GB2508267A - Dunnage forming apparatus - Google Patents

Dunnage forming apparatus Download PDF

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Publication number
GB2508267A
GB2508267A GB201316412A GB201316412A GB2508267A GB 2508267 A GB2508267 A GB 2508267A GB 201316412 A GB201316412 A GB 201316412A GB 201316412 A GB201316412 A GB 201316412A GB 2508267 A GB2508267 A GB 2508267A
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GB
United Kingdom
Prior art keywords
rollers
apparatus
paper
set
packaging material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB201316412A
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GB201316412D0 (en
GB2508267B (en
Inventor
Dan Steedman
Original Assignee
Dan Steedman
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Application filed by Dan Steedman filed Critical Dan Steedman
Priority to GB201316412A priority Critical patent/GB2508267B/en
Publication of GB201316412D0 publication Critical patent/GB201316412D0/en
Publication of GB2508267A publication Critical patent/GB2508267A/en
Application granted granted Critical
Publication of GB2508267B publication Critical patent/GB2508267B/en
Application status is Active legal-status Critical
Anticipated expiration legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D5/00Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
    • B31D5/0039Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
    • B31D5/0043Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material
    • B31D5/0047Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material involving toothed wheels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D5/00Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
    • B31D5/0039Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D5/00Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
    • B31D5/0039Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
    • B31D5/0043Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D5/00Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
    • B31D5/0039Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
    • B31D5/0043Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material
    • B31D5/0052Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material involving rollers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/05Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/051Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using pillow-like elements filled with cushioning material, e.g. elastic foam, fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00Multiple-step processes for making three-dimensional articles
    • B31D2205/0005Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00Multiple-step processes for making three-dimensional articles
    • B31D2205/0005Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/0017Providing stock material in a particular form
    • B31D2205/0023Providing stock material in a particular form as web from a roll

Abstract

Packaging material, or dunnage, forming apparatus features a feed of pre-folded material 30, a former 80, which opens the paper into a tubular form, a first set of rollers 100, rotatable at a speed faster than a second set of rollers 120, so as to partially crush the paper tube, the second set of rollers 120 further crimping the paper tube. The apparatus may produce lengths of cushioning packaging material or dunnage.

Description

Packaging tnateria[ forming apparatus The present invenkim relates generally to a packaging material forming apparatus aix] a method of method of producing packaging material an(l tinds S particular, although not exclusive, utility in producmg lengths of paper cushioning material.

It is known to provide loose material, known as dunnage, for use as a packing material around items placed in boxes to protect the items (luring transit. llowever, this material is difficult to dispose of in that it consists of many hundreds of individual lO pieces. Apparatus is also known which crushes partially paper to produce cushion-like lengths of packaging. Such apparatus initially folds the paper and as a consequence is relatively bulky and complicated. For a business with relatively litde space a smaller more compact machine which has relatively simple construction and operation is desirable.

In a first aspect, the present invention provides packaging material forming apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former for partially opening the folded ptper into a linear tubular forrri, and first arid second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is armnged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together.

The pre-folded paper may have a width of 600mm (when unfolded), with one edge folded over 175mm from one linear side and the other edge folded over 175mm from the other opposite linear side such that the two edges overlap by I 00mm. The paper may he initially folded flat having a width of 250mm. The roll of paper may he 30Dm long.

The fonner may be inserted into the folded paper such that as the paper moves across the former, into the apparatus, the portions of paper forming the two side folds are pushed away from the base portion of the paper to create the tubular form.

Both of the rollers in the second set may comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another. The second set of rollers

I

may be arranged to produce the crimp along the middle of the partially crushed tubular paper form in the direction of feeding through the machine. This crimp or seal may he effected by the teeth squeezing the paper between them. The seal may he effected between the two Hnear edges of the paper and the base portion of the paper such that a cross-section of the resultant packaging material is an approximate figure of eight with two cushion-like forms, one either side of a crimped middle section.

The apparatus may further comprise two rotatable rollers upon \vhich the roil of paper may rest and rotate. The rollers may he freely rotatable.

The apparatus may comprise a frame and either or both of the first and second lO set of rollers may be resiliently mounted to the frame such that they are movable relative to it to accommodate the irregularities of the tubular paper form. The resilience may be achieved by using springs or other such resilient mountings between bracket,retainrng a shaft upon which the rollers are mounted, and the frame.

The radial outer surfaces of both of the rollers in the first set may he niilled. In this regard, the term "milled" may mean a series of grooves, or a pattern of raised pimPles. The milling may aid the initial feeding of the paper into the apparatus as it may more easily "grab" the end of the paper and pull it through. Furthermore, it may assist iii maintaining the rate of entry of ptper into the apparatus.

The apparatus may further comprise a cowling being arranged to accept the paper after it has been fed through the former and direct it to between the first set of rollers which are located immediately downstream thereof; the cowling having sides which taper inwardly so as to reduce the width of the paper as it passes therethrough.

The sides of the cowling are closer together at the downstream end compared to the upstream inlet to inwardly reduce the width of the tubular paper form to approximately 130 mm. In other words, the cowling may he funnel-shape.

The apparatus may further comprise a cutting mechanism for cutting the partially crushed linear tubular paper form into desired lengths.

The cutting mechanism may comprise a stationary blade and a reciprocating blade, the reciprocating blade being driven by a crank and connecting rod.

The blades may both be "V" shape with the angle between the arms of the "V" shape stationary blade being less than the angle between the arms of the "V" shape reciprocating blade.

The resultant packaging material may be dispensed via a dispensing chute. This may he located downstream of the cutting mechanism.

The apparatus tiny further comprise sensing means for sensing the presence or absence of packaging material in the chute, and a PCLT for controlling the Ilrst and second sets of rollers and the cutting mechanism.

The PC U may control the first and second sets of rollers by controlling a drive motor. The FCC may be programmed to stop the first and second sets of rollers before operating the cutting mechanism.

The FCC may operate the first and second of rollers to produce packaging lO material when the sensor senses the absence of packaging material in the dispensing chute. In this respect, the apparatus may not be producing packaging material when the sensor senses the presence of packaging material in the chute. In this way, a user may withdraw each length of packaging material, as required, without having to manually control the apparatus and without the apparatus prod ueing more packaging than is immediately necessary. The apparatus may produce packaging material on demand and as required.

The FCC may be programmed to produce a predetermined number of individual lengths of packaging triaterial; the dirjierision of each length also being predetermined.

The FCC may be programmed and the apparatus arranged such that a user is presented \vith various lengths to choose from and/or various numbers of lengths to select. The apparatus may indude buttons assigned with these choices for ease of operabilty.

In a second aspect, the invention provides a method of producing packaging material comprising the steps of providing a packaging material forming apparatus according to the first aspect; providing a roll of pre-folded paper; feeding the free end of the paper through the former and between the first set of rollers; the former partially opening the folded paper into a linear tubular form, and operating the apparatus such that the first set of rollers rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together.

In this method the two outside corners of the free end of the roll of pre-folded paper may be cut-off prior to berng fed thnrngh the former and between the first set of rollers such that the free end of the paper is separated into three separate sheets.

The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, \vhich illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings.

lO Figure I is a schematic side overview of part of one example of the apparatus; Figure 2 is a schematic side view of part of the apparatus of Figure 1; Figure 3 is a cross-sectional side view of one example of the pre-folded paper; Figure 4 is a perspective view of the former of Figure 3 on its own; Figure 5 is a perspective view of the former of Figure 4 together with a portion of the pre-folded paper having been opened by the former; and Figure 6 is a perspective schematic view of one exatnple of the cutting mechanism.

The present invention will he described with respect to certain drawings hut the invention is not limited thereto hut only by the claims. The drawings described are only schematic and are non-limiting. Each drawing may not include all of the features of the invention and therefore should not necessarily be considered to be an embodiment of the invention. In the drawings, the size of some of the elements may he exaggerated and not drawn to scale for illustrative purposes. The dimensions and the relative dimensions do nor correspond to actual reductions to practice of the invention.

Furthermore, the tertns first, second, third anti the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to he understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other sequences than described or illustrated herein.

Moreovcr, the terms top, bottom, over, under and the hke in the descripthn and the claims are used for descriptive purposes and not necessarily for describing relative positions. It is to he understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other orientations than described or illustrated herein.

It is to he noticed that the term "comprising", used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to he interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means i0 that with respect to the present invention, the only relevant components of the device are A and B. Reference throughout this specification to "an embodiment" or "an aspect" means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the present invention. Thus, appearances of the phrases "in one embodiment", "in an embodiment", or "in an aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different ernhodinierits or aspects. Furtherrriore, the particular features, structures or characteristics of any embodiment or aspect of the invention may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this

disclosure, in one or more embodiments or aspects.

Similarly, it should he appreciated that in the description various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to he interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, the description of any individual drawing or aspect should not ncccssarily he considered to bc an embodiment of the invention. Rather, as the following claims reflect, inventive aspects lie in fewer than all features of a single foregoing disclosed embodiment. Thus, the claims flillowing the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.

Furtherniore, while some embodiments described herein include some features included in other embodiments, combi ations of features of different embodiments are meant to be xvithin the scope of the invention, and form yet further embodi ients, as will he understood by those skilled in the art. For example, in the following claims, any of the claimed embodiments can he used in any combination.

In the description provided herein, numerous specific details arc set forth.

However, it is understood that embodiments of the invention may be practised without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of

this description.

In the discussion of the invention, unkrss stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of said values is more highly preferred than the other, is to he construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

The use of the term at least one'' may rjiean only uric ii certain circurTistauces.

The pnnciples of the invention will now he described by a detailed description of at krast one dra\ving rdating to exemplary features of the invention. It is clear that other arrangements can be configured according to the knowledge of persons skilled in the art without departing from the underlying concept or technical teaching of the invention, the invention being limited only by the terms of the appended clainm.

In Figure 1, an apparatus 10 for producing packaging material, or dunnage, using a rugation process, from paper or similar material, is shown in schematic fonn. The figure does not include all of the various elements such as electric motors, instead showing only the key features.

A frame 20 indudes a support 40 at one upper end for holding a pre-folded roll of paper 30. The roll may rotate on an axle (not shown) passing through its centre, the axle being supported by the support 40. Alternative'y, the roll of paper may rest on parallel rollers (not shown) without a central axle/spindle. This improves the ease with which the roll of paper may be rep'aced. An end of the paper 35 is led from the roll 30 over two individual tensioning rollers 50 so that the pap 35 may he fed hori7ontally into the main part 200 of the apparatus. Before it enters this main part 200 it passes between two further rollers 60 acting as guides.

The paper then passes through and around a former 80 which expands the pre-folded paper 35 from a substantially fiat web into a substantially linear tubular form.

The former is described with reference to Figures 4 and 5 in more detail below.

The substantially tubular form has a base 36 and two sides 37, 38 which extend from the base 35 upS, around and over the base to form the sides and top of the tubular form.

The linear centre of the tubular form of paper 35 then passes between two rollers 100 which squeeze together the top and bottom surfaces of the centre of the tubular form to create two cushion-like forms either side of a substantially flat compressed strip running in the direction of the linear length of the paper 110.

The rollers 100 may he more wheel-like in form having a thickness in the range of 10mm to 20mm and a diameter in the range of 100mm to 200mm. The outer circumferential surface of the rollers may he milled or include dimples. The rollers may comprise metal.

The paper 35 is propelled through this first set of rollers 100 at a speed in the range of 10 to 50 metres per minute.

The paper ItO then passes between a second set of rollers which are rotating at a speed approximately half the speed of rotation of the first set of rollers such that the paper exits the second set of rollers in the range 5 to 25 metres per minute.

Due to this speed reduction the paper 35 is crumpled between the first and second sets of rollers such that its longitudinal linear length is reduced.

Each of the second set of rollers 120 includes teeth, the two sets of teeth interlocking d uring rotation. The teeth are rounded in a sinusoidal manner so that they do not puncture, rip or tear the paper. The interaction of the two sets of teeth help to seal the central, previously compressed, strip such that it does not separate.

The second set of rollers 120 may also be more wheel-like in form having a thickness in the range of 20mm to 50mm and a diameter in the range of 100mm to 200mm. The rollers may comprise metal.

The resultant paper form 130 is thus comprised of linearly crumpled paper having two cushion-like forms either side of a central compressed and sealed strip.

This dunnage 130 may then be cut into required length by a cutting mechanism 140, described in mote detail below. The dunnage 130 may he used as packaging to prevent goods from being damaged in transit.

The resultant paper may he dispensed via a dispensing chute (not shown) provided downstream of the cutting mechanism.

With the roll of paper 30 located above the frame 20 and the apparatus 10 being relatively simple; it is possible to produce packaging material with equipment that occupies a relatively small space.

Figure 2, shows the main part 20 of the apparatus comprising a frame 23. The lO paper 35 enters the apparatus in the direction 200 on the right and exits on the left in the direction 201. The frame supports a lower first roller IOOA and a lower second roller 120A. A support 24 extends from approximately the centre of the lower part of the frame 23 upwardly and a pivot point is provided towards the top thereof. From this l'° point 27, two arms 28 extend one rearwardly towards the first set of rollers 100 and one forwardly towards the second set of rollers 120. At the end of the rearwardly extending arm 28, the upper first roller 10011 is pivotally connected. Similarly, at the end of the fonvardly extending arm 28, the upper second roller 12011 is pivotally connected.

These upper first t 0011 and second l2OB rollers may thus move up and down relative to the fixed lower first lOOA and second 120A rollers. This movement allows for the crumpled paper 110 to pass through the second set of rollers 120A, 120B without blocktng occurring.

The upper first 10013 and second 12011 rollers are biased downvvardly against the upper side of the frame 23 by individual coil springs 29 the force of each being adjustable via a threaded bar 25 as will he understood by the skilled pson. This ensures good traction between the upper and lower rollers.

Although not shown, it will he understood that a motor is used to drive the rollers. A gear system may he employed to drive the first and second sets of rollers at different speeds.

Figure 3 shows a cross-section of the pre-folded paper 35. It comprises a single laminar sheet wherein the two longitudinal edges have been folded over the central portion 36. One edge has been folded over initially and then the other folded over such that an upper portion 38 overlies a middle portion 37 which, in turn, overlies the lower portion 36. The figure shows the paper slightly opened for the sake of clarity. In reality the paper 35 will feed off the toll 30 with tight folds such that the upper portion 38 will he substantially immediately aFx)ve and on the middle portion 37 which will he substantially immediately above and on the lower poruon 36.

With the initial paper roll 30 being provided in this way the amount of space required is rninimiscd.

Figures 4 and 3 show the former 80 which is used to open the folded paper into an approximate tubular form. The former 80 comprises two lobes 81, 82, located one at either end of a first rectilinear bar 83. The lobes 81, 82 each comprise a cylinder with a lO dome shape at either longitudinal end. A second rectilinear bar 84 is provided extending from one lobe 81 towards the other lob 82, parallel with, but slightly spaced from the first rectilinear bar 83. This second bar 84 does not extend all the way to the lobe 82. Rather, it turns through 90 degrees and extends upwardly 85. This upwardly extending bar is only partially shown in Figure 4. The direction of its extent is indicated by broken lines. It is used to affix the former to the apparatus 10. The upwardly extending bar 85 is located closer to the lobe 82 than the lobe 81 from which it extends.

This allows for upwardly extending bar 85 to be located approximately at the position of the longitudinal edge of the upper portiot' 38 of paper.

In use, the former 80 is arranged such that the direction of the movement of the paper 35 as it passes past the former 80 is substantially perpendicular to the axis of the two rectilinear bars 83, 84.

The paper 33 passes the former such that the lower portion 36 passes underneath the first rectilinear bar 83, the middle portion 37 passes between the first and second rectilinear bars 83, 84, and the upper portion 38 passes over the upper second rectilinear bar 84.

The former is positioned inside the folded pap 35 such that as the pap passes past the former 80 the two lobes move the pap into an approximate tubular form 90. The upwardly extending bar 85 allows the paper to pass it by extending beyond the longitudinal edge of the upper portion 38 as may be more clearly seen in Figure 5.

The resultant tubular form of paper 90 includes enlarged cushion hke forms 33, 34 each around the lobes 81, 82.

For an initial feeding of the paper 35 into the apparatus 10, the longitudinal end of the paper 35 is trimmed with scissors such that a substantially friangular shape is formed. In other words the two outer corners are cut off. This leaves the three leaves (upper 38, middle 37, and lower 36) substantially separate with no connecting folds at the sides. This allows the three separate leaves 36, 37, 38 to he fed under, between and over thc two rectilinear bars 83, 84 without having to pull the folded paper open so as to fit around the lobes 81, 82. The paper is then fed manually to the first set of rollers which when rotating pull the paper into the apparatus 10. The paper is then automatically pulled around the lobes as it progresses into the apparatus such that the lO folded flat paper form is opened into the approximate tubular form.

In Figure 6 a cutting mechanism 140 is shown. This comprises of a fixed lower blade 160 and a movable upper blade 150. This upper blade 150 may move to\vard and away from the lower blade such that the finished crumpled dunnage which passes between the blades through the opening 145 therehetween is cut into desired lengths.

The upper and lower blades are "V" shape, with the middle of the CC\7' pointing downwards. The angle of the upper blades 150 on either side of the CCV shape lie in the range 10 to 40 degrees from the horizontal. The angle of the lower blades 160 on either side of the "V'' shape lie in the range 30 to 50 degrees from the horizontal.

Typically, the lower blades t60 have a steeper angle from the horizontal than the upper blades 150. It is found that this improves the cutting action.

The upper blade is shown supported bya cross member 163 which moves upwards and downwards guided by two vertical guides 165 one on either side of the opening 145.

The cross-member 163 is driven in a reciprocating manner upwards and downwards by an attn and crank assembly 170. This assembly 170 may he povere1 by the same motor as which drives the first 100 and second 120 sets of rollers.

The first 100 and second 120 sets of rollers may he stopped when the cutting mechanism is required to cut the paper.

Claims (18)

  1. CLAIMS1. Packaging material forming apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is arranged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of lO rollers being arranged to crimp the two linear sides of the paper together.
  2. 2. The apparatus of claim I, wherein both of the rollers in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another.
  3. 3. The apparatus of either one of claims I and 2, wherein the second set of rollers are arranged to produce the crimp along the middle of the partially crushed tubular paper form in the direction of feeding through the machine.
  4. 4. The apparatus of any preceding claim, further comprising two rotatable rollers upon which the roll of paper may test and rotate.
  5. 5. The apparatus of any preceding claim, comprising a frame and wherein either or both of the first and second set of rollers are resiliendy mounted to the frame such that they are movable relative to it to accommodate the irregularities of the tubular paper fonn.
  6. 6. The apparatus of any preceding claim, wheretn the radial outer surfaces of both of the rollers in the first set are milled.
  7. 7. The apparatus of claim 6, further comprising a cowling being arranged to accept the paper after it has been fed through the former and direct it to between the first set of rollers which are ocated immediately downstream thereof; the cowling having sides which taper inwardly so as to reduce the width of the paper as it passes therethrough.II
  8. 8. The apparatus of any preceding claim, further comprising a cutting mechanism for cutting the partially crushed linear tubular paper form into desired lengths.
  9. 9. The apparatus of claim 8, wherein the cutting mechanism comprises a stationary blade and a reciprocating blade, the reciprocating blade being driven by a crank and connecting rod.
  10. 10. The apparatus of claim 8, wherein the blades are both "V" shape ant] the angle between the arms of the "\/" shape stationary blade is less than the angle between the arms of the "\/" shape reciprocating blade.
  11. ii. The apparatus of any preceding claim, wherein the resultant packaging tnaterial is dispensed via a dispensing chute.
  12. 12. The apparatus of claim 11, when dependent directly or indirectly on claim 8, further comprising sensing means for sensing the presence or absence of packaging material in the chute, and a PCI] for controlling the first and second sets of rollers and the cutting mechanistn.
  13. 13. The apparatus of claim 12, wherein the PCI] operates the flrst alit] second of rollers to produce packaging material when the sensor senses the absence of packaging material in the dispensing chute.
  14. 14. The apparatus of either one of claims 12 and 13, wherein the PCI] is programmed to produce a pret]etemuitiec] number of individual lengths of packaging material; the dimension of each length also being predetermined.
  15. 15. A method of producing packaging material comprising the steps of providing a packaging tnaterial fomnng apparatus according to any preceding claim; providing a roll of pre-folded paper; feeding the free end of the paper through the former and between the first set of rollers; the former partially opening the folded paper into a linear tubular form, and operating the apparatus such that the first set of rollers rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together.
  16. 16. The method of claim 15, wherein the two outside corners of the free end of the roll of pie-folded paper are cut-off prior to being fed through the former and between the first set of rollers such that the free end of the paper is separated into three separate sheets.
  17. 17. A packaging material forming apparatus substantially as hereinhefore described with reference to the accompanying drawings.
  18. 18. A method of producing packaging material substantially as hereinbefore described with reference to the accompanying drawings.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS: (:liums 1. Packaging material fonning apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus compnsing a fonner for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is arranged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the tvo linear sides of the paper together, and wherein both of the rollers in the second set comprise teeth, the tvo sets of teeth being arranged to interlock and correspond with one another.2. The apparatus of claim 1. wherein the second set of rollers is arranged to produce the crimp along the middle of the partially crushed tubular paper form in the direction of feeding through the machine.3. The apparatus of any preceding claim, further comprising two rotatable rollers o upon which the roll of paper may rest and rotate.4. lEe apparatus of any preceding claim, comprising a frame and wherein either or r ----both of the first and second set ot rollers are resiliently mounted to the frame such that they are movable relative to it to accommodate the irregularities of the tubular paper form.5. The apparatus of any preceding claim, wherein the radial outer surfaces of both of the rollers in the first set are milled.6. The apparatus of claim 5, ftirther comprising a cowling being arranged to accept the paper after it has been fed through the former and direct it to between the first set of rollers which are located immediately downstream thereof; the cowling having sides which taper inwardly so as to reduce the width of the paper as it passes thercthrough.7. The apparatus of any preceding claini, further comprising a cutting mechanism for cutting the partially crushed linear tubular pap fonu into desired lengths.8. the apparatus of ciaim 7, wherein the cutting mechanism comprises a stationary blade and a reciprocafing blade, the reciprocating blade being driven by a crank and connecting rod.9. The apparatus of claim 8, wherein the blades are both CC shape and the angle between the am-is of the "V" shape stationary blade is less than the angle between the arms of the "\T" shape reciprocating blade.10. the apparatus of any preceding claim, wherein the resultant packaging material is dispensed via a dispensing chute.ii. The apparatus of claim 10, when dependent directly or indirectly on claim 7.further comprising sensing means for sensing the presence or absence of packaging material in the chute, and a PCU for controlling the first and second sets of rollers and the cutting mechanism.o 20 12. The apparatus of claim 11, wherein the PCU operates the first and second of rollers to produce packaging material when the sensor senses the absence of r packaging material in the dispensing chute.13. lEe apparatus of either one of claims 11 and 12, wherein the PCU is programmed to produce a predeternained number of individual lengths of packaging material; the dimension of each length also being predetermined.14. A method of producing packaging material comprising the steps of providing a packaging material forniing apparatus according to any preceding claim; providing a roll of pre-folded paper; feeding the free end of the paper through the former and bettveen the first set of rollers; the former partially opening the folded paper into a linear tubular form, and operating the apparatus such that the first set of rollers rotate at a speed greater than the second set of rollers to enable the tubular paper form to he partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together.13. The method of claim 14, wherein the Iwo outside corners of the free end of the roll of pre-foded paper are cut-off pnor to being fed through the former and between the first set of roUers such that the free end of the paper is separated into three separate sheets.16. A packaging material forming apparatus substantially as hereinbefore described with reference to the accompanying drawings.17. A method of producing packaging material substantially as hereinbefore described with reference to the accompanying drawings. r
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016114342A1 (en) * 2016-08-03 2018-02-08 Storopack Hans Reichenecker Gmbh Method and apparatus for producing a cushioning product and padding product
DE102017109330A1 (en) * 2017-05-02 2018-11-08 Storopack Hans Reichenecker Gmbh Apparatus for providing cushioning material for packaging purposes, as well as reforming unit of such a device
DE102018110595A1 (en) 2017-06-02 2018-12-06 Karl Lindner Method and apparatus for producing a packaging cushion

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997014553A1 (en) * 1995-10-16 1997-04-24 Ranpak Corp. Compact cushioning conversion machine and method using pre-folded paper
US20070122575A1 (en) * 2002-09-17 2007-05-31 Storopack Hans Reichenecker Gmbh Cushioning product and method and apparatus for making same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997014553A1 (en) * 1995-10-16 1997-04-24 Ranpak Corp. Compact cushioning conversion machine and method using pre-folded paper
US20070122575A1 (en) * 2002-09-17 2007-05-31 Storopack Hans Reichenecker Gmbh Cushioning product and method and apparatus for making same

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102016114342A1 (en) * 2016-08-03 2018-02-08 Storopack Hans Reichenecker Gmbh Method and apparatus for producing a cushioning product and padding product
DE102017109330A1 (en) * 2017-05-02 2018-11-08 Storopack Hans Reichenecker Gmbh Apparatus for providing cushioning material for packaging purposes, as well as reforming unit of such a device
DE102018110595A1 (en) 2017-06-02 2018-12-06 Karl Lindner Method and apparatus for producing a packaging cushion

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