WO2020227586A1 - Correction de trajet de matériaux en bande gonflables - Google Patents

Correction de trajet de matériaux en bande gonflables Download PDF

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Publication number
WO2020227586A1
WO2020227586A1 PCT/US2020/031985 US2020031985W WO2020227586A1 WO 2020227586 A1 WO2020227586 A1 WO 2020227586A1 US 2020031985 W US2020031985 W US 2020031985W WO 2020227586 A1 WO2020227586 A1 WO 2020227586A1
Authority
WO
WIPO (PCT)
Prior art keywords
web material
idler shaft
channel
nozzle
wedge guide
Prior art date
Application number
PCT/US2020/031985
Other languages
English (en)
Inventor
Garrett P. DYER
Original Assignee
Sealed Air Corporation (Us)
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 Sealed Air Corporation (Us) filed Critical Sealed Air Corporation (Us)
Publication of WO2020227586A1 publication Critical patent/WO2020227586A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D5/00Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
    • B31D5/0039Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
    • B31D5/0073Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including pillow forming
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00Multiple-step processes for making three-dimensional articles
    • B31D2205/0005Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/0017Providing stock material in a particular form
    • B31D2205/0023Providing stock material in a particular form as web from a roll
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31DMAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00Multiple-step processes for making three-dimensional articles
    • B31D2205/0005Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/0047Feeding, guiding or shaping the material

Definitions

  • the present disclosure is in the technical field of path correction of inflatable web materials. More particularly, the present disclosure is directed to systems that feed inflatable web materials in a way that reduces the likelihood of misfeeding and puncturing of the web materials.
  • the outer walls of cushioned mailers are typically formed from protective materials, such as Kraft paper, cardstock, polyethylene- coated paper, other paper-based materials, polyethylene film, or other resilient materials.
  • the inner walls of cushioned mailers are lined with cushioning materials, such as air cellular material (e.g., BUBBLE WRAPTM air cellular material sold by Sealed Air Corporation), foam sheets, or any other cushioning material.
  • the outer walls are typically adhered (e.g., laminated) to the cushioning material when forming the mailers.
  • Inflated cushions, pillows, or other inflated containers are common void fill materials that are either placed loose in a container with an object or wrapped around an object that is then placed in a container.
  • the cushions protect the packaged item by absorbing impacts that may otherwise be fully transmitted to the packaged item during transit, and also restrict movement of the packaged item within the carton to further reduce the likelihood of damage to the item.
  • Another common form of void fill material is paper, such as Kraft paper, that has been folded or crumped into a low-density, three-dimensional pad or wad that is capable of filling void space without adding significant weight to the container.
  • a system is usable for feeding a web material.
  • the web material includes a first channel located proximate a first longitudinal edge of the web material, a second longitudinal edge, and chambers that are in fluid
  • the system includes a supply of the web material, a first nozzle, a second nozzle, an idler shaft, and a tensioning system.
  • the web material in the supply is folded about a longitudinal fold so that the first and second longitudinal edges are located adjacent to each other.
  • the first nozzle is configured such that the first channel can be fed over the first nozzle.
  • the first nozzle is configured to insert gas into the first channel.
  • the idler shaft is positioned such that the web material can be fed from the supply, around a portion of the idler shaft, and to the first nozzle.
  • the tensioning system is configured to introduce tension into the web material between the idler shaft and the nozzle.
  • the tensioning system of the first embodiment includes a belt looped around idler shaft.
  • ends of the belt of the second embodiment are fixedly coupled to a belt tensioner.
  • the belt tensioner is biased so that the belt remains in constant contact with the idler shaft.
  • the system of the third embodiment is configured such that the belt tensioner is rotatably coupled to a surface and the tensioning system includes a biasing member configured to rotationally bias the belt tensioner with respect to the surface.
  • the belt of any of the second to fifth embodiments is looped around the idler shaft at a location where the web material does not pass idler shaft.
  • system of any of the previous embodiments further includes a nip roller positioned with respect to the idler shaft to form a nip
  • the idler shaft and the nip roller are positioned such that the web material can be fed from the supply, through the nip between the idler shaft and the nip roller, and to the first nozzle.
  • the system of the sixth embodiment is configured such that the idler shaft is longer than a transverse width of the web material, the nip roller spans the width of the channels, and the web material can be fed through the nip between idler shaft and the nip roller such that the first and second longitudinal edges pass through the nip between the idler shaft and the nip roller.
  • the idler shaft and the nip roller of the seventh embodiment are arranged to prevent the gas inserted into the first channel by the first nozzle from passing upstream of the nip between the idler shaft and the nip roller.
  • the system of any of the previous embodiments is configured such that the web material further includes a second channel located proximate the second longitudinal edge, the system further includes a second nozzle configured such that the second channel can be fed over the second nozzle, the second nozzle is configured to insert gas into the second channel, the web material can be fed from the supply, around a portion of the idler shaft, and to the first and second nozzles, and the tensioning system is configured to introduce tension into the web material between the idler shaft and the first and second nozzles.
  • a system is usable for feeding a web material.
  • the web material includes a common channel located proximate a first longitudinal edge of the web material and chambers that are in fluid communication with the common channel and extend substantially transversely across the web material.
  • the system includes a supply of the web material, a support structure, a wedge guide, a nozzle, and an idler shaft.
  • the web material in the supply is folded about a longitudinal fold so that the first longitudinal edge and a second longitudinal edge of the web material are located adjacent to each other.
  • the wedge guide is positioned with respect to the support structure to form a channel therebetween.
  • the nozzle is configured such that the common channel can be fed over the nozzle.
  • the nozzle is positioned within the channel between the support structure and the wedge guide, and the nozzle is configured to insert gas into the common channel.
  • the idler shaft positioned such that the web material can be fed from the supply and around a portion of the idler shaft.
  • the wedge guide is positioned such that, after the web material is fed past the idler shaft, the first and second longitudinal edges diverge and the first and second longitudinal edges of the web material pass the wedge guide on different sides of the wedge guide.
  • the wedge guide of the tenth embodiment has a shape that is substantially similar to a parallelogram.
  • the wedge guide of any of the tenth to eleventh embodiments is positioned such that the first longitudinal edge of the web material passes a side of the wedge guide that includes the channel.
  • the nozzle of any of the tenth to twelfth is a thirteenth embodiment, the nozzle of any of the tenth to twelfth
  • embodiments includes one or more outlets oriented downward so that gas exiting the outlets is directed into the common channel toward the chambers of the web material.
  • a width of the channel of any of the tenth to thirteenth embodiments is selected such that the support structure and the wedge guide constrain the web material during inflation of the web material by the nozzle.
  • a distance between the idler shaft and the wedge guide of any of the tenth to fourteenth embodiments is selected to reduce an opportunity for the web material to bow between the idler shaft and the wedge guide.
  • system of any of the tenth to fifteenth embodiments further includes a sealing system configured to seal closed the chambers after inflation of the chambers.
  • embodiment includes two counterrotating rollers, one of which includes a
  • circumferential heating element configured to form a heat seal in the web material as the web material passes through the channel.
  • the support structure and the wedge guide of any of the tenth to seventeenth embodiments are configured to cause the first and second longitudinal edges of the web material to converge after passing the wedge guide.
  • the system of the eighteenth embodiment further includes rollers located downstream of a point at which the first and second longitudinal edges converge after passing the wedge guide.
  • the rollers of the ninetieth embodiment are configured to counterrotate with the web material passing therebetween so that the web material is pulled from the supply, around the idler shaft, and past the wedge guide.
  • the second longitudinal edge of the web material of any of the tenth to twentieth embodiments is not tracked as the second
  • longitudinal edge passes the wedge guide other than tracking by the wedge guide itself.
  • FIGs. 1A, 1 B, and 1 C depict front, cross-sectional side, and back views, respectively, of an embodiment of a web material that has two channels and is in a folded state, in accordance with embodiments disclosed herein;
  • FIGs. 2A and 2B depict top views of instances of an embodiment of a system that shows one example of difficulty feeding the web material shown in Figs. 1A-1 C and maintaining the integrity of the web material;
  • FIGS. 3A, 3B, and 3C depict top, side, and partial perspective views, respectively, of a web feeding system configured to feed a web material without bowing of the web material, in accordance with embodiments disclosed herein;
  • Figs. 4A, 4B, and 4C depict bottom, side, and partial cross-sectional views, respectively, of an embodiment of an automated packaging station configured to feed a web material without bowing of the web material, in accordance with embodiments disclosed herein; and
  • FIGs. 5A and 5B depict top and bottom views, respectively, of a web feeding system configured to feed a web material without bowing of the web material, in accordance with embodiments disclosed herein.
  • inventions of systems that feed inflatable web materials in a way that reduces the likelihood of misfeeding and/or puncturing of the web materials.
  • the misfeeding and/or puncturing of an inflatable web material can be caused based on the reaction of the web material to the gas inserted into the web material during inflation of the web material.
  • embodiments of web material feeding systems are configured to reduce, minimize, or eliminate the amount of bowing in web materials during inflation of the web materials to reduce the likelihood of or eliminate misfeeding and/or puncturing of the inflatable web materials.
  • Web materials can be formed into a pouch for packaging an object.
  • web materials are inflatable air cellular material.
  • air cellular material refers to bubble cushioning material, such as BUBBLE WRAP® air cushioning material sold by Sealed Air Corporation, where a first film or laminate is formed (e.g., thermoformed, embossed, calendared, or otherwise processed) to define a plurality of cavities and a second film or laminate is adhered to the first film or laminate in order to close the cavities. Examples of air cellular materials are shown in U.S. Patent. Nos. 3,142,599, 3,208,898, 3,285,793,
  • an“object” may comprise a single item for packaging or grouping of several distinct items where the grouping is to be in a single package. Further, an object may include an accompanying informational item, such as a packing slip, tracking code, a manifest, an invoice, or printed sheet comprising machine-readable information (e.g., a bar code) for sensing by an object reader (e.g., a bar code scanner).
  • each of the objects includes an object identifier.
  • the object identifier includes one or more of a barcode, a quick response (QR) code, a radio frequency identification (RFID) tag, any other form a machine-readable information, human-readable information, or any combination thereof.
  • a web material includes two longitudinal edges.
  • the chambers are in an uninflated state and the chambers are capable of being inflated.
  • each of the chambers extends substantially transversely across the web material and the pattern of the chambers generally repeats in the longitudinal direction.
  • each of the chambers includes a port that is open and a distal end that is closed.
  • the ports can be located proximate one of the two longitudinal edges and the distal ends located proximate the other of the two longitudinal edges so that the ports extend substantially transversely across the web material.
  • the juxtaposed sheets are sealed between the ports and the distal ends such that each of the chambers has substantially circular cells that are
  • the chambers are capable of being inflated by inserting a gas (e.g., air) through the ports. Once the chambers are inflated, the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers. In some embodiments, a pair of adjacent chambers are offset so that the cells of one of the chambers are aligned with the interconnecting channels of a subsequent one of the chambers.
  • a gas e.g., air
  • the web material can include a common channel that is in fluid communication with each of the chambers.
  • a nozzle can be inserted in the common channel and direct a gas into the common channel.
  • the gas inserted into the common channel can pass through the ports to inflate the chambers.
  • Coupled to the nozzle may be a sealing device configured to close the ports after inflation of the chambers. Examples of web materials with common channels are described in U.S. Patent Application No.
  • the common channel of an inflatable web material can be an“open” channel where the two sheets are not connected to each other.
  • An open channel allows a nozzle to be located in the common channel while the two sheets of the channel are able to pass on either side of the nozzle without cutting the channel.
  • the common channel of an inflatable web material can be a“closed” channel where the two sheets are connected to each other.
  • a nozzle can be inserted into the closed channel.
  • the closed channel may improve inflatability of the chambers because the possibility of the gas to exit a closed channel is significantly lower than with an open channel.
  • a closed channel requires the two sheets to be cut before the sheets can pass on either side of the nozzle.
  • Web materials with two longitudinal closed channels can be inflated and sealed to form pouches.
  • the pouches can be filled with objects and then the pouches can be sealed to form packages. Examples of automated packaging stations capable of forming such web materials into pouches and then in to packages are described in described in U.S. Patent Application No. 62/783,250 and in U.S. Patent Application No. 62/845,354.
  • FIGs. 1A, 1 B, and 1 C are front, cross-sectional side, and back views, respectively, of an embodiment of a web material 200 that has two channels and is in a folded state.
  • the web material 200 includes a first longitudinal edge 202 and a second longitudinal edge 204. Between the first and second longitudinal edges 202 and 204 are two juxtaposed sheets (e.g., sheets of film) that are sealed together to form chambers 206.
  • the chambers 206 are in an uninflated state and the chambers 206 are capable of being inflated.
  • each of the chambers 206 extends substantially transversely across the web material 200 and the pattern of the chambers 206 generally repeats in the longitudinal direction.
  • each of the chambers 206 includes a port 208 that is open and a distal end 210 that is closed.
  • the ports 208 are located proximate the first longitudinal edge 202 and the distal ends 210 are located proximate the second longitudinal edge 204 so that the ports 208 and the distal ends 210 extend substantially transversely across the web material 200.
  • the juxtaposed sheets are sealed between the ports 208 and the distal ends 210 such that each of the chambers 206 has substantially circular cells that are interconnected by channels that are narrower than the widest point of the cells.
  • the chambers 206 are capable of being inflated by inserting a gas (e.g., air) through the ports 208.
  • a gas e.g., air
  • the cells form three-dimensional shapes (sometimes referred to as“bubbles”) along the inflated chambers 206.
  • a pair of adjacent chambers 206 are offset so that the cells of one of the chambers 206 are aligned with the interconnecting channels of a subsequent one of the chambers 206.
  • the web material includes a first channel 212 and a second channel 222.
  • the first channel 212 is located proximate the first longitudinal edge 202 and the second channel 222 is located proximate the second longitudinal edge 204.
  • each of the first and second channels 212 and 222 is a “closed” channel because the two sides of the first channel 212 are connected at the first longitudinal edge 202 and the two sides of the second channel 222 are connected at the second longitudinal edge 204.
  • the first channel 212 forms a loop above the ports 208 and the second channel 222 forms a loop above the distal ends 210.
  • one or both of the first and second channels 212 and 222 can be an“open” channel where the two sides of the channel do not meet at the longitudinal edge.
  • the first channel 212 is in fluid communication with the chambers 206.
  • a nozzle can be inserted in the first channel 212 and direct a gas into the first channel 212.
  • the gas inserted into the first channel 212 can pass through the ports 208 to inflate the chambers 206.
  • the nozzle may remain fixed while located within the first channel 212 and the web material 200 is moved longitudinally such that the nozzle sequentially inflates the chambers 206.
  • Coupled to the nozzle may be a sealing device configured to close (e.g., seal closed) the ports 208 after inflation of the chambers 206.
  • the second channel 222 is not in fluid communication with the chambers 206.
  • a longitudinal seal 220 is located in the web material 200 between the distal ends 210 and the second channel 222.
  • the longitudinal seal 220 deters any passage of gas between the chambers 206 and the second channel 222.
  • the longitudinal seal 220 may be replaced by a port between each of the chambers 206 and the second channel 222.
  • the web material 200 can be folded and formed into a pouch for holding and cushioning an object. An object can be inserted into the pouch and then the pouch can be closed to form a package around the object.
  • the web material 200 is formed from a material that is suitable for shipping the object.
  • the web material 200 may be opaque.
  • the web material 200 is in a folded state where a longitudinal fold 214 has been formed in the web material 200.
  • the web material 200 is C-folded such that the longitudinal fold 214 substantially equidistant from the first and second longitudinal edges 202 and 204.
  • the first and second channels 212 and 222 are located adjacent to each other.
  • the web material 200 is J-folded such that the longitudinal fold 214 is offset from the middle of the web material 200 between the first and second longitudinal edges 202 and 204.
  • the web material 200 can be stored for later use by an automated packaging station.
  • the web material 200 can be wound around a cylindrical core initially to form a supply roll of the web material 200.
  • the longitudinal fold 214 would be on one side of the supply roll and the first and second channels 212 and 222 would be on the other side of the supply roll.
  • the web material 200 may be suitable for supplying an automated packaging station that can inflate and seal the web material 200 and then form the inflated web material 200 into a pouch for packaging an object.
  • the web material 200 in the folded state shown in Figs. 1A to 1 C can be stored in configurations other than a supply roll for later use by an automated packaging station.
  • FIGs. 2A and 2B are top views of instances of an embodiment of a system 10 that shows one example of difficulty feeding the web material 200 and maintaining the integrity of the web material 200.
  • the system 10 includes a supply 12 of the web material 200.
  • the supply 12 is in the form of a roll with the web material 200 wound around a core.
  • the supply 12 is arranged such that the axis of the roll is substantially vertical.
  • the web material 200 is arranged with respect to the axis of the supply 12 so that the longitudinal fold 214 of the web material 200 is on the lower (bottom) side of the supply 12 and the first and second channels 212 and 222 are on the upper (top) side of the supply 12. While on the supply 12, the chambers 206 of the web material 200 are in a non-inflated state such that the web material 200 is in a“flat” condition on the supply 12 and can be wound tightly on the roll.
  • the web material 200 is fed from the supply 12 and around an idler shaft 14.
  • the idler shaft 14 rotates due to friction between the idler shaft 14 and the web material 200 as the web material 200 is fed.
  • the longitudinal edge 202 of the web material 200 is fed to a nozzle 16 and the longitudinal edge 204 of the web material 200 is fed to a nozzle 18.
  • the nozzles 16 and 18 are separated from each other so that the longitudinal edges 202 and 204 separate from each other, causing the longitudinal fold 214 to partially unfold.
  • the idler shaft 14 is positioned so that, regardless of the thickness of the web material 200 on the supply 12, the web material 200 is fed toward the nozzles 16 and 18 from substantially the same location (e.g. , from the edge of the idler shaft 14).
  • Fig. 2A depicts the feeding of the web material 200 before the start of inflation of the channels 212 and 222 by the nozzles 16 and 18. More specifically, Fig. 2A depicts the feeding of the web material 200 from the supply 12, around the idler shaft 14, and toward the nozzles 16 and 18. As depicted, the web material 200 travels in substantially in a direct path from the supply 12 to the idler shaft 14, the longitudinal edge 202 of the web material 200 travels in substantially in a direct path from the idler shaft 14 to the nozzle 16, and the longitudinal edge 204 of the web material 200 travels in substantially in a direct path from the idler shaft 14 to the nozzle 18.
  • Fig. 2B depicts the feeding of the web material 200 after the start of inflation of the channels 212 and 222 by the nozzles 16 and 18.
  • the inflation of the channels 212 and 222 by the nozzles 16 and 18, respectively, can pull additional web material 200 from the supply 12 so that there is slack in the web material 200 between the supply 12 and the nozzles 16 and 18.
  • the gas in the channel 212 has caused the longitudinal edge 202 to bow away from the intended path 22 of the longitudinal edge 202 between the idler shaft 14 and the nozzle 16.
  • the gas in the channel 222 has caused the longitudinal edge 204 to bow away from the intended path 24 of the longitudinal edge 204 between the idler shaft 14 and the nozzle 18.
  • the gas in the channels 212 and 222 has caused the web material 200 to bow away from the intended path 20 of the web material 200 between the supply 12 and the idler shaft 14.
  • the bowing of the web material 200 can cause difficulty feeding the web material 200 and maintaining the integrity of the web material 200.
  • the bowing of the web material 200 before the idler shaft 14 may cause the web material 200 to contact the idler shaft 14 in a non-flat condition, which may cause the web material 200 to track off of its intended position on the idler shaft 14.
  • the bowing of the longitudinal edges 202 and 204 may cause the channels 212 and 222 to fail to feed properly past the nozzles 16 and 18.
  • the bowing of the longitudinal edges 202 and 204 may cause one of the channels 212 and 222 to contact the tip of one of the nozzles 16 and 18, to cause the one of the channels 212 and 222 to be punctured. Described below are embodiments of systems and method of feeding web materials to avoid bowing and the effects thereof.
  • FIGs. 3A, 3B, and 3C are top, side, and partial perspective views, respectively, of a web feeding system 100 configured to feed the web material 200 without the bowing noted above.
  • the system 100 includes an idler shaft 102 and a nip roller 104 that form a nip therebetween for feeding of the web material 200.
  • the web material 200 can be fed from a supply 101 , around the idler shaft 102, through the nip between the idler shaft 102 and the nip roller 104, and toward a nozzle 108 and a nozzle 1 10.
  • the idler shaft 102 extends between a lower surface 120 and an upper surface 122 and the nip roller 104 is coupled to the upper surface 122.
  • the idler shaft 102 is longer than the transverse width of the web material 200 (e.g., the width from the longitudinal edges 202 and 204 to the longitudinal fold 214).
  • the nip roller 104 spans the width of the channels 212 and 222 (e.g., the nip roller 104 extends from above the longitudinal edges 202 and 204 to below the top of the ports 208).
  • the system 100 also includes a tensioning system 130.
  • the tensioning system 130 is configured to introduce tension into the web material 200 between the idler shaft 102 and the nozzles 108 and 1 10.
  • the tensioning system 130 is configured to resist rotational motion of the idler shaft 102 in order to produce tension in the web material 200.
  • the tensioning system 130 includes a belt 132 that is looped around the idler shaft 102.
  • the belt 132 is looped around the idler shaft 102 at a location where the web material 200 does not pass. Both ends of the belt 132 are fixedly coupled to a belt tensioner 134.
  • the belt tensioner 134 is rotatably coupled to the lower surface 120.
  • the tensioning system 130 includes a biasing member 136 configured to bias the belt tensioner 134 so that the belt 132 remains in contact with the idler shaft 102.
  • the biasing member 136 is a torsional spring configured to rotationally bias the belt tensioner 134 with respect to the lower surface 120.
  • the constant contact of the belt 132 with the idler shaft 102 causes tension in the web material 200 between the idler shaft 102 and the nozzles 108 and 1 10.
  • the web feeding system 100 is configured to prevent bowing in the web material 200 during inflation by the nozzles 108 and 1 10.
  • the tensioning system 130 creates tension in the web material 200 between the idler shaft 102 and the nozzles 108 and 1 10.
  • the tension in that portion of the web material 200 prevents bowing in the longitudinal edge 202 between the idler shaft 102 and the nozzle 108 and prevents bowing in the longitudinal edge 204 between the idler shaft 102 and the nozzle 1 10.
  • the combination of the idler shaft 102 and the nip roller 104 also prevents bowing in the web material 200 between the idler shaft 102 and the supply 101.
  • the combination of the idler shaft 102 and the nip roller 104 prevents gas from passing into portions of the channels 212 and 222 that are upstream of the idler shaft 102 and the nip roller 104. I n this way, the inflation of the channels 212 and 222 by the nozzles 108 and 1 10 does not affect the portion of the web material 200 that is upstream of the idler shaft 102 and the nip roller 104.
  • the tensioning system 130 can prevent bowing of the web material 200 during inflation of the channels 212 and 222.
  • FIGs. 4A and 4B Depicted in Figs. 4A and 4B are bottom and side views, respectively, of an embodiment of an automated packaging station 300 configured to feed the web material 200 without the bowing noted above.
  • the portion of the automated packaging station 300 depicted in Figs. 4A and 4B may be merely a portion of the entire automated packaging station 300, such as a portion of any of the automated packaging stations shown in U.S. Patent Application No. 62/783,250, the contents of which are hereby incorporated by reference herein by reference in their entirety.
  • the automated packaging station 300 includes a supply 302 of the web material 200.
  • the supply 302 is in the form of a roll with the web material 200 wound around a core.
  • the supply 302 is arranged such that the axis of the roll is substantially vertical.
  • the web material 200 is arranged with respect to the axis of the supply 302 so that the longitudinal fold 214 of the web material 200 is on the lower (bottom) side of the supply 302 and the first and second channels 212 and 222 are on the upper (top) side of the supply 302.
  • the chambers 206 of the web material 200 are in a non- inflated state such that the web material 200 is in a“flat” condition on the supply 302 and can be wound tightly on the roll.
  • the supply 302 is located on a substantially vertical spindle that is configured to rotate freely such that the web material 200 unwinds from the supply 302 as the web material 200 is pulled from the supply 302.
  • the supply can be powered to actively unwind the web material 200 from the supply 302.
  • the automated packaging station 300 includes a positioning roller 304.
  • the web material 200 can be fed from the supply 302 to the positioning roller 304.
  • the web material 200 may pass from the supply 302 to the positioning roller 304 along a number of different paths 306, depending on the amount of the web material 200 remaining the supply 302.
  • the positioning roller 304 is arranged so that the web material 200 leaves the positioning roller 304 at substantially the same location regardless of which of the paths 306 that the web material 200 passes from the supply 302 to the positioning roller 304.
  • the positioning roller 304 is driven so that it rotates at times when the web material 200 is fed by the positioning roller 304.
  • the positioning roller 304 is an idle roller that rotates in response to contact from the web material 200 as the web material 200 is fed by the positioning roller 304.
  • the automated packaging station 300 includes a first rail 308 and a second rail 310.
  • the first longitudinal edge 202 of the web material 200 is fed toward a leading end 312 of the first rail 308 and the second longitudinal edge 202 of the web material 200 is fed toward a leading end 314 of the second rail 310.
  • leading ends 312 and 314 of the first and second rails 308 and 310 are cantilevered from a support structure 316 of the automated packaging station 300 so that the first channel 212 can be slid over the leading end 312 of the first rail 308 and the second channel 222 can be slid over the leading end 314 of the second rail 310.
  • first and second rails 308 and 310 serve as a track for guiding the web material 200.
  • first and second rails 308 and 310 can also serve as nozzles for introducing gas into the first and second channels 212 and 222.
  • each of the first and second rails 308 and 310 is a hollow tube and the leading ends 312 and 314 of the first and second rails 308 and 310 are closed.
  • the first rail 308 has a trailing end 318 and the second rail 310 has a trailing end 320.
  • Each of the trailing ends 318 and 320 can be coupled to a source of pressurized gas, such as a cylinder of pressurized gas, a gas compressor, and the like.
  • the first rail 308 has outlets 322 and the second rail 310 has outlets 324.
  • the pressurized gas can be introduced into the first and second rails 308 and 310, proceed down the first and second rails 308 and 310, and then exit the first and second rails 308 and 310 through the outlets 322 and 324 into the first and second channels 212 and 222, respectively, of the web material 200.
  • the outlets 322 form a nozzle that is integrated into the first rail 308 and the outlets 324 form a nozzle that is integrated into to the second rail 310.
  • the automated packaging station 300 also includes rollers that are capable of engaging the web material 200 to advance the web material 200.
  • the automated packaging station 300 includes pairs of rollers 326, 328, 330, 332, 334, and 336 that are configured to drive the film.
  • Each of the pairs of rollers 326, 328, 330, 332, 334, and 336 includes two rollers that have concave profiles so that the rollers can be placed around one or both of the first and second rails 308 and 310.
  • An example of concave profiles of the set of rollers 332 around the first rail 308 is shown in a cross-sectional view depicted in Fig. 4C.
  • the automated packaging station 300 also includes a sealing system 338.
  • the sealing system 338 includes rollers 340.
  • the rollers 340 of the sealing system 338 are located below the first rail 308.
  • the rollers 340 form a nip therebetween so that the web material 200 passes through the rollers 340.
  • the rollers 340 are positioned such that a portion of the web material 200 that includes the ports 208 of the chambers 206 passes between the rollers 340.
  • the rollers 340 are configured to form longitudinal seals in the web material 200 through the ports 208 to seal the chambers 206.
  • the chambers 206 can be inflated by the gas that is inserted into the first channel 212 through the outlets 322 and the sealing system 338 can seal the chambers 206 closed in an inflated state.
  • one of the rollers 340 includes a circumferential heating element that contacts the web material 200 as it passes between the rollers 340 to form a heat seal in the web material 200.
  • the sealing system 338 may include drag sealers or any other form of sealer to form the longitudinal seals.
  • the ports 208 may include one-way seals that allow gas to enter the chambers 206 and holds the gas within the chambers 206 without the need of additional heat seals.
  • outlets 322 there are a number of the outlets 322 along the first rail 308 before the sealing system 338. Having a greater number of the outlets 322 can increase dwell time of each of the chambers 206 under one of the outlets 322 as the web material 200 is fed along the first rail 308.
  • the outlets 322 could include a single outlet or a plurality of outlets.
  • the second rail 310 includes outlets 324 through which gas may be directed into the second channel 222. Because the second channel 222 is not in fluid communication with the chambers 206, the gas that passes into the second channel 222 will not inflate the chambers 206 in any way. However, inserting gas into the second channel 222 may cause the second channel 222 to have similar properties with respect to the second rail 310 (e.g., a coefficient of friction) that the first channel 212 has with respect to the first rail 308. In this way, both of the first and second channels 212 and 222 may“act” in similar ways as the web material 200 is being fed along the first and second rails 308 and 310.
  • the second rail 310 e.g., a coefficient of friction
  • the sets of rollers 326 and 328 are located along the first and second rails 308 and 310, respectively, at similar locations in the downstream direction (i.e. , from left to right in the depiction shown in Fig. 4A).
  • the rollers 326 and the rollers 328 are likely to engage the first channel 212 and the second channel 222, respectively, of the web material 200 at close to the same time.
  • the forces imparted by the rollers 326 and 328 on the web material 200 may be substantially symmetrical so that the web material 200 is advanced without any twisting or torqueing of the web material 200.
  • at least some of the outlets 322 are located in the first rail 308 upstream of the rollers 326 and at least some of the outlets 324 are located in the second rail 308 upstream of the rollers 328. This allows the first and second channels 212 and 222 to be at least partially inflated by the time they reach the rollers 326 and 328 so that the first and second channels 212 and 222 are more likely to contact and be driven properly by the rollers 326 and 328.
  • the rollers 340 in the sealing system 338 and the set of rollers 330 are located along the first and second rails 308 and 310, respectively, at similar locations in the downstream direction.
  • the rollers 340 and the rollers 330 are likely to engage the first channel 212 and the second channel 222, respectively, of the web material 200 at close to the same time.
  • the forces imparted by the rollers 340 and 330 on the web material 200 may be substantially symmetrical so that the web material 200 is advanced without any twisting or torqueing of the web material 200.
  • the sets of rollers 332 and 334 are located along the first and second rails 308 and 310, respectively, at similar locations in the downstream direction.
  • the rollers 332 and the rollers 334 are likely to engage the first channel 212 and the second channel 222, respectively, of the web material 200 at close to the same time.
  • the forces imparted by the rollers 332 and 334 on the web material 200 may be substantially symmetrical so that the web material 200 is advanced without any twisting or torqueing of the web material 200.
  • the rollers 336 are located on either side of the first and second rails 308 and 310 at a location where the first and second rails 308 and 310 come together. This arrangement brings the first and second channels 212 and 222 back into proximity with each other so that both of the first and second channels 212 and 222 pass between the rollers 336. As the rollers 336 drive the web material 200, the forces imparted by the rollers 336 on the web material 200 may be substantially
  • the automated packaging station 300 includes a cutting element 342 located above the first rail 308.
  • the cutting element 342 is an angled blade positioned above the first rail 308.
  • the cutting element 342 is positioned so that the cutting element 342 cuts the first channel 212. After the first channel 212 has been cut, the first channel 212 can be fed off of the first rail 308. In some embodiments, the cutting element is located along the first rail 308 between the sealing system 338 and the point at which the first and second rails 308 and 310 come together. This positioning allows the first channel to be removed from the first rail 308 before the first rail 308 comes into contact with the second rail 310. While not visible in Fig. 4B, another cutting element can be located on the second rail 310 and provide the same function with respect to the second channel 222 as the cutting element 342 provides with respect to the first channel 212.
  • first and second rails 308 and 310 can cause the first and second longitudinal edges 202 and 204 of the web material 200 to diverge before and/or during inflation of the chambers 206.
  • the first and second rails 308 and 310 diverge over the range where the outlets 322 and 324 are located.
  • This divergence of the first and second rails 308 and 310 increases the likelihood that the longitudinal fold 214 will unfold sufficiently to permit inflation of the entirety of the chambers 206.
  • the divergence of the first and second rails 308 and 310 can cause the web material to transition from having a V-shaped cross-section to having a U-shaped cross-section.
  • the automated packaging station 300 also includes a guide 344 that can increase the likelihood that the chambers 206 will properly inflate.
  • the guide 344 is in the form of a static guide that is located below the rollers and is configured to contact portions of the web material 200 below the first channel 212 and the second channel 222.
  • the position and shape of the guide 344 may further encourage the longitudinal fold 214 will unfold sufficiently to permit inflation of the entirety of the chambers 206.
  • the guide 344 may have more of a biasing effect on the web material 200 that encourages unfolding of the longitudinal fold 214.
  • the longitudinal sides of the guide 344 have a shape similar to the shape of the first and second rails 308 and 310.
  • the first and second rails 308 and 310 can be shaped based on an expected change in shape of the web material 200 during inflation.
  • the first and second rails 308 and 310 diverge in the areas where the outlets 322 and 324 are located. This divergence may be similar to the expected divergence of the channels 212 and 222 during inflation so that there is no bowing of the web material 200 beyond the paths of the first and second rails 308 and 310.
  • the distance between the positioning roller 304 and the leading ends 312 and 314 of the first and second rails 308 and 310 can be minimized.
  • the distance between the positioning roller 304 and the leading ends 312 and 314 there is minimal opportunity for the web material 200 to bow between the positioning roller 304 and the leading ends 312 and 314.
  • the web material 200 likely will not, prior to reaching the leading ends 312 and 314, bow sufficiently to cause the web material 200 to misfeed on the first and second rails 308 and 310.
  • outlets 322 and 324 are oriented such that gas is inserted into the channels 212 and 222 downward in the direction of the ports 208 and the chambers 206 as opposed being inserted into the channels 212 and 222 in the upstream direction through the channels 212 and 222.
  • the force from the insertion of the gas into the channels 212 and 222 is less likely to cause bowing of the channels 212 and 222.
  • FIGs. 5A and 5B Depicted in Figs. 5A and 5B are top and bottom views, respectively, of a web feeding system 400 configured to feed the web material 200 without the bowing noted above.
  • the web material 200 itself is not depicted in Figs. 5A and 5B; instead, Figs. 5A and 5B depict a web material path 200’, a first longitudinal edge path 202’, and a second longitudinal edge path 204’.
  • the web material path 200’ indicates an expected path of the web material 200 when the first and second longitudinal edges 202 and 204 are in proximity to each other.
  • the first and second longitudinal edge paths 202’ and 204’ indicate expected paths of the first and second longitudinal edges 202 and 204, respectively, when the first and second longitudinal edges 202 and 204 are separated from each other.
  • the web feeding system 400 includes an idler shaft 404.
  • the web material path 200’ proceeds from a supply of the web material 200 (not shown) and around the idler shaft 404.
  • the idler shaft 404 is configured to cause the web material path 200’ to pass downstream from the idler shaft 404 at the same location regardless of an amount of the web material 200 remaining on the supply.
  • the web feeding system 400 also includes support structures 410 and 412. In the depicted embodiment, the idler shaft 404 is located beneath the support structure 410 and is rotatably coupled to the support structure 410.
  • the web feeding system 400 also includes a wedge guide 414.
  • the wedge guide 414 is configured to be located such that the first and second longitudinal edge paths 202’ and 204’ pass on either side of the wedge guide 414.
  • the wedge guide 414 is fixedly coupled to a bottom side of the support structure 410.
  • the wedge guide 414 has a shape that is substantially similar to a parallelogram. In other embodiments, the wedge guide 414 can have other shapes, such as triangular, elliptical, and the like.
  • the wedge guide 414 is positioned with respect to the support structure 412 to form a channel 416 between the wedge guide 414 and the support structure 412.
  • the first longitudinal edge path 202’ passes through the channel 416 between the wedge guide 414 and the support structure 412.
  • the second longitudinal edge path 204’ passes on the other side of the wedge guide 414 from the first longitudinal edge path 202’.
  • the web feeding system 400 includes a nozzle 420 that is located in the channel 416 between the wedge guide 414 and the support structure 412.
  • the nozzle 420 arranged and sized such that the channel 212 can pass over the nozzle 420 and the nozzle 420 can insert gas into the channel 212.
  • the nozzle 420 includes outlets 422 that are oriented downward so that the gas exiting the outlets 422 is directed into the channel 212 toward the chambers 206 of the web material 200.
  • the web feeding system 400 also includes a sealing system 424 configured to seal closed the chambers 206 (e.g., seal closed the ports 208) after inflation of the chambers 206.
  • the sealing system 424 includes two counterrotating rollers, one of which includes a
  • the sealing system 424 may include any other type of sealing element configured to seal closed the chambers 206.
  • the web feeding system 400 is configured to feed the web material along the web material path 200’ and the first and second longitudinal edge paths 202’ and 204’.
  • the first and second longitudinal edge paths 202’ and 204’ converge after the wedge guide 414 so that, when the web material 200 is fed, the first and second longitudinal edges 202 and 204 converge after passing the wedge guide 414.
  • the web feeding system 400 includes rollers 430 located downstream of a point at which the first and second longitudinal edges 202 and 204 converge after passing the wedge guide 414.
  • the rollers 430 are configured to be driven to advance the web material 200 therethrough.
  • the rollers 430 are positioned on the web material path 200’ downstream from the wedge guide 414.
  • the rollers 430 are configured to counterrotate with the web material 200 passing between them so that the web material 200 is pulled from the supply, around the idler shaft 102, and past the wedge guide 414.
  • the idler shaft 404, the wedge guide 414, and the rollers 430 are positions such that no tracking of the web material 200 through the second longitudinal edge path 204’ is required beyond the tracking provided by the wedge guide 414.
  • the web feeding system 400 includes a handle 432 that is coupled to one or both of the rollers in the sealing system 424 and the rollers 430. When the handle 432 is in the position shown in Figs.
  • the rollers in the sealing system 424 and/or the rollers 430 are brought together to form a nip therebetween to tightly hold the web material 200.
  • the handle 432 can be toggled to another position, which causes rollers in the sealing system 424 and/or the rollers 430 to separate in order to remove the web material 200 from the web feeding system 400 and/or initially feed the web material 200 through the web feeding system 400.
  • the web feeding system 400 is arranged to minimize bowing of the web material 200 during inflation of the web material 200.
  • the width of the channel 416 e.g., the distance between the wedge guide 414 and the support structure 412 is minimized. Because the channel 416 has a minimal width, the channel 416 constrains the web material 200 during the inflation of the web material 200 by the nozzle 420. This constraint of the web material 200 in the channel 416 reduces the possibility of any bowing by the web material 200.
  • the distance between the idler shaft 404 and the wedge guide 414 can be minimized.
  • the web material 200 By minimizing the distance between the idler shaft 404 and the wedge guide 414, there is minimal opportunity for the web material 200 to bow between the idler shaft 404 and the wedge guide 414. Thus, the web material 200 likely will not, prior to reaching the wedge guide 414, bow sufficiently to cause the web material 200 to misfeed around the wedge guide 414 and/or along the nozzle 420.

Landscapes

  • Making Paper Articles (AREA)

Abstract

L'invention concerne un système conçu pour alimenter un matériau en bande. Le système comprend une alimentation en matériau en bande, une buse, un arbre intermédiaire et un système de tension. Le matériau en bande dans l'alimentation est plié autour d'un pli longitudinal de telle sorte que des bords longitudinaux du matériau en bande soient situés adjacents l'un à l'autre. La buse est conçue de telle sorte qu'un canal dans l'un des deux bords longitudinaux passe sur la buse. La buse introduit un gaz dans le canal. L'arbre intermédiaire est positionné de telle sorte que le matériau en bande puisse être alimenté à partir de l'alimentation, autour d'une partie de l'arbre intermédiaire, et à la buse. Le système de tension est conçu pour introduire une tension dans le matériau en bande entre l'arbre intermédiaire et la buse.
PCT/US2020/031985 2019-05-09 2020-05-08 Correction de trajet de matériaux en bande gonflables WO2020227586A1 (fr)

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US201962845371P 2019-05-09 2019-05-09
US62/845,371 2019-05-09

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WO2020227586A1 true WO2020227586A1 (fr) 2020-11-12

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US3208898A (en) 1960-03-09 1965-09-28 Sealed Air Corp Apparatus for embossing and laminating materials
US3285793A (en) 1962-07-19 1966-11-15 Sealed Air Corp Method of manufacturing a composite cellular material
US3508992A (en) 1963-12-26 1970-04-28 Sealed Air Corp Method of making laminated material having cells between the layers
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US3660189A (en) 1969-04-28 1972-05-02 Constantine T Troy Closed cell structure and methods and apparatus for its manufacture
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US20150075114A1 (en) 2013-09-18 2015-03-19 Sealed Air Corporation (Us) Machine for Inflating and Sealing an Inflatable Web

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