WO1989000919A1 - Appareil de production d'un produit a coussin d'air - Google Patents

Appareil de production d'un produit a coussin d'air Download PDF

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Publication number
WO1989000919A1
WO1989000919A1 PCT/US1988/002494 US8802494W WO8900919A1 WO 1989000919 A1 WO1989000919 A1 WO 1989000919A1 US 8802494 W US8802494 W US 8802494W WO 8900919 A1 WO8900919 A1 WO 8900919A1
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WO
WIPO (PCT)
Prior art keywords
roller
film
air
roll
cushioning material
Prior art date
Application number
PCT/US1988/002494
Other languages
English (en)
Inventor
Garry L. Caputo
Original Assignee
Caputo Garry L
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Caputo Garry L filed Critical Caputo Garry L
Publication of WO1989000919A1 publication Critical patent/WO1989000919A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18—Thermoforming apparatus
    • B29C51/20—Thermoforming apparatus having movable moulds or mould parts
    • B29C51/22—Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
    • B29C51/225—Thermoforming apparatus having movable moulds or mould parts rotatable about an axis mounted on a vacuum drum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/68—Vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B32B2553/02—Shock absorbing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B32B2553/02—Shock absorbing
    • B32B2553/023—Shock absorbing for use in loose form, e.g. dunnage

Definitions

  • This invention pertains to apparatus similar that disclosed by the Applicant in his U.S. Patents Nos. 4,576,669, as issued March 18, 1986, and entitled ' "On-Demand” Apparatus and Method For Producing Air-Cushioning Product, and 4,579,516, -as issued April 1, 1986, and entitled Forming Roller For Producing Air-Cushioning Product. To the extent applicable, reference is made to these patents.
  • Air-cushioning material is well known as packing dunnage both for its low cost and light weight and also for its convenience and strength.
  • This dunnage product utilizes flexible plastic sheet material and in the present invention is directed to and toward thermoplastic films in strip or roll form.
  • the storage of the material in roll form is economical of space and cost and the present invention contemplates a capability leading to an almost immediate supply of cushioning material.
  • the method and apparatus for producing such product includes a heat-sealable plastic sheet which is heated to bring a surface to a temperature in the proximity of fusion, welding or melting. This sheet is shaped by a multiplicity of cavities provided in an embossing drum or plate. Vacuum is used to form this sheet.
  • Another sheet or strip of film is heated to a fusion or welding temperature and then laminated to the thermoformed sheet of film.
  • the welding or laminating step anticipates that both films have their facing surfaces sufficiently heated to weld and pressure applied to form this weld, thus adhering the ' two films together. At least the temperatures of the film surfaces at the weld are sufficient for the weld to be achieved, and are of course equalized when fusion or welding is achieved.
  • U.S. Patent Nos. 3,416,984 and 3,392,081 show basic construction methods
  • U.S. Patent Nos. 4,415,398 and 4,427,474 show plural sheets and/or drum apparatus.
  • the prior art apparatus contemplated is for high-volume/production and the resulting product is sold as big rolls or packages.
  • Applicant's apparatus is for use by a manufacturer at and in his packing room. This apparatus is small and, more or less, self-contained. The simplicity of apparatus enables interruption of production and, when required, easy repair of the apparatus.
  • the known apparatus and methods do not anticipate the forming of air-cushioning product where the plies of thermoplastic film are less than one mil in thickness.
  • the apparatus to be more fully shown and described, has successfully produced an air-cushioning product where each ply of material is one-half mil (0.0005 inches) in thickness. This reduces cost in both manufacture and in the weight of air-cushioning product. This is very important where many items using such cushioning are shipped by air.
  • the invention of Applicant provides apparatus and a method for the production of air-cushioning dunnage with flexible sheeting material supplied in roll form.
  • the films are of high strength and high resistance to loss from the produced cells.
  • the apparatus of this invention is small in size and can be interrupted conveniently in operation without, destroying the desired product and its intended end use. If desired, the dunnage product can and may be stored in a small roll form.
  • This invention may be summarized, at least in part, with reference to its objects. It is an object of this invention to provide, and it does provide, a novel apparatus and method for the production of air-cushioning dunnage in strip form with and of a flexible thermoplastic film requiring a minimum of apparatus.
  • This forming roller is provided with a vacuum conduit and an air-cool assist is provided for cooling.
  • this apparatus employs very little room as it is designed for use in the packing or shipping room. Attendant time or skill is minimal for the operation of this apparatus in which supply is from two storage rolls of thermoplastic film.
  • One or both films may be laminated films structured to inhibit air escape. The surfaces of the film are adapted to be softened so as to weld to another film with sufficient heat and pressure.
  • a forming roll has cavities of a desired configuration and depth. Each cavity communicates to a manifold connected to a source of vacuum.
  • One of the strips which is structured for thermoforming into pockets is fed to a heated roll to a whereat and whereon the advancing film is heated to a forming temperature. The film passes from this heated roll to a forming roll having the cavity formations.
  • the vacumm draws the softened and heated film strip into the formed cavities, and as this roll is coated with a thin sheet of silicone rubber, there is not only provided resiliency to accommodate irregularities in surface but also to provide insulation for loss of heat in these films.
  • the shaped film is carried on this forming roll to the second heated film whereat the two heated films are pressed together at those areas around the cavities to form seals or welds at the interstices between pockets.
  • the product is fed to a chill, roll which sets the weld plies of film, after which the air-cushioning dunnage is cut to length for packing use or wound on an accumulating roll for storage for subsequent use.
  • thermoplastic materials include unsupported polyethylene, polypropylene, PVC, acrylic, polya ⁇ rylonitrile, polyester, nylon, EVA, EMA, etc. It is also versatile in running structured materials as well, as for example PET/polyethylene homo-polymer or co-polymer and EMA, etc. The simplicity of this apparatus allows usage at the end user's level to produce an even lower cost air-cushioning product.
  • This- showing in one embodiment has no added cooling on the forming roll and is contemplated to accept and • weld into air-cushion dunnage films ' in which each ply is less than one mil in thickness. One-half mil (0.0005 inches) thickness in each ply has been found to be practical.
  • An alternate embodiment contemplates additional cooling for the forming roll, but an Insulation and resilient covering of the forming roll is shown and contemplated.
  • FIG.l represents an isometric, partly diagrammatic, view of the apparatus and the relationship of the several components of this invention.
  • FIG. 2 represents a diagram of the apparatus and film supply of FIG. 1;
  • FIG. 3 represents a perspective view of the assembled apparatus of FIG. 1 and enclosed in and with supporting and associated guard portions;
  • FIG. 4 represents a plan view showing the positional relationship of the heated and forming rollers of FIG. 1;
  • FIG. 5 represents a side diagrammatic view of an alternate arrangement of apparatus used for extremely thin films;
  • FIG. 6 represents a side view, partly diagrammatic and in section, ' showing the construction of a forming roller
  • FIG. 7 represents a small, greatly enlarged view of the roller of FIG. 6 and showing an outer construction of said roller;
  • FIG. 8 represents a diagrammatic end view, partly in section, showing the relationship of the end cover and roller
  • FIG. 9 • represents a sectional view of an alternate roller configuration with water-cooling capability
  • FIG. 10 represents an end view, partly diagrammatic and in section, to illustrate the roller of FIG. 9.
  • a web of film 12 is fed to and between a heated roll 14 and forming roll 16.
  • Another-strip of thermoplastic film 20 is carried by and on a supply roll 22 and is fed to heated roll 24.
  • Both rolls 10 and 22 are rotatable on shaft means, and for the purposes of identification are numbered 26 and 28.
  • the film 12 is carried to an idler roller 29 which is positioned so as to produce a wrap of about one hundred eighty degrees around heated roller 14.
  • the idler roller 29 is usually carried on an adjustable arm (not shown) so that the wrap around roller 14 is adjusted to accommodate the thickness and character of films.
  • the film 20 carried in roll form is fed to metallic roll 24, which is heated by electrical energy.
  • Thermostatic control of the temperature to establish the surface temperature and maintain this temperature throughout the cycle of operation is contemplated. Electrical energy is contemplated, but other means may be provided and no patentable distinction is ascribed thereto.
  • Journal and shaft means for roll 24 are conventional and are not shown to reduce the descriptive explanation.
  • Roll 16 is diagrammatically shown in FIGS. 1 and 2 and is the air-cushioning forming roll which receives the heated film 12. With and by vacuum, this heated film is drawn into exposed cavities 30.
  • This roller 16 is provided with a resilient silicone rubber outer covering 32.
  • This covering is provided with shaped openings and is adhesively attached so that the multiplicity of cavities 30 is open to the heated film.
  • This outer covering 32 is contemplated to be from thirty- to one hundred-thousandths of an inch in thickness and, as shown in FIG. 7, is applied by adhesive to only the exterior of the roller 16.
  • the coating of the cavities 30 is not desired, so spraying or dipping of the forming roller to provide the resilient coating is not practical. As seen in FIG.
  • the heated roller 24 is positioned so that the heated film 20 and the formed strip 12 are brought into a welding condition. It is to be noted that film 20 is brought to and around idler roller 34 so that a determined portion of film 20 is in contact with heated roller 24. Rollers 14 and 24, although heated, are also coated with Teflon (TM DuPont) in the conventionally known manner, with this treatment assisting in the ready release of heated films from the rollers.
  • Teflon T DuPont
  • Roll 16 is diagrammatically shown in FIGS. 1 and 2 with cavities 30 and with a resilient cover material 32.
  • This roller 16 is precisely spaced from roller 24 so that films 12 and 20 are welded so as to produce an air-cushion dunnage strip identified as 36.
  • This strip 36 proceeds to a lower roller 38 which is additionally cooled as by air flow produced by blower 40, with the stream carried in a conductor 42.
  • This roller 38 may be, and preferably is, coated with Teflon for ready release.
  • This air-cushion product dunnage strip 36 proceeds to above and below feed rollers 44 and 45. There . is also depicted another downstream pair of feed rollers 47 and 48.
  • cut-off or severing means depicted as a reciprocable knife 50, with a roller 52 providing an anvil surface for the sharpened knife edge to move to and effect the cut of the strip 36.
  • vacuum is produced by a pump 54, with a conductor 56 leading from the end of roller 16 to the pump 54.
  • electric resistance heating means 58 is suggested in the near roller 14. Like heating means is provided in roller 24.
  • FIG. 3 the apparatus of FIGS. 1 and 2 is shown in an enclosure and support frame as supplied to the customer.
  • Rolls 22 and 10 are shown with shafts 28 and 26 as carried on a support stand 60 which may be a part of illustrated legs 62.
  • the legs 62 have adjustability means so as to accommodate uneven floor areas.
  • the support frame is shown with extending brackets having cutout means to receive and retain the shafts supporting the rolls.
  • ' Idler roller 29 is depicted as supported on the near side with an arm 68. From roller 29, the film 12 proceeds to heated roller 14 as described above.
  • the roller 16 is seen, as is also roller 24.
  • Film 20 is fed to idler roller 34 as described above.
  • the air-cushion material 36 is seen as proceeding to and from the apparatus.
  • This enclosure Seen in this FIG. 3 is the outside case or enclosure which provides a guard of the mechanism, and is identified as 70.
  • This enclosure has a front portion 71 in and on which is mounted simple switch means 72.
  • This enclosure has a rear portion 73 which, as depicted, extends upwardly sufficiently to enclose drive and support means for the rollers and motor means. End members are also provided so as to enclose all working components.
  • a near .(left) end 74 is seen in this FIG.
  • the outside case may be of suitable sheet metal or the like. This case is to provide a protector, preventing exposure of moving components to an attendant. Electrical components are also insulated with control circuitry usually at and with twenty-four volts.
  • FIG. 4 is a top view of the rollers shown in FIG. 1, 2 and 3 in which heated roller 14.is shown as carried on and by a shaft 76.
  • This shaft is depicted as supported by frame members 77 and 78.
  • the vacuum forming roller 16 is shown as spaced a short distance from roller 14 and is carried on a shaft 80, also journaled and supported in fixed relationship by frame members 77 and 78.
  • This roller is shown with silicone rubber outer surface 32 and shaped cavities 30 (identified above).
  • Roller 24, which is also heated, is in very close proximity to roller 16. The spacing between the peripheries of rollers 16 and 24 is adjusted so that pressing together of the two films 12 and 20 is achieved to effect a welding of the interstice portions.
  • Roller 24 is shown as carried on and by shaft 82.
  • FIGS. 1 and 2 In the apparatus shown in FIG. 5, the concept of FIGS. 1 and 2 is substantially duplicated, but this apparatus arrangement is for air-cushioning materials where the films are one mil (one-thousandth of an ' inch) or less. This arrangement is for films that are sufficiently thin for rapid cooling or heat loss.
  • Rolls 10 and 22 are of thermoplastic films, with strips 12 and 20 fed to the idler rollers 29 and 34 substantially as in FIGS. 1 and 2.
  • the heated film from roller 14 proceeds to the vacuum forming roller generally identified as 16, but the silicone rubber outer cover 32 may be only about one thirty-second of an inch.
  • This roller has vacuum produced by pump 54 and which is conducted by a substantially rigid pipe 5 ' 6. This pipe conductor is attached to an end plate generally identified as 84.
  • This end plate is figuratively shown as illustrative thereof and is non-rotative (fixed) .
  • This plate 84 includes an arcuate vacuum-conducting pathway 86 disposed to extend one-half the circle of the communication conductors leading to vacuum passages from the cavities 30. This particular construction is shown in greater . detail and described hereinafter in FIGS. 6, 7 and 8.
  • An added blower 88 and conductor 90 are illustrated, and it is noted that the air from this blower 88 is dispersed so as to cool the outer resilient surface of roller 16.
  • roller 38 is shown as having a plurality of cooling passageways 92 which are supplied by air conductor 42 from blower 40.
  • a distributor plate 94 is adapted to carry this air to the several passageways 92. It is to be noted that in this embodiment it is contemplated that only air and vacuum are utilized for the air-cushioning dunnage product. Severing or an accumulating roll for a stored product are a matter of preference and use.
  • FIGS. 6, 7 and 8 pertains to the apparatus of FIG. 5, but many of the concepts used therewith are also applicable to alternative embodiments.
  • the roller generally identified as 16, is depicted as having a resilient silicone rubber cover 32 interposed at all interstice areas.
  • the cavities 30 are sized and shaped to suit the desired air-cushioning sealed pocket.
  • the inner ends of each cavity 30 are in flow communication with longitudinal conductors 96.
  • the far or left end of each conductor is closed by a plug 98 so that only the right end is open to vacuum.
  • This roller is shown as carried on and by shaft 80.
  • the end plate 84 is provided with a wiping seal so that said arcuate pathway 86 is in flow communication with the vacuum pump 54 (FIG.
  • FIG. 7 an enlarged (very fragmentary) view shows that the peripheral portion of roll 16 illustrates that formed cavities 30 have their inner extents in flow communication with longitudinal conductors 96.
  • the outer interstice surface between cavities is covered with attached silicone rubber sheeting 32.
  • This resilient cover 32 provides insulation to prevent unwanted cooling of the heated film 12 while being formed and while being brought to welding position.
  • FIG. 8 is diagrammatically shown the roller of FIG. 6.
  • This roller 16 is depicted with formed cavities 30 and therebetween are interstice portions with resilient covering 32 thereon.
  • End plate 84 is shown with arcuate conductor 86 extending about one hundred eighty degrees.
  • the resilient cover 32 and the cavities 30 are integral with the roll 16 as shown and rotates as the roll is moved.
  • the cover 84 includes a wiper seal against the end of the revolving roller. This seal is not depicted as many are known and are conventionally used.
  • FIGS. 9 and 10 an alternate construction of a forming roller.
  • this roller is generally identified as 100.
  • This roller has water cooling depicted and indicates the forming rollers may be cooled with both air, vacuum and also with water.
  • an outer resilient tubular member is secured to a roller having a multiplicity of cavities 30 (FIG. 7) which conventionally are in line. These cavities extend to and through the resilient surface 32 of the tubular member 102.
  • a gasket 106 is provided at each end of the member 104 to provide a seal of tubular member 104 to a contoured ring-end 108. Alignment and retention are provided by flat-heat screw members 110 which- are shown as entered into threaded holes in member 102.
  • Another tubular member 112 is shown and provides an inner sleeve adapted to contain water or like fluid. It is noted that grooves 114 are made in this inner tubular member 112 and similar grooves are formed interior of member 104. These grooves 114 and 116 are disposed opposite each other and retain a rubber seal 118, conventionally an extrusion of resilient material, and in position is compressed to a tight excluding fit and disposed lengthwise and extending to an end member 120 which is disposed at one end (left shown) and at the other end is a closed plate to close off the flow or action of vacuum.
  • This end member 120 like end plate 84 (FIGS. 6 and 8), is formed with an arcuate vacuum-conducting portion 122.
  • the ring-end is formed with an inwardly-extending plug 124 disposed to engage and support tubular member 112 and also to provide a lengthwise stop.
  • This plug is shown as supporting the inside of member 112, but the support of this inner member may be by other means and the length of member ' 112 and the diameter of plug 124 are merely a matter of selection.
  • the arcuate conducting pathway 122 . is only about one hundred eighty degrees.
  • a shaft, identified as 126 has a water conductor 128 which is disposed so as to carry water into the cavity adjacent inner tubular member 112.
  • a bearing 130 is depicted to prevent undue wear or scoring of the shaft 126 as it rotates relative to end member 120.
  • a key 132 is suggested as a means of insuring that the roller 100 is rotated with and by the shaft 126.
  • Vacuum is shown as connected to the arcuate conducting pathway 122. This vacuum conductor is, or is substantially, like conductor 56 seen in FIG. 5 described above.
  • 0-ring seals not shown , or other means such as compounds may be used to prevent vacuum, water or fluid escape from the cavity portion to and along the inserted shaft.
  • a tight fit may be used without a key 132 to insure positive rotation of the roller 100 by and with the shaft 126.
  • Arrangements to suit the apparatus provided may be changed to accommodate the requirements of the product.
  • the apparatus of FIGS. 1 and 5 illustrates the preferred arrangement of components. Downstream rollers are shown as a means for moving the air-cushioning material from cooling roller 38. Rollers 29 and 34 are shown as a preferred arrangement, but this is not definitive of the disclosed apparatus.
  • the non-rotative end member (84, FIG. 6; 120, FIG. 10) may be of a plastic having anti-friction properties so that added bearing means between the shaft and end plate may not be required.
  • the insulating and resilient portion 32 used on the forming roller provides a slowing barrier to the flow of heat to the roller, it is also a barrier to the cooling of the interior portion of the forming roller.
  • the thickness of the film, the heating temperature to said film and the speed of travel is a needed evaluation and consideration for the arrangement of the components used in the apparatus.
  • the vacuum to the forming cavities 30, auxiliary air cooing as shown in and by blower 88 in FIG. 5, and/or water cooling as in FIGS. 9 and 10 may be and is contemplated for conditioning temperatures as provided by the engineer of the apparatus.
  • the apparatus shown in Patent 4,576,669 (as identified above) is conventionally provided for such films.
  • the pressure roller does not include a resilient covering, but the forming roller has an insulating resilient cover to accommodate the pressure required for welding.
  • thin plastic plies conventionally pertain to two-thousandths of an inch or less, with the above-described apparatus usually used with plies of one-half thousandth of an inch to slightly greater than one-thousandth of an inch.
  • the forming roller with its resilient insulating outer covering is anticipated to accommodate temperatures of up to three hundred fifty degrees F. (158.9 degrees C), depending on the film to be run.
  • the positioning of the pressure roller 24 from the thermoforming roller 16 is adjustably provided to accommodate the thickness of the films.
  • This means is usually pneumatic, as noted in the Patent No. 4,576,669 (above referenced) , but other means may be provided.
  • this apparatus with the forming and production of air-cushioning materials anticipates that said material. being from two rolls of thermoplastic material such as polyethylene or the like may be combined with other plastic materials to provide air passage-inhibiting properties; said method, providing means for a start and stop of the apparatus for manufacture and supplying of air-cushioning material, includes the steps of: providing a first roll of thin, thermoplastic film having thermoforming properties when heat-softened; carrying said roll on a supported shaft and as a continuous strip of film and replacing said roll on said shaft when replenishing the film on the first roll is desired or required; rotating and driving a first heat-conductive roller to and carrying on said roller the strip of first film around which the wrap extend is at least one hundred fifty degrees of arc;
  • said forming roller having its outer peripheral surface formed with a multiplicity of shaped cavities, -and providing each cavity at its inner extent a small conductor leading to and terminating at a conductor and further connecting said conductor to source of vacuum;
  • valve means in association with a conductor to said source of vacuum, and providing with this valve means a mask of a determined extent or sector therewith, and opening o_f about one-half of the small conductors from the shaped cavities to a source of vacuum so that the heat-softened first film is drawn by vacuum into these shaped cavities forming shaped cell forms, said resilient covering providing sufficient insulation that the now formed heat-softened plastic film is tightly carried thereon by vacuum;
  • thermoformed and heated film is brought in way of this second heated, lidding film, pressing these films together into a welded condition, the cover on the driven forming roller sufficiently resilient so that with a minimum of applied pressure the .second heated film is pressed to and into the first thermoformed film so that at the peripheral interstices between shaped cavities and at the outer surface of the forming roller and the welding is achieved, the peripheral speed of the driven pressure roller and the forming roller substantially in coincidence, the welding of the two plies of film material providing in the thermoformed air-cushioning material a multiplicity of air-encased cells of said first and second electrically heated rollers and maintaining the temperatures in the formed film and in the lidding material during welding;
  • thermoforming roll is conventionally rotatably supported by and in bearing means so that the shaft is fixed in relation to the frame.
  • the pressure roll is controlled in its ba ⁇ k-and-forth movement.
  • the heating is usually by a resistance element as it is one of the less expensive ways to thermostatically control the desired temperature. Alternate heating means such as radiation energy may be made practical so the claims and drawings are merely illustrative of electrical heating * .
  • the cooling of the thermoforming roll may be by means such as air or water or both.
  • the cooling is controlled as to its capability and degree since the speed and type of film establishes the cooling required.
  • the stripping of the air-cushioned product after welding is usually easily achieved since the air-cell cavities in the forming roller are usually of a tapered configuration, lending the formed cells themselves to easy removal. If the removal of the welded air-cushioning material from the forming roller is difficult, air may be used in conjunction with the small conductors and the arcuate valve means. A blast of air may also be used to assist in removal.
  • the several rolls used in this apparatus are contemplated to be coated with an anti-adhesion material so that the film, whether heated or unheated, does not stick to the roll surfaces.
  • This treatment is usually a baked-on tetrafluorothylene (Teflon TM DuPont) or similar material which surface treatment is also of a high-heat resistance, well above the temperatures of the heated films used in the process described above.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

Un appareil de formation d'un matériau mince à coussin d'air (36) comprend un premier rouleau chauffé (14), un rouleau de formage (16), un rouleau de pression chauffé (24) et un rouleau de refroidissement (38). Deux bandes de matériau thermoplastique (12, 20) sont amenées aux rouleaux chauffés (14, 24), respectivement. Le matériau thermoplastique (12) est formé sur le rouleau de formage (16) qui présente des cavités (30) reliées à une source à vide (540 par un conduit (56). La surface périphérique externe du rouleau de formage (16) possède une couverture fixée, résiliente et isolante (32) dépourvue de cavités (30). Les deux films (12, 20) sont pressés et soudés l'un à l'autre au niveau du pincement formé entre le rouleau de pression (24) et le rouleau de formage (16) de manière à former le matériau (36). Le matériau (36) est ensuite refroidi sur le rouleau de refroidissement (38).
PCT/US1988/002494 1987-07-27 1988-07-27 Appareil de production d'un produit a coussin d'air WO1989000919A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US7838587A 1987-07-27 1987-07-27
US078,385 1987-07-27

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WO1989000919A1 true WO1989000919A1 (fr) 1989-02-09

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PCT/US1988/002494 WO1989000919A1 (fr) 1987-07-27 1988-07-27 Appareil de production d'un produit a coussin d'air

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AU (1) AU2312688A (fr)
CA (1) CA1320117C (fr)
WO (1) WO1989000919A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0494661A1 (fr) * 1991-01-10 1992-07-15 W.R. Grace & Co.-Conn. Feuille stratifiée avec coussins d'air, antistatique de façon permanente, et sachet fabriqué de cette feuille
DE4114506A1 (de) * 1991-05-03 1992-11-05 Wilfried Jung Luftkissenfolie, verfahren zu ihrer herstellung und vorrichtung zur durchfuehrung des verfahrens
WO2002022351A1 (fr) * 2000-09-12 2002-03-21 Peter Neils Thomsen Bande continue a compartiments fermes
US6423166B1 (en) * 1999-04-22 2002-07-23 Ebrahim Simhaee Method of making collapsed air cell dunnage suitable for inflation
EP1338413A1 (fr) * 2002-02-25 2003-08-27 Sealed Air Corporation (US) Produit laminé à cuisson d'air ayant une couche barrière de résine de polyester recyclé
WO2004030896A1 (fr) * 2002-08-22 2004-04-15 Sealed Air Corporation (Us) Procede de fabrication d'article de film stratifie comportant des chambres gonflables
US9999546B2 (en) 2014-06-16 2018-06-19 Illinois Tool Works Inc. Protective headwear with airflow
EP3769609B1 (fr) 2020-06-26 2022-07-13 Cooling-Global s.r.o. Conduit d'air pour diffuser de l'air dans une serre
US11812816B2 (en) 2017-05-11 2023-11-14 Illinois Tool Works Inc. Protective headwear with airflow

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US3082925A (en) * 1960-12-05 1963-03-26 Soroban Engineering Inc Vacuum capstans
US3346438A (en) * 1963-09-10 1967-10-10 Sealed Air Corp Method and apparatus for making cushioning and insulating material
US3392081A (en) * 1962-07-19 1968-07-09 Sealed Air Corp Multi-laminate cushioning material
US3440125A (en) * 1964-02-06 1969-04-22 Tetra Pak Ab Device for use in machines for manufacturing plastic foil covered paper
US3655486A (en) * 1969-05-26 1972-04-11 Hagino Kiko Co Ltd Apparatus for producing thermoplastic synthetic resin laminated material having a large number of independent air cells
US3660189A (en) * 1969-04-28 1972-05-02 Constantine T Troy Closed cell structure and methods and apparatus for its manufacture
US4412879A (en) * 1981-11-02 1983-11-01 Ranpak Corp. Cushioning dunnage apparatus and method
US4576669A (en) * 1984-11-09 1986-03-18 Caputo Garry L "On demand" apparatus and method for producing air-cushioning product
US4579516A (en) * 1985-07-15 1986-04-01 Caputo Garry L Forming roller for producing air-cushioning product

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3082925A (en) * 1960-12-05 1963-03-26 Soroban Engineering Inc Vacuum capstans
US3392081A (en) * 1962-07-19 1968-07-09 Sealed Air Corp Multi-laminate cushioning material
US3346438A (en) * 1963-09-10 1967-10-10 Sealed Air Corp Method and apparatus for making cushioning and insulating material
US3440125A (en) * 1964-02-06 1969-04-22 Tetra Pak Ab Device for use in machines for manufacturing plastic foil covered paper
US3660189A (en) * 1969-04-28 1972-05-02 Constantine T Troy Closed cell structure and methods and apparatus for its manufacture
US3655486A (en) * 1969-05-26 1972-04-11 Hagino Kiko Co Ltd Apparatus for producing thermoplastic synthetic resin laminated material having a large number of independent air cells
US4412879A (en) * 1981-11-02 1983-11-01 Ranpak Corp. Cushioning dunnage apparatus and method
US4576669A (en) * 1984-11-09 1986-03-18 Caputo Garry L "On demand" apparatus and method for producing air-cushioning product
US4579516A (en) * 1985-07-15 1986-04-01 Caputo Garry L Forming roller for producing air-cushioning product

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0494661A1 (fr) * 1991-01-10 1992-07-15 W.R. Grace & Co.-Conn. Feuille stratifiée avec coussins d'air, antistatique de façon permanente, et sachet fabriqué de cette feuille
DE4114506A1 (de) * 1991-05-03 1992-11-05 Wilfried Jung Luftkissenfolie, verfahren zu ihrer herstellung und vorrichtung zur durchfuehrung des verfahrens
US6423166B1 (en) * 1999-04-22 2002-07-23 Ebrahim Simhaee Method of making collapsed air cell dunnage suitable for inflation
US7041361B2 (en) 2000-09-12 2006-05-09 Peter Neils Thomsen Web with sealed pockets
WO2002022351A1 (fr) * 2000-09-12 2002-03-21 Peter Neils Thomsen Bande continue a compartiments fermes
EP1338413A1 (fr) * 2002-02-25 2003-08-27 Sealed Air Corporation (US) Produit laminé à cuisson d'air ayant une couche barrière de résine de polyester recyclé
WO2004030896A1 (fr) * 2002-08-22 2004-04-15 Sealed Air Corporation (Us) Procede de fabrication d'article de film stratifie comportant des chambres gonflables
AU2002331667B2 (en) * 2002-08-22 2009-02-05 Sealed Air Corporation (Us) Process for making laminated film article having inflatable chambers
AU2002331667B8 (en) * 2002-08-22 2009-03-05 Sealed Air Corporation (Us) Process for making laminated film article having inflatable chambers
US9999546B2 (en) 2014-06-16 2018-06-19 Illinois Tool Works Inc. Protective headwear with airflow
US11166852B2 (en) 2014-06-16 2021-11-09 Illinois Tool Works Inc. Protective headwear with airflow
US11812816B2 (en) 2017-05-11 2023-11-14 Illinois Tool Works Inc. Protective headwear with airflow
EP3769609B1 (fr) 2020-06-26 2022-07-13 Cooling-Global s.r.o. Conduit d'air pour diffuser de l'air dans une serre

Also Published As

Publication number Publication date
CA1320117C (fr) 1993-07-13
AU2312688A (en) 1989-03-01

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