other sweeteners are dispensed with hot beverages while packets of ketchup and salt are dispensed with french fires and hamburgers.
  • packets or sugar or other sweeteners are dispensed with hot beverages while packets of ketchup and salt are dispensed with french fires and hamburgers.
  • packets or sugar or other sweeteners are dispensed with hot beverages while packets of ketchup and salt are dispensed with french fires and hamburgers.
  • packets or sugar or other sweeteners are dispensed with hot beverages while packets of ketchup and salt are dispensed with french fires and hamburgers.
  • Albrecht et al. '430 describes making a bandoleer including a series of packets encased in a sleeve and separated by closed portions of the sleeve, while an adhesive strip extends along a length of the sleeve and is covered by a release liner.
  • the process involves separately forming a series of interconnected packets and an adhesive coated release liner and then aligning them and laminating them together by means of rollers. The combined assembly is then perforated between the packages to enable them to be separated for use. Adhesive may be applied to the series of packages instead of the release liner.
  • Albrecht et al. '722 describes another bandoleer package and method for manufacturing it. In this method, the adhesive strip is also applied to the completed packages.
  • a better method for enabling a large quantity of separable packets to be combined into a single, easily handled unit, with the packets being readily separable for use in connection with a dispensed product, is desired.
  • Another object of the present invention is to provide a new roll of material-filled packets, in particular packets which can be adhesively attached to objects upon removal from the roll.
  • a first embodiment of a method for making a series of material-filled packets comprises forming a plurality of labels on a liner with only a part of each label being attached to the liner, then placing a quantity of material onto the part of each label attached to the liner, then folding an unattached part of each label over the material, and then attaching the unattached part of each label to the attached part of the label to seal the material therebetween and thereby form a series of material-filled packets connected together by the liner.
  • the liner may be provided as a roll which is unwound prior to placement of the material onto the part of each label attached to the liner and wound into or onto a roll after attachment of the unattached part of each label to the attached part of the label to thereby form a roll of interconnected material-filled packets.
  • the labels are formed by applying a plurality of adhesive strips to the liner and then pressing only part of individual labels against the liner, each against a respective adhesive strips. Attachment of the unattached part of each label to the attached part of the label may entail heat-sealing or pressure-sealing edge regions of the unattached part and attached part together. Further, a side of the labels opposite a side facing the liner may be coated with a coating capable of melting to itself when heat-sealed and capable of being crimped when pressure-sealed. Graphics and/or text may be printed on a side of the labels facing the liner to thereby enable the printed material to be seen upon formation of the material-filled packets.
  • a plurality of labels are formed on a liner with only a part of each label being attached to the liner and an unattached part of each label is folded to a position opposite the part of the label attached to the liner.
  • the method then entails only partially attaching the unattached part of the label to the attached part of the label to form a partially sealed packet having a filling opening at a top, orienting the liner in a substantially vertical orientation and then placing a quantity of material into the partially sealed packet through the filling opening while the liner is in a vertical orientation, and then completing the attachment of the unattached part of the label to the attached part of the label to thereby form a series of material-filled packets connected together by the liner.
  • the partially sealed packet thus forms a receptacle with an opening at the top through which the liquid material can be inserted.
  • a system for making a series of material-filled packets in accordance with the invention includes a liner having a plurality of individual labels partially attached thereto, a folding device for folding an unattached part of each label to a position opposite the part of the label attached to the liner, a dispensing device for placing a quantity of material onto a part of each label attached to the liner, and an attachment device for attaching the unattached part of each label to the attached part.
  • the liner is directed past the folding device, the dispensing device and the attachment device such that a series of material-filled packets connected together by the liner is formed.
  • the liner is directed in a substantially horizontal plane through or by the dispensing device and the attachment device is arranged to attach the unattached part of each label to the attached part of the label only after the dispensing device places material on the attached part of the label.
  • the liner is directed in a substantially vertical plane by the dispensing device and the attachment device is arranged to initially only partially attach the unattached part of each label to the attached part of the label to form a partially sealed packet having a filling opening at a top and then complete the attachment of the unattached part of each label to the attached part of the label after the dispensing device places material into the packet through the filling opening.
  • adhesive may be arranged between the liner and the attached part of each label for adhesively and removably bonding each label to the liner and enabling each material-filled packet to be adhesive attached to an object upon removal from the liner.
  • FIG. 1 is a schematic diagram of a first system for making a roll of packets in accordance with the invention.
  • FIGS. 2A, 2B , 2 C and 2 D show a liner in various stages during the manufacture of material-filled packets using the system shown in FIG. 1 .
  • FIG. 3 is a schematic diagram of a system for forming a roll of liner with adhesive labels for use in the invention.
  • FIG. 4 is a schematic showing the steps in one exemplifying method for making a series of material-filled packets using the system shown in FIG. 1 .
  • FIG. 5 is a schematic diagram of a second system for making a roll of packets in accordance with the invention.
  • FIGS. 6A and 6B show a liner in various stages during the manufacture of material-filled packets using the system shown in FIG. 5 .
  • FIG. 7 is a schematic showing the steps in one exemplifying method for making a series of material-filled packets using the system shown in FIG. 5 .
  • FIG. 1 shows a first embodiment of a system for making an interconnected series of material-filled packets in accordance with the invention which is designated generally as 10 , and is used in particular for solid materials (although it could also be used for liquid materials in certain situations, e.g., for a highly viscous liquid).
  • System 10 includes a roll 12 of liner 14 having a plurality of individual labels 16 only partially attached thereto (part 16 A as shown in FIG. 2A ).
  • a remaining part of each label 16 designated part 16 B, is unattached to the liner 14 .
  • Approximately half of the label 16 may be attached to the liner 14 , leaving about half or a little more unattached to the liner 14 .
  • Roll 12 is situated in an unwinding station from which it is unwound.
  • Dispensing device 18 is arranged after the unwinding station and the liner 14 is passed through or by the dispensing device 18 which places a quantity of material 20 onto the part 16 A of each label 16 attached to the liner 14 . In some cases, material 20 is placed only onto the attached part 16 A of each label 16 (see FIG. 2B ). Downstream of the dispensing device 18 is a folding device 22 which folds the unattached part 16 B of each label 16 to a position opposite the attached part 16 A of the label 16 (see FIG. 2C ).
  • an attachment device 24 Downstream of the folding device 22 is an attachment device 24 which attaches the unattached part 16 B of each label 16 to the attached part 16 A, e.g., it seals edge portions of the unattached part 16 B of the label 16 to opposed edge portions of the attached part 16 A of the label 16 with the material 20 being sandwiched therebetween to thereby form a material-filled packet 26 (see FIG. 2D ).
  • a series of material-filled packets 26 connected together by the liner 14 is formed.
  • This series of packets 26 can be wound into a roll 28 in a winding station. Movement of the liner 14 from roll 12 to roll 28 can be effected by applying rotational force to roll 28 (in the clockwise direction in the configuration shown in FIG. 1 ).
  • Devices for supporting and unwinding roll 12 in the unwinding station and supporting and winding roll 28 in the winding station can be any winding and unwinding devices used in a roll-based manufacturing process.
  • the liner 14 when placing a solid material onto the attached part 16 A of the labels 16 and until the packet 28 is formed, the liner 14 is maintained in a substantially horizontal, flat position so that the solid material 20 remains in place on the attached part 16 A of the label 16 .
  • the liner 14 can be directed over a horizontally oriented substrate such as the top of a table, during the dispensing, folding and attachment stages effected by dispensing device 18 , folding device 22 and attachment device 24 .
  • solid materials which can be packaged using the system 10 include granular materials such as sugar, artificial sweeteners, and salt.
  • Attachment device 24 may be designed to heat-seal and/or pressure seal the edge portions of the unattached part 16 B of each label 16 to the attached part 16 A of the label 16 , or vice versa.
  • the label 16 is rectangular, then after material 20 is placed onto the attached part 16 A of the label 16 , the label 16 is folded about a fold line 30 to bring the edge portions 32 of the unattached part 16 B opposite the edge portions 34 of the attached part 16 A.
  • a plastic laminate or gloss can be applied or coated onto the side of the label 16 which will be brought into contact with itself during the sealing process. The gloss melts to itself and seals with heat. The gloss can also be crimped and made to seal with pressure.
  • the labels 16 can be made entirely of a heat sealable material, such as chemically treated paper, without a gloss, or partially out of the heat sealable material, i.e., only at the edge portions 32 , 34 which will be bonded to one another.
  • Folding device 22 and attachment device 24 may be incorporated into a single mechanism which performs both the folding step and the attachment and sealing step.
  • the dispensing device 18 and folding device 22 may be incorporated into a single mechanism which performs both the material dispensing step and the folding step.
  • Any equipment for dispensing a regulated quantity of material known in the art can be used as dispensing device 18 .
  • Any equipment for folding material known in the art can be used as folding device 22 and any equipment known in the art for sealing packets can be used as attachment device 24 .
  • attachment device 24 may include an arm shaped like a heatable branding iron which descends onto the folded-over unattached part 16 B of the label 16 and covers the three open sides of the label 16 , and then stamps the folded label 16 with head and pressure thereby sealing it to form the packet 26 .
  • each of the dispensing device 18 , folding device 22 and attachment device 24 should be considered to represent any equipment capable of performing the functions described as being performed by these devices.
  • the roll 12 of liner 14 with labels attached thereto can be formed off-line, i.e., pre-formed and brought ready to use into the system 10 , or formed on-line. In either case, there are several methods for forming the roll 12 of liner 14 with labels attached thereto. As shown in FIG. 3 , a roll 36 of liner paper 38 is unwound in an unwinding station and passed through or by an adhesive coater 40 which applies adhesive in the form of thin strips onto a surface of the liner paper 38 .
  • the thin strips of adhesive are preferably spaced apart from one another the same distance sought to be provided between adjacent packets in the interconnected series, have a length approximately equal to the length of each packet and have a width about 1 ⁇ 2 of the width of the label to be adhered thereto, or a little less.
  • the width should not exceed 1 ⁇ 2 of the width of the label 16 as this would prevent the unattached part 16 B of the label 16 from being foldable to cover the material.
  • the adhesive applied by adhesive coater 40 can depend on the material 20 being packaged. A heavier material would require a stronger adhesive whereas a lighter filling material would enable use of a relatively weaker adhesive. The selection of which adhesive to use as a function of, e.g, the weight of the material, would be readily ascertainable by those skilled in the art.
  • a label placement device 42 is arranged after the adhesive coater 40 in the downstream direction and receives a stack of labels 16 and presses the lowermost label or the label stack against the liner paper 38 such that the lowermost label in the stack is pressed against an adhesive strip on the liner paper 38 . Timing between the pressing of the lowermost label against the liner paper 38 is controlled to ensure each label is properly pressed against an adhesive strip on the liner paper 38 .
  • labels 16 are positioned to align with the adhesive strips on the liner paper 38 so that about 1 ⁇ 2 of each label 16 contacts a respective adhesive strip and is firmly pressed against it.
  • a the roll of liner paper with adhesively applied labels is directed to the dispensing device 18 as shown in FIG. 1 .
  • an alternative label-application technique would be to arrange a roll of labels in an unwinding station and unwound the roll and pass the labels 16 into contact with the exposed adhesive strips on the liner paper 38 .
  • a pair of rollers forming a nip is provided through which the liner paper and adhered label pass to thereby firmly pressed the label against the liner paper 38 .
  • Other techniques and devices which adhesively attach only part of a flat label to liner paper can also be applied in accordance with the invention.
  • a roll i.e., the roll 12 of the liner 14 , the roll 28 of packets 26 and the roll 36 of liner paper 38
  • other forms in which the size of a large length of material is reduced are also envision for use.
  • an accordion-folded length of liner 14 with adhesively applied labels can be used in the invention.
  • the liner 14 could be unpacked and fed into a device which moves it past the dispensing device 18 , the folding device 22 and the attachment device 24 , e.g., a rotated roll 28 .
  • a roll is therefore used herein an one, non-limiting example of a form which substantially reduces the linear length of a sheet of material.
  • FIG. 4 is a schematic showing the steps in an exemplifying and non-limiting method for making a series of material-filled packets using the system shown in FIG. 1 .
  • the first step 44 is to insert the roll 12 of liner 14 into an unwinding station.
  • the roll 12 of liner 14 is then unwound when the system 10 is ready for operation, i.e., once material to be inserted into the packets is prepared and placed into the dispensing device 18 (step 46 ).
  • the liner 14 is then oriented in a horizontal plane (step 48 ) and passed through or by the dispensing device 18 so that material 20 is placed onto the attached part 16 A of each label 16 (step 50 ).
  • Orientation of the liner 14 in the horizontal plane may occur as the liner 14 is unwound or at any time after the unwinding and before the placement of the material 20 onto the attached part 16 A of the liner 14 .
  • the unattached part 16 B of each label 16 is then folded over the material 20 (step 52 ) into a position opposite the attached part 16 A and then sealed thereto (step 54 ).
  • the packets 26 thus-formed on the liner 14 are then rolled into a roll 28 in a winding station (step 56 ).
  • the roll 28 can be used to dispense packets 26 simply by lifting the packets 26 off of the liner 14 , i.e., pulling them off of the liner 14 to which they are adhesively attached.
  • a roll 36 of liner paper 38 is placed into the unwind station, unwound and adhesive is applied to the liner paper 38 (step 58 ), part of a label 16 is attached to each adhesive portion (step 60 ) and then the liner paper 38 is oriented in the horizontal plane (step 48 ).
  • the labels 16 can be printed on the side part of which is adhesively attached to the liner 14 . As such, when the label 16 is folded over by folding device 22 , the printed side forms the outer side of the packets 26 .
  • FIG. 5 shows a second embodiment of a system for making an interconnected series of material-filled packets in accordance with the invention which is designated generally as 62 and is used in particular for liquid materials.
  • System 62 includes a roll 12 of liner 14 having a plurality of individual labels 16 only partially attached thereto as in the embodiment described above with respect to FIG. 1 .
  • the alternative formations of a roll with adhesive labels described with respect to FIG. 3 can be used in system 62 as well.
  • a folding and attachment device 64 is arranged downstream of the unwinding station in which roll 12 is situated and roll 12 is unwound to cause the liner 14 to pass through or by the folding and attachment device 64 .
  • Folding and attachment device 64 folds the unattached part 16 B of the label 16 to a position opposite the attached part 16 A of the label 16 and only partially attaches the unattached part 16 B of each label 16 to the attached part 16 A to form a partially closed packet 66 or pouch (see FIG. 6A ).
  • edge portions 68 of the label 16 are attached to one another but edge portions 70 are not so that when the label 16 is oriented in a vertical plane, a filling opening 72 is formed at a top of the packet 66 between edge portions 70 .
  • the attachment provided by the folding and attachment device 64 may be a heat-seal and/or pressure-seal of the edge portions 68 of the label 16 together.
  • the filling opening may extend across the entire top of the packet 66 or only across a portion thereof.
  • a dispensing device 74 Downstream of the folding and attachment device 64 is a dispensing device 74 which places a quantity of material 76 into the packet 66 through the filling opening 72 (see FIG. 6B ).
  • the packet 66 is oriented vertically with the filling opening 72 at the top when the dispensing device 74 directs the material therein so that a liquid material can easily be placed into the packet 66 (although a solid material could likewise be placed into the packet 66 ).
  • the vertical orientation of the packets 66 can be facilitated using rollers as commonly used in the food-processing art.
  • a sealing device 78 Downstream of the dispensing device 74 is a sealing device 78 which seals the filling opening 72 by attaching the edge portions 70 of the parts 16 A, 16 B of the label 16 together, e.g., it seals edge portion 70 of the unattached part 16 B of the label 16 to the opposed edge portion 70 of the attached part 16 A of the label 16 with the material 76 being sandwiched therebetween to thereby form a material-filled packet.
  • a series of material-filled packets connected together by the liner 14 is formed.
  • This series of packets can be wound into a roll 80 .
  • Movement of the liner 14 from roll 12 to roll 80 can be effected by applying rotational force to roll 80 (in the clockwise direction in the configuration shown in FIG. 5 ).
  • Devices for supporting and unwinding roll 12 in the unwinding station and supporting and winding roll 80 in the winding station can be any winding and unwinding devices used in a roll-based manufacturing process.
  • Folding and attachment device 64 may be designed to heat-seal and/or pressure seal the edge portions 68 of the unattached part 16 B of each label 16 to the attached part 16 A of the label 16 .
  • the same techniques described above for system 10 can be applied here as well.
  • Folding and attachment device 64 is shown as a single mechanism but can alternatively, be formed as two devices separated from one another, i.e., a separate folding device can be provided followed by an attachment and sealing device for partially attaching the unattached part 16 B of the label 16 to the attached part 16 A of the label 16 .
  • each of the folding and attachment device 64 , dispensing device 74 and sealing device 78 should be considered to represent any equipment capable of performing the functions described as being performed by these devices.
  • FIG. 7 is a schematic showing the steps in an exemplifying and non-limiting method for making a series of material-filled packets using the system shown in FIG. 5 .
  • the first step 82 is to insert the roll 12 of liner 14 into an unwinding station.
  • the roll 12 of liner 14 is then unwound when the system 10 is ready for operation, i.e., once material to be inserted into the packets is prepared and placed into the dispensing device 74 (step 84 ).
  • the liner 14 is then through a folding and attachment station wherein each label 16 on the liner 14 is folded and partially sealed to itself to form a filling opening 72 (step 86 ), e.g., via the folding and attachment device 64 .
  • the liner 14 is then oriented in a vertical plane (step 88 ) and passed into a dispensing station wherein material 76 is directed through the filling opening 72 (step 90 ), e.g., via the dispensing device 74 . Orientation of the liner 14 in the vertical plane may occur as the liner 14 is unwound or at any time after the unwinding and before the placement of the material 76 through the filling opening 76 into the packet 66 .
  • the filling opening 72 is then sealed via the sealing device 78 (step 92 ) and the material-filled packets 66 thus-formed on the liner 14 are then rolled into a roll 80 in a winding station (step 94 ).
  • the roll 80 can be used to dispense packets 66 simply by lifting the packets 66 off of the liner 14 , i.e., pulling them off of the liner 14 to which they are adhesively attached.
  • the labels 16 can be printed on the side, part of which is adhesively attached to the liner 14 . As such, when the label 16 is folded over by folding and attachment device 64 , the printed side forms the outer side of the packets 66 .
  • the material-filled packet forming systems and methods described above therefore provided a technique to form a series of packets adhesively attached to a roll of liner material which can be rotatably mounted to thereby enable each packet to be easily removed from the roll by lifting the packets off of the liner as the roll rotates about its axis.
  • a roll can be mounted at the site at which the packets are to be dispensed.
  • the presence of the adhesive on the packets is not eliminated when the packets are removed from the liner material so that after removal from the liner material, the packets themselves can be adhesively attached to another object.
  • a packet of salt or ketchup can therefore be adhered to a container of french fries, a packet of sugar can be attached to a cup of coffee or tea.
  • a machine wold be provided to receive such a roll and enable automatic dispensing of the packets upon controlled rotation of the roll.

Abstract

Method and system for making a series of material-filled packets in which a plurality of labels are formed on a liner with only a part of each label being attached to the liner, a quantity of material is placed by a dispensing device onto the part of each label attached to the liner, an unattached part of each label is folded over the material by a folding device, and the unattached part of each label is attached to the attached part of the label to seal the material therebetween by an attachment and/or sealing device. A series of material-filled packets connected together by the liner is thereby formed.

Description

    FIELD OF THE INVENTION
  • The present invention relates generally to a method and system for manufacturing material-filled packets and more particularly to a method and system for manufacturing a roll of material-filled packets adhesively bonded to a substrate and enabling easily dispensing of the packets from the substrate upon rotation of the roll. The present invention also relates to a roll of material-filled packets which can be adhesively attached to objects upon removal from the roll.
  • BACKGROUND OF THE INVENTION
  • In typical retail establishments, small packets of granular or liquid material are often dispensed with products being sold. For example, packets or sugar or other sweeteners are dispensed with hot beverages while packets of ketchup and salt are dispensed with french fires and hamburgers. Currently, most if not all packets are loose, i.e., individual packets separate from one another, and placed into a container or bin accessible to the purchaser. The purchaser inserts their hand into the container and grabs the desired quantity of packets. The container is replenished with more packets when necessary.
  • One problem with the use of loose packets is that it is cumbersome to handle the relatively large quantities of loose packets needed to replenished the containers, and that such replenishment may be required quite frequently. It would therefore be beneficial to enable large quantities of packets to be easily handled while also possibly reducing the need to frequently replenish containers.
  • To this end, prior art relating to single units containing a large number of packets include U.S. Pat. No. 5,611,430 (Albrecht et al.) and U.S. Pat. No. 5,887,722 (Albrecht et al.).
  • Albrecht et al. '430 describes making a bandoleer including a series of packets encased in a sleeve and separated by closed portions of the sleeve, while an adhesive strip extends along a length of the sleeve and is covered by a release liner. The process involves separately forming a series of interconnected packets and an adhesive coated release liner and then aligning them and laminating them together by means of rollers. The combined assembly is then perforated between the packages to enable them to be separated for use. Adhesive may be applied to the series of packages instead of the release liner.
  • Albrecht et al. '722 describes another bandoleer package and method for manufacturing it. In this method, the adhesive strip is also applied to the completed packages.
  • A better method for enabling a large quantity of separable packets to be combined into a single, easily handled unit, with the packets being readily separable for use in connection with a dispensed product, is desired.
  • OBJECTS AND SUMMARY OF THE INVENTION
  • Accordingly, it is an object of the present invention to provide a new and improved method and system for manufacturing material-filled packets.
  • It is another object of the present invention to provide a new and improved a method and system for manufacturing a roll of material-filled packets adhesively bonded to a substrate and enabling easily dispensing of the packets from the substrate upon rotation of the roll.
  • Another object of the present invention is to provide a new roll of material-filled packets, in particular packets which can be adhesively attached to objects upon removal from the roll.
  • In order to achieve these objects and others, a first embodiment of a method for making a series of material-filled packets comprises forming a plurality of labels on a liner with only a part of each label being attached to the liner, then placing a quantity of material onto the part of each label attached to the liner, then folding an unattached part of each label over the material, and then attaching the unattached part of each label to the attached part of the label to seal the material therebetween and thereby form a series of material-filled packets connected together by the liner. The liner may be provided as a roll which is unwound prior to placement of the material onto the part of each label attached to the liner and wound into or onto a roll after attachment of the unattached part of each label to the attached part of the label to thereby form a roll of interconnected material-filled packets.
  • In one embodiment, the labels are formed by applying a plurality of adhesive strips to the liner and then pressing only part of individual labels against the liner, each against a respective adhesive strips. Attachment of the unattached part of each label to the attached part of the label may entail heat-sealing or pressure-sealing edge regions of the unattached part and attached part together. Further, a side of the labels opposite a side facing the liner may be coated with a coating capable of melting to itself when heat-sealed and capable of being crimped when pressure-sealed. Graphics and/or text may be printed on a side of the labels facing the liner to thereby enable the printed material to be seen upon formation of the material-filled packets.
  • In another method for making a series of material-filled packets particularly suited for (but not limited to) liquid materials, a plurality of labels are formed on a liner with only a part of each label being attached to the liner and an unattached part of each label is folded to a position opposite the part of the label attached to the liner. The method then entails only partially attaching the unattached part of the label to the attached part of the label to form a partially sealed packet having a filling opening at a top, orienting the liner in a substantially vertical orientation and then placing a quantity of material into the partially sealed packet through the filling opening while the liner is in a vertical orientation, and then completing the attachment of the unattached part of the label to the attached part of the label to thereby form a series of material-filled packets connected together by the liner. The partially sealed packet thus forms a receptacle with an opening at the top through which the liquid material can be inserted.
  • A system for making a series of material-filled packets in accordance with the invention includes a liner having a plurality of individual labels partially attached thereto, a folding device for folding an unattached part of each label to a position opposite the part of the label attached to the liner, a dispensing device for placing a quantity of material onto a part of each label attached to the liner, and an attachment device for attaching the unattached part of each label to the attached part. The liner is directed past the folding device, the dispensing device and the attachment device such that a series of material-filled packets connected together by the liner is formed. In one embodiment, the liner is directed in a substantially horizontal plane through or by the dispensing device and the attachment device is arranged to attach the unattached part of each label to the attached part of the label only after the dispensing device places material on the attached part of the label. In another embodiment, the liner is directed in a substantially vertical plane by the dispensing device and the attachment device is arranged to initially only partially attach the unattached part of each label to the attached part of the label to form a partially sealed packet having a filling opening at a top and then complete the attachment of the unattached part of each label to the attached part of the label after the dispensing device places material into the packet through the filling opening.
  • In the methods and systems descried above, adhesive may be arranged between the liner and the attached part of each label for adhesively and removably bonding each label to the liner and enabling each material-filled packet to be adhesive attached to an object upon removal from the liner.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The following drawings are illustrative of embodiments of the invention and are not meant to limit the scope of the invention as encompassed by the claims.
  • FIG. 1 is a schematic diagram of a first system for making a roll of packets in accordance with the invention.
  • FIGS. 2A, 2B, 2C and 2D show a liner in various stages during the manufacture of material-filled packets using the system shown in FIG. 1.
  • FIG. 3 is a schematic diagram of a system for forming a roll of liner with adhesive labels for use in the invention.
  • FIG. 4 is a schematic showing the steps in one exemplifying method for making a series of material-filled packets using the system shown in FIG. 1.
  • FIG. 5 is a schematic diagram of a second system for making a roll of packets in accordance with the invention.
  • FIGS. 6A and 6B show a liner in various stages during the manufacture of material-filled packets using the system shown in FIG. 5.
  • FIG. 7 is a schematic showing the steps in one exemplifying method for making a series of material-filled packets using the system shown in FIG. 5.
  • DETAILED DESCRIPTION OF THE INVENTION
  • Referring to the accompanying drawings wherein like reference numerals refer to the same or similar elements, FIG. 1 shows a first embodiment of a system for making an interconnected series of material-filled packets in accordance with the invention which is designated generally as 10, and is used in particular for solid materials (although it could also be used for liquid materials in certain situations, e.g., for a highly viscous liquid). System 10 includes a roll 12 of liner 14 having a plurality of individual labels 16 only partially attached thereto (part 16A as shown in FIG. 2A). A remaining part of each label 16, designated part 16B, is unattached to the liner 14. Approximately half of the label 16, or a little less, may be attached to the liner 14, leaving about half or a little more unattached to the liner 14.
  • Roll 12 is situated in an unwinding station from which it is unwound. Dispensing device 18 is arranged after the unwinding station and the liner 14 is passed through or by the dispensing device 18 which places a quantity of material 20 onto the part 16A of each label 16 attached to the liner 14. In some cases, material 20 is placed only onto the attached part 16A of each label 16 (see FIG. 2B). Downstream of the dispensing device 18 is a folding device 22 which folds the unattached part 16B of each label 16 to a position opposite the attached part 16A of the label 16 (see FIG. 2C). Downstream of the folding device 22 is an attachment device 24 which attaches the unattached part 16B of each label 16 to the attached part 16A, e.g., it seals edge portions of the unattached part 16B of the label 16 to opposed edge portions of the attached part 16A of the label 16 with the material 20 being sandwiched therebetween to thereby form a material-filled packet 26 (see FIG. 2D).
  • As the roll 12 continuously unwinds and the liner 14 is directed past the dispensing device 18, folding device 22 and attachment device 24, a series of material-filled packets 26 connected together by the liner 14 is formed. This series of packets 26 can be wound into a roll 28 in a winding station. Movement of the liner 14 from roll 12 to roll 28 can be effected by applying rotational force to roll 28 (in the clockwise direction in the configuration shown in FIG. 1). Devices for supporting and unwinding roll 12 in the unwinding station and supporting and winding roll 28 in the winding station can be any winding and unwinding devices used in a roll-based manufacturing process.
  • Preferably, when placing a solid material onto the attached part 16A of the labels 16 and until the packet 28 is formed, the liner 14 is maintained in a substantially horizontal, flat position so that the solid material 20 remains in place on the attached part 16A of the label 16. To this end, the liner 14 can be directed over a horizontally oriented substrate such as the top of a table, during the dispensing, folding and attachment stages effected by dispensing device 18, folding device 22 and attachment device 24. Examples of solid materials which can be packaged using the system 10 include granular materials such as sugar, artificial sweeteners, and salt.
  • Attachment device 24 may be designed to heat-seal and/or pressure seal the edge portions of the unattached part 16B of each label 16 to the attached part 16A of the label 16, or vice versa. For example, if the label 16 is rectangular, then after material 20 is placed onto the attached part 16A of the label 16, the label 16 is folded about a fold line 30 to bring the edge portions 32 of the unattached part 16B opposite the edge portions 34 of the attached part 16A. To aid in the heat-sealing and/or pressure sealing, a plastic laminate or gloss can be applied or coated onto the side of the label 16 which will be brought into contact with itself during the sealing process. The gloss melts to itself and seals with heat. The gloss can also be crimped and made to seal with pressure. Alternatively, the labels 16 can be made entirely of a heat sealable material, such as chemically treated paper, without a gloss, or partially out of the heat sealable material, i.e., only at the edge portions 32, 34 which will be bonded to one another.
  • Folding device 22 and attachment device 24 may be incorporated into a single mechanism which performs both the folding step and the attachment and sealing step. Similarly, the dispensing device 18 and folding device 22 may be incorporated into a single mechanism which performs both the material dispensing step and the folding step. Any equipment for dispensing a regulated quantity of material known in the art can be used as dispensing device 18. Any equipment for folding material known in the art can be used as folding device 22 and any equipment known in the art for sealing packets can be used as attachment device 24. For example, attachment device 24 may include an arm shaped like a heatable branding iron which descends onto the folded-over unattached part 16B of the label 16 and covers the three open sides of the label 16, and then stamps the folded label 16 with head and pressure thereby sealing it to form the packet 26. In general, each of the dispensing device 18, folding device 22 and attachment device 24 should be considered to represent any equipment capable of performing the functions described as being performed by these devices.
  • Referring now to FIG. 3, the roll 12 of liner 14 with labels attached thereto can be formed off-line, i.e., pre-formed and brought ready to use into the system 10, or formed on-line. In either case, there are several methods for forming the roll 12 of liner 14 with labels attached thereto. As shown in FIG. 3, a roll 36 of liner paper 38 is unwound in an unwinding station and passed through or by an adhesive coater 40 which applies adhesive in the form of thin strips onto a surface of the liner paper 38. The thin strips of adhesive are preferably spaced apart from one another the same distance sought to be provided between adjacent packets in the interconnected series, have a length approximately equal to the length of each packet and have a width about ½ of the width of the label to be adhered thereto, or a little less. The width should not exceed ½ of the width of the label 16 as this would prevent the unattached part 16B of the label 16 from being foldable to cover the material.
  • The adhesive applied by adhesive coater 40 can depend on the material 20 being packaged. A heavier material would require a stronger adhesive whereas a lighter filling material would enable use of a relatively weaker adhesive. The selection of which adhesive to use as a function of, e.g, the weight of the material, would be readily ascertainable by those skilled in the art.
  • A label placement device 42 is arranged after the adhesive coater 40 in the downstream direction and receives a stack of labels 16 and presses the lowermost label or the label stack against the liner paper 38 such that the lowermost label in the stack is pressed against an adhesive strip on the liner paper 38. Timing between the pressing of the lowermost label against the liner paper 38 is controlled to ensure each label is properly pressed against an adhesive strip on the liner paper 38. Preferably, labels 16 are positioned to align with the adhesive strips on the liner paper 38 so that about ½ of each label 16 contacts a respective adhesive strip and is firmly pressed against it.
  • After label placement device 42, a the roll of liner paper with adhesively applied labels is directed to the dispensing device 18 as shown in FIG. 1.
  • Instead of label placement device 42, an alternative label-application technique would be to arrange a roll of labels in an unwinding station and unwound the roll and pass the labels 16 into contact with the exposed adhesive strips on the liner paper 38. Optionally, a pair of rollers forming a nip is provided through which the liner paper and adhered label pass to thereby firmly pressed the label against the liner paper 38. Other techniques and devices which adhesively attach only part of a flat label to liner paper can also be applied in accordance with the invention.
  • Whenever mention is made of use of a roll, i.e., the roll 12 of the liner 14, the roll 28 of packets 26 and the roll 36 of liner paper 38, other forms in which the size of a large length of material is reduced are also envision for use. For example, an accordion-folded length of liner 14 with adhesively applied labels can be used in the invention. In this case, the liner 14 could be unpacked and fed into a device which moves it past the dispensing device 18, the folding device 22 and the attachment device 24, e.g., a rotated roll 28. A roll is therefore used herein an one, non-limiting example of a form which substantially reduces the linear length of a sheet of material.
  • FIG. 4 is a schematic showing the steps in an exemplifying and non-limiting method for making a series of material-filled packets using the system shown in FIG. 1. The first step 44 is to insert the roll 12 of liner 14 into an unwinding station. The roll 12 of liner 14 is then unwound when the system 10 is ready for operation, i.e., once material to be inserted into the packets is prepared and placed into the dispensing device 18 (step 46). The liner 14 is then oriented in a horizontal plane (step 48) and passed through or by the dispensing device 18 so that material 20 is placed onto the attached part 16A of each label 16 (step 50). Orientation of the liner 14 in the horizontal plane may occur as the liner 14 is unwound or at any time after the unwinding and before the placement of the material 20 onto the attached part 16A of the liner 14. The unattached part 16B of each label 16 is then folded over the material 20 (step 52) into a position opposite the attached part 16A and then sealed thereto (step 54). The packets 26 thus-formed on the liner 14 are then rolled into a roll 28 in a winding station (step 56). The roll 28 can be used to dispense packets 26 simply by lifting the packets 26 off of the liner 14, i.e., pulling them off of the liner 14 to which they are adhesively attached.
  • If the roll 12 of liner 14 with labels 16 thereon is not formed off-line, then a roll 36 of liner paper 38 is placed into the unwind station, unwound and adhesive is applied to the liner paper 38 (step 58), part of a label 16 is attached to each adhesive portion (step 60) and then the liner paper 38 is oriented in the horizontal plane (step 48).
  • To provide printed matter on the exposed surfaces of the packets 26, the labels 16 can be printed on the side part of which is adhesively attached to the liner 14. As such, when the label 16 is folded over by folding device 22, the printed side forms the outer side of the packets 26.
  • FIG. 5 shows a second embodiment of a system for making an interconnected series of material-filled packets in accordance with the invention which is designated generally as 62 and is used in particular for liquid materials. System 62 includes a roll 12 of liner 14 having a plurality of individual labels 16 only partially attached thereto as in the embodiment described above with respect to FIG. 1. The alternative formations of a roll with adhesive labels described with respect to FIG. 3 can be used in system 62 as well.
  • A folding and attachment device 64 is arranged downstream of the unwinding station in which roll 12 is situated and roll 12 is unwound to cause the liner 14 to pass through or by the folding and attachment device 64. Folding and attachment device 64 folds the unattached part 16B of the label 16 to a position opposite the attached part 16A of the label 16 and only partially attaches the unattached part 16B of each label 16 to the attached part 16A to form a partially closed packet 66 or pouch (see FIG. 6A). As shown in FIG. 6A, edge portions 68 of the label 16 are attached to one another but edge portions 70 are not so that when the label 16 is oriented in a vertical plane, a filling opening 72 is formed at a top of the packet 66 between edge portions 70. The attachment provided by the folding and attachment device 64 may be a heat-seal and/or pressure-seal of the edge portions 68 of the label 16 together. The filling opening may extend across the entire top of the packet 66 or only across a portion thereof.
  • Downstream of the folding and attachment device 64 is a dispensing device 74 which places a quantity of material 76 into the packet 66 through the filling opening 72 (see FIG. 6B). The packet 66 is oriented vertically with the filling opening 72 at the top when the dispensing device 74 directs the material therein so that a liquid material can easily be placed into the packet 66 (although a solid material could likewise be placed into the packet 66). The vertical orientation of the packets 66 can be facilitated using rollers as commonly used in the food-processing art.
  • Downstream of the dispensing device 74 is a sealing device 78 which seals the filling opening 72 by attaching the edge portions 70 of the parts 16A, 16B of the label 16 together, e.g., it seals edge portion 70 of the unattached part 16B of the label 16 to the opposed edge portion 70 of the attached part 16A of the label 16 with the material 76 being sandwiched therebetween to thereby form a material-filled packet.
  • As the roll 12 continuously unwinds and the liner 14 is directed past the folding and attachment device 64, the dispensing device 74 and the sealing device 78, a series of material-filled packets connected together by the liner 14 is formed. This series of packets can be wound into a roll 80. Movement of the liner 14 from roll 12 to roll 80 can be effected by applying rotational force to roll 80 (in the clockwise direction in the configuration shown in FIG. 5). Devices for supporting and unwinding roll 12 in the unwinding station and supporting and winding roll 80 in the winding station can be any winding and unwinding devices used in a roll-based manufacturing process.
  • Folding and attachment device 64 may be designed to heat-seal and/or pressure seal the edge portions 68 of the unattached part 16B of each label 16 to the attached part 16A of the label 16. To aid in the heat-sealing and/or pressure sealing, the same techniques described above for system 10 can be applied here as well.
  • Folding and attachment device 64 is shown as a single mechanism but can alternatively, be formed as two devices separated from one another, i.e., a separate folding device can be provided followed by an attachment and sealing device for partially attaching the unattached part 16B of the label 16 to the attached part 16A of the label 16. Thus, each of the folding and attachment device 64, dispensing device 74 and sealing device 78 should be considered to represent any equipment capable of performing the functions described as being performed by these devices.
  • FIG. 7 is a schematic showing the steps in an exemplifying and non-limiting method for making a series of material-filled packets using the system shown in FIG. 5. The first step 82 is to insert the roll 12 of liner 14 into an unwinding station. The roll 12 of liner 14 is then unwound when the system 10 is ready for operation, i.e., once material to be inserted into the packets is prepared and placed into the dispensing device 74 (step 84). The liner 14 is then through a folding and attachment station wherein each label 16 on the liner 14 is folded and partially sealed to itself to form a filling opening 72 (step 86), e.g., via the folding and attachment device 64. The liner 14 is then oriented in a vertical plane (step 88) and passed into a dispensing station wherein material 76 is directed through the filling opening 72 (step 90), e.g., via the dispensing device 74. Orientation of the liner 14 in the vertical plane may occur as the liner 14 is unwound or at any time after the unwinding and before the placement of the material 76 through the filling opening 76 into the packet 66. The filling opening 72 is then sealed via the sealing device 78 (step 92) and the material-filled packets 66 thus-formed on the liner 14 are then rolled into a roll 80 in a winding station (step 94). The roll 80 can be used to dispense packets 66 simply by lifting the packets 66 off of the liner 14, i.e., pulling them off of the liner 14 to which they are adhesively attached.
  • To provide printed matter on the exposed surfaces of the packets 66, the labels 16 can be printed on the side, part of which is adhesively attached to the liner 14. As such, when the label 16 is folded over by folding and attachment device 64, the printed side forms the outer side of the packets 66.
  • The material-filled packet forming systems and methods described above therefore provided a technique to form a series of packets adhesively attached to a roll of liner material which can be rotatably mounted to thereby enable each packet to be easily removed from the roll by lifting the packets off of the liner as the roll rotates about its axis. Such a roll can be mounted at the site at which the packets are to be dispensed.
  • Moreover, the presence of the adhesive on the packets is not eliminated when the packets are removed from the liner material so that after removal from the liner material, the packets themselves can be adhesively attached to another object. A packet of salt or ketchup can therefore be adhered to a container of french fries, a packet of sugar can be attached to a cup of coffee or tea. A machine wold be provided to receive such a roll and enable automatic dispensing of the packets upon controlled rotation of the roll.
  • While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.

Claims (18)

1. A method for making a series of material-filled packets, comprising:
forming a plurality of labels on a liner with only a part of each label being attached to the liner; then
placing a quantity of material onto the part of each label attached to the liner; then
folding an unattached part of each label over the material; and then
attaching the unattached part of each label to the attached part of the label to seal the material therebetween and thereby form a series of material-filled packets connected together by the liner.
2. The method of claim 1, further comprising;
providing the liner as a roll;
unwinding the roll of liner prior to placement of the material onto the part of each label attached to the liner; and
winding the liner into a roll after attachment of the unattached part of each label to the attached part of the label.
3. The method of claim 1, wherein the plurality of labels are formed by applying a plurality of adhesive strips to the liner and then pressing only part of individual labels against the liner each against a respective one of the adhesive strips.
4. The method of claim 1, wherein attachment of the unattached part of each label to the attached part of the label comprises heat-sealing or pressure-sealing edge regions of the unattached part and attached part together.
5. The method of claim 4, further comprising coating a side of the labels opposite a side facing the liner with a coating capable of melting to itself when heat-sealed and capable of being crimped when pressure-sealed.
6. The method of claim 1, further comprising printing graphics and/or text on a side of the labels facing the liner.
7. The method of claim 1, further comprising orienting the liner in a substantially horizontal orientation when the material is placed onto the attached part of the label.
8. A method for making a series of material-filled packets, comprising:
forming a plurality of labels on a liner with only a part of each label being attached to the liner;
folding an unattached part of each label to a position opposite the part of the label attached to the liner;
only partially attaching the unattached part of the label to the attached part of the label to form a partially sealed packet having a filling opening at a top;
orienting the liner in a substantially vertical orientation and then placing a quantity of material into the partially sealed packet through the filling opening while the liner is in a vertical orientation; and then
completing the attachment of the unattached part of the label to the attached part of the label to thereby form a series of material-filled packets connected together by the liner.
9. The method of claim 8, further comprising;
providing the liner as a roll;
unwinding the roll of liner prior to placement of the material onto the part of each label attached to the liner; and
winding the liner into a roll after attachment of the unattached part of each label to the attached part of the label is completed.
10. The method of claim 8, wherein the plurality of labels are formed by applying a plurality of adhesive strips to the liner and then pressing only part of individual labels against the liner each against a respective one of the adhesive strips.
11. The method of claim 8, wherein attachment of the unattached part of each label to the attached part of the label comprises heat-sealing or pressure-sealing edge regions of the unattached part and attached part together.
12. The method of claim 11, further comprising coating a side of the labels opposite a side facing the liner with a coating capable of melting to itself when heat-sealed and capable of being crimped when pressure-sealed.
13. The method of claim 8, further comprising printing graphics and/or text on a side of the labels facing the liner.
14. A system for making a series of material-filled packets, comprising:
a liner having a plurality of individual labels partially attached thereto;
a folding device for folding an unattached part of each label to a position opposite the part of said label attached to said liner;
a dispensing device for placing a quantity of material onto a part of each label attached to said liner; and
an attachment device for attaching the unattached part of each label to the attached part,
said liner being directed past said folding device, said dispensing device and said attachment device such that a series of material-filled packets connected together by said liner is formed.
15. The system of claim 14, wherein said liner is directed in a substantially horizontal plane by said dispensing device and said attachment device is arranged to attach the unattached part of each label to the attached part of the label only after said dispensing device places material on the attached part of said label.
16. The system of claim 14, wherein said liner is directed in a substantially vertical plane by said dispensing device and said attachment device is arranged to initially only partially attach the unattached part of each label to the attached part of the label to form a partially sealed packet having a filling opening at a top and then complete the attachment of the unattached part of each label to the attached part of the label after said dispensing device places material into the packet through said filling opening.
17. The system of claim 14, wherein said liner is a roll and said series of material-filled packets is wound into a roll.
18. The system of claim 14, further comprising adhesive arranged between said liner and the attached part of each label for adhesively and removably bonding each label to said liner and enabling each material-filled packet to be adhesive attached to an object upon removal from said liner.
US11/183,597 2005-07-18 2005-07-18 Method and system for manufacturing adhesive packets Abandoned US20070011993A1 (en)

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