ENVELOPES WITH FLOOD-COATED BONDING ELEMENT
Envelopes have a bonding element, such as an adhesive material, applied to a majority of the interior surface of at least one wall of the container, so that seals defining dimensions of the containers can be formed from the bonding element at any desired position along the height or length of a web from which the container is formed.
1 . A method for forming an envelope configured to hold an item to be packaged, the method comprising:
providing a web stock comprising: a first wall; a second wall overlying the first wall and affixed to the first flexible wall about at least a portion of a pocket border that encloses a pocket defined between the first and second walls and configured to contain the item; and a bonding element covering a majority of a surface of at least one of the first and second walls, the bonding element forming a first seal extending in a generally lengthwise direction of the web stock; and
forming, from the bonding element, a second seal and a third seal between the first and second walls, wherein at least the second and third seals form a portion of the pocket.
2 . The method of claim 1 , wherein:
the second and third seals extend in a generally transverse direction of the web stock; and
the method further comprises advancing the web stock in a lengthwise direction of the web stock by a first distance after forming the second seal and before forming the third seal, the first distance corresponding to a desired dimension of the envelope in a lengthwise direction of the envelope.
3 . The method of claim 2 , wherein:
forming the second seal and the third seal comprises forming the second seal and the third seal using a sealing device configured to apply heat to the web stock; and
advancing the web stock in a lengthwise direction of the web stock by a first distance comprises advancing the web stock to align a location on the web stock at which the third seal is to be formed with the sealing device.
4 . The method of claim 3 , further comprising:
inserting the item to be packaged into the pocket after forming the second seal and before forming the third seal; and
separating the envelope from the web stock by forming a line of separation through the third seal.
5 . The method of claim 4 , wherein:
the envelope is a first envelope; and
the method further comprises advancing the web stock by a second distance after separating the envelope from the web stock, the second distance corresponding to a desired lengthwise dimension of a second envelope to be formed from the web stock.
6 . The method of claim 5 , wherein the second distance is unequal to the first distance.
7 . The method of claim 1 , wherein forming a third seal between the first and second walls comprises forming the third seal at a location spaced from the second seal in the lengthwise direction of the web stock by a distance about equal to a desired dimension of the envelope in the lengthwise direction of the web stock.
8 . The method of claim 1 . further comprising varying a spacing between the second and third seals to provide the envelope with a predetermined dimension in the lengthwise direction of the web stock.