EP1642836A1

EP1642836A1 - Wicketed bag fabrication and packaging process

Info

Publication number: EP1642836A1
Application number: EP05256117A
Authority: EP
Inventors: Peter R. Hudetz; Ronald R. Hatch
Original assignee: Solar Communications Inc
Current assignee: Solar Communications Inc
Priority date: 2004-10-01
Filing date: 2005-09-29
Publication date: 2006-04-05
Also published as: US20060070351A1

Abstract

A wicketed bag fabrication and packaging process includes forming a continuous series of wicketed bags (10) by feeding a continuous web (52) and attaching articles to the web (52). A continuous series of pre-packaged articles or individual pre-formed articles are provided and attached to the web (52) to form wicketed bags (10) having one or more of the pre-packaged articles or pre-formed articles attached thereto.

Description

TECHNICAL FIELD

The present invention relates, generally, to wicketed bag manufacturing bag processes and, more particularly, to methods of making wicketed bags having secondary or external compartments, such as kangaroo pouches, and the like.

BACKGROUND

Wicketed bags have traditionally been used for packaging an assortment items, such as purchased consumer products, newspapers, magazines, advertising flyers, and other commercial materials. Printed materials are typically widely distributed to large numbers of customers at both residential and commercial locations. To take advantage of the advertising potential associated with the wide-spread distribution of such materials, external compartments have been added to the wicketed bags. The external compartments or pouches are used to enclose various articles, such as advertising literature and product samples, and the like. In the newspaper industry, for example, newspapers are delivered to subscribers in wicketed bags configured to include sealed pouches for enclosing additional articles. It is common in the newspaper industry to have the product samples or printed materials inserted into a kangaroo style pouch. The kangaroo pouch is either formed on, or an integral part of, a lower portion of the wicketed bag. Typically, the newspaper distributors receive the wicketed bags having articles already sealed in the pouches. The distributor then inserts the newspapers into the wicketed bags for delivery to subscribers.
To provide users such as retailers, event marketers, newspaper publishers, and the like with wicketed bags having articles enclosed within the kangaroo pouch, manufacturing processes for fabricating wicketed bags having external compartments have been developed. Typically, wicketed bags are fabricated by high-speed bag machines, known as wicketer machines. These machines operate at a high speed using a roll of plastic film that is known in the industry as a web. The web is processed in the bag machine to form a compartment. The web is first folded to produce a bottom edge and then cross sealed and cut to form individual wicketed bags. Once the wicketed bags are formed, they can be suspended from a wicket holder for delivery to a media distributor or other user.
Several techniques have been developed for creating an external compartment on the outside of wicketed bags. Many of these techniques include the use of an additional web that is brought together with the web used to fabricate the wicketed bag. The external compartment is then formed by heat sealing the second web to the first web. Other methods use sophisticated folding and sealing techniques of a single web or multiple webs to create two compartments. The fabrication method produces wicketed bags having a large internal compartment and a smaller external compartment.
Once the wicketed bags having the external compartment are fabricated, articles, such as printed materials or advertising samples are inserted into the external compartments. The bags can have articles inserted into the external compartment immediately after fabrication, or the bags are transferred to a third party for insertion of the articles into the external compartment. The placement of the articles into the external compartment is typically carried out by hand or by an automatic insertion process. After the articles are placed in the external compartment, the compartment may or may not be sealed and the wicketed bags are delivered to a media distributor, such as a newspaper distributor, for placement of newspapers in the larger internal compartment of the wicketed bag.
Overall, the process of fabricating wicketed bags having articles enclosed within an external compartment involves first fabricating the wicketed bag and the external compartment, then inserting articles in the external compartment or delivering the wicketed bag to a third party, who then inserts articles into the external compartment. The insertion of articles is typically done by hand, after which the external compartment may or may not be sealed. Lastly, the bags containing the articles are shipped to a marketer or a media distributor for further use. In the case of a media distributor, the distributor inserts newspapers or advertising into the wicketed bags for delivery to a customer or subscriber.
The process of creating wicketed bags with external compartments, and inserting articles into the compartments is lengthy and labor intensive. Although bag forming processes have been developed for fabricating wicketed bags having external compartments, human intervention is often required at the process stage between bag fabrication and delivery to a marketer or distributor for final processing.

BRIEF SUMMARY

In accordance with one embodiment of the invention there is provided a wicketed bag fabrication and packaging process. The packaging process includes forming a continuous series of wicketed bags. A plurality of articles is provided, and the articles are attached to the wicketed bags.
In another embodiment of the invention, a method for fabricating wicketed bags includes folding a web to form an outer surface and articles are provided and attached to the outer surface.
In yet another embodiment of the invention, a method for fabricating wicketed bags includes feeding a continuous web at a web feed rate and folding the web to form an outer surface. A continuous series of articles are fed in substantial synchronization with the web feed rate and continuously attached to the outer surface.
In still another embodiment of the invention, a method for fabricating wicketed bags includes providing a web having an outer surface and providing a plurality of individual articles. The individual articles are sequentially attached to the outer surface.
In a further embodiment of the invention, a packaging process includes forming a continuous series of wicketed bags at a bag process rate. A continuous bandolier of pre-packaged articles is fed in substantial synchronization with the bag process rate, and the pre-packaged articles are continuously attached to the wicketed bags.
In a still further embodiment of the invention, a packaging process includes forming a continuous series of wicketed bags at a bag process rate.
A continuous roll of pre-packaged articles is fed in substantial synchronization with the bag process rate, and the pre-packaged articles are continuously attached to the wicketed bags.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1a is a plan view of a wicketed bag having an external compartment fabricated in accordance with one embodiment of the invention;
FIG. 1b is a cross-sectional view of the wicketed bag of FIG. 1a, taken along section line 1b-1b of FIG. 1a.;
FIG. 2a is a plan view of wicketed bag having an external compartment fabricated in accordance with another embodiment of the invention;
FIG. 2b is a cross-sectional view of the wicketed bag of FIG. 1a, taken along section line 2b-2b of FIG. 2a;
FIG. 2c is an expanded view of a the external compartment illustrated in FIG. 2a and 2b;
FIG. 3 is a schematic diagram illustrating a bag fabrication process in accordance with a first processing embodiment of the invention;
FIG. 4 is a schematic diagram of a continuous series of pre-packaged articles and a feeding apparatus for the pre-packaged articles, arranged in accordance with an embodiment of the invention;
FIG. 5 is a schematic diagram of a bag fabrication process in accordance with a second processing embodiment of the invention;
FIG. 6a is a schematic diagram of a device for feeding pre-packaged articles in the bag fabrication process in accordance with an embodiment of the invention;
FIG. 6b is a schematic diagram of another device for feeding pre-packaged articles in the bag fabrication process in accordance with an embodiment of the invention; and
FIG. 7 is a schematic diagram of a bag fabrication process in accordance with a third processing embodiment of the invention.
It will be appreciated that for simplicity and clarity of illustration, elements shown in the Figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements are exaggerated relative to each other for clarity. Further, where considered appropriate, reference numerals have been repeated among the Figures to indicate corresponding elements.

DETAILED DESCRIPTION

Shown in FIGs. 1a and 1b is a wicketed bag 10 having an external compartment 12 attached to an outer surface 14 of wicketed bag 10. Wicketed bag 10 is preferably fabricated from a thermoplastic material and has a folded edge 16 and sealed edges 18 and 20. An internal compartment 22 in wicketed bag 10 is created by folding the thermoplastic material to create folded edge 16 and cross sealing the thermoplastic to form sealed edges 18 and 20.
FIG. 1b is a cross-sectional view of wicketed bag 10, taken along section line 1b-1b of FIG. 1a. As illustrated in FIG. 1b, external compartment 12 is attached to a lower portion 24 of wicketed bag 10. External compartment 12 contains an article 26 within a compartment 28 of external compartment 12. External compartment 12 includes a closure seal 30, which can be a perforated seal, in an upper portion of external compartment 12. In other embodiments, closure seal 30 can be a lap seal, heat seam, grooved seal, folded flap seal, and the like.
In the embodiment illustrated in FIGs. 1a and 1b, external compartment 12 is attached to lower portion 24 of wicketed bag 10 by a variety of attachment methods. For example, external compartment 12 can be attached by an adhesive material placed directly on either lower portion 24 of wicketed bag 10 or on the upper portion of external compartment 12. Additionally, external compartment 12 can be attached to wicketed bag 10 by a double-sided adhesive tape that includes a backing material and a coating of adhesive on both sides of the backing material (not shown). Further, external compartment 12 can be attached to wicketed bag 10 by heat sealing the plastic materials of wicketed bag 10 and external compartment 12 to form a continuous melt of thermoplastic material. Further, other types of attachment mechanisms are contemplated, such as fiber thread stitching, sewing, weaving, and the like.
Wicketed bag 10 also includes holes 32 in an upper portion of the wicketed bag. Holes 32 can be used to suspend wicketed bag 10 from a wicket holder, or other bag attached device.
Wicketed bag 10 and external compartment 12 are configured to enclose a variety of articles within internal compartment 22 and internal compartment 28, respectively. Those skilled in the art will appreciate that the bag structure illustrated in FIGs. 1a and 1b can be used to package a wide variety of materials, including printed materials, advertising samples, physical objects, such as product samples, plastic bottles, promotional items, and the like.
FIG. 2a is a plan view of a wicketed bag 34 fabricated in accordance with another embodiment of the invention. FIG. 2b is a cross-sectional view of wicketed bag 34 taken along section line 2b-2b of FIG. 2a. Wicketed bag 34 includes an external compartment 36 attached to an outer surface 38 of wicketed bag 34. FIG. 2c is an expanded view of external compartment 36 detached from wicketed bag 34.
In the embodiment illustrated in FIGs. 2a-2c, external compartment 36 is attached to outer surface 38 of wicketed bag 34 at a position on outer surface 38 displaced away from a fold 40 of wicketed bag 34. External compartment 36 encloses an article 42 within an internal compartment 44. External compartment 36 is closed by a flap seal 46. Alternatively, external compartment 36 can be closed by a perforated seal, glue seam, and the like.
External compartment 36 can be attached to outer surface 38 of wicketed bag 34 using attachment techniques similar to those described above for attachment of external compartment 12. Further, external compartment 36 can be attached to outer surface 38 along the entirety of an interface 48 between external compartment 36 and outer surface 38 of wicketed bag 34. Alternatively, external compartment 36 can be attached to outer surface 38 at only an upper portion of the interface, or at regular or irregular intervals along interface 48. In the illustrated embodiment, external compartment 36 is attached to wicketed bag 34 at flap seal 46. Alternatively, the external compartment can be attached by an adhesive 49 to one or more locations along the interface 48.
In similarity to the embodiment illustrated in FIGs. 1a and 1b, wicketed bag 34 includes holes 50 in an upper portion of the wicketed for attachment to a wicket holder, or other containment device. In the embodiment invention illustrated in FIGs. 2a-2c, article 42 can be any of a wide variety of articles including written materials, physical objects, plastic articles, including toys and other promotional articles, and the like.
FIG. 3 is a schematic diagram of a process in accordance with a first embodiment of the invention for fabricating wicketed bags having pre-packaged articles attached thereto. The processes illustrated herein employ a variety of processing equipment known to those skilled in the art. Accordingly, the processing equipment is only generally depicted in schematic form. Further, many component parts of the actual equipment used in bag machines have been omitted to improve the clarity of the illustration.
In the illustrated embodiment, a web 52 of thermoplastic material is fed from a roll 54 through a plough fold 56. Plough fold 56 includes a top roller 58 and a roller pair 60. The process illustrated in FIG. 3 can be used to fabricate wicketed bag 10 having external compartment 12 attached thereto. In the illustrated process, external compartment 12 is pre-packaged to enclose article 26 within compartment 28 prior to being provided for attachment to the thermoplastic material forming wicketed bag 10. In the illustrated embodiment, a horizontal or vertical form and fill packaging is configured to fabricate wicketed bags having pre-packaged external compartments attached in a continuous process.
Web 52 is continuously fed from roll 54 to plough fold 56 and is continuously conveyed in a process direction 62 at a predetermined web feed rate. In the illustrated embodiment a continuous series of pre-packaged enclosures is fed from a roll 66 and aligned to folded web 68. An adhesive or other attachment device, such as a tape, and the like, is applied to an upper edge of pre-packaged enclosure 64. In the illustrated embodiment, a hot melt glue applicator 70 extrudes a stream of glue along an upper edge 72 of pre-packaged enclosure 64. The feed rate of pre-packaged enclosure 64 from roll 66 is substantially synchronous with the transfer rate of folded web 68 and process direction 62. Accordingly, pre-packaged enclosure 64 are brought into contact with folded web 68 under conditions in which both pre-packaged enclosures 64 and folded web 68 are moving in process direction 62 at substantially the same rate. A pressure roller 74 applies pressure to a support roller 76 and provides a compression force for adhesively attaching pre-packaged enclosure 64 to folded web 68. Those skilled in the art will appreciate that other devices can be used for compressing folded web 68 against pre-packaged enclosure 64. For example, pressure can be applied by a pneumatically-actuated surface or spring-loaded mechanical device, and the like. Further, the pre-packaged enclosures can be attached to the upper surface of folded web 68 rather than to the lower surface as depicted in the illustrated embodiment.
Simultaneous with the attachment of pre-packaged enclosure 64 to folded web 68, a series of holes 32 are punched in an upper portion of folded web 68 by a perforating device 78.
Once pre-packaged enclosure 64 are attached to folded web 68 and holes 32 are punched in folded web 68, the web and the pre-packaged enclosures are transversely sectioned by a cross sealing device 80. Cross sealing device transversely cuts folded web 68 and pre-packaged enclosures and simultaneously forms sealed edges to produce individual units, such as wicketed bag 10 having external compartment 12 attached thereto.
After separating individual units, the wicketed bags are stacked by a bag stacking device 82 and placed on wicket holders 84. Accordingly, a process in accordance with the illustrated embodiment produces a large volume of wicketed bags having pre-packaged enclosures in a continuous process carried out at a high process rate. Once the wicketed bags and pre-packaged enclosures are separated into individual units, they can be shipped to distributors for insertion of desired articles into the internal compartments, such as internal compartment 22 of the wicketed bags. Since articles are already pre-packaged in the external compartments, the distributor or other user does not have to provide facilities and personnel for inserting articles into the attached enclosures. Once the process in accordance with the illustrated embodiment, no further action is required by a user to insert articles into the external compartment. Those skilled in the art will appreciate that automated means can also be carried out for inserting articles into the internal compartments of the wicketed bag for ultimate delivery to subscribers or to customers.
An apparatus and method for providing a continuous series of prepackaged articles is illustrated in FIG. 4. A continuous series of pre-packaged articles 86 is contained within a carton 88. Pre-packaged articles 86 are arranged in a bandolier that lays in multiple folds within carton 88. A feed roller pulls the bandolier of pre-packaged articles 86 out of carton 88 and transports the prepackaged articles and process direction 62. The bandolier is continuously fed in process direction 62 at a rate that is substantially synchronous with the feed rate of folded web 68. In the embodiment illustrated in FIG. 4, the bandolier of prepackaged articles 86 can be attached at a distal end 92 to another bandolier of pre-packaged articles (not shown) that is fed from an additional carton (not shown). In this way, a continuous series of pre-packaged articles can be fed into the wicketed bag fabrication process without the need to interrupt the process in order to provide a fresh carton of pre-packaged articles. Those skilled in the art will appreciate that different methods of feeding the bandolier of pre-packaged articles can be used to draw the continuous series out of carton 88. For example, a friction-feed device, a conveyer mechanism, or other handling device can be provided inside of or proximate to carton 88. '
A process for fabricating wicketed bags having pre-packaged articles attached thereto in accordance with a second processing embodiment is illustrated in FIG. 5. In similarity to the process embodiment described above, a continuous web 92 of thermoplastic material is fed from a roll 94 through a plough fold 96. Plough fold 96 folds the web into a folded web 98 that punched by hole punch 99 and transported in a process direction 100. An applicator 102 applies adhesive 104 to folded web 98. Adhesive 104 can be a variety of adhesive materials including epoxies, cements, glues, and the like. Further, adhesive 104 can be delivered to folded web 98 in the form of a backing material having an adhesive layer on the front and backside of the backing material. Those skilled in the art will recognize that a number of adhesive tapes and labels commonly used in the packaging industry can be employed to provide a region of adhesive material on folded web 98. Further, rather than place adhesive on the web, adhesive can be placed on the articles prior to positioning on the web.
A feeding device 106 sequentially places individual pre-packaged articles onto adhesive 104, such that a series of pre-packaged articles 108 are sequentially positioned on folded web 98.
Once pre-packaged articles 108 are attached to folded web 98, a cross cutting and sealing process and a wicket stacking process is carried out in a manner similar to that described above. A cross sealing device cross seals folded web 98 and cuts the web into individual units, such as a wicketed bag 34, where each wicketed bag 34 has an external compartment 36 attached thereto.
A stacking device 110 sequentially stacks wicketed bags 34 on a wicket holder 112. The wicket holder remains stationary while the bags are stacked on a pair of wires. Once a predetermined number of wicketed bags are stacked on a given pair of wires, the wicket holder is indexed. The index rate is set so as to permit the predetermined number of bags to be sequentially stacked on each pair of wires.
In similarity to the processing embodiment described above, once articles are attached to the wicketed bags, they can be subsequently packaged and delivered to a marketer, distributor, or other user. Those skilled in the art will appreciate that the process illustrated in FIG. 5 can also be used to attach various objects to the wicketed bags, such as plastic promotional items, bound booklets, folded paper materials, and the like.
FIGs. 6a and 6b illustrate alternative embodiments of the invention for delivering individual pre-packaged articles 108 to folded web 98. FIG. 6a illustrates a shuttle device 114 that uses a roller 116 and a friction belt 118 to deliver pre-packaged articles 108 from a stacking bin 120.
FIG. 6b is a schematic diagram of a rotary feed device 122 that delivers pre-packaged articles 108 from a stacking bin 124 and a vacuum rotary 126.
Those skilled in the art will appreciate that other feeding devices exist and can be used to deliver pre-packaged articles 108 to folded web 98. For example, a pick and place machine or other type of vacuum conveying device can also be used.
FIG. 7 is a schematic diagram that illustrates a process for fabricating wicketed bags having pre-packaged articles attached thereto in accordance with a third processing embodiment of the invention. The process illustrated in FIG. 7 is substantially similar to that of the second processing embodiment described above. Once web 92 is fed from roll 94 through plough fold 96 and punched by hole punch 99, applicator 102 places adhesive 104 on folded web 98. In the present embodiment, applicator 102 places an additional adhesive 105 at a location displaced along folded web 98 a predetermined distance from adhesive 104. Further, applicator 102 alternates the dispensing of adhesive, such that adhesive 104 and 105 are staggered on folded web 98 along processing direction 100. Alternatively, the adhesive can be applied to the pre-packaged articles prior to placement on the web.
A feeding device 128 provides pre-packaged articles for attachment to both adhesive 104 and adhesive 105. Accordingly, one group of pre-packaged articles 130 is attached to adhesive 104, while a second group of pre-packaged articles 132 is attached by adhesive 105.
Once the pre-packaged articles are attached to folded web 98, cross sealing and stacking operations are carried out in a manner substantially similar to that described above with respect to the first and second processing embodiments. The process in accordance with the third processing embodiment of the invention produces two groups of wicketed bags 134 and 136, each having pre-packaged articles attached at different locations along the outer surface of the wicketed bag. The first group of wicketed bags 134 has pre-packaged articles 130 attached in a lower portion of the outer surface, while a second group of wicketed bags 136 has pre-packaged articles 132 attached at an upper portion of the outer surface. In another embodiment, the pre-packaged articles can be attached in an alternating fashion to the left and right sides of the wicketed bags.
Wicketed bags produced in accordance with the third processing embodiment can provide bags having pre-packaged articles attached at different locations on the outer surface of the wicketed bag. When the articles are arranged in an alternating location on the wicked bags, the wickets bags do not stack to the same height as bags in which the articles are all at the same location on the wicketed bags. Accordingly, by attaching the pre-packaged articles at alternating locations, the wicketed bags can be stacked on wicket holders 112 and handled in an efficient manner.
Further, the attachment of articles at different locations on the wicketed bags can be particularly advantageous for customized delivery of wicketed bags to different distributors and other users. For example, one type of article, such as advertising literature, may be better positioned on the wicketed bag by placement in either an upper or lower location on the outer surface. Further, where the pre-packaged articles are objects such as promotional items, it may be advantageous to locate the promotional item at a particular place on the outer surface of the wicketed bag.
Those skilled in the art will recognize that a process carried out in accordance with the various embodiments of the invention can be used to fabricate wicketed bags that alternatively contain different pre-packaged articles and non-packaged articles. For example, first group of wicketed bags 134 can be fabricated to include objects within the external compartment, while second group of wicketed bags 136 can be fabricated to include written materials in the external compartment. Further, more than one article can be inserted in the external compartment.
Thus, it is apparent that there has been described a wicketed bag fabrication and packaging process that provides the advantages set forth above. Although the invention has been described and illustrated with reference to specific illustrative embodiments thereof, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in the art will recognize that variations and modifications can be made without departing from the spirit of the invention. For example, various packaging materials can be used to fabricate the wicketed bags and the external compartments. For example, rather than plastic materials, paper materials can be used. It is, therefore, intended to include within the invention all such variations and modifications that fall within the scope of the appended claims and equivalence thereof.

Claims

A packaging process comprising:
forming a continuous series of wicketed bags;

providing a plurality of articles; and

attaching the articles to the wicketed bags.
The packaging process of claim 1, wherein attaching the articles comprises attaching pre-packaged articles to a lower portion of the wicketed bags.
The packaging process of claim 1, wherein attaching the articles comprises attaching the articles to an outer surface of the wicketed bags.
The packaging process of claim 1, wherein attaching the articles comprises alternately attaching at least two different articles to at least two different locations on the wicketed bags.
The packaging process of claim 1 further comprising forming holes in an upper portion of the wicketed bags and suspending the wicketed bags on a wicket holder.
A method for fabricating wicketed bags comprising:
folding a web to form an outer surface;

providing articles; and

attaching the articles to the outer surface.
The method of claim 6, wherein folding the web comprises forming a folded bottom edge and an open top edge.
The method of claim 6 further comprising cross-cutting the web into individual sections after folding the web.
The method of claim 6, wherein providing articles comprises providing sealed enclosures each containing at least one item.
The method of claim 9, wherein providing sealed enclosures each containing at least one item comprises providing sealed enclosures containing printed material.
The method of claim 9, wherein providing sealed enclosures each containing at least one item comprises providing sealed enclosures containing a physical object.
The method of claim 9, wherein providing sealed enclosures comprises providing plastic pouches sealed on at least two sides and having a perforation line therein.
The method of claim 6, wherein attaching the articles to the outer surface comprises heat sealing the articles to the outer surface.
The method of claim 6, wherein attaching the articles to the outer surface comprises providing a backing material having an adhesive thereon and adhesively attaching the articles to the outer surface.
The method of claim 6, wherein attaching the articles to the outer surface comprises gluing the articles to the outer surface.
The method of claim 6 further comprising feeding the web at a web feed rate, and wherein providing articles comprises providing a continuous supply of pre-packaged articles and feeding the pre-packaged articles from the continuous supply at a rate substantially synchronized with the web feed rate.
The method of claim 16 further comprising simultaneously cross cutting the web and the continuous supply of pre-packaged articles.
The method of claim 16, wherein providing a continuous supply of pre packaged articles comprises providing a continuous roll supply of pre-packaged physical objects.
The method of claim 16, wherein providing a continuous supply of pre packaged articles comprises providing a continuous roll supply of pre-packaged printed materials.
The method of claim 6, wherein providing articles comprises providing a feeding device containing a plurality of individual articles, and wherein attaching the articles to the outer surface comprises applying adhesive and sequentially attaching the articles with the adhesive.
The method of claim 20, wherein applying adhesive comprises applying adhesive to the outer surface of the web.
The method of claim 20, wherein applying adhesive comprises applying adhesive to the articles.
The method of claim 20 further comprising cross-cutting the web to form individual units.
The method of claim 20, wherein providing a feeding device comprises providing at least two feeding devices positioned at different locations in proximity to the outer surface of the web.
The method of claim 20 further comprising forming holes in an upper portion of the web, and suspending the individual units on a wicket holder.
The method of claim 6, wherein providing articles comprises providing an article selected from the group consisting of envelopes, folded paper, and paper wrap.
The method of claim 6, wherein providing articles comprises providing bound booklets.
The method of claim 6, wherein providing articles comprises providing plastic vessels.
The method of claim 6, wherein providing articles comprises providing boxes.