CN1639009B - 用于充气和密封充气包装垫的机器和方法 - Google Patents

用于充气和密封充气包装垫的机器和方法 Download PDF

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CN1639009B
CN1639009B CN03804501XA CN03804501A CN1639009B CN 1639009 B CN1639009 B CN 1639009B CN 03804501X A CN03804501X A CN 03804501XA CN 03804501 A CN03804501 A CN 03804501A CN 1639009 B CN1639009 B CN 1639009B
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安德鲁·珀金斯
奥利弗·M·雷耶斯
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Abstract

本发明公开一种从成卷的预制薄膜材料(11)制成充气包装垫的方法和机器，该预制薄膜材料卷具有靠近材料的一端的纵向延伸的充气通道(19)，以及通过横向延伸通路(23)与通道(19)连通的腔室(21，22)。该薄膜材料从所述卷(28)被馈送到延伸进入充气通道的充气管(52)，空气通过充气管(52)被引入到腔室(21，22)中，从而对垫子进行充气，在垫子被充气后纵向延伸的密封(89)被形成为横跨通道(19)和腔室(21，22)之间的通路(23)。

Description

用于充气和密封充气包装垫的机器和方法
技术领域
本发明大体涉及包装材料，更特别地讲，本发明涉及一种用于制造充气包装垫的机器和方法。 
背景技术
目前充气衬垫或垫子在运输纸箱和类似物中被用作包装材料和间隙填充物。这种垫子典型地具有两层塑料薄膜材料，它们密封起来以形成充满空气的腔室。该垫子通常被做成连续的串状，在连续的垫子之间形成有穿孔，从而使它们可以被撕开而彼此分离。 
尽管在重量上很轻，可是充气垫子却会占据相当大的空间，为了减少运送和存储时所占的空间，这种垫子通常在使用地点或附近被制成。为了避免包装工和运输工在工厂中对复杂制垫机器的需求，充气包装垫子的供应商向他们的顾客提供预制好的薄膜材料，在这些材料中已经形成好主要的密封和穿孔。这些材料通常会缠绕成卷或折叠进盒子中，以便运输和存储。 
向使用预制薄膜材料的包装工和运输工提供相对简单、不贵的机器用于充气和密封材料，从而可使他们在使用地点或附近制成垫子。这种机器的例子在美国专利6,209,286中以及No.09/638,843和09/717,782共审申请可以找到，其内容通过参考结合于此。 
发明内容
总体上，本发明的目的在于提供一种用于制造充气包装垫的新的、经改进的机器和方法。 
本发明的另一个目的在于，提供一种具有上述特征的机器和方法，其可以克服现有技术的局限和不足。 
通过提供一种机器和方法以达到根据本发明的这些和其它目的，该机器用于从具有两层的预制薄膜材料卷来制成充气包装垫，这所述两层被密封在一起以在材料的一个边缘附近形成纵向延伸的充气通道，成排的腔室延伸横 跨该材料，流动通路使每排中的腔室互连，并且入口通路在入口通路和每排腔室中的其中一个腔室之间延伸穿过。 
所述卷搁置于一对间隔开的水平延伸的辊子上。薄膜材料从所述卷被馈送到充气管，该充气管延伸进入充气通道，空气通过充气管被引入到腔室中，从而所述垫进行充气，并且在所述垫被充气之后，纵向延伸的密封跨过通道和腔室之间的通路形成。 
附图说明
图1是平面图，其示出用于制造根据本发明的充气包装垫的预制薄膜材料实施例的局部剖面图； 
图2是等轴测视图，其示出用于对根据本发明的充气包装垫进行充气和密封的机器的实施例； 
图3是图1中所示实施例的分解等轴测视图； 
图4是图2中所示实施例中的密封单元片断的侧视图； 
图5是图4中密封单元片断的剖面图； 
图6是图2中所示实施例将预制的薄膜材料变成充气包装垫的操作视图； 
图7是平面图，其示出用于制造根据本发明的充气包装垫的预制薄膜材料另一实施例。 
具体实施方式
图1中所示的预制薄膜材料包括由诸如高密度聚乙烯或低密度聚乙烯的适合薄膜材料所构成的两个层12，13。该材料是连接在一起的扁平管状，或沿其纵向边缘16，17是封闭的，或者它可以沿一边或两边打开。在示出的实施例中，薄膜材料的单个长片或条沿它的中心线折叠以形成边缘16。该边缘被关闭，边缘17打开。 
薄膜的两个层被密封在一起以形成充气通道19和可充气的腔室21，22。在材料的其中一个边缘附近，该通道纵向延伸，并且腔室被成对并排地横过材料布置。入口通路23在充气通道和每对腔室中的其中一个之间延伸，通路24互连着所述腔室。出口通路25在充气通道和材料开口边缘17之间延伸。 
在最终的产品里，每行或成对的腔室形成单个的垫子。已经发现，在某些应用中，有两个或更多互连腔室的这些垫子和其它垫子比仅有一个腔室的垫子可提供更好的缓冲和吸震。通过互连的腔室，当压力作用在垫子的不同部分上时，空气可从一个腔室移动到另一个腔室。 
横向成排的穿孔26延伸穿过连续垫子的腔室之间的管道，从而有利于在腔室充气之前或在腔室充气形成垫子之后材料的分离。 
预制薄膜材料缠绕在圆柱形的圆柱形芯杆27上以形成用于运输和存储的卷28。 
图2示出用于对根据本发明的预制薄膜材料进行充气和密封的紧凑、整装的机器。该机器具有相对小的箱体31，其适于放置在桌面或其它支承表面上。该箱体具有带有用在该箱体顶侧和后侧的竖立前壁33、端壁34、36和可移动盖子37的L型的基底32。 
一对间隔开、水平延伸的辊子39，41被安装在箱体的上侧，用于容纳预制薄膜材料卷。所述卷停留在辊子上，并且当材料从其上被拉出时可自由转动。辊子之间的间隙要小于芯杆的直径，从而使所述卷在尺寸减少时，不会掉落在辊子之间。如果需要的话，为了将所述卷朝向机器的一侧保持靠着一个止动件，所述辊子中的一个或两个辊子的轴线可以稍稍地倾斜，即倾斜大约10度。 
辊子39可转动地安装在静止轴42上，该静止轴42在靠近前箱体的端壁34，36之间延伸。辊子41包括两个相对短的辊子41a，41b，它们在辊子39后面安装在转动安装轴43上。这两个辊子朝向机器的相对侧定位，用于朝向所述卷的边缘与薄膜材料卷相配合。轧辊44接着辊子41b被安装在轴43上，并且正好位于预制薄膜中的充气通道19的下面。定时盘46也安装在轴43上，带有开口47，通过对开口47的光学检测来监视所述卷的旋转和从所述卷上的材料去除。 
朝向箱体一侧定位的止动件49作为用于在辊子上定位所述卷的引导部件。所述卷被放置在辊子上，其边缘靠近紧邻着止动件49的充气通道，从而使通道和入口通路总是处于相同的位置，而与所述卷的宽度无关。如上所述，一个或两个辊子可以朝向箱体的一侧倾斜，在该侧定位的止动件会帮助所述卷靠着止动件。虽然一个或两个辊子以这种方式倾斜，它们仍旧基本上是水平的，并且所述卷的轴线基本上平行于辊子的轴线。所述卷可以是任何 希望的宽度，并且所述卷甚至可以悬于与止动件相对的箱体的一侧之上，只要它不是太宽以致使悬挂的重量导致所述卷在辊子上倾斜或不稳定。 
驱动机构51、充气管52和密封组件53被组合到单个组件单元54中，该单元朝向机器的前部定位。如图3所示，这个单元是可移除地安装在端壁36的外侧上，突出穿过该壁中的开口56，并且具有封闭该单元部分的端盖57和前盖58。 
该驱动装置包括输入辊子61-64和输出辊子66-69，这些辊子与薄膜材料的边缘部分相配合并且将薄膜材料馈送通过该机器。该输入和输出辊子被安排成双组，用于在充气通道的相对侧上接合薄膜材料。因此，输入辊子61、62和输出辊子66、67在充气通道和材料边缘之间与薄膜材料接合，而输入辊子63、64和输出辊子68、69在该通道和腔室之间与薄膜材料接合。 
馈送辊子由电机71驱动，该电机安装在箱体的内部，带有位于电机轴(未示出)传动机构72上的传动齿轮，该传动齿轮被固定在安装有辊子的轴上。为了拉紧薄膜材料，并且在其穿过密封组件时保持更好的控制，该传动装置使输出辊子的旋转要稍快于输入辊子(例如，比率为8∶7)。 
充气管52被定位在内外馈送辊子之间并且以向上的方向延伸，随着该充气管向内弯曲，它插入到薄膜材料的充气通道中。空气由气泵73在0.5至10 psig数量级的压力下被提供到该充气管，气泵73也可以被安装在箱体中。如果需要的话，一个调节器(未示出)可以被连接在气泵和充气管之间，以允许使用者通过调整气压来控制对垫子的充气的坚硬程度。 
处于充气管上端部的扩大球状体52a利于位于该管端部区域上方的薄膜材料的运动，并且也帮助防止空气沿管从充气通道泄露。附件52b位于管的另一端用于与气泵的联接。 
密封组件53被定位在输入和输出辊子之间，并且包括加热元件76以及辊子77，该辊子77将薄膜材料压紧在加热元件上。该加热元件安装在静止位置上，辊子安装在机架78上。当机器处于操作状态时，该辊子借助于凸轮79压靠着加热元件，并且当机器空转时该辊子借助于弹簧从加热元件缩回。 
如图4和图5所示，该加热元件包括具有相对小直径、垂直延伸的不锈钢杆80，这样该加热元件平行于薄膜行进的方向并且垂直于辊子77的轴线。因此，加热元件和辊子的弯曲表面在非常小的点处合在一起，从而使薄膜材料上的给定点与加热元件仅以大约一毫秒的时间相接触。随着这种短暂的接触，可以使用更高温度的加热元件，这会产生比现有技术优异的密封效果。 
密封组件53在某种程度上类似于示出在No.09/638,843中的密封单元，其公开内容作为参考结合于此。但是，该加热元件包括一对涂覆有特福龙(Teflon)带的镍铬耐热合金线，该特福龙带可防止薄膜材料与线的直接接触。因此，该薄膜材料不会被加热到如在本发明中其与加热元件直接接触时被加热到的温度。同样的，在示出于No.09/638,843中的单元中，辊子被安装在固定位置上，并且加热元件借助于气动致动器从辊子被缩回。 
盖子58正好终止于穿过馈送辊子和密封组件的薄膜材料的行进路径的前面，并且从箱体前壁延伸、与盖子左侧对齐的凸缘81正好终止于薄膜行进路径的后面。导块82，83被安装在所述盖子和凸缘的相对边缘以限定用于薄膜材料的通过开口84，并且帮助将材料引导进入馈送辊子。另一个导向块86朝向位于充气管和馈送辊子上方的箱体的前面定位，从而朝向充气管和馈送辊子引导薄膜材料。 
控制面板87位于端盖57的倾斜部分上，该部分处于驱动组件的右侧。该面板包括控制装置，其控制着对机器的开关，用于控制诸如制造多少个垫子和垫子硬度的各种操作。 
机器的操作和使用，以及本发明的方法可通过参考图6进行最好地说明。将预制薄膜材料卷28放置在辊子39，41上，所述卷19的充气通道侧紧邻着止动件49，从而使充气通道自己与轧辊44和充气管52对准。 
将薄膜材料的自由端下拉到导向块86的上方并且位于充气管上，管子延伸进入充气通道19。操作者连续地下拉材料直至它与上馈送辊子接合，并且所述材料随后由辊子馈送。该空气管充当一个导向件，用于将薄膜材料正确地与辊子保持对准，并且管子的曲率帮助将材料导入到辊子中。 
当薄膜材料沿着空气管行进时，通过管子注入的空气流过通路23，24，并且进入位于所述卷和管子之间薄膜部分中的腔室21，22，因此对垫子进行充气。当空气经过所述卷的周围并且由轧辊44压紧封闭(pinched closed)时，利用充气通道的结构，所述空气主要被限制在薄膜的这个部分中。根据所述卷的直径，薄膜材料从充气通道被辊子紧压封闭的地方以大约90度至180度从所述卷中被抽出来。充气通道以这种方式被封闭，比起空气在填充和密封单元上游扩散进入薄膜材料的主要部分的系统，可以更有效、更均匀地对垫子进行充气。 
紧接着充气，该薄膜材料行进通过密封组件53，在这里辊子77将该材料下压直接与加热元件76接触。因此薄膜材料的两个层沿相对窄的密封线89被熔合在一起，该密封线89沿薄膜材料的纵向延伸，并且横跨入口通路23以密封腔室。 
在垫子被充气和密封后，该薄膜材料行经刀具(未示出)，该刀具切开紧接着充气通道的材料边缘，从而使充气管可以从通道中退出。 
在图7中所示的薄膜材料中，每个垫子90具有一个全尺寸的腔室91和两个半尺寸的腔室92。该全尺寸的腔室具有四个区域93，它们一个挨着一个横过该薄膜材料，在它们之间有通路94。每个半个尺寸的腔室具有三个区域96，在它们之间有通路97。 
入口通路98，99横向地延伸在纵向延伸的充气通道101和每个腔室中的第一区域之间，并且出口通路102延伸在充气通道和相邻薄膜材料边缘之间。用于将垫子分开的穿孔103位于垫子之间。 
图7的薄膜材料是以和图1中相同的材料被制成垫子的。该薄膜材料由馈送辊子61-69馈送通过机器，延伸进入充气通道101的充气管52传送用于向垫子充气的空气，并且密封组件53形成横跨入口通路98、99的纵向延伸密封以将充气垫密封。 
随着馈送辊子和充气管仅与薄膜材料的一个边缘部分接合，该机器可以通过对具有任何需要宽度的材料进行处理来生产具有任何需要数量腔室的垫子，包括那种具有单个占据整个材料宽度的腔室的垫子。 
从上述的说明中可以看出，已经很明显地提供了一个新的、经改进的用于对充气包装垫进行充气和密封的机器和方法。虽然仅对特定的优选实施例进行了详细地说明，可是对本领域技术人员来说，在不背离由权利要求所限定的本发明的范围的前提下，可以执行某些改变和修改。 

Claims (20)

1.一种用于对充气包装垫进行充气和密封的机器，包括：
具有两层的预制薄膜材料卷，所述两层被密封在一起以形成位于材料的一个边缘附近的纵向延伸通道、延伸横跨过该材料的成排的腔室、使位于每排中的腔室互连的流动通路、以及在纵向延伸通道和每排中的其中一个腔室之间延伸的入口通路；
一对间隔开的、水平延伸的辊子，薄膜材料卷位于所述一对辊子上，所述纵向延伸通道由其中一个辊子压紧封闭；
连接到一空气源的充气管，该充气管位于所述辊子下面，并且以向上方向延伸，用于将空气注射到所述腔室从而对所述垫进行充气；
密封单元，在所述垫被充气后，所述密封单元用于形成横跨入口通路的纵向延伸的密封；以及
用于从所述卷经过所述充气管和密封单元以大致向下方向抽出薄膜材料的馈送机构。
2.根据权利要求1所述的机器，其中，所述密封单元包括被驱策在一起的圆柱形加热元件和轮子，所述加热元件的轴线垂直于轮子的轴线，并且所述加热元件被暴露以直接与薄膜材料相接触。
3.根据权利要求2所述的机器，其中，加热元件包括不锈钢杆。
4.一种用于从预制薄膜材料卷制成充气包装垫的机器，该预制薄膜材料卷具有两层，这两层密封在一起以形成位于该材料的一个边缘附近的纵向延伸通道、至所述通道一侧的多个腔室、以及横向地在纵向延伸通道和所述腔室之间延伸的入口通路，该机器包括：
一对间隔开的、水平延伸的辊子，薄膜材料卷位于所述一对辊子上，所述纵向延伸通道由其中一个辊子压紧封闭；
连接到一空气源的充气管，该充气管位于所述辊子下面，并且以向上方向延伸，用于将空气注射到所述腔室从而对所述垫进行充气；密封单元，在所述垫被充气后，所述密封单元用于形成横跨入口通路的纵向延伸的密封；以及
用于从所述卷经过所述充气管和密封单元以大致向下方向抽出薄膜材料的馈送机构。
5.根据权利要求4所述的机器，其中，所述密封单元包括被驱策在一起的圆柱形加热元件和轮子，所述加热元件的轴线垂直于轮子的轴线，并且所述加热元件被暴露以直接与薄膜材料相接触。
6.根据权利要求5所述的机器，其中，加热元件包括不锈钢杆。
7.根据权利要求4所述的机器，其中，该馈送机构包括定位在充气管相对侧上的双套馈送辊子，用于与位于纵向延伸通道相对侧上的薄膜材料接合，从而将来自于所述卷的薄膜材料馈送经过充气管和密封单元。
8.根据权利要求4所述的机器，其中，所述纵向延伸通道由其中一个辊子压紧封闭，以及所述充气管被定位成用于将空气注射到所述一部分材料中的纵向延伸通道中，所述材料已经从所述卷中被抽出，纵向延伸通道内的空气在所述卷周围流动，仅流到通道被辊子压紧封闭的地方。
9.根据权利要求8所述的机器，其中，薄膜材料从所述卷中被拉出，距离纵向延伸通道被辊子压紧封闭的地方是90度至180度。
10.根据权利要求4所述的机器，其中，所述充气管延伸进入纵向延伸通道，以及所述馈送机构包括定位于所述充气管相对侧上的双馈送辊子，用于与位于纵向延伸通道相对侧上的薄膜材料接合。
11.一种用于从预制薄膜材料卷制成充气包装垫的方法，该预制薄膜材料卷具有两层，这两层密封在一起以形成位于该材料的一个边缘附近的纵向延伸通道、至所述通道一侧的多个腔室、以及横向地在纵向延伸通道和所述腔室之间延伸的入口通路，所述方法包括如下步骤：
将薄膜材料卷放置于一对间隔开的、水平延伸的辊子上，所述纵向延伸通道由其中一个辊子压紧封闭；
将薄膜材料从所述卷以向下方向馈送至充气管，该充气管被定位成将空气导入所述腔室；
通过所述充气管将空气引入到所述腔室中，从而对所述垫进行充气；以及
在所述垫被充气后，形成横跨入口通路的纵向延伸的密封。
12.根据权利要求11所述的方法，其中，所述纵向延伸通道由其中一个辊子压紧封闭，以及空气被注射到一部分材料中的纵向延伸通道中，所述材料已经从卷中抽出，纵向延伸通道内的空气在所述卷周围流动，仅流到通道被辊子压紧封闭的地方。
13.根据权利要求12所述的方法，其中，薄膜材料从所述卷中被拉出，距离纵向延伸通道被辊子压紧封闭的地方是90度至180度。
14.一种用于从具有纵向延伸通道、多个腔室和在所述通道以及与所述通道相邻的腔室之间延伸的入口通路的预制薄膜材料卷来制成充气包装垫的机器，该机器包括：
一对间隔开的、水平延伸的辊子，薄膜材料卷放置于所述一对辊子上，所述纵向延伸通道由其中一个辊子压紧封闭；
用于将薄膜材料从所述卷中抽出的馈送机构；以及
用于将空气注入所述材料的一部分中的纵向延伸通道内的充气管，该材料已经从所述卷中抽出，纵向延伸通道内的空气在所述卷周围流动，仅流到通道被辊子压紧封闭的地方。
15.根据权利要求14所述的机器，其中，薄膜材料从所述卷中被拉出，距离纵向延伸通道被辊子压紧封闭的地方是90度至180度。
16.一种用于从具有纵向延伸通道、多个腔室和在所述通道以及与所述通道相邻的腔室之间延伸的入口通路的预制薄膜材料卷来制成充气包装垫的方法，所述方法包括如下步骤：
将薄膜材料卷放置于一对间隔开的、水平延伸的辊子上，纵向延伸通道由其中一个辊子压紧封闭；
将薄膜材料从所述卷中抽出；以及
将空气注入所述材料的一部分中的纵向延伸通道内，该材料已经从所述卷中抽出，纵向延伸通道中的空气在所述卷周围流动，仅流到通道被辊子压紧封闭的地方。
17.根据权利要求16所述的方法，其中，将薄膜材料从所述卷中拉出，距离纵向延伸通道被辊子压紧封闭的地方是90度至180度。
18.一种用于从具有纵向延伸通道以及通过横向延伸的入口通路与所述通道连通的多个腔室的预制薄膜材料卷来制成充气包装垫的桌面型机器，包括：
适合放置在相对小的水平支承表面上的箱体；
在箱体上侧一对间隔开、水平延伸的辊子，所述纵向延伸通道由其中一个辊子压紧封闭，所述辊子以将所述薄膜材料卷放置在所述辊子上的方式接纳着该卷；
朝向箱体前面定位的馈送机构，用于将薄膜材料从所述卷中以向下方向抽出；
从馈送机构以向上方向延伸的充气管，该充气管适于被接纳在从所述卷中被抽出的薄膜材料的纵向延伸通道中；
箱体中的空气源，连接到充气管以将空气引入到所述腔室中，从而对所述垫进行充气；以及
密封单元，用于在纵向延伸通道和所述垫之间的薄膜材料中形成纵向延伸的密封，从而在所述垫已经被充气后封闭所述入口通路。
19.根据权利要求18所述的桌面型机器，其中，所述密封单元包括被驱策在一起的圆柱形加热元件和轮子，所述加热元件的轴线垂直于轮子的轴线，并且所述加热元件被暴露以直接与薄膜材料相接触。
20.根据权利要求19所述的桌面型机器，其中，加热元件包括不锈钢杆。
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US20060112663A1 (en) 2006-06-01
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AU2003213081B8 (en) 2010-04-29
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KR100970024B1 (ko) 2010-07-16
KR20040091669A (ko) 2004-10-28
DE60332428D1 (de) 2010-06-17
ATE466723T1 (de) 2010-05-15
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JP2005518969A (ja) 2005-06-30
US7150136B2 (en) 2006-12-19
US7174696B2 (en) 2007-02-13
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