NZ619691B2 - Air cushion inflation machine - Google Patents
Air cushion inflation machine Download PDFInfo
- Publication number
- NZ619691B2 NZ619691B2 NZ619691A NZ61969112A NZ619691B2 NZ 619691 B2 NZ619691 B2 NZ 619691B2 NZ 619691 A NZ619691 A NZ 619691A NZ 61969112 A NZ61969112 A NZ 61969112A NZ 619691 B2 NZ619691 B2 NZ 619691B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- web
- machine
- inflation
- arrangement
- sealing
- Prior art date
Links
- 238000007789 sealing Methods 0.000 claims abstract description 163
- 238000003780 insertion Methods 0.000 claims description 4
- 238000002788 crimping Methods 0.000 claims description 2
- 230000000593 degrading Effects 0.000 abstract 2
- 238000010438 heat treatment Methods 0.000 description 35
- 239000000463 material Substances 0.000 description 30
- 238000000926 separation method Methods 0.000 description 21
- 239000000919 ceramic Substances 0.000 description 9
- 230000000712 assembly Effects 0.000 description 6
- 238000001816 cooling Methods 0.000 description 4
- 230000001808 coupling Effects 0.000 description 3
- 238000010168 coupling process Methods 0.000 description 3
- 238000005859 coupling reaction Methods 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 210000000088 Lip Anatomy 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 230000003247 decreasing Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- 239000004698 Polyethylene (PE) Substances 0.000 description 1
- 210000001138 Tears Anatomy 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000000875 corresponding Effects 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 238000009998 heat setting Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006011 modification reaction Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 238000004382 potting Methods 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
- B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
- B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
- B29C65/222—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip comprising at least a single heated wire
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
- B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
- B29C65/30—Electrical means
- B29C65/305—Electrical means involving the use of cartridge heaters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
- B29C65/7861—In-line machines, i.e. feeding, joining and discharging are in one production line
- B29C65/787—In-line machines, i.e. feeding, joining and discharging are in one production line using conveyor belts or conveyor chains
- B29C65/7873—In-line machines, i.e. feeding, joining and discharging are in one production line using conveyor belts or conveyor chains using cooperating conveyor belts or cooperating conveyor chains
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/03—After-treatments in the joint area
- B29C66/034—Thermal after-treatments
- B29C66/0342—Cooling, e.g. transporting through welding and cooling zone
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/343—Making tension-free or wrinkle-free joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/344—Stretching or tensioning the joint area during joining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/439—Joining sheets for making inflated articles without using a mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/816—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the mounting of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8161—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the mounting of the pressing elements, e.g. of the welding jaws or clamps said pressing elements being supported or backed-up by springs or by resilient material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/816—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the mounting of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8167—Quick change joining tools or surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
- B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
- B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
- B29C66/83421—Roller, cylinder or drum types; Band or belt types; Ball types band or belt types
- B29C66/83423—Roller, cylinder or drum types; Band or belt types; Ball types band or belt types cooperating bands or belts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/87—Auxiliary operations or devices
- B29C66/872—Starting or stopping procedures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/87—Auxiliary operations or devices
- B29C66/874—Safety measures or devices
- B29C66/8744—Preventing overheating of the parts to be joined, e.g. if the machine stops or slows down
- B29C66/87443—Preventing overheating of the parts to be joined, e.g. if the machine stops or slows down by withdrawing the heating tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
- B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
- B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
- B29C66/91212—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods involving measurement means being part of the welding jaws, e.g. integrated in the welding jaws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
- B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
- B29C66/91231—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the joining tool
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
- B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
- B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
- B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
- B29C66/91431—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being kept constant over time
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
- B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
- B29C66/91641—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
- B29C66/934—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
- B29C66/961—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D22/00—Producing hollow articles
- B29D22/02—Inflatable articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
- B29K2023/06—PE, i.e. polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2909/00—Use of inorganic materials not provided for in groups B29K2803/00 - B29K2807/00, as mould material
- B29K2909/02—Ceramics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7138—Shock absorbing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING 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
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
- B31D2205/0047—Feeding, guiding or shaping the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING 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
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0076—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads involving particular machinery details
- B31D2205/0082—General layout of the machinery or relative arrangement of its subunits
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING 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
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D2205/00—Multiple-step processes for making three-dimensional articles
- B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
- B31D2205/0076—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads involving particular machinery details
- B31D2205/0088—Control means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING 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
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D5/00—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
- B31D5/0039—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
- B31D5/0073—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including pillow forming
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS 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
- B65D81/00—Containers, 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
- B65D81/02—Containers, 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
- B65D81/05—Containers, 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
- B65D81/051—Containers, 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
- B65D81/052—Containers, 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 filled with fluid, e.g. inflatable elements
Abstract
machine for converting a web (10) of preformed pouches (26) into inflated cushions (12) or dunnage units. The pouches are defined by transverse seals (24) extending from a remote edge (18) to within a predetermined distance from an inflation edge (20). The machine includes a tensioning device (not shown) for frictional engagement with the web, an inflation arrangement (160) for inflation of the preformed pouches, a sealing arrangement (162), and a clamping arrangement (110). The sealing arrangement may be positioned to provide a longitudinal seal (42) that intersects the transverse seals to close the preformed pouches and form the cushion. The sealing arrangement comprises at least two sealing belts positioned to engage the surface of the web and pull the web through sealing elements positioned on either side of the web. The clamping arrangement may comprise at least two pinching belts positioned to engage the surface of the web and pull the web through the sealing elements, wherein the two sealing belts are disposed between the two pinching belts and the inflation edge. The clamping arrangement may prevent the air pressure within the inflated cushion from degrading the quality of the longitudinal seal. The tensioning device holds the web taught during downstream travel. shown) for frictional engagement with the web, an inflation arrangement (160) for inflation of the preformed pouches, a sealing arrangement (162), and a clamping arrangement (110). The sealing arrangement may be positioned to provide a longitudinal seal (42) that intersects the transverse seals to close the preformed pouches and form the cushion. The sealing arrangement comprises at least two sealing belts positioned to engage the surface of the web and pull the web through sealing elements positioned on either side of the web. The clamping arrangement may comprise at least two pinching belts positioned to engage the surface of the web and pull the web through the sealing elements, wherein the two sealing belts are disposed between the two pinching belts and the inflation edge. The clamping arrangement may prevent the air pressure within the inflated cushion from degrading the quality of the longitudinal seal. The tensioning device holds the web taught during downstream travel.
Description
AIR CUSHION INFLATION MACHINE
CROSS-REFERENCE TO RELATED-APPLICATION
This application claims the benefit of United States Provisional Patent Application Serial
No. 61/505,261, entitled AIR CUSHION INFLATION MACHINE and filed July 7, 2011, the
entire disclosure of which is incorporated herein by reference, to the extent that it is not
conflicting with the present application.
TECHNICAL FIELD
Embodiments relate generally to fluid filled units and more particularly to a novel and
improved machine for converting a web of preformed pouches to dunnage units.
BACKGROUND
Machines for forming and filling dunnage units from sheets of plastic are known.
Machines which produce dunnage units by inflating preformed pouches in a preformed web
are also known. For many applications, machines which utilize preformed webs are preferred.
[0003a] Any discussion of documents, acts, materials, devices, articles or the like which has been
included in the present specification is not to be taken as an admission that any or all of these
matters form part of the prior art base or were common general knowledge in the field relevant to
the present disclosure as it existed before the priority date of each claim of this application.
[0003b] Throughout this specification the word "comprise", or variations such as "comprises" or
"comprising", will be understood to imply the inclusion of a stated element, integer or step, or
group of elements, integers or steps, but not the exclusion of any other element, integer or step,
or group of elements, integers or steps.
SUMMARY
[0003c] Some embodiments relate to a machine for converting a web of preformed pouches into
inflated dunnage units, the pouches defined by transverse seals extending from a remote edge to
within a predetermined distance from an inflation edge, the machine comprising:
a guide pin for insertion between the transverse seals and the inflation edge to define a
path of travel of the web;
a tensioning device for frictional engagement with the web, wherein the tensioning device holds
the web taut during downstream travel;
an inflation arrangement for inflation of the preformed pouches;
a sealing arrangement positioned to provide a longitudinal seal that intersects the
transverse seals to close the preformed pouches and form a dunnage unit, the sealing
arrangement having at least two sealing belts, each belt powered by a drive roller and positioned
to engage a surface of the web and pull the web through sealing elements positioned on either
side of the web; and
a clamping arrangement positioned to pinch the two layers of the web during travel
through the sealing elements, the clamping arrangement having at least two pinching belts, each
belt powered by a drive roller and positioned to engage a surface of the web and pull the web and
pinch the web through the sealing elements wherein the two sealing belts are disposed between
the two pinching belts and the inflation edge;
wherein the at least two sealing belts and the at least two crimping belts are driven in
sync.
[0003d] Some embodiments relate to a machine for converting a web of preformed pouches into
inflated dunnage units, the pouches defined by transverse seals extending from a remote edge to
within a predetermined distance from an inflation edge, the machine comprising:
a guide pin for insertion between the transverse seals and the inflation edge to define a
path of travel of the web;
a tensioning device for frictional engagement with the web, the tensioning device having
a shelf member with a horizontal portion and a downstream and upwardly angled portion, and a
pivotable arm mounted to the machine, with one end of the arm attached to a spring and a roller
rotatably attached to the other end of the arm;
an inflation arrangement for inflation of the preformed pouches;
a sealing arrangement positioned to provide a longitudinal seal that intersects the
transverse seals to close the preformed pouches and form a dunnage unit, the sealing
arrangement having at least two sealing belts, each belt powered by a drive roller and positioned
to engage a surface of the web and pull the web through sealing elements positioned on either
side of the web; and
a clamping arrangement positioned to pinch the two layers of the web during travel
through the sealing elements;
wherein the tensioning device holds the web taut during downstream travel by
engagement of the web by the roller.
[0003e] Some embodiments relate to a machine for converting a web of preformed pouches into
inflated dunnage units, the pouches defined by transverse seals extending from a remote edge to
within a predetermined distance from an inflation edge, the machine comprising:
a tensioning device for frictional engagement with the web, the tensioning device having
a shelf member with a horizontal portion and a downstream and upwardly angled portion, and a
pivotable arm mounted to the machine, with one end of the arm attached to a spring and a roller
rotatably attached to the other end of the arm;
wherein the roller forces the web against the horizontal portion of the shelf member and
against the upwardly angled portion of the shelf member to hold the web taut during downstream
travel.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a plan view of an exemplary embodiment of air cushion material;
Fig. lA is a top plan view of an exemplary embodiment of an air cushion inflation
machine;
Fig. IB is a view taken along lines
IB-IB in Fig. 1A;
Fig. 1C is a view taken along lines 1C-1C in Fig. 1A;
Fig. 2 is a view similar to Fig. 1A with a web of air cushion material installed in the air
cushion inflation machine;
Fig. 2A is a plain view of inflated and sealed air cushions;
Fig. 3 is a flow chart illustrating an exemplary embodiment of a control algorithm for an
air cushion inflation machine;
Fig. 4A is a flow chart illustrating an exemplary embodiment of an idle sequence of a
control algorithm for an air cushion inflation machine;
Figs. 4B-4D illustrate an example of states of components of an air cushion inflation
machine when the air cushion inflation machine is in an idle condition;
Fig. 5A is a flow chart illustrating an exemplary embodiment of a start sequence of a
control algorithm for an air cushion inflation machine;
Figs. 5B-5F illustrate an example of states of components of an air cushion inflation
machine when the air cushion inflation machine is in a start condition;
Fig. 6 is a flow chart illustrating an exemplary embodiment of a run sequence of a control
algorithm for an air cushion inflation machine;
Fig. 7A is a flow chart illustrating an exemplary embodiment of a stop sequence of a
control algorithm for an air cushion inflation machine;
Figs. 7B-7D illustrate an example of states of components of an air cushion inflation
machine when the air cushion inflation machine is in a stop condition;
Fig. 8 is a perspective view of an exemplary embodiment of an air cushion inflation
machine;
Fig. 9 is a perspective view of the air cushion inflation machine of Fig. 8 with cover
components removed;
Fig. 10 is a front view of the air cushion inflation machine shown in Fig. 9;
Fig. 11 is a perspective view of the sealing and clamp assemblies of the air cushion
inflation machine shown in Fig. 9;
Fig. 12 is a view taken as indicated by lines 12-12 in Fig. 11;
Fig. 12A is an enlarged portion of Fig. 12;
Fig. 12B is a view similar to Fig. 12A illustrating routing of inflation cushion material
into the machine;
Fig. 13 is a view taken as indicated by lines 13-13 in Fig. 11;
Fig. 14 is a rear perspective view of the sealing and clamp assemblies shown in Fig. 11;
Fig. 15 is a perspective view of a sealing assembly of the air cushion inflation machine
shown in Fig. 9;
Fig. 16 is a view taken as indicated by lines 16-16 in Fig. 15;
Fig. 17 is a view taken as indicated by lines 17-17 in Fig. 15;
Fig. 18 is a perspective view of a clamping assembly of the air cushion inflation machine
shown in Fig. 9;
Fig. 19 is a view taken as indicated by lines 19-19 in Fig. 18;
Fig. 20 is a partial rear view of the sealing and clamping assemblies shown in Fig. 11;
Fig. 21 is a sectioned perspective view with the section being taken as indicated by lines
21-21 in Fig. 20;
Fig. 22 is a sectional view taken along the plane indicated by lines 21-21 in Fig. 20;
Fig. 23 is a partial rear view of the sealing and clamping assemblies shown in Fig. 11;
Fig. 24 is a sectioned perspective view with the section being taken as indicated by lines
24-24 in Fig. 23; and
Fig. 25 is a sectional view taken along the plane indicated by lines 24-24 in Fig. 23.
DETAILED DESCRIPTION
As described herein, when one or more components are described as being connected,
joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be
direct as between the components or may be indirect such as through the use of one or more
intermediary components. Also as described herein, reference to a "member," "component," or
"portion" shall not be limited to a single structural member, component, or element but can
include an assembly of components, members or elements.
Fig. 1 illustrates an example of a preformed web 10 that can be processed by a new
machine 50 (See Figs. lA and 8) to produce inflated air cushions 12 (See Fig. 2A). The
preformed web can take a wide variety of different forms. Any preformed web that can be
inflated, sealed and then separated from the machine 50 can be used. Examples of acceptable
webs 10 include, but are not limited to, any of the webs shown and/or described by United States
Patent Nos. D633792; 7897220; 7897219; D630945; 7767288; 7757459; 7718028; 7694495;
D603705; 7571584; D596031; 7550191; 7125463; 7125463; 6889739; or 7,975,457; or United
States Patent Application Pub. Nos.: 20100281828A1; 20100221466A1; 20090293427A1; and
20090110864A1, which are all incorporated herein by reference in their entirety. It should be
readily apparent that other preformed webs could be used in the machine 50 to produce dunnage
units.
The illustrated web 10 is formed of a heat sealable plastic film, such as polyethylene.
However, any heat sealable material can be used. The web 10 includes superposed top and
bottom, elongate layers 14, 16 connected together along spaced seal and inflation side edges 18,
hermetically connected along the seal side edge 18. In the illustrated embodiment, the inflation
being spaced apart from and running parallel to the inflation side edge 20. In another
embodiment, the inflation side edge 20 is not perforated and a line of perforations is included in
each of the layers 14, 16, with the lines of perforations being spaced apart from and running
A plurality of longitudinally spaced, transverse seals 22 join the top and bottom layers 14,
. Each of the edges may be either a fold or a seal. The superposed layers 14, 16 are
side edge 20 is perforated. In another embodiment, the inflation side edge 20 is not perforated
and a line of perforations is included in one of the layers 14, 16, with the line of perforations
parallel to the inflation side edge 20. In yet another embodiment, the layers 14, 16 are not
connected together at the inflation side edge.
16. Referring to Figures 1 and 2, the transverse seals 22 extend from the seal edge 18 to within a
short distance of the inflation edge 20 to form pouches 26. An optional pocket 23 is formed
between the transverse seals 22 and the inflation edge 20. A pocket is not formed if the inflation
edges of the layers 14, 16 are not connected. A line of perforations 24 extends through the top
and bottom layers. Fig. 2A illustrates a length of the web 10 after it has been inflated and sealed
to form inflated cushions 12. An inflation seal 42, closes the pouches 26 defined by the
transverse seals 22 and the seal side edge 18 to form the inflated cushions. The illustrated
inflated cushions 12 include gaps G between each pair of adjacent cushions. A web 10 that is
specially constructed to form the gaps G was used in the illustrated embodiment. In other
embodiments, a web 10 may be used that does not form the illustrated gaps G.
Figs. 1A-1C and 2 schematically illustrate an exemplary embodiment of a machine 50 for
converting a preformed web 10 (see Fig. 1) to inflated cushions 12 (see Fig. 2A). The machine
50 may take a wide variety of different forms and the inflation, sealing and separation
arrangements described below may be in the order/positions described or in any other
order/position that facilitates inflation of the web 10, sealing of the web, and separation of the
web from the machine 50. In the example illustrated by Figs. 1A-1C and 2, the machine 50
includes an inflation arrangement 160, a sealing arrangement 162, a clamping arrangement 110,
and a web separation device 158.
The inflation arrangement 160 can take a wide variety of different forms. Any
arrangement capable of providing air under increased pressure (above atmosphere) to the
pouches 26 can be used. In the illustrated embodiment, the inflation arrangement 160 includes a
hollow, longitudinally extending guide pin 56 and a blower 60. Referring to Fig. 2, a web 10 is
routed from a supply and the pocket 23 is placed around the guide pin 56, such that the guide pin
56 is between the inflation side edge 20 and the transverse seals 22. The guide pin 56 aligns the
web as it is pulled through the machine 50. The guide pin 56 includes an inflation opening 102
that is fluidly connected to the blower 60 by a conduit 104. The blower 60 inflates the web
pouches 26 as the web moves past the inflation opening 102.
In an exemplary embodiment, the inflation arrangement 160 also includes a blower
control 106. The blower control 106 can take a wide variety of different forms. For example,
the blower control 106 can be any arrangement that is operable to control the flow rate and/or
pressure of air provided by the inflation arrangement 160 to the pouches 26. In one embodiment,
the blower control 106 is a speed controller that controls the operation speed of the blower. Such
a speed controller speeds the blower up to provide air at higher pressures and/or flow rates and
reduces the blower speed to reduce the pressure and/or flow rate. In another embodiment, the
blower control 106 comprises a flow control valve in the conduit 104 between the blower 60 and
the inflation opening 102.
The sealing arrangement 162 forms the seal 42 (Fig. 2) to create sealed inflated
cushions 12. The sealing arrangement 162 can take a wide variety of different forms. For
example, the sealing arrangement 162 can be any arrangement capable of forming a hermetic
seal between the layers 14, 16. Referring to Fig. 1C, the sealing arrangement 162 includes a
heated sealing element 64, a heat sealing backing member or a second heated sealing element 65,
a temperature control arrangement 165, a heat sealing element positioning device 66, a pair of
drive rollers 68, a belt speed control 67, and a pair of drive belts 70. In an alternate embodiment,
a pair of cooling elements are provided downstream of the heated sealing element 64 and the
heat sealing backing member 65. Each belt 70 is provided around its respective drive roller and
its respective heat sealing element 64 or backing member 65. Each belt 70 is driven by its
respective drive roller 68. The speed of the drive rollers 68 and belts 70 are controlled by the
belt speed control 67. The belts 70 are in close proximity or engage one another, such that the
belts 70 pull the web 10 through the heat sealing element 64 and the heat sealing backing
member or a second heated sealing element 65. The seal 42 is formed as the web 10 passes
through first the heated sealing elements 64 and the heat sealing backing member or a second
heated sealing element 65.
The heating element 64 can take a wide variety of different forms. Any arrangement
capable of raising the temperature of the layers 14 and/or 16 to a point where the layers will
hermetically bond together can be used. For example, the heating element 64 may be a heating
wire, ceramic element or other member that provides heat upon the application of power. For
example, resistance of the heating element 64 causes the heating element 64 to heat up when
voltage is applied across the heating element.
Referring to Fig. 1C, in the illustrated embodiment the temperature control arrangement
165 is coupled to the heating element 64 to control the temperature of the heating element. The
temperature control arrangement 165 may take a wide variety of different forms. Any
arrangement capable of controlling the heating element 64 can be used. In one exemplary
embodiment, the temperature control arrangement 165 includes a thermocouple. The
thermocouple may be coupled to the heating element 64 in a variety of different ways. In one
exemplary embodiment, the heating element 64 includes a ceramic member that is encapsulated
with the thermocouple. The encapsulation of the ceramic member with the thermocouple
provides for very accurate measurement of the temperature of the heating element 64. The
temperature measured by the thermocouple is used to adjust the power applied to the heating
element and thereby control the temperature of the heating element.
In the illustrated embodiment, the heat sealing element positioning device 66 is coupled
to the heating element 64 to position the heating element 64 with respect to the path of travel of
the web 10. The heat sealing element positioning device 66 may take a wide variety of different
forms. Any arrangement capable of positioning the heating element 64 with respect to the path
of travel of the web 10 may be employed. For example, the heat sealing element positioning
device 66 may be an actuator that moves the upper belt 70, drive roller 68, and heated sealing
element 64 relatively away from the lower belt, drive roller, and heat sealing backing member or
a second heated sealing element 65. Or, the heat sealing element positioning device 66 may be
an actuator that moves the heated sealing element 64 away from the upper belt (see Fig. 4D).
The heat sealing element positioning device 66 may be used to quickly control when heat is
applied and removed from the web layers 14, 16 by the heating element 64. For example, the
heat sealing element positioning device is operable to remove heat from the seal when the
machine is idle.
Fig. 1B illustrates an exemplary embodiment of a clamping arrangement. The clamping
arrangement 110 is positioned to pinch the top and bottom layers 14, 16 two layers of the
preformed web together. The clamping arrangement 110 inhibits air under pressure P (Fig. 2) in
the inflated webs from applying force to the molten longitudinal seal 42. This prevents the air
under pressure P from blowing the molten longitudinal seal 42 open and/or creating undesirable
stresses that weaken the longitudinal seal.
The clamping arrangement 110 can take a wide variety of different forms. For example,
the clamping arrangement 110 can be any arrangement capable of squeezing the layers 14, 16 in
an area where the material of the layers is molten, soft or not yet completely solidified and cool.
In the illustrated embodiment of Fig. 1B, the clamping arrangement 110 includes a pair of drive
rollers 268, and a pair of drive belts 270, a pair of clamping members 271 and an optional
clamping member positioning device 266. Each belt 270 is disposed around its respective drive
roller 268. Each belt 270 is driven by its respective drive roller 268. The drive rollers 268 may
be coupled to the drive rollers 68 of the heat sealing belts 70 or the drive rollers 268 may be
driven independently of the drive rollers 68. The belts 270 engage one another, such that the
belts 270 pull the web 10 and pinch the web as the web moves through the heat sealing element
64 and the heat sealing backing member or a second heated sealing element 65. Another
exemplary clamping arrangement is disclosed by U.S. Patent No. 7,571,584, which is
incorporated herein by reference in its entirety.
In the illustrated embodiment, the clamping arrangement 110 includes a positioning
device 266. The positioning device 266 is coupled to the clamping arrangement to selectively
grip and release the web 10. This allows the web 10 to be manually loaded into the machine,
allows the web to be manually removed from the machine, and/or allows any misfeads of the
web 10 to be cleared. The positioning device 266 may take a wide variety of different forms.
Any arrangement capable of positioning the belt(s) 270 of the clamping arrangement 110 with
respect to the path of travel of the web 10 may be employed. For example, the clamping
arrangement positioning device 266 may be an actuator that moves the upper belt 270 relatively
away from the lower belt.
Referring to Fig. 2, the web separation device 158 can take a wide variety of different
forms. For example, when the web 10 includes a line of perforations at or along the seal side
edge 18, the web separation device 158 may be a blunt surface, when the inflation edge 20 is not
perforated the separation device 158 may be a sharp knife edge, and when the layers 14, 16 are
not connected together at the seal side edge the web separation device may be omitted. In the
illustrated embodiment, the web separation device 158 is positioned along the path of travel of
the web at the heat sealing element 64. The web separation device 158 is positioned behind the
heat sealing element so that the web separation device opens the pocket 23 of the web at the
same time the pouches 26 are being sealed. However, the web separation device can be
positioned anywhere along the path of travel of the web. For example, the web separation device
158 can be positioned before the sealing arrangement 162, after the sealing arrangement, before
the inflation opening 102, or after the inflation opening. The illustrated separation device 158
extends from the pin 56. However, the separation device 158 may be mounted to the machine 50
in any manner. The separation device 158 opens the web 10 at or near the inflation side edge 20
as the web moves through the machine 50.
Fig. 3 illustrates an exemplary embodiment of a control algorithm 300 for the inflation
machine 50. In the illustrated embodiment, the control algorithm 300 includes an off state 302,
an idle sequence 304, a start sequence 306, a run sequence 308, and a stop sequence 310. In the
off state, the inflation arrangement 160 and the sealing arrangement 162 are both turned off.
Fig. 4A illustrates the idle sequence 304 and Figs. 4B-4D illustrate the states of the
components of the machine 50 when the machine executes the idle sequence. When the machine
50 is turned on 400, the machine begins the idle sequence 304. In the idle sequence 304, the
sealing elements 64 are set 402 to an idle temperature by the temperature control
arrangement 165. The inflation arrangement 160 is set 404 to an idle output or speed by the
inflation control 106. Referring to Fig. 4D, in an exemplary embodiment, the belt speed control
67 stops the belts 70, 270, the positioning device 66 separates the heating element 64 from the
web 10. As such, when the machine 50 executes the idle sequence 304, the inflation
Fig. 5A illustrates the start sequence 306 and Figs. 5B-5G illustrate the states of the
web 10, and the positioning device 266 optionally causes the clamping device 110 to clamp the
arrangement 160 pre-inflates the pouches 26 and the heating element 64 is pre-heated, but spaced
apart from the web. This pre-inflation and pre-heating reduces the time it takes for the machine
to transition to production of inflated cushioning members.
components as the machine 50 executes the start sequence. When the machine 50 is turned 420
(Fig. 4A) from the idle sequence 304 to the start sequence 306, the machine 50 identifies 500 the
type of material being inflated and sealed. For example, the machine may determine that that the
material is a pillow type material (see for example Fig. 1) or a wrap type material (see for
example U.S. Patent Nos. D633792 and D630945). The machine may also determine the size
and type of material the web 10 is made from in this step.
In the start sequence 304, the sealing elements 64 are raised from the idle temperature to
a sealing temperature (when the sealing temperature is higher than the idle temperature) by the
temperature control arrangement 165 at steps 502 and 504. At step 506, if the material is a wrap
type material, the inflation arrangement 160 is ramped up 508 from the idle output or speed to
the inflation output or speed. The ramp up from the idle output or speed to the inflation output or
speed may be controlled in a variety of different ways. For example, the inflation arrangement
may be ramped up until an inflation pressure set point in the web 10 is reached, until the inflation
device reaches a speed set point, and/or until a predetermined period of time has elapsed after the
inflation device reaches a speed set point. In the Fig. 5A example, inflation device prefills 510
the wrap type material for a predetermined period of time after the inflation device reaches the
speed set point.
In the exemplary embodiment, the machine closes (See Fig 5G) the sealing element 64 at
steps 512 and 514. Pouch type material is substantially pre-inflated by operation of the inflation
device 160 at idle output or speed when the sealing element 64 closes on the web. Similarly,
wrap type material is substantially pre-inflated by the ramp up to the inflation output by the
inflation device 160. In this manner, very little or no material is wasted upon start up of the
machine, regardless of the type of material that is being used. That is, the first pouches 26 that
are fed into the machine 50 are inflated and sealed, rather than being un-inflated or under-
inflated.
In the exemplary embodiment, the machine determines 520 whether the inflation
arrangement 160 has already been ramped to the inflation speed or output after the sealing
element has closed on the web 10. For example, if the material is a pouch type material, the
blower ramps 522 from the idle output to the inflation output after the sealing element 64 is
closed on the web 10. Once the sealing element 64 is closed on the web 10, the belt speed
control 67 starts 524 the belts 70, 270 (see arrows in Fig. 5G) and the machine begins producing
sealed and inflated cushions and moves on 525 to the run sequence.
In one exemplary embodiment, control of the sealing arrangement 162, inflation
arrangement 160, and/or the drive rollers 68 are interrelated. For example, the sealing
arrangement 162, inflation arrangement 160, and/or the drive rollers 68 are controlled based on
input from one or more of the temperature control arrangement 165, belt speed control 67 and/or
the blower control 106. By interrelating the sealing arrangement 162, inflation arrangement 162,
and/or the drive rollers 68, the air/pressure in the pouches and/or the quality of the inflation seal
41, may be precisely controlled.
In an exemplary embodiment, the belt speed may be controlled based on feedback from
the blower control 106 and/or the temperature control arrangement 165. If the temperature of the
sealing element 64 is lower than a predetermined set point, the belt speed may be reduced to
ensure that enough heat is applied to the web to form a high quality seal. Similarly, if the
temperature of the sealing element 64 is higher than a predetermined set point, the belt speed
may be increased to ensure that too much heat is not applied to the web and thereby ensure that a
high quality seal is formed. If the output or speed of the inflation arrangement 160 is lower than
a predetermined set point, the belt speed may be reduced to ensure that the pouches 26 are
optimally filled. In an exemplary embodiment, the blower output or speed and/or the heating
element temperature 64 are continuously controlled to bring the blower output or speed and the
heating element temperature to predetermined setpoints. The speed of the belts may be
continuously updated based on the feedback from the blower control 106 and/or the temperature
control arrangement 165 to optimize the seal quality and pouch filling, especially as the inflation
arrangement and/or the sealing element are being ramped to their normal operating conditions.
In an exemplary embodiment, the temperature of the sealing element 64 may be
controlled based on feedback from the inflation control 106 and/or the belt speed control 67. If
the belt speed is lower than a predetermined set point, the temperature of the sealing element 64
may be reduced to ensure that too much heat is not applied to the web and ensure that a high
quality seal is formed. Similarly, if the belt speed is higher than a predetermined set point, the
temperature of the sealing element 64 may be increased to ensure that enough heat is applied to
the web and a high quality seal is formed. In an exemplary embodiment, the blower output or
speed and/or the belt speed control 67 are continuously controlled to bring the blower output or
speed and the belt speed to predetermined setpoints. The temperature of the sealing element 64
may be continuously updated based on the feedback from the blower control 106 and/or the belt
speed to optimize the seal quality and pouch filling, especially as the inflation arrangement
and/or the belt speed are being ramped to their normal operating conditions.
In an exemplary embodiment, the inflation arrangement 160 may be controlled based on
feedback from the belt speed control 67 and/or the temperature control arrangement 165. If the
temperature of the sealing element 64 is lower than a predetermined set point, the blower output
or speed may be changed to ensure proper inflation and sealing of the air filled cushions. If the
belt speed is lower than a predetermined set point, the blower output or speed may be changed to
ensure proper inflation and sealing of the air filled cushions. In an exemplary embodiment, the
belt speed and/or the heating element temperature are continuously controlled to bring the belt
speed and/or the heating element temperature to predetermined setpoints. The blower speed or
output may be continuously updated based on the feedback from the drive roller control 67
and/or the temperature control arrangement 165 to optimize the seal quality and pouch filling,
especially as the belt speed and/or the sealing temperature are being ramped to their normal
operating conditions.
In one exemplary embodiment, the temperature of the sealing arrangement 162 is
independent of feedback from inflation control and belt control. In this embodiment, belt speed
may be controlled based solely on feedback from the sealing arrangement 162. Similarly, in this
embodiment, the inflation arrangement 162 may be controlled based solely on feedback from the
sealing arrangement 162. In an exemplary embodiment, the machine 50 is programmed with a
control loop that brings the sealing arrangement to 162 to a temperature setpoint and to hold the
temperature at the setpoint. During execution of this control loop, the current temperature of the
sealing arrangement is monitored and is used to control the belt speed and inflation arrangement
162.
Fig. 6 illustrates an exemplary embodiment of a run sequence 308 where control of the
sealing arrangement 162, inflation arrangement 160, and/or the drive rollers 68 are interrelated.
It should be appreciated that the control of the sealing arrangement 162, inflation arrangement
160, and/or the drive rollers 68 can be interrelated in a wide variety of different ways and that
Fig. 6 illustrates one of the many possibilities. In Fig. 6, relationships of the belt speed and
inflation device speed or output with respect to the temperature of the heating device are set 600.
The belt speed and inflation device speed or output are set 602 based on the current temperature
of the sealing element 64. At optional step 604, if the set point of the sealing element 64 and/or
the set point of the inflation arrangement 160 have changed (for example, due to user input), the
updated setpoints are retrieved 606 and the relationships of the belt speed and inflation device
speed or output with respect to the temperature of the heating device are reset 600. If the set
point of the sealing element 64 and/or the set point of the inflation arrangement 160 have not
changed, the sequence checks 608 to see if the sealing element 64 has reached the temperature
set point. If the sealing element 64 has not reached the temperature set point, the belt speed and
inflation device speed or output are updated 602 based on the current temperature of the sealing
element 64. This process is repeated until the sealing element 64 reaches the temperature set
point.
Once the sealing element 64 is at the temperature setting 610 and the belt speed and
inflation device output are at the corresponding setpoints 612, the relationships between the belt
speed and inflation device speed or output with respect to the temperature of the heating device
may optionally be disregarded 614 until the machine is stopped or for a predetermined period of
time or until an event is detected that triggers updating of the belt speed and/or inflation device
output. At this point, the machine 50 is running at a full or optimal speed 615 and continues to
do so until an inflation setting changes 616, a heat setting changes 618, or the machine is stopped
620. When an inflation device setting changes, the inflation device speed or output is increased
or decreased 622 based on the new setting. When a temperature setting changes, the heating
device temperature set point is increased or decreased 624 based on the new setting. When the
machine is stopped, the sequence proceeds 626 to the stop sequence 310.
Fig. 7A illustrates and exemplary stop sequence and Figs. 7B-7D illustrate examples of
conditions of components of the machine 50 during the stop sequence. In the stop sequence 310,
the belt speed control 67 stops 700 the belts 70, 270 (Fig. 7D). At optional step 702, if the
material is pillow type material, the inflation arrangement 160 is braked 703. At step 704, the
sequence confirms that the belts 70, 270 have been stopped. Once the belts 70, 270 are stopped,
the machine opens 706 the sealing element 64. At optional step 708, if the material is wrap type
material, the sequence allows 710 a predetermined period of time to elapse and then the inflation
arrangement 160 is braked 712. At step 714, the sequence confirms 716 that both the belts 70,
270 and the inflation arrangement 160 are stopped and the sequence returns to the idle sequence
304 or the stop state 302.
The machine 50 may take a wide variety of different forms. Figs. 8-25 illustrate one,
non-limiting, exemplary embodiment of the machine 50 in detail. In the example illustrated by
Figs. 8-25, the machine 50 includes an inflation arrangement 960 (see Figs. 12 and 13), a sealing
arrangement 962 (see Fig. 15), a clamping arrangement 910 (see Fig. 18), a web separation
device 958 (see Fig. 13), and a web tensioning device 875 (see Fig. 12). Fig. 8 illustrates the
machine 50 with a cover 802 disposed over the sealing arrangement 962 and the clamping
arrangement 910. Figs. 8-10 illustrate the machine 50 with the cover removed.
Referring to Figs. 8-10, the web 10 is routed from a supply to and around a pair of
elongated, transversely extending guide rollers 854. The web 10 is then routed to a
longitudinally extending guide pin 856. The guide pin 856 is disposed between the inflation
edge 20 and the transverse seals 22 of the web 10. The guide pin 856 aligns the web as it is
pulled through the machine. The web 10 is routed along the guide pin 856 through the web
tensioning device 875.
The tensioning device 875 keeps the web 10 (see Fig. 12B) taught as the web is pulled
through the machine 50 (see Fig. 12). Keeping the web taught in the sealing arrangement 962
prevents wrinkles from forming in the seal 23. The tensioning device can take a wide variety of
different forms. Any arrangement that applies tension to the web 10 can be used. Referring to
Figs. 12A and 12B, in the illustrated embodiment the tensioning device 875 includes a roller 877,
a spring loaded pivot arm 879, and a shelf member 881. The shelf member 881 is fixed with
respect to the path of travel of the web 10. The illustrated shelf member 881 includes a
substantially horizontal portion 883 and an upwardly extending portion 885 that extends upward
at an obtuse angle from the substantially horizontal portion 883.
The substantially horizontal portion 883 and the upwardly extending portion 885 can take
a variety of different forms. In Fig. 12A, a centerline 1252 (the midpoint between the top and
the bottom) of the guide pin 856 is depicted. In an exemplary embodiment, an upper surface
1260 of the substantially horizontal portion 883 is lower than the centerline 1252. In the
example illustrated by Fig. 12A, an upper surface 1260 of the substantially horizontal portion
883 is lower than a bottom 1262 of the guide pin 856. In Fig. 12A, a horizontal line 1250 that is
tangent to the top or uppermost surface of the upwardly extending portion 885 is depicted. In an
exemplary embodiment, the top or uppermost surface 1250 is positioned to keep the pocket 23
taught against the guide pin 856, but not so taught that the perforations of the pocket 23 break.
By pulling the pocket 23 of the web 10 taught against the guide pin 856, wrinkles in the web are
eliminated as the web passes through the sealing arrangement 162. In one exemplary
embodiment, the uppermost surface 1250 is positioned at or above the centerline 1252 of the
guide pin 856. For example, the uppermost surface 1250 may be positioned at a distance D
above the centerline. The distance D may be less than or equal to 0.250 inches, less than or
equal to 0.218 inches, less than or equal to 0.187 inches, less than or equal to 0.156 inches, less
than or equal to 0.125 inches, less than or equal to 0.093 inches, less than or equal to 0.062
inches, or less than or equal to 0.031 inches.
Referring to Fig. 12B, the pivot arm 879 is pivotally mounted to the machine 50 at a
pivot 887. A spring 889 is attached to a first end of the pivot arm and to the machine 50. The
roller 877 is rotatably attached to the second end of the pivot arm 879. The spring 889 forces the
roller 877 against the shelf member 881 at the intersection of the substantially horizontal portion
the web 10. In one exemplary embodiment, the width of the contact area between the roller 877
and the shelf member 881 is between 0.062 and 0.375 inches, between 0.093 and 0.250 inches,
of the machine 50.
883 and the upwardly extending portion 885. It should be readily apparent that the roller 877,
the pivot arm 879 and/or the spring 889 can be replaced with any arrangement that frictionally
engages the web. The frictional force is selected to keep the web 10 taught as the web passes
through the sealing arrangement 162, but the frictional force is not great enough to cause the web
to tear. In one exemplary embodiment, the force applied between the roller 877 and the shelf
881 is between 5 lbs and 10 lbs, such as about 7 lbs or 7 lbs. The width of the contact area
between the roller 877 and the shelf member 881 also influences the frictional force applied to
between 0.125 and 0.187 inches, about 0.140 inches, or 0.140 inches.
Referring to Fig. 12B, the web 10 is routed between the roller 877 and the shelf member
881 such that the roller and the shelf member frictionally engage the layers 14, 16 of the web 10.
The web 10 passes under the roller 877, up and over the upwardly extending portion 885 of the
shelf member, and then into the sealing arrangement 962. The friction between the web 10, the
roller 877, and the shelf member 881 keeps the web taught as the web is pulled through the
sealing arrangement 962.
The inflation arrangement 960 can take a wide variety of different forms. Referring to
Figs. 12 and 13, in the illustrated embodiment, the inflation arrangement 960 includes the
hollow, longitudinally extending guide pin 856 and an inlet opening 857 for fluid connection to a
blower or other source of air under pressure or other fluid under pressure. The illustrated guide
pin 856 includes a plurality of inflation openings 102 (See Fig. 12). The inflation openings 102
can take a wide variety of different forms. In the illustrated embodiment, the guide pin 856
includes a first, relatively large, opening 1200 and a plurality of smaller openings 1202. The
illustrated opening 1200 is a slot with semi-circular ends. The illustrated smaller openings 1202
are circular in shape. The blower and blower control are disposed in a housing 1204 (Figs. 8-10)
The sealing arrangement 962 forms the seal 42 to create sealed inflated cushions 12. The
sealing arrangement 962 can take a wide variety of different forms. Referring to Figs. 15-17, the
sealing assembly 962 includes heated sealing elements 864, 865, a heat sealing element
positioning device 866, drive rollers 868, idler rollers 869, and sealing belts 870. Each belt 870
is disposed around its respective heat sealing elements 864, 865, drive roller 868, and idler
rollers 869. Each belt 870 is driven by its respective drive roller 868. In an exemplary
embodiment, the speed of the drive rollers 868 and belts 870 are controlled by a belt speed
control that is disposed in the housing 1204 of the machine. The belt speed control may be part
of an overall controller for the machine or the belt speed controller may be a separate device that
interfaces with other devices. The belts 870 engage one another, such that the belts 870 pull the
web 10 through the heat sealing elements 864, 865. The seal 42 is formed as the web 10 passes
through the heated sealing elements 864, 865.
Referring to Fig. 21, in the illustrated example the heat sealing element 864 is biased
toward the heat sealing element 865 by a biasing assembly 2100. The biasing assembly 2100
can take a wide variety of different forms. The biasing arrangement may be any arrangement
that biases the heat sealing elements 864, 865 relatively toward one another. In the illustrated
example, the biasing assembly 2100 includes a support member 2101, a shaft member 2102, a
spring 2104 disposed around the shaft member, and a coupling member 2106 connected to the
heat sealing element 864. A head 2108 of the shaft member 2102 is disposed in a counterbore
2110 of the support member 2101 with a shaft portion 2112 of the shaft member extending
through a hole 2114 in the support member 2101. The shaft member 2102 is free to move
axially in the counterbore. An end of the shaft portion is connected to the coupling member
2106. The spring 2104 pushes the coupling member 2106 and attached heat sealing element 864
downward. The biasing assembly 2100 ensures that the heat sealing elements 864, 865 securely
engage the web 10 between the belts 870 whenever the belts are engaged.
The heating element 864 can take a wide variety of different forms. Referring to Fig. 21,
in the illustrated example the heating element 864 includes an outer body 1600, an internal
ceramic element 1602, and an internal thermocouple 1604 or other device for measuring the
temperature of the internal ceramic element 1602. A potting material or other encapsulating
material surrounds the internal ceramic element 1602 and the thermocouple 1604. In an
exemplary embodiment, the thermocouple 1604 is disposed directly on the ceramic element
1602.
A temperature control arrangement is coupled to the thermocouple 1602 and the ceramic
element 1602 for controlling the temperature of the ceramic element 1602 based on feedback
from the thermocouple 1604. The temperature measured by the thermocouple is used to adjust
the power applied to the heating element and thereby control the temperature of the heating
element. The temperature control arrangement is disposed in the housing 1204 of the machine.
The temperature control arrangement may be part of an overall controller for the machine or the
temperature control arrangement may be a separate device that interfaces with other devices.
The heating sealing element positioning device 866 can take a wide variety of different
forms. Referring to Figs. 13, 14, 21, and 22, in the illustrated example the heat sealing elements
864, 865 are coupled to the upper support members 2101 and a lower support member 2103.
The heat sealing element 864 is coupled to the upper support member 2101 by the biasing
assembly 2100 as described above. The lower heat sealing element 865 is fixed to the lower
support member 2103. However, the lower heat sealing element may be coupled to the lower
support member 2103 in any manner. For example, the lower heat sealing element 865 may be
coupled to the lower support member 2103 by a second biasing assembly. In the illustrated
embodiment, the heat sealing element positioning device 866 comprises two upper actuators
1300, 1302 and two lower actuators 1304, 1306. The two upper actuators 1300, 1302 are each
operably connected to the upper support member 2101 and a fixed component of the machine 50,
such as the housing 1204. The two lower actuators 1304, 1306 are each operably connected to
the lower support member 2103 and a fixed component of the machine 50, such as the housing
1204. The actuators 1300, 1302, 1304, 1306 are operable to move the upper and lower support
members 2101, 2103 and coupled heat sealing elements 864, 865 relatively toward and away
from one another. As such, the heating elements 864, 865 are positioned with respect to the path
of travel of the web 10 such that the sealing belts 870 selectively engage and disengage the web
Referring to Figs. 24 and 25, the illustrated upper and lower support members 2101, 2103
include seal cooling portions 2401, 2403. The seal cooling portions 2401, 2403 engage the belts
870 and compress the material of the seal downstream of the sealing elements 864, 865. Heat of
the seal is transferred through the belts 870 and into the seal cooling portions 2401, 2403 of the
support members 2101, 2103 to cool the material of the seal. The illustrated upper and lower
support members 2101, 2103 include optional holes 2410. The holes 2410 increase the surface
area of the upper and lower support members 2101, 2103 to increase their effectiveness as heat
sinks and reduce their weight. The upper and lower support members 2101, 2103 can be made
from a wide variety of different materials. In an exemplary embodiment, the support members
are made from a thermally conductive material such as aluminum or copper.
The clamping arrangement 910 is positioned to pinch the top and bottom layers 14, 16 of
the preformed web together. The clamping arrangement 910 can take a wide variety of different
forms. Referring to Figs. 18 and 19, the clamping arrangement 910 includes drive rollers 1068,
idler rollers 1069, spring loaded clamping assemblies 1800, a clamping portion 1802 of the lower
support member 2103, and a pair of drive belts 1070. The illustrated clamping portion 1802 of
the lower support member 2103 includes a support surface 1810 or groove and a lip 1812. The
width of the support surface 1810 or groove corresponds to the width of the belts 1070. The
support surface 1810 supports the lower belt 1070 and the lip 1812 retains the belt or the support
surface.
Referring to Figs. 24 and 25, each spring loaded clamping assembly 1800 includes a
clamping member 1900, a shaft member 1902, and a spring 1904 disposed around the shaft
member. The clamping members 1900, shaft members 1902, and springs are coupled to a
support member 1901. Each clamping member 1900 is biased toward the clamping portion 1802
of the lower support portion 2103 by the springs 1902. A head 1908 of each shaft member 1902
is disposed on the support member 1901 with a shaft portion 1912 of the shaft member extending
through a hole 1914 in the support member 1901. The shaft member 1902 is free to move
axially in the counterbore. An end of each shaft portion 1912 is connected to a clamping
member 1900. The springs 1904 push the clamping members 1900 downward. The biasing
assemblies 1800 ensure that the belts 1070 securely engage the web 10 whenever the belts are
engaged.
Each belt 1070 is disposed around its respective drive rollers 1068 and idler rollers 1069.
Each belt 1070 is driven by its respective drive roller 1068, which is attached to a drive roller
868. As such, the sealing belts 870 and the pinching belts 1070 are driven in sync. The belts
1070 engage one another, such that the belts 1070 pull the web 10 and pinch the web as the web
moves through the heat sealing elements 864, 865.
In the illustrated embodiment, the clamping arrangement 910 is positioned by the same
positioning device 866 that positions the heat sealing elements 864. Since the clamping
arrangement 910 moves with the upper and lower support members 2101, 2103, movement of
the upper and lower support members 2101, 2103 by the positioning device 866 also moves the
clamping arrangement 910. The positioning device 866 is coupled to the clamping arrangement
910 to selectively grip and release the web 10. This allows the web 10 to be manually loaded
into the machine 50, allows the web to be manually removed from the machine, and/or allows
any misfeads of the web 10 to be cleared.
Referring to Figs. 13 and 14, the illustrated web separation device 958 is mounted to the
guide pin 856. The web separation device 958 includes an edge 1350. The edge 1350 engages
the web 10 to open the pocket and allow the web 10 to pass through the machine. The edge 1350
may be a blunt edge or a sharp edge, depending on the configuration of the web 10. For
example, when the web 10 includes a line of perforations at or along the seal side edge 18, the
edge 1350 may be a blunt surface, when the seal side edge 18 is not perforated the edge may be
sharp. Referring to Fig. 13, in the illustrated embodiment the web separation device 958 is
positioned along the path of travel at the heat sealing element 864. The web separation device
958 is positioned behind the heat sealing element so that the web separation device opens the
pocket 23 of the web at the same time the pouches 26 are being sealed.
While various inventive aspects, concepts and features of the inventions may be
described and illustrated herein as embodied in combination in the exemplary embodiments,
these various aspects, concepts and features may be used in many alternative embodiments,
either individually or in various combinations and sub-combinations thereof. Unless expressly
excluded herein all such combinations and sub-combinations are intended to be within the scope
of the present inventions. Still further, while various alternative embodiments as to the various
aspects, concepts and features of the inventions--such as alternative materials, structures,
configurations, methods, circuits, devices and components, hardware, alternatives as to form, fit
and function, and so on--may be described herein, such descriptions are not intended to be a
complete or exhaustive list of available alternative embodiments, whether presently known or
inventions even if such embodiments are not expressly disclosed herein. Additionally, even
though some features, concepts or aspects of the inventions may be described herein as being a
later developed. Those skilled in the art may readily adopt one or more of the inventive aspects,
concepts or features into additional embodiments and uses within the scope of the present
preferred arrangement or method, such description is not intended to suggest that such feature is
required or necessary unless expressly so stated. Still further, exemplary or representative values
and ranges may be included to assist in understanding the present disclosure, however, such
values and ranges are not to be construed in a limiting sense and are intended to be critical values
or ranges only if so expressly stated. Moreover, while various aspects, features and concepts
may be expressly identified herein as being inventive or forming part of an invention, such
identification is not intended to be exclusive, but rather there may be inventive aspects, concepts
and features that are fully described herein without being expressly identified as such or as part
of a specific invention. Descriptions of exemplary methods or processes are not limited to
inclusion of all steps as being required in all cases, nor is the order that the steps are presented to
be construed as required or necessary unless expressly so stated.
While the present invention has been illustrated by the description of embodiments
thereof, and while the embodiments have been described in considerable detail, it is not the
intention of the applicant to restrict or in any way limit the scope of the invention to such detail.
Additional advantages and modifications will readily appear to those skilled in the art. For
example, the specific locations of the component connections and interplacements can be
modified. Therefore, the invention, in its broader aspects, is not limited to the specific details,
the representative apparatus, and illustrative examples shown and described. Accordingly,
departures can be made from such details without departing from the spirit or scope of the
applicant's general inventive concept.
Claims (15)
- A machine for converting a web of preformed pouches into inflated dunnage units, the pouches defined by transverse seals extending from a remote edge to within a predetermined distance from an inflation edge, the machine comprising: a guide pin for insertion between the transverse seals and the inflation edge to define a path of travel of the web; a tensioning device for frictional engagement with the web, wherein the tensioning device holds the web taut during downstream travel; an inflation arrangement for inflation of the preformed pouches; a sealing arrangement positioned to provide a longitudinal seal that intersects the transverse seals to close the preformed pouches and form a dunnage unit, the sealing arrangement having at least two sealing belts, each belt powered by a drive roller and positioned to engage a surface of the web and pull the web through sealing elements positioned on either side of the web; and a clamping arrangement positioned to pinch the two layers of the web during travel through the sealing elements, the clamping arrangement having at least two pinching belts, each belt powered by a drive roller and positioned to engage a surface of the web and pull the web and pinch the web through the sealing elements wherein the two sealing belts are disposed between the two pinching belts and the inflation edge; wherein the at least two sealing belts and the at least two crimping belts are driven in sync.
- The machine of claim 1 wherein the tensioning device comprises: a shelf member with a horizontal portion and a downstream and upwardly angled portion; and a pivotable arm mounted to the machine, with one end of the arm attached to a spring and a roller rotatably attached to the other end of the arm; wherein the roller engages the web.
- The machine of claim 2, wherein the roller forces the web against the horizontal portion of the shelf member.
- The machine of claim 2 or 3, wherein the roller forces the web against the upwardly angled portion of the shelf member.
- The machine of any one of claims 2 to 4, wherein the roller engages the web at the intersection of the horizontal portion and the upwardly angled portion of the shelf member.
- The machine of claim 5, wherein the roller forces the web against the horizontal portion of the shelf member and against the upwardly angled portion of the shelf member.
- The machine of any one of claims 2 to 6, wherein the upwardly angled portion of the shelf member extends upward at an obtuse angle relative the horizontal portion of the shelf member.
- The machine of any one of claims 2 to 7, wherein the web travels under the roller, up and over the upwardly angled portion of the shelf member, and immediately downstream to the sealing arrangement.
- A machine for converting a web of preformed pouches into inflated dunnage units, the pouches defined by transverse seals extending from a remote edge to within a predetermined distance from an inflation edge, the machine comprising: a guide pin for insertion between the transverse seals and the inflation edge to define a path of travel of the web; a tensioning device for frictional engagement with the web, the tensioning device having a shelf member with a horizontal portion and a downstream and upwardly angled portion, and a pivotable arm mounted to the machine, with one end of the arm attached to a spring and a roller rotatably attached to the other end of the arm; an inflation arrangement for inflation of the preformed pouches; a sealing arrangement positioned to provide a longitudinal seal that intersects the transverse seals to close the preformed pouches and form a dunnage unit, the sealing arrangement having at least two sealing belts, each belt powered by a drive roller and positioned to engage a surface of the web and pull the web through sealing elements positioned on either side of the web; and a clamping arrangement positioned to pinch the two layers of the web during travel through the sealing elements; wherein the tensioning device holds the web taut during downstream travel by engagement of the web by the roller.
- The machine of claim 9, wherein the clamping arrangement has at least two pinching belts, each belt powered by a drive roller and positioned to engage a surface of the web and pull the web and pinch the web through the sealing elements.
- 11. The machine of claim 9 or 10, wherein the roller forces the web against the horizontal portion of the shelf member.
- The machine of any one of claims 9 to 11, wherein the roller forces the web against the upwardly angled portion of the shelf member.
- The machine of any one of claims 9 to 12, wherein the roller engages the web at the intersection of the horizontal portion and the upwardly angled portion of the shelf member.
- The machine of claim 13 wherein the roller forces the web against the horizontal portion of the shelf member and against the upwardly angled portion of the shelf member.
- 15. The machine of any one of claims 9 to 14, wherein the upwardly angled portion of the shelf member extends upward at an obtuse angle relative the horizontal portion of the shelf member. The machine of any one of claims 9 to 15, wherein the web travels under the roller, up and over the upwardly angled portion of the shelf member, and immediately downstream to the sealing arrangement.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ717011A NZ717011B2 (en) | 2011-07-07 | 2012-07-06 | Air cushion inflation machine |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161505261P | 2011-07-07 | 2011-07-07 | |
US61/505,261 | 2011-07-07 | ||
PCT/US2012/045718 WO2013006779A1 (en) | 2011-07-07 | 2012-07-06 | Air cushion inflation machine |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ619691A NZ619691A (en) | 2016-03-31 |
NZ619691B2 true NZ619691B2 (en) | 2016-07-01 |
Family
ID=
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