Method and system for manufacturing adhesive packets
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.
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 INVENTIONIn 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 INVENTIONAccordingly, 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 DRAWINGSThe 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.
Referring to the accompanying drawings wherein like reference numerals refer to the same or similar elements,
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
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
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
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
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.
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.
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
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
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
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.
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
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.
Type: Application
Filed: Jul 18, 2005
Publication Date: Jan 18, 2007
Inventor: Jack Salvatore Mannoia (Peru, VT)
Application Number: 11/183,597
International Classification: B65B 43/02 (20060101);