System and method for automatically packaging an item

Abstract

A system, apparatus, and method for automatically packaging one or more articles as a set of items to be shipped is disclosed. The system, apparatus, and method processes packaging material based at least in part on a scan of the set of items to be shipped, and forms cushioning of two matched streams of packaging material, with height of each package automated to size for the set, yielding shipping-ready customized packages. The customized packages are configured to conform to each individual article's size. The packaging material preferably is fully recyclable and is made from paper which is selectively expandable to create a cushioning layer around the set.

What is claimed: 
     
         1 . A method of making a packaging enclosure for an article, said method comprising:
 providing a pair of rolls of an expandable packaging material;   unrolling a section of the expandable packaging material per each of the pair of rolls into webs;   aligning the webs;   matching the webs into a web set;   providing the web set to a package section;   expanding the expandable packaging material of the web set in a form zone of the package section;
 wherein the expandable packaging material is configured to have a first layer that increases in length and a second layer that increases in thickness; and 
   forming the packaging enclosure from the web set after the expanding.   
     
     
         2 . The method according to  claim 1 , wherein:
 at least the first layer of the expandable packaging material comprises a crepe paper, a crinkled paper, a crimped paper, or a corrugated paper; and   at least the second layer of the expandable packaging material comprises a paper having a plurality of slits formed therein.   
     
     
         3 . The method according to  claim 2 , wherein expanding is performed by subjecting the web set to tensioning in the form zone. 
     
     
         4 . The method according to  claim 3 , wherein tensioning expands the first layer of the expandable packaging material in a first direction and expands the second layer of the expandable packaging material in the first direction and in a second direction orthogonal to the first direction. 
     
     
         5 . The method according to  claim 4 , wherein the first layer of the expandable packaging material decreases in thickness when expanding in the first direction. 
     
     
         6 . The method according to  claim 5 , wherein the second layer of the expandable packaging material decreases in width when expanding in the first direction and increases in thickness when expanding in the second direction. 
     
     
         7 . The method according to  claim 1 , wherein forming the packaging enclosure comprises:
 sealing a posterior edge of the web set;   gripping a lower portion of the web set;   gripping an upper portion of the web set; and   maintaining a separation between webs of the web set at an anterior edge of the web set.   
     
     
         8 . The method according to  claim 7 , wherein the first layer of the expandable packaging material forms an exterior surface of the packaging enclosure. 
     
     
         9 . The method of  claim 8 , further comprising:
 applying a label to the exterior surface of the packaging enclosure.   
     
     
         10 . The method of  claim 7 , further comprising:
 creating a pouch bounded and defined by the webs of the web set that are sealed by the posterior edge of the web set and gripped by the lower portion and the upper portion;   moving the gripping of the upper portion towards the lower portion; and   spreading the webs of the web set apart from each other, widening the separation thereby creating an entrance to the pouch; wherein spreading comprises:
 inserting a spreader set between the separated webs of the web set; and 
 inserting a loading chute between the separated webs of the web set. 
   
     
     
         11 . The method of  claim 10 , further comprising:
 inserting the article into the pouch;   withdrawing the loading chute;   withdrawing the spreader set; and   moving the gripping of the upper portion away from the lower portion;
 wherein the moving away from assists in securing the anterior edge of the web set such that the packaging enclosure surrounds the article. 
   
     
     
         12 . The method of  claim 11 , further comprising:
 indexing the packaging enclosure to a finish zone of the package section;   sealing the upper portion of the web set;   sealing the anterior edge of the web set; and   separating the packaging enclosure from the web above the sealing of the upper portion of the web set.   
     
     
         13 . The method according to  claim 7 , wherein:
 the step of sealing comprises:
 providing an adhesive coating on a surface of one of the first layer of the expandable packaging material and the second layer of the expandable packaging material; 
 activating the adhesive coating after expanding the web set; and 
 bonding the webs of the web set to one another with the activated adhesive coating. 
   
     
     
         14 . The method according to  claim 13 , wherein activating the adhesive coating comprises subjecting the section of the packaging material to one of heat, pressure, moisture, or combinations of the same after expanding the section of the packaging material. 
     
     
         15 . A packaging enclosure for an item; said packaging enclosure comprising:
 a packaging material comprising:
 a first layer; 
 a second layer; 
 a third layer, wherein the second layer is interposed between the first layer and the third layer; 
 at least one attachment point is provided between at least the first layer and the second layer; 
 wherein the first layer, the second layer, and the third layer, together are rolled onto a roll of a pair of rolls in an unexpanded condition and together are of a first thickness; 
 wherein a section of the packaging material unrolled from each of the rolls of the pair of rolls are matched and form a web set;
 wherein the web set is moved to an expanded condition configured to be of a second thickness that is greater than the first thickness; 
 wherein the web set is controlled such that an anterior portion has a separation maintained between a respective section of the packaging material from each of the rolls of the pair of rolls; 
 
 wherein the web set forms a front and a back of the packaging enclosure while in the expanded condition; and 
 wherein edges of the web set are secured to one another such that a pouch is bounded and defined by the front and the back, and the pouch is adapted to receive the item therein. 
   
     
     
         16 . The packaging enclosure according to  claim 15 , wherein the first layer and the third layer comprise one or more undulations therein that flatten when the section of the packaging material is moved to the expanded condition. 
     
     
         17 . The packaging enclosure according to  claim 16 , wherein the first layer and the third layer are comprised of at least one of a crepe paper, a crinkled paper, a crimped paper, and a corrugated paper. 
     
     
         18 . The packaging enclosure according to  claim 16 , wherein the second layer comprises a sheet of paper having a plurality of slits formed therein, and wherein the plurality of slits expands to form honeycomb openings in the second layer when the section of the packaging material is moved to the expanded condition. 
     
     
         19 . The packaging enclosure according to  claim 15 , wherein:
 the edges of the web set being secured comprise:
 edges of the web set temporarily being gripped together; or 
 edges of the web set being sealed together; or 
 the edges of the web set temporarily being gripped together being sealed together; and 
 wherein sealing provides:
 an adhesive coating having been applied on a surface of one of the first layer of the expandable packaging material and the second layer of the expandable packaging material; 
 an activation of the adhesive coating after the web set has been moved to the expanded condition; and 
 a bonding of the webs of the web set to one another with the activated adhesive coating. 
 
   
     
     
         20 . The packaging enclosure according to  claim 19 , wherein:
 the activation of the adhesive coating comprises subjecting the web set to one of heat, pressure, moisture, or combinations of the same after the web set has been moved to the expanded condition.