SPECIFICATION BACKGROUND

[0001] The present disclosure is in the technical field of forming flexible packages. More particularly, the present disclosure is directed to using a stream of gas to improve separability of consecutive flexible packages.

[0002] Objects are regularly packaged and shipped in flexible packages, such as bags formed from polyethylene film. Objects can be packaged in a continuous flow of objects using a continuous flow wrap machine. Examples of such continuous flow wrap machines are described, for example, in U.S. Patent No. 4,219,988 and are available from Sealed Air Corporation (Charlotte, NC) under the Shanklin FloWrap Series trademark. Once the objects are packaged in the flexible packages, the flexible packages can be prepared for shipping, such as by adhering a shipping label to the exterior of the flexible package, and then shipped, such as by delivering the flexible package to a shipping company. The flexible packages provide an appropriate package for certain objects because they are lightweight and provide protection from being damaged or dirtied during shipment. SUMMARY

[0003] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. [0004] In one embodiment, a system for forming a flexible package includes a packaging system, an end sealer, and a gas delivery system. The packaging system is configured to form a flexible package and fill the flexible package with an object. The end sealer is configured to form a seal in an end of the flexible package to close the flexible package with the object inside of the flexible package. The gas delivery system is configured to direct a stream of gas toward the end of the flexible package after the seal is formed.

[0005] In one example, the packaging system is configured to form the flexible package from a continuous supply of film. In another example, the system is configured to feed the film in a direction and the gas delivery system configured to direct the stream of gas along a side of the end sealer that is downstream with respect to the direction of the film. In another example, the gas delivery system configured to direct the stream of gas at a location where the end sealer is configured to form the seal in the continuous supply of film. In another example, the end sealer includes a cutting element integrated with a seal bar, the cutting element is configured to cut the film, and the seal bar is configured to form seal in the continuous supply of film. In another example, the stream of gas is configured to cause at least one of deflection of the end of the flexible package with the seal or an increased rate of solidification of the seal. In another example, the gas delivery system is further configured to direct the stream of gas toward the end of the flexible package during at least one of a time when the seal is formed or a time before the seal is formed.

[0006] In another example, the end sealer includes a first jaw assembly that has a cutting mechanism configured to cut the film and a seal bar configured to form the seal in the film and a second jaw assembly that has a jaw pad configured to back the film during formation of the seal in the film by the seal bar. In another example, at least a portion of the gas delivery system is integrated into at least one of the first jaw assembly and the second jaw assembly. In another example, the gas delivery system is not integrated into the first jaw assembly or the second jaw assembly. In another example, the gas delivery system is coupled to at least one of the first jaw assembly or the second jaw assembly. In another example, the gas delivery system includes a gas passage in the second jaw assembly. In another example, the gas passage includes an inlet that is couplable to a gas line configured to supply pressurized gas into the gas passage and an outlet configured to permit the pressurized gas to exit the gas passage on a downstream side of the end sealer. In another example, the outlet is located on the second jaw assembly and is in fluid communication with the gas passage and the outlet includes at least one of a single hole, a plurality of holes, or a slot. In another example, the jaw pad includes a slot configured to accommodate the cutting mechanism. In another example, the first jaw assembly includes a film clamp configured to stabilize the film against the jaw pad while the cutting mechanism cuts the film.

[0007] In another embodiment, a method is used to form a flexible package. The method includes forming a flexible package and filling the flexible package with an object. Forming the flexible package includes forming a first transverse seal in a first end of the flexible package. The method further includes closing the flexible package with the object located inside the flexible package. Closing the flexible package includes forming a second transverse seal in a second end of the flexible package. The method further includes directing a stream of gas toward the second end of the flexible package after the second transverse seal has been formed.

[0008] In one example, forming the first transverse seal in the first end of the flexible package includes forming the first transverse seal in an end of a tube of film and closing the flexible package includes cutting the tube of film to separate the flexible package from the tube of film. In another example, filling the flexible package with the object is performed at one or more of the following times: before the first transverse seal is formed in the first end of the flexible package, while the first transverse seal is formed in first end of the flexible package, or after the first transverse seal is formed in first end of the flexible package. In another example, the stream of gas is configured to cause at least one of deflection of the second end of the flexible package or an increased rate of solidification of the second transverse seal. In another example, the method further includes controlling the stream of gas to be directed toward the second end of the flexible package during a specific time and the specific time includes a time after the second transverse seal has been formed. In another example, the specific time includes at least one of a time when the second transverse seal is formed or a time before the second transverse seal is formed.

BRIEF DESCRIPTION OF THE DRAWING

[0009] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0010] Fig. 1 depicts an embodiment of a system that includes a packaging system, in accordance with the embodiments described herein;

[0011] Figs. 2A to 2D depict cross-sectional views of an embodiment of an end sealer and a series of instances of operation of the end sealer, in accordance with the embodiments described herein;

[0012] Fig. 3 depicts one example of a problem of subsequent flexible packages having end seals coupled to each other, in accordance with the embodiments described herein;

[0013] Figs. 4A to 4D depict cross-sectional views of an embodiment of an end sealer and a series of instances of operation of the end sealer, in accordance with the embodiments described herein;

[0014] Figs. 5A to 5C depict examples of different forms of outlets usable on the end sealer depicted in Figs. 4A to 4D, in accordance with the embodiments described herein; [0015] Figs. 6A and 6B depict embodiments of an end sealer that has a gas delivery system that is not integrated with either an upper jaw assembly or a lower jaw assembly of the end sealer, in accordance with the embodiments described herein;

[0016] Fig. 7 depicts an embodiment of a method of forming a separable flexible package, in accordance with the embodiments described herein;

[0017] Fig. 8 depicts a cross-sectional view of another embodiment of an end sealer, in accordance with the embodiments described herein; and

[0018] Fig. 9 depicts a perspective view of another embodiment of a lower jaw assembly and a gas delivery system, in accordance with the embodiments described herein.

DETAILED DESCRIPTION

[0019] The present disclosure describes embodiments of systems and methods of forming flexible packages. As described in greater detail herein, flexible packages can be formed from a continuous supply of flexible material, such as a flexible film. In some cases, the flexible packages are formed on a continuous basis by a form-fill- seal machine that forms the packages, fills the packages, and seals the packages. One drawback to such systems is that consecutive packages can be made inseparable when the trailing seal of one package becomes coupled to the leading seal of a subsequent package. This is particularly the case when the two seals come into contact while the seals are in a molten or semi-molten state. The systems and methods described herein include a stream of gas directed to a trailing end of the flexible package after a seal is made in the flexible package to increase the likelihood that the flexible package will be separated from a following flexible package. [0020] In some embodiments described herein, a system includes a packaging system, an end sealer, and a gas delivery system. The packaging system forms a flexible package and fills the flexible package with an object. The end sealer forms a seal in an end of the flexible package to close the flexible package with the object inside of the flexible package. The gas delivery system directs a stream of gas toward the end of the flexible package after the seal is formed. In some instances, the stream of gas makes the formed flexible package more easily separable by causing at least one of deflection of the end of the flexible package with the seal or an increased rate of solidification of the seal. [0021] In some embodiments described herein, a method includes forming a flexible package. Forming the flexible package includes forming a first transverse seal in a first end of the flexible package. The method further includes filling the flexible package with an object. The method further includes closing the flexible package with the object located inside the flexible package. Closing the flexible package includes forming a second transverse seal in a second end of the flexible package. The method further includes directing a stream of gas toward the second end of the flexible package after the second transverse seal has been formed. In some instances, directing the stream of gas toward the second end of the flexible package makes the formed flexible package more easily separable by causing at least one of deflection of the second end of the flexible package or an increased rate of solidification of the second transverse seal.

[0022] Fig. 1 depicts an embodiment of a system 10 that includes a packaging system 12. In the depicted embodiment, the packaging system 12 is a continuous flow wrap machine (e.g., a form-fill-seal wrapper). In other embodiments, the packaging system 12 is a non-continuous packaging system. In the depicted embodiment, the packaging system 12 includes a film dispenser 18, a transfer head 20 including an inverting head 22, an infeed conveyor 24, a longitudinal sealer 26, and an end sealer 28, as will be described in more detail herein. Examples of continuous flow wrap machines are described, for example, in U.S. Patent No. 4,219,988, U.S. Patent Application No. 62/157, 164, and PCT Application No.

PCT/US2016/030630, the contents of which are incorporated herein by reference in their entirety, and are available from Sealed Air Corporation (Charlotte, NC) under the Shanklin FloWrap Series trademark. [0023] The film dispenser 18 of the continuous flow wrap machine supplies a web of film 30 from roll 32. Systems for supplying webs of film are known in art and may include unwind mechanisms and other features. In some embodiments, the film 30 on the roll 32 is a center folded film. In other embodiments, the film 30 on roll 32 is a flat wound film. In some embodiments, the film 30 includes any sheet or film material suitable for packaging objects 36, in particular for flexible packages 34 for use as a mailer containing an object. Suitable materials include polymers, for example thermoplastic polymers (e.g., polyethylene), that are suitable for heat sealing. In some embodiments, the film 30 has a thickness of any of at least 2, 3, 5, 7, 10, and 15 mils; and/or at most any of 25, 20, 16, 12, 10, 8, 6 and 5 mils. In some embodiments, the film 30 is multilayered, and has an outer layer adapted for heat sealing the film to itself to form a seal.

[0024] The transfer head 20 of the packaging system 10 receives the web of film 30 from the film dispenser 18. The transfer head 20 is adapted to manage (e.g., form) the web of film 30 into a configuration for eventual sealing into a tube. In the depicted embodiment, the transfer head 20 is an inverting head 22 of continuous flow wrap that receives a center folded web of film 30 from the film dispenser 18 and redirects the web of film over the top and bottom inverting head arms 40, 42 to travel in a conveyance direction 38 by turning the web of film inside out. In this manner, the transfer head 20 is adapted to manage the web of film 30 to provide an interior space 44 bounded by the film 30.

[0025] In some embodiments, the transfer head 20 in the configuration of a forming box receives the lay flat web of film 30 from the film dispenser 18 and redirects the web of film over the forming head to travel in the conveyance direction 38 by turning the web of film inside out. In this manner, the transfer head 20 is adapted to manage the web of film 30 to provide an interior space 44 bounded by film 30.

[0026] The infeed conveyor 24 of packaging system 12 is adapted to transport a series of objects 36 and sequentially deliver them in the conveyance direction 38. In some embodiments, the infeed conveyor is adapted to convey a series of objects 36. In the embodiment depicted in Fig. 1 , the objects 36 have a similar size. In other embodiments, the objects have varied or differing sizes. Within the series of objects 36 in sequential order, a "preceding" object is upstream from a "following" object. The infeed conveyor 24 is configured to deliver in repeating fashion a preceding object upstream from a following object into the interior space 44 of the web of film 30. In some embodiments, the objects 36 are delivered in spaced or gapped arrangement from each other.

[0027] An "object," as used herein, may comprise a single item for packaging, or may comprise a grouping of several distinct items where the grouping is to be in a single package. Further, an object may include an accompanying informational item, such as a packing slip, tracking code, a manifest, an invoice, or printed sheet comprising machine-readable information (e.g., a bar code) for sensing by an object reader (e.g., a bar code scanner).

[0028] Downstream from the infeed conveyor 24 is an object conveyor 48, which is adapted to support and transport the web of film 30 and the object 36 downstream together to the end sealer 28. A discharge conveyor 50 transports the series of flexible packages 34 from the end sealer 28.

[0029] As each object 36 of the series of objects sequentially travels through the packaging system 12, its position within the machine is tracked. This is

accomplished by ways known in the art. For example, an infeed eye system

(horizontal or vertical) determines the location of the front edge 52 of each object and the location of the rear edge 54 of each object as the object travels along the conveyor. This location information is communicated to a controller (i.e., a programmable logic controller or "PLC"). A system of encoders and counters, also in communication with the PLC, determines the amount of travel of the conveyor on which the object is positioned. In this manner, the position of the object 36 itself is determined and known by the PLC. The PLC is also in communication with the end sealer 28 to provide the object position information for a particular object to these unit operations.

[0030] In the depicted embodiment, the packaging system 12 includes longitudinal sealers 26 adapted to continuously seal sides of the film 30 together to form a tube 56 enveloping one of the objects 36. In the depicted embodiment, the longitudinal sealers 26 are located at sides of the tube 56, where each of the longitudinal sealers 26 forms a side seal between two edge portions of the film 30. In other

embodiments, a The longitudinal sealer 26 may be located beneath the tube 56, where the sealer may form, for example, a center fin seal between two edge portions of the web of film 30. As two edge portion of film 30 are brought together at the longitudinal sealer 26 to form the tube 56, they are sealed together, for example, by a combination of heat and pressure, to form a continuous fin or a side seal.

Appropriate longitudinal sealers are known in the art, and include, for example, heat sealers. [0031] The packaging system 12 includes end sealer 28, which is adapted to provide or perform in repeating fashion, while the tube 56 is traveling: (i) a trailing edge seal 58 that is transverse to tube 56 and upstream from a preceding object to create flexible package 34 and (ii) a leading edge seal 60 transverse to the tube 56 and downstream from a following object. Further, the end sealer 28 is adapted to sever the flexible package 34 from the tube 56 by cutting between the trailing edge seal 58 and the leading edge seal 60. Generally, the end sealer 28 uses temperature and pressure to make two seals (trailing edge seal 58 and leading edge seal 60) and cuts between them, thus creating the final, trailing seal of one finished, preceding package and the first, leading edge seal of the following package. Advantageously, the end sealer unit may be adapted to simultaneously sever the flexible package 34 from the tube 56 while providing the trailing edge seal 58 and leading edge seal 60.

[0032] Useful end sealer units are known in the art. These include, for example, rotary type of end sealer units, having matched heated bars mounted on rotating shafts. As the film tube passes through the rotary type, the rotation is timed so it coincides with the gap between objects. A double seal is produced and the gap between the two seals is cut by an integral blade to separate individual packs.

Another type of end seal unit is the box motion type, having a motion that describes a "box" shape so that its horizontal movement increases the contact time between the seal bars and the film. Still another type of end sealer unit is the continuous type, which includes a sealing bar that moves down with the tube while sealing.

[0033] Depicted in Figs. 2A to 2D are cross-sectional views of an embodiment of an end sealer 100. Figs. 2A to 2D also depict a series of instances of operation of the end sealer 100. The end sealer 100 is capable of forming transverse cuts and seals in packages, such as those formed from film 130 (e.g., polyethylene film). In the particular series of instances depicted in Figs. 2A to 2D, as the film 130 moves in a downstream direction 138, the end sealer 100 make a cut between a tube 156 of the film 130 and a flexible package 134 and the end sealer 100 forms seals at a trailing end 158 of the flexible package 134 and at a leading end 160 of the tube 156. [0034] The end sealer 100 includes an upper jaw assembly 1 10 and a lower jaw assembly 120. The upper jaw assembly 1 10 includes a cutting mechanism 1 12 configured to cut the film 130. The cutting mechanism 1 12 is a blade is the depicted embodiment, but the cutting mechanism 1 12 may be any other device that is capable of cutting the film 130, such as a heated wire, a cutting roller, and the like. The upper jaw assembly 1 10 also includes seal bars 1 14, each of which is capable of forming a seal in two plies of the film 130. The seal bars 1 14 are positioned on either side of the cutting mechanism 1 12 so the seal bars 1 14 form one seal at the trailing end 158 of the flexible package 134 and another seal at the leading end 160 of the tube 156. The upper jaw assembly 1 10 also includes a film clamp 1 16 that is capable of stabilizing the film 130 on either side of the seal bars 1 14 while the cutting mechanism 1 12 cuts the film 130 and the seal bars 1 14 form seals in the film 130.

[0035] The lower jaw assembly 120 is positioned on an opposite side of the film 130 from the upper jaw assembly 1 10. The lower jaw assembly 120 includes a lower jaw pad 122. The lower jaw pad 122 is configured to provide a backing for the film 130 when the seal bars 1 14 and the film clamp 1 16 contact the film 130. The lower jaw pad 122 includes a slot 124 that is arranged to accommodate the cutting

mechanism 1 12. The lower jaw assembly 120 also has a lower jaw holder 126 that provides structure and stabilization to the lower jaw pad 122. The lower jaw holder 126 is backed by a lower jaw bar 128. The lower jaw bar 128 is held in place by a lower jaw truss 132.

[0036] The instances depicted in Figs. 2A to 2D depict operation of the end sealer 100 and one way in which the end sealer 100 can fail. In Fig. 2A, the film 130 is passing in the direction 138. The film 130 is located between the upper jaw assembly 1 10 and the lower jaw assembly 120. In Fig. 2B, the upper jaw assembly 1 10 has been brought down into contact with the lower jaw assembly 120 with the film 130 in between. The film clamp 1 16 is applying a force through the film 130 into the lower jaw pad 122 to stabilize the film 130 on either side of the seal bars 1 14. The seal bars 1 14 are also in contact with the film 130. In some embodiments, the seal bars 1 14 are heated so that the seal bars 1 14 heat portions of the film 130 between the seal bars 1 14 and the lower jaw pad 122. The cutting mechanism 1 12 has also cut through the film 130 and a portion of the cutting mechanism 1 12 is located in the slot 124 of the lower jaw pad 122. In this way, the slot 124

accommodates the cutting mechanism 1 12 to permit cutting of the film 130.

[0037] In Fig. 2C, the upper jaw assembly 1 10 has been withdrawn upward into a position where the upper jaw assembly 1 10 is not in contact with the lower jaw assembly 120. The flexible package 134 has been separated from the tube 156 by the cut in the film 130 made by the cutting mechanism 1 12. The trailing end 158 of the flexible package 134 has a seal 162 made by one of the seal bars 1 14 on the downstream side of the cutting mechanism 1 12. The leading end 160 of the tube 156 has a seal 164 made by one of the seal bars on the upstream side of the cutting mechanism 1 12. Depending on the speed of the film 130 in the direction 138 and the speed of the upper jaw assembly 1 10, the seals 162 and 164 may still be in a molten state or a semi-molten state where the film material in the seals 162 and 164 has not fully solidified.

[0038] In Fig. 2D, the upper jaw assembly 1 10 has been further withdrawn from the lower jaw assembly 120. The upper jaw assembly 1 10 is sufficiently far away from the lower jaw assembly 120 so that the film 130 is able to pass between the upper jaw assembly 1 10 and the lower jaw assembly 120. The flexible package 134 and the tube 156 have moved in the direction 138 from the position at which they were located in Fig. 2C. Because the flexible package 134 has been separated from the tube 156, the flexible package 134 and the tube 156 are capable of moving independently of each other (e.g., moving in the direction 138 at different rates of speed).

[0039] One potential problem with the end sealer 100 is also depicted in Fig. 2D. In the depicted embodiment, the tube 156 has moved further in the direction 138 than the flexible package 134 has moved. The tube 156 has moved to the point where the seal 162 has contacted the seal 164. If the seals 162 and 164 were in a molten or semi-molten state at the time that the seals 162 and 164 contacted each other, portions of the seals 162 and 164 could solidify together, resulting in the flexible package 134 remaining coupled to the tube 156. Such a result would prevent separation of the flexible package 134 from the tube 156 or from a subsequent flexible package formed from the tube 156.

[0040] One example of a problem of subsequent flexible packages having end seals coupled to each other is depicted with respect to the partial perspective view of a form-fill-seal system 102 shown in Fig. 3. The system 102 includes the end sealer 100 positioned between an object conveyor 148 and a discharge conveyor 150. The tube 156 of the film 130 passes over object conveyor 148 with one or more objects (not visible in Fig. 3) located therein. The object conveyor 148 is adapted to support and transport the tube 156 of film 130 and the object(s) downstream together to the end sealer 100. The end sealer 100 makes cuts in the film 130 to form flexible packages ^* \ 34^ and 134 ₂ from the tube 156, forms seals 164^ 164 ₂ , and 164 ₃ , respectively, in the leading ends 160^ 160 ₂ , and 160 ₃ of the flexible packages ^* \ 34^ and 134 ₂ and the tube 156, and forms seals ^* \ 62 and 162 ₂ , respectively, in the trailing ends 158i and 158 ₂ of the flexible packages 134i and 134 ₂ . The discharge conveyor 150 transports the flexible packages ^* \ 34^ and 134 ₂ from the end sealer 100.

[0041] In the depicted embodiment, at least a portion of the seal ^* \ 62 is connected to at least a portion of the seal 164 ₂ . In this way, the flexible package ^* \ 34^ is coupled to the flexible package 134 ₂ . If an attempt is made to separate the flexible package

134 ₁ from the flexible package 134 ₂ , one or both of the flexible packages 134i and

134 ₂ may be torn open or otherwise made unsuitable for use as a package.

Similarly, at least a portion of the seal 162 ₂ is connected to at least a portion of the seal 164 ₃ . Because of this, the flexible package 134 ₂ is coupled to the tube 156 of the film 130. If an attempt is made to separate the flexible package 134 ₂ from the tube 156, the flexible package 134 ₂ may be torn open or otherwise made unsuitable for use as a package or tube 156 may be torn or dislodged the system that feeds the film 130. Examples of problems associated with the flexible packages ^* \ 34^ and 134 ₂ and/or the tube 156 being coupled to each other include the time and effort required to separate the flexible packages ^* \ 34^ and 134 ₂ , the down time of the system 102 during separation of the flexible packages ^* \ 34^ and 134 ₂ and/or the tube 156, and, in some instance, the time and possible human error that can result from repackaging of objects in different flexible packages. [0042] Depicted in Figs. 4A to 4D are cross-sectional views of an embodiment of an end sealer 200. Figs. 4A to 4D also depict a series of instances of operation of the end sealer 200. The end sealer 200 is capable of forming transverse cuts and seals in packages, such as those formed from film 230 (e.g., polyethylene film). In the particular series of instances depicted in Figs. 4A to 4D, as the film 230 moves in a downstream direction 238, the end sealer 200 makes a cut between a tube 256 of the film 230 and a flexible package 234 and the end sealer 200 forms seals at a trailing end 258 of the flexible package 234 and at a leading end 260 of the tube 256.

[0043] The end sealer 200 includes an upper jaw assembly 210 and a lower jaw assembly 220. The upper jaw assembly 210 includes a cutting mechanism 212 configured to cut the film 230. The cutting mechanism 212 is a blade is the depicted embodiment, but the cutting mechanism 212 may be any other device that is capable of cutting the film 230, such as a heated wire, a cutting roller, and the like. The upper jaw assembly 210 also includes seal bars 214, each of which is capable of forming a seal in two plies of the film 230. The seal bars 214 are positioned on either side of the cutting mechanism 212 so the seal bars 214 form one seal at the trailing end 258 of the flexible package 234 and another seal at the leading end 260 of the tube 256. The upper jaw assembly 210 also includes a film clamp 216 that is capable of stabilizing the film 230 on either side of the seal bars 214 while the cutting mechanism 212 cuts the film 230 and the seal bars 214 form seals in the film 230.

[0044] The lower jaw assembly 220 is positioned on an opposite side of the film 230 from the upper jaw assembly 210. The lower jaw assembly 220 includes a lower jaw pad 222. The lower jaw pad 222 is configured to provide a backing for the film 230 when the seal bars 214 and the film clamp 216 contact the film 230. The lower jaw pad 222 includes a slot 224 that is arranged to accommodate the cutting

mechanism 212. The lower jaw assembly 220 also has a lower jaw holder 226 that provides structure and stabilization to the lower jaw pad 222. The lower jaw holder 226 is backed by a lower jaw bar 228. The lower jaw bar 228 is held in place by a lower jaw truss 232. [0045] The end sealer 200 also includes a gas delivery system 240 that is configured to direct a stream of gas toward the film 230 on the downstream side of the lower jaw assembly 220. The gas delivery system 240 includes a gas passage 242 through the lower jaw bar 228. The gas passage 242 is configured to permit gas to pass from an inlet 244 to an outlet 246 located near the top of the lower jaw assembly 220 on the downstream side of the lower jaw assembly 220. In various embodiments, the outlet 246 may take a number of different forms, such as the example embodiments of the lower jaw assembly 220 depicted in Figs. 5A to 5C. In the embodiment shown in Fig. 5A, the outlet 246 includes a single hole that is in fluid communication with the gas passage 242 and is located on the downstream side of the lower jaw assembly 220. In the embodiment shown in Fig. 5B, the outlet 246 includes a number of holes that are in fluid communication with the gas passage 242 and are located on the downstream side of the lower jaw assembly 220. In the embodiment shown in Fig. 5C, the outlet 246 includes one slot that is in fluid communication with the gas passage 242 and is located on the downstream side of the lower jaw assembly 220. Any other arrangement and number of holes, slots, or other forms of outlets are possible.

[0046] Referring back to the embodiment of the end sealer 200 depicted in Figs. 4A to 4D, the gas delivery system 240 also includes a gas line 248 configured to be selectively coupled to the inlet 244 of the gas passage 242. The gas line 248 is configured to supply a stream of pressurized gas from a gas source (e.g., a package of pressurized gas, an air compressor, etc.) into the inlet 244 of the gas passage 242. In the depicted embodiment, the gas line 248 is releasably couplable to the inlet 244 by way of external threads on the end of the gas line 248 that engage internal threads on the inlet 244. In other embodiments, the gas line 248 is releasably couplable to the inlet 244 by way of any other type of threads, a quick connect and disconnect system, or any other coupling mechanism.

[0047] The instances depicted in Figs. 4A to 4D depict operation of the end sealer 200 and one way in which the end sealer 200 reduces the possibility of consecutive flexible packages becoming coupled together. In Fig. 4A, the film 230 is passing in the direction 238. The film 230 is located between the upper jaw assembly 210 and the lower jaw assembly 220. In Fig. 4B, the upper jaw assembly 210 has been brought down into contact with the lower jaw assembly 220 through the film 230. The film clamp 216 is applying a force through the film 230 into the lower jaw pad 222 to stabilizing the film 230 on either side of the seal bars 214. The seal bars 214 are also in contact with the film 230. In some embodiments, the seal bars 214 are heated so that the seal bars 214 heat portions of the film 230 between the seal bars 214 and the lower jaw pad 222. The cutting mechanism 212 has also cut through the film 230 and a portion of the cutting mechanism 212 is located in the slot 224 of the lower jaw pad 222. In this way, the slot 224 accommodates the cutting mechanism 212 to permit cutting of the film 230.

[0048] In the time between the instance in Fig. 4A and the instance in Fig. 4B, the gas line 248 has been coupled to the inlet 244 of the gas passage 242. As seen in Fig. 4B, the gas line 248 supplies pressurized gas into the inlet 244, the gas passes through the gas passage 242, and a stream of gas 250 is directed out of the outlet 246 toward the film 230. In some embodiments, the stream of gas 250 is run constantly during operation of the end sealer 200. In other embodiments, the stream of gas 250 is controlled so that it is run at particular times (e.g., the stream of gas 250 starts when the end sealer 200 makes a cut and forms seals in the film 230). In some examples, the pressure and/or flow of the stream of gas 250 is controlled by a computing device such as a programmable logic controller (PLC) and/or any other manual, semi-automatic, or automatic controller. In some embodiments, the stream of gas 250 is controlled so that a particular amount of gas is supplied. In some embodiments, the gas is supplied within a range of pressures, such as in a range from about 5 kPa to about 0.6 MPa. In some embodiments, the range of pressure is greater than or equal to about 5 kPa, including pressures that are higher that about 0.6 MPa. In some embodiments, the flow rate of the stream of gas 250 is controlled to provide at least one of a constant stream, an intermittent pulse, a controlled patterned sequence of pulses, or pulses of specific durations. In some

embodiments, the flow rate of the stream of gas 250 is controlled so that the flow rate is in a range that is less than or equal to about 14 m ³ /min. In some

embodiments, the flow rate of the stream of gas 250 is controlled so that the flow rate is in a range that is greater than or equal to about 283 l/min.

[0049] In Fig. 4C, the upper jaw assembly 210 has been withdrawn upward into a position where the upper jaw assembly 210 is not in contact with the lower jaw assembly 220. The flexible package 234 has been separated from the tube 256 by the cut in the film 230 made by the cutting mechanism 212. The trailing end 258 of the flexible package 234 has a seal 262 made by one of the seal bars 214 on the downstream side of the cutting mechanism 212. The leading end 260 of the tube 256 has a seal 264 made by one of the seal bars on the upstream side of the cutting mechanism 212. Depending on the speed of the film 230 in the direction 238 and the speed of the upper jaw assembly 210, the seals 262 and 264 may still be in a molten state or a semi-molten state where the film material in the seals 262 and 264 has not fully solidified. [0050] In Fig. 4D, the upper jaw assembly 210 has been further withdrawn from the lower jaw assembly 220. The upper jaw assembly 210 is sufficiently far away from the lower jaw assembly 220 so that the film 230 is able to pass between the upper jaw assembly 210 and the lower jaw assembly 220. The flexible package 234 and the tube 256 have moved in the direction 238 from the position at which they were located in Fig. 4C. Because the flexible package 234 has been separated from the tube 156, the flexible package 234 and the tube 256 are capable of moving independently of each other (e.g., in the direction 238 at different rates of speed).

[0051] As can be seen in the depicted embodiment, the stream of gas 250 can cause the trailing end 258 of the flexible package 234 to deflect away from the leading end 260 of the tube 256. This deflection reduces the possibility of the seal 262 contacting the seal 264. In addition, the stream of gas 250 causes the seal 262 and/or the seal 264 to solidify faster than would occur without the stream of gas 250. This increased rate of solidification decreases the possibility of the seals 262 and 264 contacting each other while the seals 262 and 264 are in a molten or semi- molten state. In both of these examples, the stream of gas 250 reduces the possibility of the seals 262 and 264 connecting to each other and the flexible package 234 being coupled to the tube 256 after the film 230 is cut by the cutting mechanism 212.

[0052] In the embodiment depicted in Figs. 4A to 4D, at least a portion of the gas delivery system 240 is an integrated part of the lower jaw assembly 220. More specifically, the gas passage 242, the inlet 244, and the outlet 246 are formed in the lower jaw bar 228 of the lower jaw assembly 220. In other embodiments, portions of a gas delivery system may be integrated into an upper jaw assembly of an end sealer. In other embodiments, gas delivery systems may be integrated into either an upper jaw assembly or a lower jaw assembly.

[0053] Figs. 6A and 6B depict embodiments of an end sealer 300 that has a gas delivery system 340 that is not integrated with either an upper jaw assembly 310 or a lower jaw assembly 320 of the end sealer 300. In both embodiments, the gas delivery system 340 includes a gas line 342 that supplies pressurized gas from a gas source (not shown) to a nozzle 344. The nozzle 344 directs a stream of gas 350 along a downstream side of the end sealer 300. In the embodiment depicted in Fig. 6A, the gas delivery system 340 is coupled to the lower jaw assembly 320 by coupling mechanisms 346 (e.g., clasps, brackets, rings, etc.) and the stream of gas 350 is directed along the downstream side of the end sealer 300 toward the upper jaw assembly 310. In the embodiment depicted in Fig. 6B, the gas delivery system 340 is coupled to the upper jaw assembly 310 by the coupling mechanisms 346 and the stream of gas 350 is directed along the downstream side of the end sealer 300 toward the lower jaw assembly 320.

[0054] Depicted in Fig. 7 is an embodiment of a method 400 of forming a separable flexible package. At block 402, a flexible package is formed. The formation of the flexible package includes forming a first transverse seal in a first end of the flexible package. In an example using the system 10 depicted in Fig. 1 , the flexible package is formed by the film 30 being formed into the tube 56 and a transverse seal being formed in the leading end 60 of one of the flexible packages 34. At block 404, the flexible package is filled with one or more objects. In practice, filling the flexible package with the one or more objects may occur at least partially with the formation of the flexible package at block 402. Returning to the example using the system 10 in Fig. 1 , filling the flexible package may include placing one or more of the objects 36 between the two sides of the film and/or in the tube 56.

[0055] At block 406, the flexible package is closed with the one or more objects inside. Closing the flexible package includes forming a second transverse seal in a second end of the flexible package. In the example using the system 10 depicted in Fig. 1 , the flexible package is closed by a transverse seal being formed in the trailing end 60 of the one of the flexible packages 34. At block 408, a stream of gas is directed toward the second end of the flexible package at least after the second transverse seal is formed. Two examples of directing a stream of gas at a second end of a flexible package after the second transverse seal is formed are depicted in Figs. 4C and 4D. In those figures, the stream of gas 250 is directed at the trailing end 258 of the flexible package 234 after the seal 262 has been formed. The stream of gas may also be directed toward the flexible package at other times, such as when the second transverse seal is formed. An example of this is depicted in Fig.

4B, where the stream of gas 250 is being directed toward the trailing end 258 of the flexible package 234 while the seal 262 is being formed.

[0056] Depicted in Fig. 8 is a cross-sectional view of an embodiment of an end sealer 500. The end sealer 500 is capable of forming transverse cuts and seals in packages, such as those formed from film (e.g., polyethylene film). The end sealer 500 includes an upper jaw assembly 510 and a lower jaw assembly 520. The upper jaw assembly 510 includes a cutting mechanism 512 configured to cut the film. The upper jaw assembly 510 also includes seal bars 514, each of which is capable of forming a seal in two plies of the film. In the depicted embodiment, the cutting mechanism 512 is integrated with the seal bars 514 in a V-shape so that the cutting mechanism 512 and the seal bars 514 can be moved together to both cut and seal the film. The cutting mechanism 512 and the seal bars 514 shown in Fig. 8 are capable of being used in any of the other embodiments of end sealers described herein, such as a replacement of the cutting mechanism 212 and the seal bars 214 in end sealer 200. Similarly, the other embodiments of cutting mechanisms and seal bars described herein, such as the cutting mechanism 212 and the seal bars 214 shown in Figs. 4A to 4D, are capable of being used as a replacement of the cutting mechanism 512 and the seal bars 514 in end sealer 500. The upper jaw assembly 510 also includes a film clamp 516 that is capable of stabilizing the film on either side of the seal bars 514 while the cutting mechanism 512 cuts the film and the seal bars 514 form seals in the film.

[0057] The lower jaw assembly 520 is positioned on an opposite side of the film from the upper jaw assembly 510. The lower jaw assembly 520 includes a lower jaw pad 522. The lower jaw pad 522 is configured to provide a backing for the film when the seal bars 514 and the film clamp 516 contact the film. The lower jaw pad 522 includes a slot 524 that is arranged to accommodate the cutting mechanism 512. The lower jaw assembly 520 also has a lower jaw holder 526 that provides structure and stabilization to the lower jaw pad 522. The lower jaw holder 526 is backed by a lower jaw bar 528. The lower jaw bar 528 is held in place by a lower jar truss 532.

[0058] The end sealer 500 also includes a gas delivery system 540 that is configured to direct a stream of gas toward a location where the end sealer 500 forms seals in the film. The gas delivery system 540 includes a gas passage 542 through the lower jaw bar 528. The gas passage 542 is configured to permit gas to pass from an inlet 544 to an outlet 546 located in the slot 524 of the lower jaw pad 522. In various embodiments, the outlet 546 may take a number of different forms, such as a single hole that is in fluid communication with the gas passage 542 and is located in the slot 524, a number of holes that are in fluid communication with the gas passage 542 and are located in the slot 524, or one slot that is in fluid communication with the gas passage 542 and is located in the slot 524. Any other arrangement and number of holes, slots, or other forms of outlets are possible. The gas delivery system 540 shown in Fig. 8 is capable of being used in any of the other embodiments of end sealers described herein, such as a replacement of the gas delivery system 240 in end sealer 200. Similarly, the other embodiments of gas delivery systems described herein, such as the gas delivery system 240 shown in Figs. 4A to 4D, are capable of being used as a replacement of the gas delivery system 540 in end sealer 500.

[0059] The gas delivery system 540 also includes a gas line 548 configured to be selectively coupled to the inlet 544 of the gas passage 542. The gas line 548 is configured to supply a stream of pressurized gas from a gas source (e.g., a package of pressurized gas, an air compressor, etc.) into the inlet 544 of the gas passage 542. In the depicted embodiment, the gas line 548 is releasably couplable to the inlet 544 by way of external threads on the end of the gas line 548 that engage internal threads on the inlet 544. In other embodiments, the gas line 548 is releasably couplable to the inlet 544 by way of any other type of threads, a quick connect and disconnect system, or any other coupling mechanism.

[0060] The end sealer 500 is capable of being operated to cut and seal packages, similar to the operation of the end sealed described above with respect to Figs. 4A to 4D to reduce the possibility of consecutive flexible packages becoming coupled together. Film is capable of being fed between the upper jaw assembly 510 and the lower jaw assembly 520. At a particular point, the upper jaw assembly 510 and the lower jaw assembly can be moved with respect to each other such that the film clamp 516 stabilizes the film, the cutting mechanism 512 cuts the film, and the seal bars 514 form seals the film on either side of the cut by the butting mechanism. The gas delivery system 540 also directs a stream of gas 550 through the slot 524 toward the location at which the seal bars 514 formed the seals. In particular, the stream of gas 550 is directed toward the seal that closes the package which has been cut from the film by the cutting mechanism 512. The stream of gas 550 causes deflection of the end of the package and/or increased rate of solidification of the seal when the seal is in a molten or semi-molten state. The effects of the stream of gas 550 increases the likelihood of separability of the package that was cut free from the film by the cutting mechanism 512 and closed by one of the seals made by the seal bars 514. [0061] One benefit to the embodiment shown in Fig. 8 with the outlet 546 located in the slot 524 is that the stream of gas 550 flowing through the slot 524 may reduce the possibility of film jamming in the slot 524. During operation without the stream of gas 550, film can be cut by the cutting mechanism 512 and then the film can be advanced (e.g., moved to the right in Fig. 8) to form another flexible package. As the film is advanced, the cut end of the film can catch on the slot 524, causing a jam of the film. This jam may occur particularly if film clamp 516 does not properly contact the film or there is slippage of the film against the film clamp 516. However, when the stream of gas 550 flows through the slot 524, the stream of gas 550 tends to cause the end of the film to deflect out of the slot 524. Because the end of the film to deflect out of the slot 524, the film is less likely to be caught in the slot 524 and cause a jam of the film in the slot 524.

[0062] Depicted in Fig. 9 is a lower jaw assembly 620 and a gas delivery system 640 that is configured to direct a stream of gas at a location where an end sealer forms a seal in a continuous supply of film. The lower jaw assembly 620 includes a lower jaw pad 622. The lower jaw pad 622 is configured to provide a backing for the film when seal bars and a film clamp contact the film. The lower jaw pad 622 includes a slot 624 that is arranged to accommodate a cutting mechanism. The lower jaw assembly 620 also has a lower jaw holder 626 that provides structure and stabilization to the lower jaw pad 622. The lower jaw holder 626 is backed by a lower jaw bar 628. The lower jaw bar 628 is held in place by a lower jar truss 632.

[0063] The gas delivery system 640 is configured to direct a stream of gas toward a location where an end sealer forms seals in the film. The gas delivery system 640 includes gas lines 642 _! and 642 ₂ that respectively supply pressurized gas from a gas source (not shown) to nozzles 644 and 644 ₂ . The nozzles 644 and 644 ₂ respectively direct streams of gas 650 _! and 650 ₂ along the slot 624 of the lower jaw assembly 620. The gas lines 642i and 642 ₂ may be fixedly coupled to the lower jaw assembly 620 or to any part of an end sealer of which the lower jaw assembly 620 is a component. The streams of gas 650 _! and 650 ₂ along the slot 624 are capable of deflecting ends of flexible packages formed in part by the lower jaw assembly 620 and/or increasing the rate of solidification of seals in the ends of flexible packages formed in part by the lower jaw assembly 620.

[0064] For purposes of this disclosure, terminology such as "upper," "lower,"

"vertical," "horizontal," "inwardly," "outwardly," "inner," "outer," "front," "rear," and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms "connected," "coupled," and "mounted" and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms "substantially," "approximately," and the like are used to mean within 5% of a target value.

[0065] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the

embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and

equivalents fall within the spirit and scope of the present disclosure, as claimed.