Method for packaging of mass-fabricated custom items

• US 8,438,817 B2
• Filed: 05/25/2010
• Issued: 05/14/2013
• Est. Priority Date: 11/28/2006
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Sankaran, Stanley E., Kuo, Eric, Conlon, Kevin M., Van Riper, Josh
• Primary Examiner(s): GERRITY, STEPHEN FRANCIS
• Application Number:
  US12/787,288
• Publication Number:
  US 20100234982A1
• Time in Patent Office: 1,085 Days
• Field of Search: 534/11, 534/45, 534/59, 534/74, 531312-1315, 531/68, 531/55, 531/70, 532/63, 532/38, 532/37, 700/216, 700/225, 700/235
• US Class Current: 53/411
• 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 method of packaging mass-customized items sorted by group in a predetermined sequence, each item being associated with predefined item 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;

associating item information received from the database with each outer container;

providing a series of inner packs;

associating item information received from the database with each inner pack;

filling each inner pack with at least one item matched to that 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 associated 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 the item grouping information for a specific group of items, and the inner packs are inserted into an outer container with matching item grouping information in the sequence determined by the item sequencing information.

2. The method of claim 1, wherein the item information is received from the database via a local area network (LAN).

3. The method of claim 1, wherein the item information is applied to the outer containers and the inner packs so as to be readable by an optical scanner.

4. The method of claim 1, wherein the filling step includes (a) delivering each 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 with which each of the inner packs is associated.

5. The method of claim 4, wherein the items are delivered in item carriers provided with an RFID chip encoded with the item information, and wherein the step of reading the encoded item information includes reading the RFID-encoded information.

6. The method of claim 4, 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.

7. The method of claim 1, 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.

8. The method of claim 7, 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.

9. The method of claim 1, 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;

10. The method of claim 9, 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.

11. A method of packaging mass-customized items, comprising:

(a) creating a database in which each item in a plurality of mass-customized items is associated with predefined item identification information unique to that item;

(b) providing a plurality of outer containers, each of which is associated with item identification information received from the database for at least one of the plurality of mass-customized items;

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

(d) filling each inner pack with at least one specific item of the plurality of mass-customized items matched to that inner pack by the item identification information received from the database, wherein each item of the plurality of mass-customized items is associated with its unique item identification information and is inserted into an inner pack with matching item identification information; and

(e) loading each outer container with at least one inner pack matched to that outer container by the item identification information unique to each specific item in the at least one inner pack.

12. The method of claim 11, wherein the item identification information is received from the database via a local area network (LAN).

13. The method of claim 11,wherein the item identification information is applied to the outer containers and the inner packs so as to be readable by an optical scanner.

14. The method of claim 11, wherein the filling step includes (a) delivering each of the items with its unique item identification information in encoded form;

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 each of the inner packs is associated.

15. The method of claim 14, wherein the items are delivered in item carriers provided with an RFID chip encoded with the item identification information, and wherein the step of reading the encoded item identification information includes reading the RFID-encoded information.

16. The method of claim 14, 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.

17. The method of claim 11 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.

18. The method of claim 17, 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.

19. The method of claim 11, 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;

20. The method of claim 19, further comprising installing a divider in each box so as to divide the interior of each box into at least two compartments.