SYSTEM AND METHOD FOR PACKAGING OF MASS-FABRICATED CUSTOM ITEMS

• US 20080121537A1
• Filed: 02/02/2007
• Published: 05/29/2008
• Est. Priority Date: 11/28/2006
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Kuo, Eric, Sankaran, Stanley E., Conlon, Kevin M., Van Riper, Josh
• Granted Patent: US 7,748,199 B2
• Time in Patent Office: Days
• US Class Current: 206/223
• CPC Class Codes: B65B 35/10 Feeding, e.g. conveying, single articles
• CPC Class Codes: B65B 43/123 Feeding flat bags connected to form a series or chain
• CPC Class Codes: B65B 43/267 Opening of bags interconnected in a web
• CPC Class Codes: B65B 43/34 by internal pressure
• CPC Class Codes: B65B 5/045 in bags
• CPC Class Codes: B65B 57/00 Automatic control, checking, warning, or safety devices registering wrapping or container-forming material fed from rolls B65B41/18
• CPC Class Codes: B65B 61/025 for applying, e.g. printing, code or date marks on material prior to packaging
• CPC Class Codes: B65B 61/20 for adding cards, coupons or other inserts to package contents adding unpacking elements B65B61/18
• CPC Class Codes: B65B 65/003 Packaging lines, e.g. general layout

Abstract

A system for packaging mass-customized items includes a computer system including a database containing item identification information unique to each item; (2) outer container identification apparatus that applies the item identification information received from the database to each outer container in a plurality of outer containers; (3) inner pack identification apparatus that applies the item identification information received from the database to each inner pack in a plurality of inner packs; and (4) inner pack filling apparatus that fills each inner pack with a specific item matched to that inner pack by the item identification information received from the database. Each item is associated with its unique item identification information and is inserted into an inner pack with matching item identification information, and each outer container is presented for loading with one or more inner packs matched to that outer container by the item identification information received from the database.

Claims

1. A system for packaging mass-customized items, comprising:

a database including item identification information unique to a mass-customized item of a series of sequenced mass-customized items;

outer container identification apparatus for applying the item identification information received from the database to each outer container of a plurality of outer containers; and

filling apparatus for filling each outer container with at least two mass-customized items matched to the outer container by the item identification information;

wherein each outer container is presented for loading with the at least two mass-customized items.

2. The system of claim 1, further comprising:

an inner pack identification apparatus for applying the item identification information received from the database to an inner pack of a plurality of inner packs;

the inner pack configured to house at least one mass-customized item; and

an inner pack filling apparatus for filling each inner pack with one mass-customized item matched to the inner pack by the item identification information.

3. The system of claim 2, wherein the database further comprises item grouping information identifying a predefined group of items to which each item belongs;

wherein the outer container identification apparatus and the inner pack identification apparatus further receive the item grouping information from the database and apply the item grouping information to the outer containers and the inner packs, respectively.

4. The system of claim 3, wherein the database further comprises item sequencing information defining a predetermined sequence for the items in each group;

wherein the inner pack identification apparatus further receives the item sequencing information from the database and applies the item sequencing information to the inner packs;

wherein the inner pack filling apparatus receives the item sequencing information from the database and fills each inner pack with at least one item matched to that inner pack by the item identification information and the item grouping information; and

wherein the inner pack filling apparatus fills the inner packs identified in each group by the item grouping information in a sequence dictated by the item sequencing information.

5. The system of claim 2, wherein the outer container identification apparatus, the inner pack identification apparatus, and the inner pack filling apparatus communicate with the computer system via a local area network (LAN).

6. The system of claim 2, wherein the item identification information applied to the outer containers by the outer container identification apparatus and applied to the inner packs by the inner pack identification apparatus includes information readable by an optical scanner.

7. The system of claim 6, wherein the inner pack filling apparatus includes an optical scanner that reads the information applied to each inner pack and transmits the scanned information to the computer system for matching with the item identification information associated with the item to be inserted into each inner pack.

8. The system of claim 7, wherein the optical scanner of the inner pack filling apparatus is a first optical scanner, the system further comprising a second optical scanner that reads the outer container identification information applied to each outer container and transmits the scanned information to the computer system for matching with the item identification information scanned from each inner container.

9. The system of claim 2, wherein the items are delivered to the inner pack filling apparatus encoded with the item identification information, and wherein the inner pack filling apparatus includes a code reading mechanism that reads the encoded item identification information from each item and that transmits the item identification information to the computer system for matching against the item identification information provided on each of the inner packs.

10. A system for packaging mass-customized items, comprising:

a computer system including a database containing item information including (a) item identification information unique to each mass-customized item, (b) item grouping information identifying a predefined group of items to which each item belongs, and (c) item sequencing information defining a predetermined sequence for the items in each group;

outer container identification apparatus, communicating with and controlled by the computer system so as to apply the item identification information and the item grouping information to each outer container in a plurality of outer containers;

inner pack identification apparatus, communicating with and controlled by the computer system so as to apply the item information to each inner pack in a plurality of inner packs; and

inner pack filling apparatus, communicating with and controlled by the computer system so as to filling each of the inner packs with at least one item matched to each inner pack by information received from the database, whereby each item is associated with its unique item identification information and is inserted into a corresponding inner pack having matching item identification information, and wherein the inner packs are filled in a sequence determined by the item sequencing information;

wherein each outer container is present for loading with at least one inner pack matched to that outer container by information received from the database, whereby each outer container is associated with the item grouping information for a specific group of items, and the inner packs with matching item grouping information are inserted into the associated outer container in the sequence determined by the sequencing information.

11. The system of claim 10, wherein the inner packs are plastic bags provided to the inner pack identification apparatus in a continuous interconnected bag string, the system further comprising a bag cutting apparatus, communicating with and controlled by the computer system, that receives the bag string from the inner pack filling apparatus and that cuts the bag strings into bag strips in accordance with the item grouping information received from the database, whereby the bags in each strip are ordered in the sequence determined by the item sequencing information, and whereby all of the bags in each strip are in a single group defined by the item grouping information.

12. The system of claim 10, wherein the outer container identification apparatus, the inner pack identification apparatus, and the inner pack filling apparatus communicate with the computer system via a local area network (LAN).

13. The system of claim 10, wherein the item information applied to the outer containers by the outer container identification apparatus and to the inner packs by the inner pack identification apparatus includes information readable by an optical scanner.

14. The system of claim 13, wherein the inner pack filling apparatus includes an optical scanner that reads the information printed on each inner pack and transmits the scanned information to the computer system for matching with the item identification information associated with the item to be inserted into each inner pack.

15. The system of claim 14, wherein the optical scanner is a first optical scanner, and wherein the system further comprises a second optical scanner that reads the outer container identification information applied to each outer container and transmits the scanned information to the computer system for matching with the item identification information scanned from each inner container.

16. The system of claim 11, wherein the inner pack filling apparatus and the bag cutting apparatus are controlled by the computer system through programmable logic controllers.

17. The system of claim 10, wherein the items are delivered to the inner pack filling apparatus encoded with the item identification information, and wherein the inner pack filling apparatus includes a code reading mechanism that reads the encoded item identification information from each item and that transmits the item identification information to the computer system for matching against the item identification information provided on each of the inner packs.

18. The system of claim 17, wherein the items are delivered to the inner pack filling apparatus in RFID pucks encoded with the item identification information, and wherein the inner pack filling apparatus includes an RFID receiver that transmits the item identification information to the computer system for matching against the information printed on each of the inner packs.

19. The system of claim 11, further comprising a bag sealing apparatus for sealing the bags in the bag string after the bags are filled and before the bag strips are cut.

20. The system of claim 11, wherein each of the bags in the continuous bag string includes an open end, wherein the bags are attached along a lateral edge transverse to the open end, and wherein the bag cutting apparatus cuts the bag strings into the bag strips along selected ones of the lateral edges.

21. The system of claim 11, wherein the bags in the continuous bag string are connected end-to-end, with each bag having a first end attached to a second end of an adjacent bag along a frangible seam, wherein each bag includes a slotted opening parallel to the first end, and wherein the bag cutting apparatus separates the bag string into the bag strips along selected ones of the frangible seams.

22. A method of packaging mass-customized items, each item being associated with predefined item identification information, the method comprising:

creating a computer database containing the item information;

providing a plurality of outer containers, each of which is identified with the item identification information received from the database for at least one item;

providing a plurality of inner packs, each of which is identified with the item identification information received from the database for at least one item;

filling each inner pack with at least one specific item matched to that inner pack by the item identification information received from the database, whereby each item is associated with its unique item identification information and is inserted into an inner pack with matching item identification information; and

loading each outer container with at least two inner packs matched to that outer container by item identification information received from the database.

23. The method of claim 22, wherein the item identification information is received from the database via a local area network (LAN).

24. The method of claim 22, wherein the item identification information is applied to the outer containers and the inner packs so as to be readable by an optical scanner.

25. The method of claim 22, wherein the filling step includes (a) the delivery of the items with encoded item identification information;

and (b) reading the encoded item identification information delivered with the items and transmitting the item identification information to a computer system employing the database for matching against the item identification information with which the inner packs are provided.

26. The method of claim 25, wherein the items are delivered in RFID pucks encoded with the item identification information, and wherein the step of reading the encoded item identification information includes reading the RFID-encoded information.

27. The method of claim 25, wherein the items include the item identification information in optically scannable code, and wherein the step of reading the encoded item identification information includes optically scanning the code.

28. The method of claim 22, wherein the inner packs are plastic bags, and wherein the step of providing the inner packs comprises:

providing the bags in a continuous interconnected bag string; and

applying the item identification information to each bag in the bag string.

29. The method of claim 28, wherein the step of filling the inner packs comprises:

filling each bag in the string with at least one specific item matched to that bag by the item identification information received from the database, whereby each item is associated with its unique item identification information and is inserted into a bag with matching item identification information;

sealing the bags in the bag string; and

cutting the bag strings into strips, wherein each bag in a strip belongs to a single group determined by item grouping information received from the database.

30. The method of claim 22, wherein the outer containers are boxes, and wherein the step of providing a plurality of outer containers comprises:

forming a plurality of boxes out of cardboard sheets; and

applying a label to each box that is imprinted with the item identification information;

31. The method of claim 30, further comprising installing a divider in each box so as to divide the interior of each box into at least two compartments.

32. A method of packaging mass-customized items sorted by group in a predetermined sequence, each item being associated with predefined item identification information, the method comprising:

creating a computer database containing item information including (a) item identification information unique to each mass-customized item, (b) item grouping information identifying a predefined group of items to which each item belongs, and (c) item sequencing information defining a predetermined sequence for the items in each group;

providing a series of outer containers;

applying item information received from the database to each outer container;

providing a series of inner packs;

applying item information received from the database to each inner pack;

filling each inner pack with at least one item matched to each inner pack by information received from the database, whereby each item is associated with its unique item identification information and is inserted into an inner pack with matching item identification information, and wherein the inner packs are filled in a sequence determined by the item sequencing information; and

filling each outer container with the inner packs matched to that outer container by information received from the database, whereby each outer container is associated with the item grouping information for a specific group of items, and the inner packs with matching item grouping information are inserted into the associated box in the sequence determined by the sequencing information.

33. The method of claim 32, wherein the item information is received from the database via a local area network (LAN).

34. The method of claim 32, wherein the item information is applied to the outer containers and the inner packs so as to be readable by an optical scanner.

35. The method of claim 32, wherein the filling step includes (a) the delivery of the items with encoded item information;

and (b) reading the encoded item information delivered with the items and transmitting the item information to a computer system employing the database for matching against the item information applied to the inner packs.

36. The method of claim 35, wherein the items are delivered in RFID pucks encoded with the item information, and wherein the step of reading the encoded item information includes reading the RFID-encoded information.

37. The method of claim 35, wherein the items include the item information in optically scannable code, and wherein the step of reading the encoded item information includes optically scanning the code.

38. The method of claim 32, wherein the inner packs are plastic bags, and wherein the step of providing the inner packs comprises:

providing the bags in a continuous interconnected bag string; and

applying the item identification information to each bag in the bag string.

39. The method of claim 38, wherein the step of filling the inner packs comprises:

filling each bag in the string with at least one specific item matched to that bag by the item information received from the database, whereby each item is associated with its unique item information and is inserted into a bag with matching item information;

sealing the bags in the bag string; and

cutting the bag strings into strips, wherein each bag in a strip belongs to a single group determined by the item grouping information received from the database.

40. The method of claim 32, wherein the outer containers are boxes, and wherein the step of providing a plurality of outer containers comprises:

forming a plurality of boxes out of cardboard sheets; and

applying a label to each box that is imprinted with the item identification information;

41. The method of claim 40, wherein the step of manufacturing the boxes includes the step of installing a divider in each box so as to divide the interior of each box into at least two compartments.

42. Apparatus for installing a divider into a container having a bottom interior surface, comprising:

an adhesive applicator positioned and configured to apply an adhesive to the bottom interior surface of the container;

a pair of arms that are movable vertically between a raised and lowered position, and that are movable laterally toward each other to a closed position and away from each other to an open position; and

a sheet-holding element at the end of each of the arms;

whereby, when a cardboard sheet is held in the sheet-holding elements and the arms are moved from their open lateral position to their closed lateral position while in their raised vertical position, the sheet is folded so as to form a vertical dividing wall across the sheet; and

whereby, when the arms are moved vertically into their lowered position, the folded sheet is placed on the bottom interior surface of the container.

43. The apparatus of claim 42, further comprising:

a blade that is movable vertically between a raised and a lowered position and that is disposed relative to the arms so that, when the blade is in its raised position, it engages the sheet between the arms as the arms begin to move toward their closed position to facilitate the folding of the sheet to form the dividing wall.

44. Apparatus for inserting an item into a bag having an open end defined between opposed side walls, comprising:

an insertion mechanism, comprising a receiving bed on which an item is initially placed, a loading channel adjacent the receiving bed, and a pushing element operable to push the item from the receiving bed into the loading channel;

a bag opening mechanism, comprising a vacuum head selectably operable to engage a side wall of the bag and to open the bag, and a pair of fingers operable for selective insertion into the open end of the bag to maintain the separation of the side walls thereof; and

a ram element selectably operable to push the item from the loading channel into the bag through the open end thereof.

45. The apparatus of claim 44, wherein each item is identified by item identification information stored in a computer system database, and wherein the apparatus inserts each item into a bag identified with the item identification information associated with that item

46. The apparatus of claim 44, wherein each item is identified by item identification information stored in a computer system database, the apparatus further comprising:

means for reading the item identification information from each item and transmitting the item identification information to the computer system database; and

a bag printing mechanism that retrieves the item identification information for each item from the database and that applies the identification information to a bag in which the item is inserted.