Bandoleer Packaging With Edge Heat Sealed to Backing

Our invention relates to the field of bandoleer packaging. More specifically, we have invented a new form of bandoleer packaging that can accommodate dimensioned or relatively thick items yet allows the individual packages to be separated using a roller-type bursting mechanism. Further, our new bandoleer packaging can include an adhesive stripe to allow automated attachment of individual packages to substrates.

Bandoleer packaging generally includes a tube formed from a primary web into which items are inserted. The individual packages are typically formed by heat sealing top and bottom seams or edges of the packages along the tube. A perforation or other weakening is generally placed between the top edge of one package and the adjacent bottom edge of another package to ease separation of the packages from the bandoleer. One way to separate packages from a bandoleer is to run the bandoleer through a bursting mechanism. Burst mechanisms generally include rollers that engage the edges of the bandoleer and put tension on the bandoleer to pull packages off the end of the bandoleer.

Bandoleer packages separated by bursting mechanisms are generally limited to flat contents to avoid damage to the contents. Dimensioned objects tend to travel within the individual packages before entering the burst station. When the packages pass through the burst mechanism, dimensioned objects that have traveled toward the edges of the packages can be damaged or destroyed by the burst rollers.

Packages similar to individual bandoleer packages have been affixed to the exterior of larger packages or other substrates for various purposes. Although bandoleers are convenient for the production of such individual packages, prior art bandoleer packages must be individually separated and glued to the larger packages. This is generally too time consuming and labor intensive to be sustained for high levels of production.

Our invention provides inserts in bandoleer packages to which we bond the edges of each package, keeping the objects contained within the packages away from the edges of the packages. We prefer to provide an insert in the form of a card that has been treated with a coating that is heat sensitive, allowing us to bond the edges with heat-sealing equipment. By bonding the edges of the packages to the cards, we hold the contents far enough away from the edges that a burst mechanism can separate the packages without damaging the contents. While our invention can be used with any type of bandoleer packaging, we have designed our invention for preferred use with bandoleers made by forming a tube from the primary web.

In the preferred embodiment of our invention, the tube is formed around the secondary web and the dimensioned or relatively thick object to be packaged. We then form two seams with a perforation therebetween, one seam being the top of one package and the other being the bottom of an adjacent package. Next, we bond the edges of the packages to the secondary web, thereby confining the contents of the packages to a region far enough away from the edges of the tube as to avoid damage when the bandoleer is fed through bursting rollers.

In another embodiment of our invention, we provide an adhesive stripe to our bandoleer package in such a way that the individual packages can be separated and affixed to larger packages or other substrates automatically. The adhesive stripe can be placed on the bandoleer before or after perforations are formed between individual packages of the bandoleer. We place a release liner that is preferably unperforated over the stripe to protect the adhesive and prevent the bandoleer packages from adhering to items other than those to which they are to be affixed. The bandoleer can then be fed through an automated application machine to a separating station that separates the release liner from the bandoleer tube. The individual packages are then disconnected from the bandoleer along the perforations and affixed to the larger packages or other substrates.

FIG. 1 is a schematic view of a portion of a bandoleer made according to our invention.

FIG. 2 is a cross section of an individual package along the line II--II in FIG. 1.

FIG. 3 is a schematic of a bandoleer being assembled according to our invention.

FIG. 4 is a schematic representation of the method of our invention.

Our method 100 is particularly suited for use with modern automated packaging machinery. This type of machinery generally uses webs in the form of rolls to form bandoleers 1. There are many stations in the machinery, such as rolling, shaping, cutting, and bonding stations.

We provide and use a primary web 2, as seen particularly in FIG. 3 and as represented by block 110 of FIG. 4, to form a tube 15 from which we form a bandoleer 1 of packages 10 in all embodiments of our invention. The primary web 2 is preferably a resinous material, such as polyethylene, that can be of any suitable dimensions. We also provide and use inserts 20, as represented by block 120 of FIG. 4, preferably in the form of cards made of a relatively rigid material, such as paper card stock. We place an insert 20 adjacent a surface of the primary web 2 or vice versa such that the insert 20 is surrounded by the tube 15. This can be seen in FIG. 3 and is represented by blocks 130 and 140 in FIG. 4. The tube 15 is flattened and acquires edges 14 when we form top and bottom seams 11, 12 for packages 10 in the tube 15 at a seam-forming station 50 (refer to FIGS. 1-3 and block 150 of FIG. 4). Top and bottom seams 11, 12 are also the top and bottom edges of the individual package 10. At a point 60 after the formation of the top seam 11 of a given package 10, we bond the edges 14 of the package 10 to the insert 20 to keep a dimensioned or relatively thick object 30 in the package 10 away from the edges 14 of the package 10. This is represented by block 160 in FIG. 4 and is illustrated in FIGS. 1-3. We prefer to use inserts 20 coated with a heat-sealable material, such as polyethylene, so that we can simply use heat-sealing equipment to bond the edges 14 to the inserts 20. With the edges 14 thus bonded to the inserts 20, the packages 10 can pass through a bursting station with no damage to the objects they contain.

In the preferred embodiment of our invention, inserts 20, preferably in the form of paperboard cards, are placed on a conveyor 3 (block 120). We prefer to place the objects 30 to be packaged on the conveyor 3 with the inserts 20, but the objects 30 can also be placed on the insert 20 after the insert 20 is placed on the conveyor 3 (block 130). Where the objects 30 are placed on the conveyor 3 with the inserts 20, we prefer to attach the objects 30 to the inserts 20 with an adhesive or the like if this will not cause damage to the objects 30. We then pass the primary web 2 through plows 35 to form the tube 15 around the inserts 20 (block 140). The primary web 2 is sealed in the shape of a tube 15 by heated rollers 40 that seal the edges 16 of the primary web 2 together beneath the inserts 20 (block 140). Next, we heat seal the tube 15 to itself to form the perforations 13 between packages at a perfing station 50, at the same time forming the top seam 11 of one package 10 which includes a top edge of the package 10, and the bottom seam 12 of an adjacent or previous package 10 which includes a bottom edge of the previous package 10 (block 150). Then, we bond the edges 14 of the tube 15/packages 10 to the inserts 20 (block 160) at an edge-bonding station 60, preferably by heat sealing the tube material to a coating on the inserts 20 as illustrated by the region 21 in the Figures. We prefer to use polyethylene or polypropylene for the coating, but any suitable material can be used. Once all the seams and edges are formed, we feed the bandoleer 1 of packages 10 into a carton using a transverse fan fold. The bandoleers 1 are run through bursting rollers by the end user, who inserts individual bandoleer packages into his or her product or affixes the individual packages to larger packages as will be described below. For example, cereal manufacturers insert individual packages containing toys into boxes of their cereal. However, having the bursting station at the same place as, or even as part of, the same machinery that forms the bandoleer is within the scope of our invention.

While we prefer to form the tube 15 around the inserts 20 and objects to be packaged 30, the inserts 20 can also be inserted into the tube 15 after the bottom seam 12 of a package 10 is formed. Additionally, it is within the scope of the invention to carry out the step of bonding the edges 14 of the packages 10 to the inserts 20 at the same time as the first and second seams 11, 12 are formed. Further, while the preferred manner of bonding the edges 14 is to heat seal them to a coating on the inserts 20, other forms of bonding are within the scope of the invention as may be appropriate for the circumstances. For example, epoxy or other adhesives might be used to affix the edges to the inserts 20.

An additional feature of our invention provides for automatic affixing of the individual packages 10 to larger packages or other substrates and can be seen in FIGS. 1-4. An adhesive stripe 17 is applied to the bandoleer 1 of packages 10. This can be done before or after the perforations 13 between packages 10 are formed, but is preferably done after formation of the perforations 13, as represented by block 170 in FIG. 4, to avoid exposing the perforation-making equipment 50 to the adhesive. After the perforations 13 are formed and after the adhesive stripe 17 is applied, we place a release liner 18 over the adhesive stripe (block 180). The release liner 18, which is preferably unperforated, protects the adhesive stripe 17 and prevents adherence of the bandoleer 1 to objects other than the larger packages or other substrates to which they are to be affixed. While we prefer to use this feature of our invention with the sealed-edge type of bandoleer packaging, it is within the scope of the invention to apply our adhesive stripe and unperforated release liner to any bandoleer packaging.

When an end user wishes to affix bandoleer packages 10 to larger packages, the bandoleer 1 is run through an automated application machine to a separating station that separates the release liner 18 from the bandoleer tube 1. The individual packages 10 are then disconnected from the bandoleer 1 along the perforations 13 and affixed to the larger packages or other substrates at another station. These stations could, for example, be incorporated into the machinery shown in FIG. 3.

Since the packages 10 already have adhesive applied, and since the packages can be automatically affixed to larger packages or other substrates, high levels of production are achieved with low cost as compared to manually affixing similar packages. Because the release liner 18 is unperforated, it can be easily controlled and disposed of during and after removal from the bandoleer 1, saving on clean-up costs as well.

As mentioned above, our invention can be formed and our method performed using existing machinery, though the machinery must be modified to accommodate the bonding of the package edges, the removal of the release liner, and the affixing of the packages to larger packages or other substrates. Where the edges are bonded using heat sealing, the modification entails adding heat-sealing elements to an existing station or adding a new heat-sealing station. Where the bonding is accomplished using an adhesive compound, such as epoxy, the modification entails the addition of adhesive-application equipment. Other modifications for other methods of bonding are within the scope of the invention as well.

While our invention is intended for use with dimensioned objects, it should be apparent that our invention could be applied to the packaging of flat objects as well.