Field of Invention

[0001] The present invention relates, in general, to the field of the transportation and storage of goods and, in particular, to a container, box or box-like container or mailer box that can be fabricated, loaded with product placed upon or inserted therein and sealed for distribution in a reduced number of steps. More particularly, the present invention relates to storage containers formed and packed as mailers in a distribution hub. In another aspect, the invention relates to a method of fabricating single-sided corrugate material for use in the manufacturing of containers, box or box-like containers and mailers.

Background to the Invention

[0002] Recent advances in communications technologies enable access to the Internet from anywhere in the world. Concomitant with this, in the field of logistics, an area which has seen a significant rise in activity, is the area relating to internet delivery services industry. Moreover, there has been a shift in consumer preferences driven by convenience and an easy accessibility to the internet, assisted by the C-19 pandemic, with lockdowns of various degrees reducing or indeed preventing footfall in shops. In fact, many companies provide direct to customer goods from an online shop

[0003] Further, cyclical recessionary worries aside, the improving macro- economic environment provides strong support to the increasing income levels of consumers, which in turn boosts their willingness to spend. This is evident from the surge in demand for food delivery, online travel booking, direct marketing and media services, web hosting among others. However, an increasing demand for delivery services has caused associated industries to spring up. Rather than shops providing a mail-order service, industry has seen the growth of companies such as Amazon with distribution centres, having robot picking and highly automated packaging machinery. As is well known, the Covid-19 crisis became an unprecedented global health issue impacting communities and families across the globe; at least one internet based agency supported the UK Government by using their logistics networks to deliver test kits to the homes of essential workers. In turn such collaboration extended so as to provide new testing capacity with the creation of additional hub laboratories, test centres and a delivery service for home testing, employing return of test kits - provided in suitable mailers.

[0004] Various types of envelopes having cushioning properties for packaging precision machines, electrical parts, medical instruments, jewellery, cosmetics, CDs, cassette tapes and the like that are fragile and/or brittle have been proposed. For example, in US7108650, and as shown in Figure 1, there is taught an envelope comprising of layers of plain un-coated kraft paper and of bubblewrap polyethylene. A stack of the layers is joined at the marginal edges of the envelope by squeezing the stack between a pair of points-dies, which are formed with points that puncture the kraft paper but do not puncture the polyethylene. The points push crowns of un-punctured polyethylene through the punctured holes in the paper and the marginal edges are squeezed flat between flat-dies, the flat-dies being heated enough to cause fuse-bonding of the stretched plastics material. The margins of the finished envelope are held together not only by fusebonding, but by the presence of the crowns, which, penetrating right through the holes in the paper, serve as mechanical rivets, akin to the edge crimping of a pastry. However, in such an envelope, the paper of the envelope and the plastic bubble sheet cushioning material must be separated when discarding, which takes time and effort, which can have an effect with regard to recycling issues. Figure 2 shows a still further piece part envelope blank, with reference numeral 135 indicating corrugation direction (sheet width). Figure 3 shows an early form of bubble - wrap envelopes, per US3018015, dating from 1957. Such envelopes are fabricated from piece-part sheet material that have been stamped from a flat sheet of corrugated board, using a die-board cutting process. Many systems of providing mailers comprise the use of envelope or bag-like systems which provide a unity of construction technique, but suffers from, typically over use of materials to package small goods.

[0005]Cardboard and Corrugated cardboard is widely used in packaging. However, the construction of boxes, necessarily requires a piece-part form of manual construction, filling and closing. Moreover, there is always a problem with substantial "dead" space within a box, especially in the field of internetpurchases, where any such dead space in a box is frequently occupied by bubblebags - plastics bag filled with gas which are employed to prevent substantial movement of a product when placed within a cardboard delivery box. Again, similar to envelopes, cardboard boxes are fabricated from piece-part sheet material that have been stamped from a flat sheet of corrugated board, using a die-board cutting process, with the resultant mailers being of uniform size. Notwithstanding the above, substantially planar card is frequently employed in the mailing of magazines, calendars and the like, where the substantially rigid card ensures integrity can also be employed; pre-formed envelopes can be provided with short edge openings, but these are slow to pack and despatch; others exist with brown paper on one side with folding tongue for securement against a stiff card backing side.

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RECTIFIED SHEET (RULE 91) ISA/EP [0006] In automated systems, double-sided adhesive tape has been employed, but such methods of fastening are susceptible to dust problems. Glue based systems have not been widely successful, despite the wide range of glues available. PolyVinyl Acetate glue (PVA) or is a colourless, odourless, transparent glue that is often used with respect to cardboard and paper, and provides a benefit in that it forms a degree of water resistance, but takes hours to dry. Rubber cement comprises liquefied rubber retained within chemical solvents; when the glue dries, the solvents evaporate leaving a thin solid layer of rubber on the substrate. Whilst rubber-based glue holds pretty well for all cardboard products and benefits from providing a degree of weather-resistance, it is nonetheless, sensitive to the passage of time when the bonds become less secure and the adhesion provided will diminish over time. So called "super glue" or cyanoacrylate glue gives a fast, permanent bond on many substrates - but it can't be used on porous materials such as paper and cardboard. Craft glues can be employed in a number of situations including paper and cardboard, is relatively thicker than most glues and need time to dry. Hot melt adhesives are basically a gluing material that sticks as it cools down. The product itself came in the form of a solid stick which is dispensed by a heater applicator, but results in relatively inflexible joins between paper and cardboards. However, if too hot, the glue will take time to set and, if too cold, the glue would solidify before you could bond the other piece. Polyurethane adhesive can be applied on basically anything including wood, plastic, glass, and even concrete, but needs hours to properly adhere materials together.

[0007] There exists a need for a more adaptable process for manufacturing cardboard mailers to enable manufacture and filling thereof to be simply and sustainably created. Moreover, by providing a body formed from cardboard, then the item can be readily be recycled after use.

Object of the Invention

[0008] The present invention seeks to provide a solution to the problems addressed above. The present invention seeks to provide a postal/courier package or mailer which can be manufactured at low cost and can readily and easily be constructed. The present invention seeks to provide a postal/courier package or mailer which can be simply varied in size. The present invention seeks to provide a postal/courier package or mailer which can be varied in size from one mailer to the next, as required. Furthermore, the present invention seeks to provide a container that is manufactured from readily recyclable products and

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RECTIFIED SHEET (RULE 91 ) ISA/EP when completed can maintain goods within a protective arrangement to protect from physical damage under typical transport conditions.

Statement of Invention

[0009] In accordance with a general aspect of the invention, there is provided a system for manufacturing mailers or containers using a flexible, single-sided corrugate sheet material.

[0010] In accordance with a first aspect of the invention, there is provided a process for manufacturing and filling mailers, the process comprising the steps of; receiving a roll of single face corrugated paper comprising a first generally planar sheet and a corrugated sheet which is adhered together along a common place, the corrugations of the corrugated paper having a direction and the roll having an axis of rotation about which the roll can rotate to provide a continuous sheet of corrugated paper in a direction of output, the roll of corrugated paper having a first end distal to the roll, and a second end being at the centre of the roll; the roll of corrugated paper having a width, extending from a first peripheral side to a second peripheral side; applying a series of generally rhomboidal embossments across in a regular pattern oblique relative to the direction of corrugation, wherein the embossments provide an increased flexibility to the single face corrugated paper to enable folding operations to be performed by machinery to enable the paper to wrap about a product and to enable adhesive fastening thereof. Conveniently, the embossment is performed by a single roller device with two sets of obliquely arranged parallel upstanding members. Alternatively, the embossment is performed by a two roller devices, which apply sequentially first and second oppositely directed sets of obliquely arranged parallel upstanding members. The embossment can be also be alternatively be provided by a die board embossment device. The embossment can be performed about the peripheral regions of the corrugated sheet material.

[0011] In accordance with a further aspect of the invention, the embossed sheet is presented at a process station wherein a cutter cuts a portion of corrugated sheet material from the roll of corrugated sheet material. The or a separate cutter can be operated to trim the extent of the peripheral portions of the portion of corrugated paper sheet, to enable the amount of corrugated sheet material to correspond with a product to wrapped. The portion of corrugated paper sheet can then be presented at an adhesive application station wherein at least one of an adhesive or an adhesive tape is applied to selected areas of the corrugated sheet material. The portion of corrugated paper sheet can then be presented at a wrapping station wherein a product is placed upon a portion of the sheet.

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RECTIFIED SHEET (RULE 91 ) ISA/EP [0012] At the wrapping station the methods in accordance with claims 9 - 14 can be applied. In certain circumstances the order of applying the procedures can be varied as will be appreciated by the skilled person. An advantage of the invention is that a flexible mailer can be provided for various products including books, items of clothing and many other types of product that are provided by mail order/internet delivery companies. The lengths of the packages - under the control of an apparatus or system controller can ensure that there is a minimum amount of dead space in the packages.

[0013] In accordance with another aspect of the invention there is provided an apparatus to manufacture the mailer in accordance with any one of claims 1 to 14.

[0014] In accordance with another aspect of the invention there is provided a process according, wherein the embossed sheet is provided to a process station wherein a substantially continuous marking being parallel with the direction of output is provided to the sheet which is then fed to a sack forming machine, the process further comparing the steps of: feeding the first end of the roll having markings applied thereto into a sack forming machine; folding the corrugated paper sheet about said substantially continuous marking within the machine, whereby to define a central cavity extending from the distal end, with an overlap section depending from the distal end; placing an item to be mailed within the cavity; sealing the corrugated paper sheet at the distal end; sealing the corrugated paper sheet along the overlap section; sealing the corrugated paper sheet at a proximal end, opposite the distal end, whereby to form a mailer; cutting the corrugated paper sheet at the proximal end to release the mailer and to define a new distal end of the roll of corrugated paper, to permit the process to be repeated.

[0015] In accordance with another aspect of the invention there is provided an apparatus to manufacture the mailer in accordance with any one of claims 15 to 19.

[0016] In accordance with a further aspect of the invention there is provided a process for manufacturing and filling mailers, according to any one of claims 1 - 4, the process comprising the further steps of; presenting a distal end of the corrugated sheet material to a conveyor packing station; placing a product to be wrapped upon a central section of the corrugated sheet material; conveying the corrugated sheet material to a wrapping station where, first and second manipulator arms or directional elements are operated to cause peripheral edges of the corrugated sheet material to overlie the product and for one peripheral side edge to overlap a second peripheral edge of the sheet, with an adhesive being employed to attach opposite side portions together; moving overlapped corrugated paper sheet along the conveyor to a sealing station wherein first and second jaws apply pressure and one or more of adhesive, heat and stapling to simultaneous seal a distal end of one package and a proximal end of the adjacent package; cutting the seal by use of a cutting means across the seal whereby to permit the distal package to be separated from the corrugated sheet material. As will be appreciated, the process effects control of the movement of the corrugated sheet material such to minimize dead space, taking into account seal portions of the wrapped corrugated sheet material to seal the two together with the knowledge of the length of product, though knowledge of the specific dimensions known to a system controller or by the use of a sensor system such as an electrooptic sensor.

[0017] In accordance with a further aspect of the invention, there is provided an apparatus for manufacturing and filling mailers, the apparatus comprising; a roll support mechanism for supporting a roll of single face corrugated paper comprising a first generally planar sheet and a corrugated sheet which is adhered together along a common plane, the corrugations of the corrugated paper having a direction; the roll support mechanism providing bearings to permit the roll to rotate about an axis of rotation whereby to provide a continuous sheet of corrugated paper in a direction of output, the roll of corrugated paper having a first end distal to the roll, and a second end being at the centre of the roll, the roll of corrugated paper having a width, extending from a first peripheral side to a second peripheral side; the roll support mechanism providing the roll of corrugated sheet to a work place conveyor whereby to provide the corrugated sheet material to one or more work stations; wherein the apparatus comprises a drive system operable to enable transport of the sheet product material to an embossing machine; wherein the embossing machine comprise one or more rollers to provide an embossed finish in a general rhomboidal fashion with further creases in an oblique fashion to the corrugation direction. Conveniently, there is further provided a cutting station; an adhesive application station and a wrapping station whereby to provide a mailer with a product therein, with the mailer comprising a flexible single sided corrugated sheet material. Conveniently, there is further provided a product placement station, a wrapping and adhesive application station and a wrapping station and a sealing station, these stations being connected by means of a conveyor.

[0018] Conveniently, with respect to the embossment mechanism, the parallel markings can be simply defined by a circularly cylindrical roller element, with the roller having two series of linear upstanding elements arranged in a parallel spaced apart fashion, the two series of patterns being upstanding elements providing a rhomboidal pattern, sometimes referred to as a diamond or crisscross pattern. Conveniently, the degree of upstanding corresponds to between 70% and 95% of the flute thickness and have an equal pitch to the corrugations. Nonetheless, the angle of the upstanding element may be more acute, whereby to limit a degree of flattening to the corrugations of the board. The upstanding elements can correspond in shape with the fluting. In an alternative, the single roller with two series of parallel oblique markings could be replaced by a two rollers, with each having an alternatively directed series of oblique parallel upstanding element relative to the other, somewhat akin to having two oppositely threaded screw-thread-like elements. Irrespective of the manner of manufacture of the rhomboidal-impressed corrugated material, in accordance with a first aspect of the invention, the rhomboidal-impressed corrugated material is fed in an axial direction into a mailer production line.

[0019] In accordance with a general aspect of the invention, there is provided a process for manufacturing and filling mailers, the process comprising the steps of: receiving a roll of single face (two ply) corrugated paper comprising a first generally planar sheet and a corrugated sheet which is adhered together along a common plane, the corrugations of the corrugated paper having a direction and the roll having an axis of rotation about which the roll can rotate to provide a continuous sheet of corrugated paper in a direction of output, the roll of corrugated paper having a first end distal to the roll, and a second end being at the centre of the roll; applying a series of markings spaced one from another in a regular pattern at an angle of between 90° - 10° relative to the direction of corrugation, with a substantially continuous marking being parallel with the direction of output; feeding the first end of the roll having markings applied thereto into a sack forming machine; folding the corrugated paper sheet about said substantially continuous marking within the machine, whereby to define a central cavity extending from the distal end, with an overlap section depending from the distal end; placing an item to be mailed within the cavity; sealing the corrugated paper sheet at the distal end; sealing the corrugated paper sheet along the overlap section; sealing the corrugated paper sheet at a proximal end, opposite the distal end, whereby to form a mailer; cutting the corrugated paper sheet at the proximal end to release the mailer and to define a new distal end of the roll of corrugated paper, to permit the process to be repeated. Applicants have determined that by applying markings, conveniently by way of compressing the corrugations in a specific fashion or by the use of cutting through the corrugations, the corrugated paper is permitted to flex in a limited fashion, whereby to permit the corrugated paper to provide an enclosed container with sufficient protection for use in mailers as discussed above.

[0020] Conveniently the sealing is performed by the use of a glue which can be applied such that it provides substantially instant adhesion. Applicants have found that a starch based adhesive can provide a sufficiently rapid bond for use in sack closing operations. Further, by the use of a heater, the adhesive can act in a substantially instant fashion, noting that this starch adhesive can penetrate into paper fibre providing additional strength to the sealed edges. It is of additional benefit that starch based adhesive is readily available, provides strong bonds and can be provided at an economical cost. The starch is typically derived from sources like maize and tapioca. Presently, it is the widely used adhesive in the corrugated carton manufacturing industry. Equally, there are other plastics based glues which can perform reliably; contact adhesive tapes can be employed where heating may affect a product to be despatched in a mailer.

[0021] Conveniently, as adhesive is applied to seal a proximal edge seal of a mailer, it has been found convenient to simultaneously operate a cutter, to separate the mailer from what then becomes a distal end of the corrugated paper feed. The cutter is conveniently a guillotine device although a sharp blade, drawn across the width of the folded over mailer. It will be appreciated that other forms of cutter can be employed, but the requirement of continuous operation, presence of motor drive mechanisms can affect a particular requirement.

[0022] Conveniently the application of the markings to the upstanding corrugations reduces the height of the corrugations; alternatively, the markings comprise the applications of a scoring device or blade whereby to permit a degree of flexibility along the axis of the corrugations affected that have been scored or cut.

[0023] A benefit of the continuous marking along the middle - in respect to one embodiment - is to provide a simple fashion of folding; this may be offset form a centre; two sets of continuous markings may be applied to permit a mailer with a general triangular section; three sets of continuous markings may be applied to permit a mailer to be formed with a generally quadrilateral section.

[0024] A benefit of the continuous sets of markings along the area of the corrugated paper is to permit the length of the mailer to be variable. In a mailer system employing a sack arrangement an association is made between product dimensions and mailer product dimension so that an optimal length of axial edge seam is provided. [0025] In accordance with another aspect of the present invention, there is provided a mailer having a single sided corrugated paper and being formed from a reel of corrugated material. The mailers have a dimension such that a width corresponds to a little less than half the width of the roll of corrugated paper. The axial length is variable on a mailer by mailer basis, if desired or can be changed for different batches of product. As is known, mailer sack-packing systems associate an addressee with a product and the axial dimensions of the product - as will be received by an assistant in a manual system or as pre-determined in the case of an automatic system. Each mailer will be formed from a roll of single sided corrugated paper and is provided with a linear region about which a fold can be defined in a packaging machine, where each side of the roll are brought towards each other to enclose a product as the mailer is formed. Conveniently, a starch adhesive is employed which can dry rapidly whilst as the same time being drawn in by surface tension to create a strong bond. Conveniently, the adhesive is heated to ensure a rapid setting of the adhesive.

[0026] In accordance with a general aspect of the invention, there is provided a cardboard mailer for the transport of small - size piece goods wherein the mailer can be produced in a continuous basis; the size of the mailer can be varied between consecutive mailers and between batches of mailings.

Brief Description of the Figures

[0027] For a better understanding of the present invention, reference will now be made, by way of example only, to the Figures as shown in the accompanying drawing sheets, wherein:

Figure 1 illustrates a completed mailer formed from a blank of single face corrugated paper;

Figure 2 illustrates a plan view of a blank of a mailer prior to folding and sealing; Figure 3 shows an early form of plastics bubble-pack-lined envelope;

Figure 4 shows a typical apparatus employed for manufacturing single face corrugate paper;

Figure 5a shows a section of single face corrugate prior to treatment;

Figure 5b shows an apparatus where a single face corrugated paper is treated in accordance with an aspect of the invention;

Figure 5c shows a section of single face corrugated paper following treatment in accordance with an aspect of the invention;

Figures 5d and 5e show how an upstanding element can penetrate a corrugated flute in accordance with an aspect of the invention; Figure 6 shows a first operating station of a first embodiment in accordance with the present invention;

Figure 6a shows a second operating station of a first embodiment in accordance with the present invention;

Figures 6b shows a third operating station involving the placement of product;

Figures 6c and 6d indicate procedures that may be performed at the third operation station;

Figures 6e and 6f show two types of embossing systems to create the embossed sheet material;

Figure 7 shows an alternative mailing system;

Figure 8 shows a further apparatus of the mailer system wherein a feed of marked single sided corrugated paper is fed into a sack machine to fold the paper in a first step;

Figures 8a shows the portion of corrugate prior to product placement in a second step;

Figure 8b shows a placement of product in mailer in a third step;

Figure 8c shows mailer with product enveloped in mailer;

Figure 8d shows a mailer with distal end sealed and lateral edge partially sealed;

Figure 8e shows a mailer that has been sealed ready for separation from the reel of single corrugated paper;

Figure 8f shows a completed mailer with product fully enclosed;

Figure 8g shows a mailer that has been sealed ready for separation from the reel of single corrugated paper;

Figure 8h shows a simplified manufacturing and control layout of a system in accordance with the invention;

Detailed description of the Preferred Embodiments

[0028] There will now be described, by way of example only, the best mode contemplated by the inventor for carrying out the present invention. In the following description, numerous specific details are set out in order to provide a complete understanding to the present invention. It will be apparent to those skilled in the art, that the present invention may be put into practice with variations of the specific.

[0029] Referring now to Figure 4, there is shown an apparatus 40 for making single face corrugated paper. The apparatus 40 comprises a roller 41 for providing a first paper web 20; a corrugated roller pair 42a, 42b for corrugating a second paper web 18 to produce a corrugated paper web. A mechanism 43 comprising an adhesive tray 43a, a roller 44 operably positioned adjacent

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RECTIFIED SHEET (RULE 91 ) ISA/EP corrugated roller 42b, with the amount of glue being controlled by a limit brush 45 whereby adhesive can be applied to the upstanding peaks of the corrugated sheet of paper whereby to enable attachment of the corrugated paper with respect to the first paper web, the second corrugated roller being positioned so as to bring the peaks of the corrugated paper - having glue applied thereto - into contact with the first paper web so as to produce single face corrugated paper 22. A width of the corrugated paper is typically employed using preferred imperial units: 30" or 36", equivalent to 750mm / 900mm. Given this, paperboards employed in wrapping systems are generally in the range of 700mm - 1000mm.

[0030] Figure 5a shows a portion of single face corrugated paper 50 in plan view indicating troughs 52 and peaks 53. A central axis 55 is indicated, where the paper is conveniently folded to provide a single wrap for a mailer as shall be discussed below - but this is not necessary for all the wrapping systems described below.

[0031] Figure 5b shows an apparatus wherein single faced corrugated material 22 is treated by a roller 56 having at least one of embossing or flattening elements, the ridges elements being operable to at least emboss or flatten the upstanding peaks 53, in accordance with the pattern 57 as indicated especially in Inset Figure 5b, so as to form a rhomboidal, criss-cross or patterned arrangement of flattened or embossed upstanding elements 29 in the resulting processed single faced corrugated paper, as indicated in Figure 5c. This rhomboidal, criss-cross or patterned arrangement permits the single face corrugated paper to be more flexible in all directions, rather than being directionally flexible in the direction orthogonal to the corrugate flutings. Additionally, the central axis can also be one of flattened/compressed or cut to assist in subsequent folding if used in a dropmailer system. During tests it has been found convenient for the spacings of the parallel lines of the rollers are spaced in correspondence with the fluting size, as described below.

[0032] Whilst the roller 56 can be replaced by a flat die board with a die-board embossing elements (as opposed to sharp cutting elements), for continuous use, a roller is more convenient to use and conveniently is necessarily fixed in relation to an associated conveyor; otherwise alignment issues may arise with the use of a die-board. The roller is provided with upstanding elements to emboss, with the tips being "sharp" to enable embossing to take place without flattening the fluting. During tests, the tip has been of a width of 0.1 - 1mm - too sharp and the single face corrugated board will have its strength compromised; too blunt and the flutings will be squashed, destroying an integrity of its cushioning

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RECTIFIED SHEET (RULE 91 ) ISA/EP properties, as will be readily be discernible to an operator. With reference to Figures 5d and 5e, the embossing rollers 56 may compromise a single roller with a criss-cross / rhomboidal pattern defined by upstanding element 58, which has a height H in general correspondence with the flute but has a narrow base B relative to the fluting width (which for a standard corrugation is of a generally sinusoidal wave pattern) the base for e-flute upstanding element is conveniently about 20 - 40% of the spacing dimension - i.e. 0.3 - 0.6mm. Similar sizes are acceptable for other grades of fluting noting that the strength of the upstanding element will be enhanced when arranged upon the three-dimensional surface of a roller, noting that e-flute and b-flute are more commonly employed in the packaging industry. As a further alternative, the roller(s) may emboss the peripheral parts of a roll of a single sided material, whereby to permit simple folding of the peripheral parts of the corrugated sheet, to enable a central element to provide additional stability, noting that it will be realized that by providing mailers made out of flexible corrugated material, the material can be handled differently; voids in packaging is reduced and the increased flexibility can assist in the absorbance of shocks during transport and movement within distribution and sorting warehouses as well as when being transferred from one vehicle to another, noting that small boxes typically do not store in a regular fashion meaning that there are significant voids between boxes, whether retained in sacks or within cuboid delivery containers.

[0033] Referring now to Figure 6, there is shown a view of a machine 600 for packaging articles upon a flat conveyor. The machine 600 comprises a supply roll 601 of rhomboidal patterned single face corrugated sheet 602, which is metered out/fed out in by means of drive rollers 604 onto a flat conveyor system 605, conveniently a conveyor belt in an axial direction AD in correspondence of the conveyor direction. A first operation station 606 comprises a cutting station wherein one or two knives, blades or other suitable cutting implements 607 ensure that a sheet piece 608 of rhomboidal patterned single face corrugated material having an axial direction in correspondence with a desired length such as determined by a system controller (not indicated) with regard to the intended product to be packaged or of a predetermined standard package size. The peripheral axial edges 609, 610 of the rhomboidal patterned single face corrugated material may be reduced in width by means of one or two knives or blades or other suitable cutting implements or means. Conveniently glue is applied at this station by one or more glue (adhesive) application guns or nozzles. In the alternative there is a dedicated glue station 612 or the gluing is applied at the next operational station.

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RECTIFIED SHEET (RULE 91 ) ISA/EP [0034] Referring now to a dedicated glue station 612, per Figure 6a, the conveyor 605, conveniently provided with vacuum location assist means 619 - described in greater detail below, to ensure that the sheet product 608 remains in position upon the conveyor - enable a robotic arm 613 with a glue application nozzle 614 applies glue 613 to the upper, corrugated surface 603 of the sheet piece 608. The glue could be a cellulose glue or other form of heat setting glue as is known in the packaging industry. The glue is conveniently applied in a general "U" plan about an area where a product to be packaged will be placed, which upon wrapping will engage with a corresponding surface of the sheet material. The system controller will, ideally, take into account the length, width and height of the product to ensure that the size of the wrapped package is optimal for the size of product to ensure that there is little dead space, enabling transport costs to be minimized. This means that the sheet material 608 is the optimal size and that the appropriate amount of glue is dispensed in an optimal fashion. This is not to say that a standard size container could not be employed, but by selecting the size appropriately materials employed in packaging can be minimized and, as mentioned above, costs of transportation can be reduced.

[0035] Once the glue has been applied, the next stage of the packaging procedure can begin. The sheet material is taken to a wrapping station 618, where a vacuum assist - indicated by vacuum apertures 619 (or equivalent) maintains position of the sheet 608; a product 620 is placed upon the sheet material by, for example, robotic arms 617 or by a closed container system. Then, with reference to Figures 6c and 6d first 621 and second (not shown) arms from either side of the product 620 cause the sheet material 608 to be folded upwardly with respect to the vacuum sheet assist - noting that the vacuum holding system may limit a specific arrangement of vacuum apertures in the vacuum table to be operational, whereby to enable ethe side members to fold relatively easily. Given that the width of the sheet material needs to overlap, the side to which glue - or pressure sensitive tape (if employed) has not been applied is wrapped over the top first. The side manipulating arm 621 may extend to perform this operation or an additional robotic arm (not shown) may be employed. Subsequently, the other, preferably wider, portion of the other side of the sheet material 608 is brought up and over the top of the product 620 by means of the second manipulator arm . The product 620 enclosed by rhomboidal patterned single face corrugated sheet 608 upon conveyor 605, with crimping I heating jaws / grippers 623 (per Figure 7) or roller. The grippers or jaws 623 may act against a conveyor surface 603, but a preferred alternative would be to have opposing jaws whereby the fastening means do not affect

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RECTIFIED SHEET (RULE 91 ) ISA/EP operation of the conveyor. Upon heating and or clamping, using glue or - in the event of using pressure sensitive adhesive - bring the opposing parts firmly together. It will be important to have the proximal and distal ends sealed properly; it is believed that for certain goods, provided there is sufficient overlap - but noting that this is also dependent upon the nature of the product and axial length of the package, that the longitudinal seal is not as critical to ensure retention of product.

[0036] Figures 6e and 6f show how the supply of embossed single faced corrugate material may be supplied to the machine 600. In each case, roller 601 comprises a supply of un-embossed single face corrugated sheet material and is driven by drive motors 604 to control a rate of metering the sheet material 603 towards the operating stations. In figure 6e, a single roller 631 is provided, with a criss-cross pattern appropriate for the fluting grade; in Figure 6f, a series of two rollers 632, 633 are provided with a first roller having the parallel spaced upstanding elements 58 being opposite-obliquely directed to the second roller. The diameter of the rollers is conveniently in the range of 15 - 30 cm, with the dimension being dependent upon the axial length of the repeat pattern. The rollers will be robust to prevent bowing in use and as will be appreciated the larger the diameter, the reduced duty of the associated bearings. Of course, the provision of the embossing system may be associated with a supply of single face corrugated board and the procedure may be part of a first instance manufacture rather than being necessarily associated with a wrapping plant machine. The diameter of the supply rolls of single face corrugated material is of the order of 600mm, which will supply a length of 100 - 150m in length of b-flute; in contrast, a similarly sized winding of e-flute will supply up to 300m in length of sheet material.

[0037] It will be appreciated that the flexibility of the rhomboidal patterned single face corrugated sheet lends itself to packaging in many ways. For example, with reference to Figure 7, there is shown an alternative wherein products 620 in the form of books are enclosed by a continuous rhomboidal patterned single face corrugated sheet 602. Shaper arms 702, either side of the products 620, bring the sides of the sheet 602 upwardly, either side thereof; glue dispenser 614 applies glue 615 to an outside edge face of the sheet material, which is then heated and pressed together longitudinally across the top; a crimpling station with jaws 623 opposing each other at a break of the conveyor 605 crimp the upper and lower surfaces of the now tubular enclosure to create seals 74, which are then separated by a knife or similar cutting means (not shown).

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RECTIFIED SHEET (RULE 91 ) ISA/EP Adhesive could also be employed; stapling is also possible, but typically not preferred. Starch-based adhesives for corrugated boxes have used as corrugated adhesives since the beginning of the industry. The adhesion base is by way of a hydrogen bond between starch molecules of the glue and cellulose molecule of the paper; as will be appreciated, the corrugated sheet material is a construction whose strength depends on its "bonding points." The strength depends on glue formulation, type of starch, temperature, paper quality, paper quality, glue penetration, running speed. Starch glue, even if appropriately prepared, is water- soluble and, in a humid environment, starch glue weakens and the corrugated sheet material will lose its strength until total separation occurs. Therefore, additives will be added to a starch glue. In the alternative other heat setting adhesives can be used, noting that due to the speed of fabrication of mailers the adhesive needs to be effective almost as soon as it is placed upon the paper board. Nonetheless, for the embodiment of Figure 7, an alternative technique that could be applied could arise by the use of a heat activated adhesive if applied and permitted to dry upon an inside surface of all of the corrugated sheet yet is activated by heat, so that when it is crimped by jaws 623, heat is applied , which would activate the glue and therefore enable a sealing closure as between two adjacent packages - noting that the trimming of the sequential packages would be best performed after the gluing, but alternative systems can readily be implemented. By applying such glue over all of the inside surfaces then the process is simplified in that the application of a specific amount of glue does not need to be referenced by monitoring techniques to ensure that the crimps are applied in the exact position. Moreover, the package length can be varied at will with regard to product length, without the added complication of ensuring correspondence with the application of glue om the inside faces.

[0038] As will be known to the skilled man, corrugated paper and card is produced in many styles; First the paper from which the facing side is manufactured from can be of variable quality; it can be relatively stiff or flexible, noting that once cardboard has bene formed the flutings of corrugations add stiffness. As discussed above, effectively, a standard sheet of single faced corrugated cardboard is made from two components. Each side of the fluted material is glued to the flat paper liner during manufacture. The glue fixes the flutes in position and adds rigidity and stability to the papers. One of the key factors that define the properties of the corrugated material is the types of paper used. [0039] Despite the widespread use of cardboard, there are two main types of paper that are generally used for the liners. These are known as Kraft and Test liners. Kraft paper is manufactured from softwood trees. Due to the "virgin" fibres, it is both the strongest type of paper and also the easiest to print on. As a result, it is the most commonly used outside liner when selecting material to produce corrugated boxes and packaging. Each liner type is actually comprised of two distinct layers. A basic layer is used adhesion and strength, whilst a finer "cover" layer is used mainly for improved aesthetics and to aid printing. However, despite Kraft and Test liners being so popular, there are in fact a number of other options as can be seen form the following list of commonly available paper grades for outer and inner liners when manufacturing cardboard:

KRAFT (K): Virgin Kraft paper

TEST 2 (T2): Partly recycled liner paper

TEST 3 (T): Fully recycled liner

CHIP (C): Waste based liners

FULLY BLEACHED WHITE (BW): Fully bleached Kraft liner

WHITE TOP (WT): White coated recycled liner

MOTTLED KRAFT (MK): Mottled white Kraft

OYSTER (OY): Mottled test liner

SEMI CHEM (SC): Virgin fibres using neutral sulphite semi-chemical process

WASTE BASED (WB) 100% recycled fibres

[0040] The final two paper types listed above are those most commonly used for flutes, and less often used for liners. Another significant issue to consider is the weight of paper employed, generally expressed in grammes per square metre, gsm, whilst the type (and number) of fluting must also be considered. The flute is the "corrugated" section between the two liners, and by changing its' height (and therefore the size of the flutes) it is possible to achieve different performance characteristics. The flute is typically made from recycled materials, which can be fully recycled materials, e.g. WBF (waste based fluting) or semi-recycled materials, e.g. SC (semi-chemical process). Typical flute weights are as follows: 90 gsm WBF; 105 gsm WBF; 112 gsm SC and WBF; 150 gsm SC and WBF; 175 gsm SC. There are also a number of commonly used flute profiles or sizes, which are as follows: A Flute: 5mm; B Flute: 3mm; C Flute: 4mm; E Flute: 1.5mm; F Flute: 1.2mm. [0041] Whilst this list is not exhaustive, the issue is complicated by the fact that many producers of corrugated material make very similar products which referred to by trade names, which are very often quite arbitrary and will necessarily be exclusive to such a manufacturer or re-seller. Whilst the present invention has been described in relation to single face corrugated board, it will be appreciated that a two-faced corrugate board could also be treated in a similar fashion, although it has been found to be less successful when crushed or rolled and the use of a knife to enable bending is preferred, in a similar fashion to the cutting of slots in plywood to permit bending thereof.

[0042] An advantage of the first described embodiment is that the system through the use of sensors, product programming or similar, the length of the package can be dimension to correspond with the size of the product to be placed within a mailer package. Early indications have shown that the use of E-flute corrugated paper can provide an optimal choice for many mail-order products, providing sufficient protection whilst minimizing dead space, which is becoming a critical factor in mass delivery systems, where boxes as such are beginning to be charged more per delivery than an equivalent weight flexible mailer. It will be appreciated that whilst the fluting is normally most easily produced with the axis of the corrugate flutings being perpendicular to an axial length of corrugated paper stored on a reel, variations where the flutings are arranged in distinct angles to the perpendicular.

[0043] Sack systems are known in relation to the use of plastics films and the application of the such sack generating systems to provide and fill plastics film mailers - creating mailer bags in the process. The present invention provides an input device for a sack system whereby a proportion of previously developed technology can be adapted to provide a mailer system employing corrugated paper board. Referring in particular to Figure 8, there is shown an input device for a sack system. Embossed or otherwise marked corrugated paper 24 is input into a sack system: roller 81 permits the cardboard paper to be introduced in a downward direction: the corrugated paper 24, with the side with the corrugations, side A, shown approaches a ploughshare-like feature 82, which causes the corrugated paper to fold about the embossed feature 84, enabling the corrugated paper to overlap itself; roller 83 helps assist the cardboard to be filed, whereby side B provides an external surface to the mailer. Conveniently, the marked corrugated paper is ruled in the sense of providing the fold line 55; the left and right panels to the sides of the ruled line permit folding of the right hand side.

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RECTIFIED SHEET (RULE 91 ) ISA/EP [0044] Turning now to Figure 8a, there is shown a folded-over distal end of the reel of corrugated paper, yet to be sealed etc. Figure 8b show placement of a product 85 within the unsealed folded-over mailer, and the result is provided in Figure 8c, wherein the product 85 is retained within the mailer; Figure 6d shows how the lower edge 86 - the distal edge - is sealed and how the left peripheral edge 87 is partially sealed - an outline of the product 85 is indicated. The sack machine conveniently provides rollers which are utilised as glue is applied and preferably heated to enable setting of the adhesive in a very short period of time. When bringing the seams together, the system must be set up such that compressive forces do not permit glue to be squeezed out of a seam margin. Also, as described above, by crushing both ends in the width direction of the envelope front surface portion and the envelope back surface portion to form a glue margin portion, when the adhesive is applied in a line shape to the upper and lower sides of the envelope of the adhesive. It is possible to prevent any unwanted spread of the glue. That is to say, according to the present invention, the adhesive is compressed as described above to form an adhesive margin, and an appropriate amount of adhesive is applied to the adhesive margin from the folded portion to a predetermined range in the length direction of the envelope. It also needs to be stated that the glue is selected to set extremely quickly to prevent this from occurring and can be attached with sufficient adhesive strength. Referring now to Figure 8e, there is shown a mailer with edges 86, 87 & 88 sealed, with the item ready to be cut form the roll of corrugated paper along line 89. Figure 8f shows a completed mailer. It will be appreciated that in this respect a totally recyclable mailer can be provided. Thus, the mailer envelope is conveniently made from single corrugated paper comprising two-ply corrugated paper preferentially with the exposed corrugation flutes on the inside of the mailer giving optimum cushioning protection effect. The corrugation flutes act as a protection cushioning barrier to protect the contents of the envelope.

[0045] Referring now to Figure 8g, there is shown a mailer with edges 81, 82 & 83 sealed, with the item ready to be cut from the roll of corrugated paper along line 89. It will be appreciated that in this respect a totally recyclable mailer can be provided. Thus, the mailer envelope is conveniently made from single corrugated paper comprising two-ply corrugated paper preferentially with the exposed corrugation flutes on the inside of the mailer giving optimum cushioning protection effect. The corrugation flutes act as a protection cushioning barrier to protect the contents of the envelope. It will be apparent to the skilled man that a number of variations in the specific procedure can be changed without changing the overall result. [0046] The glue or adhesive can be applied, generally speaking, by way of a number of processes; it can be applied by brush, it can be applied by roller; it can be applied by continuous dispensing by nozzle or it can be applied by way of focussed, discrete amounts of glue; upon compression and heating the glue is substantially evenly spread. It is presently preferred to employ a liquid glue applied by jet nozzles, with a glue feeder comprising a milk churn-like container which can accommodate sufficient glue for a procedure - time limited in terms of the length of card I cardboard that can be provided from a roll in a particular application. For example, the glue feeder can comprise a 10 litre container, provided with approximately 8Kg of glue - approx. 75% full - with compressed air acting as a propellant and operating at a pressure of 50 Bar. The glue will be provided by nozzles guided to the edge portions of the mailers to be formed. As will be appreciated, a number of fixed jets could apply glue in a regular fashion to the proximal and distal edge, which are perpendicular to the axial direction of movement of the mailer; whilst the edge opposite to the fold could apply the adhesive concurrent with an axial movement of the mailer. It will be appreciated that the nozzles can be fixed, mounted for linear motion or be provide on an articulated platform. Additionally, for certain types of glue, there may need to be provided nozzle-baths for the periods of inactivity of the dispensing nozzles, so that glue does not set upon the nozzles in between use. Such nozzle-baths may also be provided with a water supply and a level control since the processing are will generally operate in a raised temperature atmosphere, noting that the systems uses heaters.

[0047] Viscosity is a principal parameter when any flow measurements of fluids, such as liquids, semi-solids, gases and even solids are made; initial results have been provided with a glue viscosity between 9000 and 1500 milli-Pascal-seconds (mPa-s). It will be appreciated that viscosity measurements are necessary to ensure uniformity of application and to enable adjustments to determined, as known to those skilled in the art of flow characterization, in research or development, etc.. Nonetheless, other manufacturers of spray systems can provide spray systems that utilise pressurized glue to enable sufficient coating on a timed basis without the use of compressed air, whereby to provide controlled delivery of glue. It is worth noting that in paper processing industries, print and glue applicators can define widths of 1mm with respect to sheet material passing such applicators at rates of 14ms' ¹ or more. By the use of spray nozzles, then articulated mounts for the nozzles can assist in ensuring appropriate uniformity of application, even when traversing about corner sections. It is typical for glue jets to be placed 1cm apart for the widths of mailers to be sealed.

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RECTIFIED SHEET (RULE 91 ) ISA/EP [0048] Referring now to Figure 6f, there is shown a first system; the roller referenced 18 in Figure 5 is powered by a motor Ml; the motor is under the control of a controller Cl, having an input console IS. The controller is also operable to control a second motor M2, which assists in folding the sheet prior to placement of the product. Additionally, the controller also provides signals to actuators associated with the glue applying system, comprising one or more glue jets operable to deposit glue across the width of the sheet JW (once folded) and along the axial path, at the side, JA, together with trimming element, which is used in conjunction with heated press, HPW and HPA, comprising a heated die and a heated roller, respectively, for enabling the glue to be heated and fasten the respective opposing distal, proximal and side edge portions. The die and the roller compress against a support surface - which supports the board as it passes through the machine. An Edge Trimmer, ET, is provided to ensure the edges of the mailer are as smooth as possible. The edge trimmer and heated side roller could be combined into a single unit. A guillotine could be provided, but the movement must be synchronized as the sack producing equipment, in operation, is continuously producing mailers.

[0049] It will be realized that when the edge seams are brought together, the system must be set up such that compressive forces do not permit glue to be squeezed out of a seam margin. Also, as described above, by crushing both ends in the width direction of the envelope front surface portion and the envelope back surface portion to form a glue margin portion, when the adhesive is applied in a line shape to the upper and lower sides of the envelope of the adhesive. It is possible to prevent any unwanted spread of the glue. That is to say, according to the present invention, the adhesive is compressed as described above to form an adhesive margin, and an appropriate amount of adhesive is applied to the adhesive margin from the folded portion to a predetermined range in the length direction of the envelope. It also needs to be stated that the glue is selected to set extremely quickly to prevent this from occurring and can be attached with sufficient adhesive strength. Whilst the width of the sealed edges can be as low as a couple of millimetres, and be greater than 1cm, however, for a normal mailer, it has been found that a width of 3 - 6mm has been found to be suitable for most applications. Notwithstanding this, it will be appreciated that the present invention need not be so limited.

[0050] It will be realized that whilst the width of the mailer is pre-determined by the width of the board introduced into the sack making machine and is approximately half - noting that the cavity will tend to reduce the width of the

20

RECTIFIED SHEET (RULE 91 ) ISA/EP package, the axial length of the edge seem is not so limited - rather it is determined by the size of the sack making machine and the capability of the seam forming wheels / plates employed to apply adhesive / glue and heat the same with a degree of compression to ensure that a good seal is consistently made.

[0051] It will be realized that whilst the width of the mailer is pre-determined by the width of the single face corrugated paper, the axial length of the edge seem is not so limited - rather it is determined by the size of the sack making machine and the capability of the seam forming wheels I plates employed to apply adhesive I glue and heat the same with a degree of compression to ensure that a good seal is consistently made.

[0052] In the case of such an envelope mailer, as described above, the singlesided corrugated cardboard is used so that the ridges of the corrugated step portion of the central base paper are perpendicular to the axial movement of the reel of single corrugated paper. Necessarily, this product is manufactured in a continuous web fashion and discrete mailers can be continuously manufactured, filled and then despatched, which lends the system to simple and rapid automation. It will be appreciated that the whilst the fluting is normally most easily produced with the axis of the corrugate flutings being perpendicular to an axial length of corrugated paper stored on a reel, variations where the flutings are arranged in distinct angles to the perpendicular.

[0053] It will be appreciated that the rulings created when forming the creases may be of two or three or more, to enable the mailer to be formed in an overall triangular, rectangular etc. in cross section.

[0054] The corrugated material in respect of either or both the liner and corrugate sheet material can be coated with a water resistant coating such as Polyethylene or BioP BS or similar bio-degradable coatings. The BioP BS coating is one of a number of coatings made from bio-degradable materials and is preferentially incorporated into the tamperproof design to water proof the exterior or interior or both. The coatings are also used to increase tensile strength plus puncture and tear strength of the envelope. The coatings also eliminate any paper smell as the coating seals the paper or envelope medium and is odourless. BioPBS is a biodegradable and compostable bioplastic material which can be used as a barrier on paper products such as cups and bowls. Available from the Mitsubishi Corporation, it is fully certified and food-safe. Nonetheless, it is preferred that the mating surfaces of the materials are not treated, given that the coating can reduce the efficacy of the starch glue.

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RECTIFIED SHEET (RULE 91 ) ISA/EP