WO2009071936A2 - Apparatus for manufacturing a packaging item - Google Patents

Apparatus for manufacturing a packaging item Download PDF

Info

Publication number
WO2009071936A2
WO2009071936A2 PCT/GB2008/051125 GB2008051125W WO2009071936A2 WO 2009071936 A2 WO2009071936 A2 WO 2009071936A2 GB 2008051125 W GB2008051125 W GB 2008051125W WO 2009071936 A2 WO2009071936 A2 WO 2009071936A2
Authority
WO
WIPO (PCT)
Prior art keywords
wheel
film
packaging item
layers
sealing means
Prior art date
Application number
PCT/GB2008/051125
Other languages
French (fr)
Other versions
WO2009071936A3 (en
Inventor
Peter Frith
Jeremy Frith
Original Assignee
Peter Frith
Jeremy Frith
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 Peter Frith, Jeremy Frith filed Critical Peter Frith
Publication of WO2009071936A2 publication Critical patent/WO2009071936A2/en
Publication of WO2009071936A3 publication Critical patent/WO2009071936A3/en

Links

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
    • 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
    • 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
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/22—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of both discrete and continuous layers
    • B32B37/223—One or more of the layers being plastic
    • B32B37/226—Laminating sheets, panels or inserts between two continuous plastic layers
    • 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
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • 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
    • 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
    • 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
    • B29C66/004—Preventing sticking together, e.g. of some areas of the parts to be joined
    • B29C66/0042—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined
    • B29C66/0044—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined using a separating sheet, e.g. fixed on the joining tool
    • 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/133—Fin-type joints, the parts to be joined being flexible
    • 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
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • 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
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B29C66/4332—Casing-in, i.e. enclosing an element between two sheets by an outlined seam by folding a sheet over
    • 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
    • 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
    • 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
    • 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
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • 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
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • 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
    • B29C66/83431—Roller, cylinder or drum types; Band or belt types; Ball types rollers, cylinders or drums cooperating with bands or belts
    • 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
    • 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
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • 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
    • B31D5/0078—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including pillow forming and filling with a material other than air or gas
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • 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
    • B32B38/04—Punching, slitting or perforating
    • 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
    • B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38—Packaging materials of special type or form
    • B65D65/46—Applications of disintegrable, dissolvable or edible materials
    • B65D65/466—Bio- or photodegradable packaging materials
    • 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
    • B65D81/03—Wrappers or envelopes with shock-absorbing properties, e.g. bubble films
    • 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
    • B29C65/245—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 the heat transfer being achieved contactless, e.g. by radiation
    • 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
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • 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
    • 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
    • B29C66/73—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • 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
    • B29C66/73—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • 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
    • B29C66/814—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 design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/849—Packaging machines
    • 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
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/953—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the humidity
    • B29C66/9534—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the humidity of the atmosphere, i.e. taking the ambient humidity into account
    • 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
    • B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04—PVOH, i.e. polyvinyl alcohol
    • 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
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B70/00—Making flexible containers, e.g. envelopes or bags
    • B31B70/60—Uniting opposed surfaces or edges; Taping
    • B31B70/64—Uniting opposed surfaces or edges; Taping by applying heat or pressure
    • 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
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B70/00—Making flexible containers, e.g. envelopes or bags
    • B31B70/60—Uniting opposed surfaces or edges; Taping
    • B31B70/64—Uniting opposed surfaces or edges; Taping by applying heat or pressure
    • B31B70/644—Making seals parallel to the direction of movement, i.e. longitudinal sealing
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • 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
    • B32B2329/00—Polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals
    • B32B2329/04—Polyvinylalcohol
    • 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

  • the present invention relates to the field of manufacturing packaging materials, in particular those comprising polymer films.
  • One form of such packaging is a vented cushioned pack which comprises a corrugated fibre board lattice surrounded by a polymer film.
  • the polymer film is preferably water soluble to enhance the biodegradability of the pack.
  • PVOH polyvinyl alcohol
  • Methods currently used on PVOH and other polymers include impulse sealing, cloud technology, thermo forming, vertical form fill and seal, horizontal form fill and seal, chemical sealing and radio frequency sealing.
  • PVOH polyvinyl alcohol
  • it is soluble in water and therefore it lends itself to applications where the material should degrade on contact with water for one reason or another.
  • this affinity with water means that exposing the material to heat as is required for the majority of sealing purposes must be undertaken in a controlled environment where the humidity of the ambient air can be strictly controlled.
  • the temperature of the ambient air can be strictly controlled.
  • any PVOH film must be very carefully stored so that it does not absorb moisture prior to use as any absorbed water, which acts as a plasticizer, will then reduce the tensile strength of the PVOH. This reduction in tensile strength can further complicate any fabrication processes involving the film.
  • the present invention provides apparatus for manufacturing a packaging item comprising two layers of polymeric film, the apparatus comprising: conveyor means for conveying the packaging item through the apparatus; cross-sealing means for forming a bond between the two layers of film at a leading edge and at a trailing edge of the packaging item; cutting means for cleaving one packaging item from the next; and lateral sealing means for forming a bond between the two layers of film at a lateral edge of the packaging item, wherein the lateral sealing means is configured to apply heat and pressure locally as the packaging item is drawn therethrough.
  • the exposure of the film to the potentially damaging heat can be readily controlled so that degradation of the polymeric film can be avoided and a high quality seal can be achieved. If the properties of the film have been affected by exposure to humidity, the film will be more sensitive to any application of heat and the advantages of the present invention become even more relevant.
  • the lateral sealing means may comprise a wheel assembly having a first wheel supported by a framework.
  • the first wheel may be heatable and may comprise a thermally conductive rim.
  • the rim of the first wheel may be a toothed rim, configured to form an intermittent lateral seal between the two layers of film or it may comprise a ridged profile, configured to form a double lateral seal between the two layers of film.
  • the wheel assembly may comprise heating means configured to elevate the temperature of the rim of the wheel.
  • the heating means may comprise a heater embedded within a body of the wheel and be in thermal communication with the rim of the wheel.
  • the heating means may comprise a radiant heater for heating the rim, the radiant heater may be located adjacent the wheel, approximately diametrically opposite a point of contact between the rim of the wheel and the layers of film.
  • the framework may be configured to receive additional mass for increasing downward pressure exerted by the wheel.
  • the two layers of film to be bonded together may be provided by two individual sheets of film and, if so, the wheel assembly of the lateral sealing means may comprise a second wheel spaced laterally from the first wheel.
  • Each wheel may be supported by a respective framework.
  • the cross-sealing means and the cutting means may be provided by a heated platen comprising a knife edge.
  • the packaging item may be a cushioned packaging item having a filler material encapsulated between the two layers of polymeric film.
  • the apparatus may comprise board processing means for processing the filler material and delivering said material to the conveyor means.
  • the conveyor means may comprise a belt for example a silicone belt or a belt comprising a silicone based material.
  • the conveyor means may comprise two cooperating contra-rotating rollers for gripping the packaging item and for driving it through the apparatus.
  • Puncturing means for puncturing at least one of the layers of polymeric film may be provided.
  • the puncturing means may comprise a spiked roller.
  • the apparatus may comprise sensing means for detecting a location of the packaging item within the apparatus.
  • the polymeric film may comprise polyvinyl alcohol.
  • the polymeric film may have a thickness in the range of 10 ⁇ m to 200 ⁇ m, preferably in the range of 20 ⁇ m to 100 ⁇ m, for example in the range of 30 ⁇ m to 40 ⁇ m.
  • Figure 1 illustrates a packaging item
  • Figure 2 illustrates apparatus for manufacturing packaging items such as that illustrated in Figure 1 ;
  • Figure 3 illustrates a lateral sealing assembly used in the apparatus of Figure 2.
  • Figure 1 illustrates a cushioned packaging item 10.
  • the item 10 comprises a corrugated partially shredded fibre board filler material 12 as shown in the detailed insert.
  • This filler material is encapsulated within a polymer film envelope 14.
  • the envelope 14 is preferably formed from two layers of polymer film 16, 18 positioned over the filler material 12 and sealed on each surrounding edge 20, 22, 24, 26.
  • One, or each, layer of film 16, 18 may be provided with perforations to enable air contained within the item 10 to be expelled therefrom.
  • these perforations or otherwise venting means may be provided by generating an imperfect seal at one or more of edges 20, 22, 24, 26.
  • FIG 2 illustrates apparatus for manufacturing a packaging item 10 such as that shown in Figure 1.
  • Apparatus 30 comprises a board processing unit 32 configured to receive one or more standard sheets of corrugated cardboard and form longitudinal perforations or cuts therein in a staggered pattern so that a lattice of cardboard is achieved. The lattice then undergoes deformation within the processing unit 32 such that some of the cardboard is deformed out of its original plane to give a three dimensional board 12 having some resilience in the through thickness direction.
  • the board processing unit 32 has an outlet 36 located adjacent to a first conveyor 38.
  • the number of sheets of cardboard used as filler material is determined by the particular application and the level of cushioning required, in this embodiment, two layers of cardboard are stacked upon each other however, four, six or eight layers are used in some applications when additional cushioning is required.
  • the cardboard used is preferably corrugated cardboard and may be virgin sock or a recycled material.
  • a clamping roller 40 is located above the first conveyor 38.
  • the height of the clamping roller 40 can be adjusted so that any thickness of board or other filler material can be accommodated between the clamping roller 40 and the first conveyor 38.
  • the clamping roller 40 has two positions, in a first position the roller is elevated above the first conveyor 38, a significant gap provided therebetween. In a second position, the clamping roller 40 is lowered towards the first conveyor 38 such that a board 12 or other filler material can be captured between the roller 40 and a belt 42 of the first conveyor 38.
  • the board is clamped with sufficient force that the board 12 is secured in place and friction becomes such that the rotary motion of the clamping roller 40 drives the board along the conveyor 38.
  • Sensing means 44 are located beyond the clamping roller 40 just above the first conveyor 38.
  • Sensing means 44 comprises a beam emitter and a beam detector respectively located at respective sides of the first conveyor 38 and, in combination, being configured to detect any disruption in a beam of light passing therebetween.
  • a first roll of film 46 is located above the first conveyor 38 and a second roll of film 48 is located below the first conveyor 38.
  • Each roll of film extends to a point beyond the first conveyor 38 and is attached to the other roll of film in a manner described hereinafter. Consequently, a wall of film 50 extends vertically beyond the first conveyor 38.
  • Two contra-rotating rollers 52, 54 are located adjacent the wall of film 50.
  • the first roller 52 is located above and spaced from the second roller 54.
  • the second roller 54 is in a fixed position whilst the first roller 52 is adjustable in a vertical plane so that the gap formed between the rollers 52, 54 may be adjusted to accommodate different thicknesses of board 12 or other filler material passing therethrough.
  • Sealing and cutting means 56 are provided beyond the contra-rotating rollers 52, 54.
  • the sealing and cutting means 56 comprises an anvil 58 in combination with a heated platen 60 for receiving one or more layers of film therebetween and applying heat and pressure thereto.
  • the platen 60 may be formed from a hollow c-section channel having a cavity formed therein.
  • a heating element (not shown) may be provided within this cavity in order to elevate the temperature of the material of the platen 60.
  • the lower edge of the platen 60 is configured to represent a knife edge in order to restrict the exposure of the film to the metal of the platen 60.
  • a separate cutter or cutting blade may be affixed to the lower edge of the platen 60.
  • the platen is made from aluminium and may be coated with a non-stick material such as polyfluourotetraethylene [PTFE] eg Teflon ® , or a ceramic coating material.
  • the platen 60 may be made from another thermally conductive material, such as a metal, e.g. stainless steel.
  • the anvil 58 is depicted below the platen 60, however, the platen 60 can be located below the anvil 58 and raised upwards to perform a sealing and cleaving action.
  • a second conveyor 62 is provided adjacent the sealing and cutting means 56.
  • the belt provided on the second conveyor 62 is made from silicone, however, alternative heat retardant materials may be used such as Kevlar.
  • Lateral sealing means 66 are provided above the second conveyor 62.
  • the lateral sealing means is illustrated in greater detail in Figure 3.
  • the lateral sealing means 66 comprises two heat sealing wheels 68, each mounted in a framework assembly 70.
  • Each heat sealing wheel 68 comprises a rim 72 having a tapered cross-section such that a narrow surface contact area 74 is formed at a radial extreme of each respective wheel 68 thereof.
  • the sealing contact area 74 has a width of 3mm but this dimension is determined by the properties of the material to be sealed together with the temperature and the speed of the wheel 68.
  • the wheel 68 is made from metal, in this example aluminium is used however brass or another alloy having good thermal transmission properties could readily be used instead. If a non-thermally conductive material such as a ceramic or composite material were used to form a body of the wheel, a thermally conducting rim is provided.
  • the surface contact area 74 may be coated with a non-stick material such as PTFE.
  • Each heat sealing wheel 68 comprises an electrical heating device mounted in a body of the wheel 68. Electrical contact may be made with the heating device in a conventional manner using a slip ring with bushes. However, a mercury slip ring may be used so that a non-contacting arrangement is achieved resulting in less wear.
  • the means for heating a rim of the wheel 68 may be provided by applying heat externally to the rim e.g. using a radiant heat source.
  • heat would preferably be applied remotely from the location of the polymer film, e.g. diametrically opposite to a contact location between the wheel 68 and the layers of polymer film.
  • the temperature to which the wheels 68 are heated is dependent on the type of film being sealed.
  • a PVOH film is used having a melting point in the range of 180-230°C depending on the moisture content therein, the wheel is heated to a temperature in the range of 120-260°C. If the composition of the film is altered, for example by adding starch or another filler material to the PVOH, the melting point and other properties of the film will be altered.
  • the thickness of the film used in the present embodiment is approximately 30 ⁇ m, however films having a thickness in the range of 20 ⁇ m to 100 ⁇ m may be used for a similar application. For other applications, the thickness of the film may reduce or increase and lie within the range of 10 ⁇ m to 200 ⁇ m.
  • the temperature, pressure and speed of the, or each, wheel are each governed by the composition and configuration (including thickness) of film used in any particular application.
  • the 'dwell time' or period of direct contact between the heated metal and the film is particularly short when using heat sealing wheels 68 rather than a conventional platen.
  • the entire platen must contact the film at the same moment in order to minimise the contact time as far as possible.
  • the accuracy required to achieve this increases the refinement and complexity of the apparatus and therefore the associated cost.
  • the extent of a large platen can lead to non-uniformity in heat delivered by the platen, especially where the surface of the platen wears inconsistently, this non-uniformity results in increased dwell times for the cooler parts of the platen leading to excessive heat being applied by the hotter parts of the platen.
  • the pressure exerted by the heat sealing wheels 68 is governed by the mass of the framework assembly 70. If a greater level of pressure is required then weights can be added to the framework assembly 70 to cause the pressure from the wheels to be increased.
  • the contact surface typically becomes dirty with residue which causes the surface to become irregular. As the platen is lowered, incomplete contact is made between the platen and the polymer film resulting in an uneven pressure and consequently an uneven seal may be achieved.
  • the heating of the polymer is less severe and so less degradation of the polymer occurs, hence the sealing contact area 74 remains clean, an even pressure can be applied and a higher quality seal is achieved.
  • the cross section of the sealing contact area 74 is shown as a flat surface, however, alternatively a convex profile may be provided.
  • a convex profile is of particular use where it is desirable to avoid forming stress concentrators in the seal which may be formed when using a flat surface contact area 74 having edges as illustrated in Figure 3.
  • the cross section of the sealing contact area 74 may be provided with a grooved profile so that a double seal may be achieved.
  • the process board 12 is dispensed from the board processing unit 32 onto the first conveyor 38. Once a leading edge of the board 12 obscures a line of sight of the sensing means 44 the board 12 is effectively detected and a signal is sent from the sensing means to the controller. The controller then instructs the clamping roller 40 to move from the first position to the second position in order to secure the board 12 relative to the belt 42 of the first conveyor 38 by exerting a downward force on the board 17.
  • the board 12 is then driven through the apparatus 30 by the translation of belt 42.
  • the leading edge of the board 12 comes into contact with the wall of film 50 and becomes encapsulated by the film.
  • the film covered board passes between the pair of contra ⁇
  • the partially formed pack passes between the heated platen 60 and the anvil 58 of the sealing and cutting means 56 without coming into contact therewith and on to the second conveyor 62. Edges of the part-formed pack are sandwiched between respective heat sealing wheels 68 of the rotary sealing means 66 and the silicone belt of the second conveyor.
  • the beam detector will detect the light beam emitted by the beam emitter indicating that the pack has passed therethrough.
  • the clamping roller 40 may drop off the end of the filler material or board 12, this displacement being detected by alternative sensing means also indicating that the board 12 has passed.
  • a signal is indicative of the position of the board 12 generated by the sensing means 44 and sent to the controller.
  • the controller permits a certain time period to pass prior to instructing the sealing and cutting means 56 to displace the heated platen 60 towards the anvil 58 thus exposing the polymer film to heat and pressure exerted between the platen 60 and the anvil 58. This application of heat and pressure result in a sealed trailing edge of the package and additionally a seal being formed between the two rolls of film 46, 48 to form a wall of film 50 ready for receiving the next board 12.
  • the pack continues to be driven along the second conveyor 62 so that the rotary sealing means 66 can complete the edge sealing of the pack.
  • toothed wheels 68 may be provided such that intermittent contact is achieved between the heated wheel 68 and the film.
  • venting may be achieved by forming perforations in one of the films. Such perforations can be achieved by incorporating a spiked roller upstream of the wall of film 50, the spiked roller is rotated as the film is drawn from the roll of film, the spikes punching the film as it passes over the spiked roller.
  • the sealing and cutting means 55 is stationary and the conveyors are paused as the sealing and cutting step is performed.
  • the sealing and cutting means 55 may be mounted as a travelling mechanism that describes a 'box' motion if it is desirable to achieve a continuous process.
  • the flexibility of the apparatus is significantly increased.
  • the platen must be changed for one of another size and shape to match the item to be manufactured.
  • the wheels may simply be displaced to accommodate any sized packaging item.
  • a single broad belt is provided on the second conveyor 62 to act in cooperation with the, or each heated wheel 68, however, multiple belts may be provided, one being located beneath each respective heated wheel 68.
  • a conventional platen typically "trims" the item being formed at the point of the seal.
  • additional material located beyond the seal may be retained.
  • This additional material is useful when the cushioned packaging item is to be further processed to form differently configured items such as padded envelopes or pouches.
  • the aforementioned flexibility of the apparatus lends itself to accommodating different sized filler materials or different quantities of additional material to be used for subsequent sealing or forming purposes. If it is desirable to trim the packaging item, as in the conventional apparatus, it is simply necessary to apply a greater amount of heat by increasing the temperature of the rim of the wheel 68.
  • a further significant advantage over the conventional platen type apparatus is provided in that the apparatus of the present invention can be more compact.
  • the size of the conventional apparatus is governed by the size of the platen which requires a large quantity of film to be unfurled from its storage roller prior to sealing undertaking the sealing process.
  • the seal is formed locally as the packaging item is manufactured the extent of film that must be dispensed from the storage roller prior to sealing is minimal. Consequently, the tension in the dispensed film can be readily maintained, which is especially hard with PVOH. Resulting benefits are that drift of the film is avoided or at least minimised and perforations may be formed in the film by providing a spiked roller adjacent to the, or each, storage roller as discussed above.
  • FIG. 4 illustrates apparatus 130 similar to that described above but having an alternative lateral sealing mechanism 166.
  • the lateral sealing mechanism 166 comprises an assembly 170 acting in combination with a second conveyer 162.
  • the assembly 170 comprises a vapour/steam dispenser 172 for dispensing a jet of moist air onto a surface of film passing through the apparatus 130.
  • the temperature of the vapour/steam is preferably between 50 0 C and 120 0 C, more preferably in the range of 55°C to 75°C.
  • the film material then passes between the wheel 168 and the second conveyer 162 such that pressure is applied to the film material and a seal is effected.
  • the lateral seal may be provided by directing a jet of vapour/steam at a local area of the film.
  • the jet may be dispensed from a stationary location as illustrated in Figure 4 to locally heat the film material.
  • the film material then passes between a wheel 168 and a surface of the second conveyer 162 such that pressure is applied to the heated and moistened film material to thereby effect a seal.
  • the wheel assembly could be moved over the film which remains static. In either embodiment relative movement between the wheel assembly and the film to be sealed is effected such that the seal is locally applied and the aforementioned advantages are achieved.
  • the configuration of the wheel 168 can vary in profile as described above to enable alternative types of seal to be achieved.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Containers And Plastic Fillers For Packaging (AREA)
  • Package Closures (AREA)
  • Making Paper Articles (AREA)
  • Basic Packing Technique (AREA)

Abstract

Apparatus for manufacturing a packaging item comprising two layers of polymeric film is provided. The apparatus comprises conveyor means for conveying the packaging item through the apparatus, sealing means for bonding the two layers of film to one another and cutting means for cleaving one packaging item from the next. The sealing means comprises a cross-sealing means configured to forma bond between the two layers of film at a leading edge and at a trailing edge of the packaging itemand lateral sealing means configured to forma bond between the two layers of film at a lateral edge of the packaging item. The lateral sealing means is configured to apply heat and pressure locally to the packaging item as relative movement between the lateral sealing means and the packaging item is effected.

Description

APPARATUS FOR MANUFACTURING A PACKAGING ITEM
The present invention relates to the field of manufacturing packaging materials, in particular those comprising polymer films.
It is desirable to provide packaging materials that are simple to form yet biodegradable in nature when the user has finished with the packaging materials.
One form of such packaging is a vented cushioned pack which comprises a corrugated fibre board lattice surrounded by a polymer film. The polymer film is preferably water soluble to enhance the biodegradability of the pack.
In preference, the polymer used for such an application is polyvinyl alcohol (PVOH). Sealing of PVOH film is inherently difficult. Methods currently used on PVOH and other polymers include impulse sealing, cloud technology, thermo forming, vertical form fill and seal, horizontal form fill and seal, chemical sealing and radio frequency sealing.
One of the characteristics of PVOH is that it is soluble in water and therefore it lends itself to applications where the material should degrade on contact with water for one reason or another. However, this affinity with water means that exposing the material to heat as is required for the majority of sealing purposes must be undertaken in a controlled environment where the humidity of the ambient air can be strictly controlled. In particular, when PVOH is partially hydrolysed the melting point is reduced and decomposition/degradation can occur more readily. Consequently, the dwell time and the sealing pressure used in sealing this material, together with the ambient humidity, are of particular importance. Furthermore, any PVOH film must be very carefully stored so that it does not absorb moisture prior to use as any absorbed water, which acts as a plasticizer, will then reduce the tensile strength of the PVOH. This reduction in tensile strength can further complicate any fabrication processes involving the film.
It is, therefore, desirable to ascertain a way of processing PVOH based or similar films in a robust and reliable manner so that the biodegradability characteristics of the material can be used in packaging whilst adopting a simple manufacturing technique. Reducing the complexity of the manufacturing technique leads to a reduction in cost of manufacture so that the beneficial properties of the material can be fully realised.
According to a first aspect the present invention provides apparatus for manufacturing a packaging item comprising two layers of polymeric film, the apparatus comprising: conveyor means for conveying the packaging item through the apparatus; cross-sealing means for forming a bond between the two layers of film at a leading edge and at a trailing edge of the packaging item; cutting means for cleaving one packaging item from the next; and lateral sealing means for forming a bond between the two layers of film at a lateral edge of the packaging item, wherein the lateral sealing means is configured to apply heat and pressure locally as the packaging item is drawn therethrough.
By providing a local application of heat and pressure to seal the two layers of polymeric film to one another, the exposure of the film to the potentially damaging heat can be readily controlled so that degradation of the polymeric film can be avoided and a high quality seal can be achieved. If the properties of the film have been affected by exposure to humidity, the film will be more sensitive to any application of heat and the advantages of the present invention become even more relevant.
By "local" we mean applying heat and pressure to a small area of the polymeric film at any given time to progressively form a seal along a length of material, rather than forming the entire length of the seal in one step. Such a seal is effected by providing relative movement between the film and the sealing means.
The lateral sealing means may comprise a wheel assembly having a first wheel supported by a framework. The first wheel may be heatable and may comprise a thermally conductive rim. The rim of the first wheel may be a toothed rim, configured to form an intermittent lateral seal between the two layers of film or it may comprise a ridged profile, configured to form a double lateral seal between the two layers of film.
The wheel assembly may comprise heating means configured to elevate the temperature of the rim of the wheel. The heating means may comprise a heater embedded within a body of the wheel and be in thermal communication with the rim of the wheel. Alternatively, the heating means may comprise a radiant heater for heating the rim, the radiant heater may be located adjacent the wheel, approximately diametrically opposite a point of contact between the rim of the wheel and the layers of film.
The framework may be configured to receive additional mass for increasing downward pressure exerted by the wheel. The two layers of film to be bonded together may be provided by two individual sheets of film and, if so, the wheel assembly of the lateral sealing means may comprise a second wheel spaced laterally from the first wheel. Each wheel may be supported by a respective framework.
The cross-sealing means and the cutting means may be provided by a heated platen comprising a knife edge.
The packaging item may be a cushioned packaging item having a filler material encapsulated between the two layers of polymeric film. The apparatus may comprise board processing means for processing the filler material and delivering said material to the conveyor means.
The conveyor means may comprise a belt for example a silicone belt or a belt comprising a silicone based material.
The conveyor means may comprise two cooperating contra-rotating rollers for gripping the packaging item and for driving it through the apparatus.
Puncturing means for puncturing at least one of the layers of polymeric film may be provided. The puncturing means may comprise a spiked roller.
The apparatus may comprise sensing means for detecting a location of the packaging item within the apparatus.
The polymeric film may comprise polyvinyl alcohol. The polymeric film may have a thickness in the range of 10μm to 200μm, preferably in the range of 20μm to 100μm, for example in the range of 30μm to 40μm.
Preferred features of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 illustrates a packaging item;
Figure 2 illustrates apparatus for manufacturing packaging items such as that illustrated in Figure 1 ; and
Figure 3 illustrates a lateral sealing assembly used in the apparatus of Figure 2.
Figure 1 illustrates a cushioned packaging item 10. The item 10 comprises a corrugated partially shredded fibre board filler material 12 as shown in the detailed insert. This filler material is encapsulated within a polymer film envelope 14. The envelope 14 is preferably formed from two layers of polymer film 16, 18 positioned over the filler material 12 and sealed on each surrounding edge 20, 22, 24, 26.
One, or each, layer of film 16, 18 may be provided with perforations to enable air contained within the item 10 to be expelled therefrom. Alternatively, these perforations or otherwise venting means may be provided by generating an imperfect seal at one or more of edges 20, 22, 24, 26.
Figure 2 illustrates apparatus for manufacturing a packaging item 10 such as that shown in Figure 1. Apparatus 30 comprises a board processing unit 32 configured to receive one or more standard sheets of corrugated cardboard and form longitudinal perforations or cuts therein in a staggered pattern so that a lattice of cardboard is achieved. The lattice then undergoes deformation within the processing unit 32 such that some of the cardboard is deformed out of its original plane to give a three dimensional board 12 having some resilience in the through thickness direction. The board processing unit 32 has an outlet 36 located adjacent to a first conveyor 38. The number of sheets of cardboard used as filler material is determined by the particular application and the level of cushioning required, in this embodiment, two layers of cardboard are stacked upon each other however, four, six or eight layers are used in some applications when additional cushioning is required. The cardboard used is preferably corrugated cardboard and may be virgin sock or a recycled material.
A clamping roller 40 is located above the first conveyor 38. The height of the clamping roller 40 can be adjusted so that any thickness of board or other filler material can be accommodated between the clamping roller 40 and the first conveyor 38. The clamping roller 40 has two positions, in a first position the roller is elevated above the first conveyor 38, a significant gap provided therebetween. In a second position, the clamping roller 40 is lowered towards the first conveyor 38 such that a board 12 or other filler material can be captured between the roller 40 and a belt 42 of the first conveyor 38. The board is clamped with sufficient force that the board 12 is secured in place and friction becomes such that the rotary motion of the clamping roller 40 drives the board along the conveyor 38. However, the clamping force provided between the clamping roller 40 and the belt 42 of the first conveyor 38 should not be so great that the board 12 experiences flattening or other deformation. Sensing means 44 are located beyond the clamping roller 40 just above the first conveyor 38. Sensing means 44 comprises a beam emitter and a beam detector respectively located at respective sides of the first conveyor 38 and, in combination, being configured to detect any disruption in a beam of light passing therebetween.
A first roll of film 46 is located above the first conveyor 38 and a second roll of film 48 is located below the first conveyor 38. Each roll of film extends to a point beyond the first conveyor 38 and is attached to the other roll of film in a manner described hereinafter. Consequently, a wall of film 50 extends vertically beyond the first conveyor 38.
Two contra-rotating rollers 52, 54 are located adjacent the wall of film 50. The first roller 52 is located above and spaced from the second roller 54. The second roller 54 is in a fixed position whilst the first roller 52 is adjustable in a vertical plane so that the gap formed between the rollers 52, 54 may be adjusted to accommodate different thicknesses of board 12 or other filler material passing therethrough.
Sealing and cutting means 56 are provided beyond the contra-rotating rollers 52, 54. The sealing and cutting means 56 comprises an anvil 58 in combination with a heated platen 60 for receiving one or more layers of film therebetween and applying heat and pressure thereto.
The platen 60 may be formed from a hollow c-section channel having a cavity formed therein. A heating element (not shown) may be provided within this cavity in order to elevate the temperature of the material of the platen 60. The lower edge of the platen 60 is configured to represent a knife edge in order to restrict the exposure of the film to the metal of the platen 60. Alternatively, a separate cutter or cutting blade may be affixed to the lower edge of the platen 60. In this example the platen is made from aluminium and may be coated with a non-stick material such as polyfluourotetraethylene [PTFE] eg Teflon®, or a ceramic coating material. The platen 60 may be made from another thermally conductive material, such as a metal, e.g. stainless steel. In this embodiment, the anvil 58 is depicted below the platen 60, however, the platen 60 can be located below the anvil 58 and raised upwards to perform a sealing and cleaving action.
A second conveyor 62 is provided adjacent the sealing and cutting means 56. In this example the belt provided on the second conveyor 62 is made from silicone, however, alternative heat retardant materials may be used such as Kevlar.
Lateral sealing means 66 are provided above the second conveyor 62. The lateral sealing means is illustrated in greater detail in Figure 3.
The lateral sealing means 66 comprises two heat sealing wheels 68, each mounted in a framework assembly 70. Each heat sealing wheel 68 comprises a rim 72 having a tapered cross-section such that a narrow surface contact area 74 is formed at a radial extreme of each respective wheel 68 thereof. In this example, the sealing contact area 74 has a width of 3mm but this dimension is determined by the properties of the material to be sealed together with the temperature and the speed of the wheel 68.
In this embodiment, the wheel 68 is made from metal, in this example aluminium is used however brass or another alloy having good thermal transmission properties could readily be used instead. If a non-thermally conductive material such as a ceramic or composite material were used to form a body of the wheel, a thermally conducting rim is provided. The surface contact area 74 may be coated with a non-stick material such as PTFE.
Each heat sealing wheel 68 comprises an electrical heating device mounted in a body of the wheel 68. Electrical contact may be made with the heating device in a conventional manner using a slip ring with bushes. However, a mercury slip ring may be used so that a non-contacting arrangement is achieved resulting in less wear.
In an alternative embodiment, the means for heating a rim of the wheel 68 may be provided by applying heat externally to the rim e.g. using a radiant heat source. In this embodiment heat would preferably be applied remotely from the location of the polymer film, e.g. diametrically opposite to a contact location between the wheel 68 and the layers of polymer film.
The temperature to which the wheels 68 are heated is dependent on the type of film being sealed. In the present embodiment, a PVOH film is used having a melting point in the range of 180-230°C depending on the moisture content therein, the wheel is heated to a temperature in the range of 120-260°C. If the composition of the film is altered, for example by adding starch or another filler material to the PVOH, the melting point and other properties of the film will be altered.
The thickness of the film used in the present embodiment is approximately 30μm, however films having a thickness in the range of 20μm to 100μm may be used for a similar application. For other applications, the thickness of the film may reduce or increase and lie within the range of 10μm to 200μm. The temperature, pressure and speed of the, or each, wheel are each governed by the composition and configuration (including thickness) of film used in any particular application.
The 'dwell time' or period of direct contact between the heated metal and the film is particularly short when using heat sealing wheels 68 rather than a conventional platen. With the conventional platen configuration, the entire platen must contact the film at the same moment in order to minimise the contact time as far as possible. The accuracy required to achieve this increases the refinement and complexity of the apparatus and therefore the associated cost. Furthermore, the extent of a large platen can lead to non-uniformity in heat delivered by the platen, especially where the surface of the platen wears inconsistently, this non-uniformity results in increased dwell times for the cooler parts of the platen leading to excessive heat being applied by the hotter parts of the platen. In using a wheel in combination with a heat resistant belt, heat is applied locally, to a restricted portion of the polymer film and so the dwell time can more easily be controlled. Additionally, near instant cooling/setting of the seal is achieved as the formed seal is rapidly moved away from the heat source through the action of the wheel and the belt.
The pressure exerted by the heat sealing wheels 68 is governed by the mass of the framework assembly 70. If a greater level of pressure is required then weights can be added to the framework assembly 70 to cause the pressure from the wheels to be increased. In a conventional platen, the contact surface typically becomes dirty with residue which causes the surface to become irregular. As the platen is lowered, incomplete contact is made between the platen and the polymer film resulting in an uneven pressure and consequently an uneven seal may be achieved. In using a wheel 68 to implement the seal, the heating of the polymer is less severe and so less degradation of the polymer occurs, hence the sealing contact area 74 remains clean, an even pressure can be applied and a higher quality seal is achieved.
The cross section of the sealing contact area 74 is shown as a flat surface, however, alternatively a convex profile may be provided. A convex profile is of particular use where it is desirable to avoid forming stress concentrators in the seal which may be formed when using a flat surface contact area 74 having edges as illustrated in Figure 3.
In an alternative embodiment, the cross section of the sealing contact area 74 may be provided with a grooved profile so that a double seal may be achieved.
In operation, the process board 12 is dispensed from the board processing unit 32 onto the first conveyor 38. Once a leading edge of the board 12 obscures a line of sight of the sensing means 44 the board 12 is effectively detected and a signal is sent from the sensing means to the controller. The controller then instructs the clamping roller 40 to move from the first position to the second position in order to secure the board 12 relative to the belt 42 of the first conveyor 38 by exerting a downward force on the board 17.
The board 12 is then driven through the apparatus 30 by the translation of belt 42. The leading edge of the board 12 comes into contact with the wall of film 50 and becomes encapsulated by the film. The film covered board passes between the pair of contra¬
i l rotating rollers 52, 54 which serve to grip the part-formed package and drive it further through the apparatus 30.
The partially formed pack passes between the heated platen 60 and the anvil 58 of the sealing and cutting means 56 without coming into contact therewith and on to the second conveyor 62. Edges of the part-formed pack are sandwiched between respective heat sealing wheels 68 of the rotary sealing means 66 and the silicone belt of the second conveyor.
Once a trailing edge of the part-formed pack passes through sensing means 44 the beam detector will detect the light beam emitted by the beam emitter indicating that the pack has passed therethrough. Alternatively, the clamping roller 40 may drop off the end of the filler material or board 12, this displacement being detected by alternative sensing means also indicating that the board 12 has passed. In either case a signal is indicative of the position of the board 12 generated by the sensing means 44 and sent to the controller. After receiving the signal, the controller permits a certain time period to pass prior to instructing the sealing and cutting means 56 to displace the heated platen 60 towards the anvil 58 thus exposing the polymer film to heat and pressure exerted between the platen 60 and the anvil 58. This application of heat and pressure result in a sealed trailing edge of the package and additionally a seal being formed between the two rolls of film 46, 48 to form a wall of film 50 ready for receiving the next board 12.
The pack continues to be driven along the second conveyor 62 so that the rotary sealing means 66 can complete the edge sealing of the pack. If partial sealing is required by the rotary sealing means 66 to enable venting along the edge of the package, toothed wheels 68 may be provided such that intermittent contact is achieved between the heated wheel 68 and the film. Alternatively, venting may be achieved by forming perforations in one of the films. Such perforations can be achieved by incorporating a spiked roller upstream of the wall of film 50, the spiked roller is rotated as the film is drawn from the roll of film, the spikes punching the film as it passes over the spiked roller.
In this embodiment the sealing and cutting means 55 is stationary and the conveyors are paused as the sealing and cutting step is performed. However, the sealing and cutting means 55 may be mounted as a travelling mechanism that describes a 'box' motion if it is desirable to achieve a continuous process.
The embodiments described above are directed towards a cushioned packaging item, however, the apparatus is equally suited to a number of other applications for example manufacture of pre-made bags.
As the apparatus uses heated wheels 68 rather than a conventional heated platen which surrounds the area to be sealed, the flexibility of the apparatus is significantly increased. In apparatus having a conventional platen the platen must be changed for one of another size and shape to match the item to be manufactured. However, in apparatus of the present invention the wheels may simply be displaced to accommodate any sized packaging item. In this embodiment, a single broad belt is provided on the second conveyor 62 to act in cooperation with the, or each heated wheel 68, however, multiple belts may be provided, one being located beneath each respective heated wheel 68.
A conventional platen typically "trims" the item being formed at the point of the seal.
Using the apparatus described herein, additional material located beyond the seal may be retained. This additional material is useful when the cushioned packaging item is to be further processed to form differently configured items such as padded envelopes or pouches. The aforementioned flexibility of the apparatus lends itself to accommodating different sized filler materials or different quantities of additional material to be used for subsequent sealing or forming purposes. If it is desirable to trim the packaging item, as in the conventional apparatus, it is simply necessary to apply a greater amount of heat by increasing the temperature of the rim of the wheel 68.
A further significant advantage over the conventional platen type apparatus is provided in that the apparatus of the present invention can be more compact. The size of the conventional apparatus is governed by the size of the platen which requires a large quantity of film to be unfurled from its storage roller prior to sealing undertaking the sealing process. However in the present invention, since the seal is formed locally as the packaging item is manufactured the extent of film that must be dispensed from the storage roller prior to sealing is minimal. Consequently, the tension in the dispensed film can be readily maintained, which is especially hard with PVOH. Resulting benefits are that drift of the film is avoided or at least minimised and perforations may be formed in the film by providing a spiked roller adjacent to the, or each, storage roller as discussed above. Figure 4 illustrates apparatus 130 similar to that described above but having an alternative lateral sealing mechanism 166. Features that are identical to those described above are not described in detail. The lateral sealing mechanism 166 comprises an assembly 170 acting in combination with a second conveyer 162. The assembly 170 comprises a vapour/steam dispenser 172 for dispensing a jet of moist air onto a surface of film passing through the apparatus 130. The temperature of the vapour/steam is preferably between 500C and 1200C, more preferably in the range of 55°C to 75°C. The film material then passes between the wheel 168 and the second conveyer 162 such that pressure is applied to the film material and a seal is effected.
In an alternative embodiment, the lateral seal may be provided by directing a jet of vapour/steam at a local area of the film. The jet may be dispensed from a stationary location as illustrated in Figure 4 to locally heat the film material. The film material then passes between a wheel 168 and a surface of the second conveyer 162 such that pressure is applied to the heated and moistened film material to thereby effect a seal. Alternatively, the wheel assembly could be moved over the film which remains static. In either embodiment relative movement between the wheel assembly and the film to be sealed is effected such that the seal is locally applied and the aforementioned advantages are achieved.
The configuration of the wheel 168 can vary in profile as described above to enable alternative types of seal to be achieved.

Claims

1. Apparatus for manufacturing a packaging item comprising two layers of polymeric film, the apparatus comprising: conveyor means for conveying the packaging item through the apparatus; cross-sealing means configured to form a bond between the two layers of film at a leading edge and at a trailing edge of the packaging item; cutting means for cleaving one packaging item from the next; and lateral sealing means configured to form a bond between the two layers of film at a lateral edge of the packaging item, wherein the lateral sealing means is configured to apply heat and pressure locally to the packaging item as relative movement between the lateral sealing means and the packaging item is effected.
2. Apparatus according to Claim 1 , configured to enable the packaging item to be drawn through the lateral sealing means.
3. Apparatus according to any preceding claim, wherein the lateral sealing means comprises dispensing means for dispensing a jet of vapour/steam.
4. Apparatus according to Claim 3, wherein the dispensing means is configured to dispense vapour/steam having a temperature in the range of 500C to 1200C.
5. Apparatus according to Claim 4, wherein the dispensing means is configured to dispense vapour having a temperature in the range of 55°C to 75°C.
6. Apparatus according to any preceding claim, wherein the lateral sealing means comprises a wheel assembly having a first wheel supported by a framework, the wheel assembly configured to act in combination with a conveyor belt of the conveyor means.
7. Apparatus according to Claim 6, wherein the first wheel is a heatable wheel.
8. Apparatus according to Claim 7, wherein the first wheel comprises a thermally conductive rim.
9. Apparatus according to any of Claims 6 to 8, wherein the rim of the first wheel is a toothed rim, configured to form an intermittent lateral seal between the two layers of film.
10. Apparatus according to any of Claims 6 to 8, wherein the rim of the first wheel comprises a ridged profile, configured to form a double lateral seal between the two layers of film.
11. Apparatus according to any of Claims 7 to 10, wherein the wheel assembly comprises heating means configured to elevate the temperature of the rim of the wheel.
12. Apparatus according to Claim 11 , wherein the heating means comprises a heater embedded within a body of the wheel and in thermal communication with the rim of the wheel.
13. Apparatus according to Claim 11 , wherein the heating means comprises a radiant heater for heating the rim, the heater being located adjacent the wheel, approximately diametrically opposite a point of interaction between the rim of the wheel and the belt of the conveyor means.
14. Apparatus according to any of Claims 6 to 13, wherein the framework is configured to receive additional mass for increasing downward pressure exerted by the wheel.
15. Apparatus according to any of Claims 6 to 14, wherein the two layers of film to be bonded together are provided by two individual sheets of film and the wheel assembly of the lateral sealing means comprises a second wheel spaced laterally from the first wheel.
16. Apparatus according to Claim 15, wherein each wheel is supported by a respective framework.
17. Apparatus according to any preceding claim, wherein both the cross-sealing means and the cutting means are provided by a heated platen comprising a knife edge.
18. Apparatus according to any preceding claim, wherein the packaging item is a cushioned packaging item having a filler material encapsulated between the two layers of polymeric film.
19. Apparatus according to Claim 18, comprising board processing means for processing the filler material and delivering said material to the conveyor means.
20. Apparatus according to any preceding claim, wherein the conveyor means comprises a belt.
21. Apparatus according to Claim 20, wherein the belt comprises a heat resistant material.
22. Apparatus according to Claim 21 , wherein the heat resistant material comprises silicone.
23. Apparatus according to any preceding claim, wherein the conveyor means comprises two cooperating contra-rotating rollers for gripping the packaging item and for driving it through the apparatus.
24. Apparatus according to any preceding claim, comprising puncturing means for puncturing at least one of the layers of polymeric film.
25. Apparatus according to Claim 24, wherein the puncturing means comprises a spiked roller.
26. Apparatus according to any preceding claim, comprising sensing means for detecting a location of the packaging item within the apparatus.
27. Apparatus according to any preceding claim, wherein the polymeric film comprises polyvinyl alcohol.
28. Apparatus according to any preceding claim, wherein the polymeric film has a thickness in the range of 10μm to 200μm.
29. Apparatus according to Claim 28, wherein the polymeric film has a thickness in the range of 20μm to 100μm.
30. Apparatus according to Claim 29, wherein the polymeric film has a thickness in the range of 30μm to 40μm.
PCT/GB2008/051125 2007-12-05 2008-11-27 Apparatus for manufacturing a packaging item WO2009071936A2 (en)

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US5014496A (en) * 1989-09-15 1991-05-14 Stewart Systems, Inc. Method of and apparatus for continuous bakery product wrapping
DE10134255A1 (en) * 2001-07-18 2003-02-13 Cyklop Gmbh Packaging machine, for film wrapping packets/bundles, has a welding station after the wrapping stage to give a continuous welding action on the projecting side edge of the wrapping film as they are carried past

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Publication number Priority date Publication date Assignee Title
US5014496A (en) * 1989-09-15 1991-05-14 Stewart Systems, Inc. Method of and apparatus for continuous bakery product wrapping
DE8912644U1 (en) * 1989-10-25 1989-12-14 Stiegler GmbH Maschinenfabrik, 7062 Rudersberg Device for continuous welding of seams on bags made of thermoplastic films
DE10134255A1 (en) * 2001-07-18 2003-02-13 Cyklop Gmbh Packaging machine, for film wrapping packets/bundles, has a welding station after the wrapping stage to give a continuous welding action on the projecting side edge of the wrapping film as they are carried past

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103818574A (en) * 2013-08-27 2014-05-28 新疆蓝山屯河型材有限公司 Automatic film sealing device and packaging device for section bars

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GB0723770D0 (en) 2008-01-16
WO2009071936A3 (en) 2009-10-15

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