Patent Grant
10654599
The present subject matter relates to shipping package forming apparatuses, systems, and related methods. In particular, the present subject matter relates to apparatuses and systems that form and aid in forming packages, such as envelopes, around physical items that are being shipped in the packages.
The advent of online purchasing, through such e-commerce website as Amazon or online box stores, such as Walmart online, have created a need for packaging items that are bought by a customer online and then shipped from a distribution center to the customer. These distribution centers must process thousands of items of various sizes.
These items include all of the various that are sold in mass on these e-commerce websites. Such items can include, but are not limited to: jewelry, such as rings, bracelets, necklaces, key rings, etc.; utility items, such as knives of various sizes, tools, etc.; electronics, such as cellular phones, tablet devices, televisions, computers, flash drives or other fobs, etc.; personal care items, such as make-up items, moisturizers and creams, razors, brushes, combs, hairdryers, etc.; apparel, such as dresses, pants, skirts, shorts, shirts, belts, shoes, socks, etc.; home furnishings, such as pillows, sheets, fabric coverings, etc.; toys of various sizes; and books of various sizes.
Due to the varied sizes of the items being processed in these distribution centers, packaging these items can be problematic. Having to separately package items can be labor intensive and time-consuming. Such problems can be partially addressed by separately items to be shipped from a fulfillment center by size. For smaller items, known as “smalls,” such as books, jewelry, apparel etc., envelope forming machines can be used to form envelope packages around the smaller items. These envelope forming machines allow placement of the smaller items between two sheets of material that for the envelope that will form the packing around the smaller item. The envelope forming machine can press and seal the sides and press, seal, and cut the ends to form the package around the smaller item.
While these envelope forming machines can speed up the packaging and shipping process, the current envelope forming machines still have many drawbacks that cost processing time, can raise labor costs, and can hurt the quality of the packages being formed. For example, with current envelope forming machines, even slight variations in height of the items can misalign the sheets of material that can in turn cause weak seals along the sides of the package, and depending on the product used to form the sealed sides, can expose adhesives, sealants, or other tacky substances to exterior of the package. Additionally, due to the mechanisms used to cut and seal the ends of the package, weakened seals are often formed leading to a tendency for one or both ends of the package to open unintentionally, for example, during shipping.
As such, a need exists, for example, for shipping package forming apparatuses and systems that can more effectively form packaging around a wider range of sizes of items to be shipped, while also providing sturdier packages that will not unintentionally open during shipping.
The present subject matter provides package forming apparatuses, systems, and related methods. In particular, the present subject matter relates to apparatuses and systems that form and aid in forming packages, such as envelopes, around physical items that are being shipped in the packages. Methods related to the manufacture and use of the shipping package forming apparatuses and systems as disclosed herein are also provided.
Thus, it is an object of the presently disclosed subject matter to provide package forming apparatuses and systems as well as methods related thereto. While one or more objects of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.
A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
travel path of a product being packaged in an embodiment of a package forming system according to the present subject matter as a package is being formed around the product;
Repeat use of reference characters in the present specification and drawings is intended to represent the seam or analogous features or elements of the present subject matter.
Reference now will be made to the embodiments of the present subject matter, one or more examples of which are set forth below. Each example is provided by way of an explanation of the present subject matter, not as a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as one embodiment can be used on another embodiment to yield still a further embodiment. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present subject matter, which broader aspects are embodied in exemplary constructions.
Although the terms first, second, right, left, front, back, top, bottom, etc. may be used herein to describe various features, elements, components, regions, layers and/or sections, these features, elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one feature, element, component, region, layer or section from another feature, element, component, region, layer or section. Thus, a first feature, element, component, region, layer or section discussed below could be termed a second feature, element, component, region, layer or section without departing from the teachings of the disclosure herein.
Similarly, when a feature or element is being described in the present disclosure as “on” or “over” another feature or element, it is to be understood that the features or elements can either be directly contacting each other or have another feature or element between them, unless expressly stated to the contrary. Thus, these terms are simply describing the relative position of the features or elements to each other and do not necessary mean “on top of” since the relative position above or below depends upon the orientation of the device to the viewer.
Embodiments of the subject matter of the disclosure are described herein with reference to schematic illustrations of embodiments that may be idealized. As such, variations from the shapes and/or positions of features, elements or components within the illustrations as a result of, for example but not limited to, user preferences, manufacturing techniques and/or tolerances are expected. Shapes, sizes and/or positions of features, elements or components illustrated in the figures may also be magnified, minimized, exaggerated, shifted or simplified to facilitate explanation of the subject matter disclosed herein. Thus, the features, elements or components illustrated in the figures are schematic in nature and their shapes and/or positions are not intended to illustrate the precise configuration of the subject matter and are not necessarily intended to limit the scope of the subject matter disclosed herein unless it specifically stated otherwise herein.
It is to be understood that the ranges and limits mentioned herein include all ranges located within the prescribed limits (i.e., subranges). For instance, a range from about 100 to about 200 also includes ranges from 110 to 150, 170 to 190, 153 to 162, and 145.3 to 149.6. Further, a limit of up to about 7 also includes a limit of up to about 5, up to 3, and up to about 4.5, as well as ranges within the limit, such as from about 1 to about 5, and from about 3.2 to about 6.5.
The term “thermoplastic” is used herein to mean any material formed from a polymer which softens and flows when heated; such a polymer may be heated and softened a number of times without suffering any basic alteration in characteristics, provided heating is below the decomposition temperature of the polymer. Examples of thermoplastic polymers include, by way of illustration only, polyolefins, polyesters, polyamides, polyurethanes, acrylic ester polymers and copolymers, polyvinyl chloride, polyvinyl acetate, etc. and copolymers thereof.
“Cohesive” or “cohesives” as used herein means substances that can be applied to a substrate and once cured generally only bond or adhere to itself and not to other non-adhesive materials or substances. Thus, cohesives are substances that, once applied and cured, generally only adhere or bond together to form a seal when a portion of the cohesive come in contact with another portion of the cohesive and generally does not form a seal with other non-adhesive materials or substances with which the cohesive comes into contact. Cohesives, as used herein, are often referred to in the industry as self-seal, cold seal, or cold seal adhesives.
“Adhesive” or “adhesives” as used herein means substances that are used to secure materials, such as substrates, together by binding or adhering to the materials with which they come in contact and resist separation of the materials even under force.
Thus, adhesives are substances that have the ability to secure together non-similar materials or substances by binding and/or adhering to the non-similar materials or substances.
“Pressure-sensitive adhesives” as used herein means adhesives that can have binding or adhesion or enhanced binding or adhesion to non-similar materials or substances when placed under some level of pressure.
“Product” as used herein means one or more physical items that are being packaged on the package forming systems and apparatuses disclosed herein. The term “product” can include, but are not limited to such items as: jewelry, such as rings, bracelets, necklaces, key rings, etc.; utility items, such as knives of various sizes, tools, etc.; electronics, such as cellular phones, tablet devices, televisions, computers, flash drives or other fobs, etc.; personal care items, such as make-up items, moisturizers and creams, razors, brushes, combs, hair dryers, etc.; apparel, such as dresses, pants, skirts, shorts, shirts, belts, shoes, socks, etc.; home furnishings, such as pillows, sheets, fabric coverings, etc.; toys of various sizes; automobile and machinery parts, such as nuts, bolts, bushings, filters, bearings, etc.; tools and hardware, such as screws, nails, screwdrivers, wrenches, pliers, hammers, etc.; and books of various sizes. Thus, the term “product” as used herein can be synonymous and can be used interchangeably with the phrase “one or more products.”
“Sheet material” as used herein means one or mere items or materials are used to create packages and that can be packed or bundled together or processed in some manner to form a unit for transport.
The present subject matter discloses shipping package forming apparatuses,
systems, and related methods. In particular, the present subject mattes discloses apparatuses and systems that form and aid in forming packages, such as envelopes, around physical items that are being shipped in the packages. The presently disclosed shipping package forming apparatuses and systems have features that improve the forming of the package around items to be shipped. For example, in some embodiments, the shipping package forming apparatuses can ensure proper placement of the item relative to the sides of the package and can ensure proper alignment of the sides of the sheet material that form the sides of the package so that the sides of the package form a stronger seal. In some embodiments, the shipping package forming apparatuses can ensure proper sealing of packages across the ends of the packages that form stronger seals at the ends of the formed packages. In some embodiments, a more efficient manner of cutting the sheet material to form the ends of the package can be provided.
Referring to
The top and bottom sheet materials TS, BS can be a variety of sheeting materials depending on the desired parameters of packaging. For example, in some embodiments, the top and bottom sheet materials TS, BS can comprise a suitable paper or other wood pulp product. In some embodiments, the top and bottom sheet materials TS, BS can comprise a paper with a cushioned backing secured thereto to for a cushioned interior of the packaging when the top and bottom sheet materials TS, BS are joined together. In some embodiments, the top and bottom sheet materials TS, BS can comprise a nonwoven fabric such as a spunbonded fabric, a meltblown fabric, or the like. In some embodiments, the top and bottom sheet materials TS, BS can comprise a polymeric film. For example, the top and bottom sheet materials TS, BS can comprise a thermoplastic film in some embodiments. The thermoplastic film can comprise a polyolefin film such as a polypropylene film, for instance. Alternatively, the thermoplastic film can comprise at least one of a polyethylene film, a nylon film, or a polyester film. In some embodiments, the top and bottom sheet materials TS, BS can comprise tri-layered films or ether multi-layered films, such as nine-layered films.
In some embodiments, to join the top and bottom sheet materials TS, BS together, one or both of the top and bottom sheet materials TS, BS can have an adhesive on an interior side, such as pressure sensitive adhesives. In some embodiments, to join the top and bottom sheet materials TS, BS together, each of the top and bottom sheet materials TS, BS can have an interior side that includes cohesive layer. The cohesives that can be used to form the cohesive layer can have different bond strength depending on the desired parameters of the respective packaging sheet.
For many applications, the cohesives that can be used to form the cohesive layer can have a high bond strength. While, depending on the bond strength, cohesives can slightly tack or stick to other non-adhesive material cohesives generally only provide a strong seal to themselves. When the cohesive layer coated on the top and bottom sheet materials TS, BS comes into contact with itself or the other sheet material coated with the same cohesive, the bond can result by applying appropriate pressure to the sheet materials with the contacted cohesives. Thus, through the use of the cohesive layer, the top and bottom sheet materials TS, BS can be bonded to itself or to the other sheet material. In some embodiments, the cohesive can compose a water-based cohesive. In some embodiments, the cohesive can comprise a solvent-based cohesive.
Examples of cohesives that can on used to more or less affect include COSEAL™ and certain ROBOND™ CS, which are supplied by the Dow Chemical Company, and the cohesives used in CRO-NEL® and NYVEL® products, which are produced and sold by Automated Solutions, LLC, to name a few.
Ideally, it is desirable to have the product P1 align with the sets of rollers SR1 and SR2 with the product P1 so that a center line CL (shown in dashed lines) of the product P1 can pass through, or proximal to the aligned nips of the sets of rollers SR1 and SR2. In this manner, the sides of the top and bottom sheet materials TS, BS can more closely align with each other to provide a better seal on the sides of the package. For example, it can be desirable to have the angles formed between the top sheet material TS and the centerline CL and between the bottom sheet material BS and the centerline CL to be the same or substantially similar.
Similarly, a cross seal device, such as a set of rollers CR can be used to seal the ends of the packages E1 and E2 as the respective package is being formed as shown in
As with the formation of the sides of the packages E1 and E2, the length of the top and bottom sheet materials TS, BS between the respective ends of the products P1 and P2 and the respective front end and the back end of the respective sides of the packages E1 and E2 is such that the front end and the back end of the respective sides of the packages E1 and E2 can at least proximately align with center lines CL1 and CL2 of the respective packages E1 and E2. In some embodiments, each of the ends of the packages E1 and E2 can be about an inch thick. With the alignment with the center lines CL1 and CL2 of the respective packages E1 and E2, the closure angles between the centerline and the top and bottom sheet materials TS, BS can be approximately the same. For example, the closure angle β between the top sheet material TS and the centerline CL1 on an end of the package E1 being formed can be equal to or substantially similar to as the closure angle β between the bottom sheet material BS and the centerline CL1 on the end of the package E1 being formed. Similarly, the closure angle ε between the top sheet material TS and the centerline CL1 on either end of the second package E2 can be equal to or substantially the same as the closure angle ε between the bottom sheet material BS and the centerline CL1 on either end of the second package E2. As shown in
For example, referring to
The package forming system 10 can also comprise a cross seal device 20 for forming ends of the package being formed. The cross seal device 20 can be a variety of devices that can form ends of packages being formed. In some embodiments, the cross seal device 20 can comprise sealing bar and knife which extends across the product pathway. The knife can pushed straight downward against the sealing bar under pressure so that the end of the package is both sealed and cut. In some embodiments, as the embodiment shown in
The package forming system 10 can also comprise a support table 30 that can be used to support a portion of the bottom sheet material BS and the product P that is placed upon the bottom sheet material BS and is being conveyed by the bottom sheet material BS. The support table 30 can include some of the guide system 14 of the bottom sheet material BS. The support table 30 can be automatically or semi-automatically adjusted upwardly or downwardly based on the centerline of the product P being packaged to align the centerline of the product P with the nips of the sets of rollers 18 as well as the nip created by the roller 24 and anvil 22 when the rollers are put under pressure.
In some embodiments, the package forming system 10 can comprise a height sensor 40 that can measure the height of the product P being processed. Additionally, the package forming system 10 can comprise in some embodiments, a weight sensor 42, such as a scale to measure the weight of the product or the package that is formed around the product and contains the product. For example, in some embodiments, a weight sensor can be positioned after the packaged is formed. Alternatively, the package that is formed around and that contains the product can be weighted in a later process. Further, in some embodiments, the package forming system 10 can include one or more sensors 44 that can measure distances related to the product P. In some embodiments, the sensors 44 can comprise length sensors that are used to measure the length of a product. In some embodiments, instead of measuring the length of the product, one or more sensors 44, such as photo eyes, can be used to measure the presence of a product on the pathway and can also measure the distance from a start position once the product is placed on the pathway to a leading edge of the product once the bottom sheet material and product are moved forward. This measurement by sensors 44 can be sent to the controller 50 and can be used to determine the amount of top and bottom sheet materials TS, BS needed to form the rear portion of the package and the amount of adjustment for the table 30 in some embodiments.
As another example, in some embodiments, a weigh station 45 can be provided on which a product P3 to be packaged can be placed before being placed on the conveying bottom sheet material BS on the support table 30. The weigh station 45 can include the scale 42 for measuring the weight of the product to be shipped. Above the scale 42, the height sensor 40 can be placed to measure the height of the product P3 as the product P3 is being weighed.
In embodiments that include a sensor 44, the sensor 44 can operate as a length sensor and can be placed along the pathway of product within the package forming system 10 as the bottom sheet material BS moves the product P along the pathway. In some embodiments, the sensor 44 can be used to measure other distances beside the length of the product P. For example, in some embodiments, the sensor 44 can be secured to the support table 30 with guide rollers/tensioning rollers secured to the table 30 that guide the bottom sheet material BS around the sensor 44 in such a manner that the sensor 44 has an unobstructed view of the product P as it passes above the length sensor 44 while, at the same time, not interfering with the ability of the bottom sheet material BS to convey the product P within the package forming system 10.
The package forming system 10 can further comprise a controller 50 that can be in communication with drive system (not shown) that can power the package forming system 10 to control the operation of the package forming system 10. Further, for embodiments that employ one or more height, weight, and/or length sensors, such as sensors 40, 42, and 44, the controller 50 can be in communication with one or more of such sensors 40, 42, 44. The controller 50 can also be in communication with the driver system (not shown) that can be used to adjust the support table 30 upwardly or downwardly. The controller 50 can comprise any capable processing unit, such as a programmable logic controller (“PLC”), a desktop computer, a laptop computer, a mini computer, or the like, including combinations thereof. The controller 50 can process the information provided by the sensors mentioned above as well as other sensors and information that the controller 50 can use to effectively operate the package forming system 10. For example, in some embodiments, one or more sensors 44, such as photo eyes, can be provided that can be used to measure the presence of a product on the pathway and can also measure the distance from a start position once the product is placed on the pathway to the leading edge of the product once the bottom sheet material and product are moved forward. This measurement by sensor 44 can be sent to the controller 50 and can be used to determine the amount of adjustment for the table 30 in some embodiments.
Regarding the adjustment of the table 30, the controller 50 can obtain and process information from the sensors, such as height sensor 40 or distance measurements from the sensor 44, to determine whether the table 30 should be moved upward or downward to position the table 30 such that the centerline of the product aligns property with the nips of the set of side rollers 18 and the roller 24 and the anvil 22. The controller 50 can then communicate with a drive system (not shown) that moves the table 30 up and down to move the table 30 to the desired position at the appropriate time once the product that was measured is placed on the bottom sheet material BS and the table 30.
Instead of using a height sensor and/or a length sensor, some embodiments can employ one or more sensors 44, such as photo eyes, that measure the distance the product moves after placement of the product by an operator on the bottom sheet material BS along the pathway of the package forming system 10. The controller 50 can use this measured distance to determine the length of the top and bottom sheet material TS and BS at the rear of the package and to determine the amount of adjustment that is needed for the table 30 to produce the package.
As described above, when packaging a product with the package forming system 10, it is desirable to have the seal on the side of the package in the center of the package top to bottom. This makes the top and bottom sheet materials TS and BS the same width with both side edges equal. One method for determining the height or thickness of the product to be packaged is for an operator to examine the package and estimate its thickness. The adjustable table 30 can have a placement gate attached, as explained in more detail below, and one or more laser guides LS can project one or more laser lines onto the bottom sheet material BS on the table 30. For example, the laser guide LS can project three (3) laser lines in front of the placement gate. The distance between the laser lines and the between the forward most laser line and the placement gate can comprise the same distance or different distances. In some embodiments, these distances can be permanently set. In some embodiments, these distances can be varied depending on the types of products being packaged. For example, in some embodiments, these three lines can each be about one (1) inch apart and the first line closest to the placement gate can be about one (1) inch from the placement gate. The operator places the material to be packaged so that its front edge is located at the approximate thickness from the gate. The laser lines being about one (1) inch apart gives the operator an opportunity to place the products to be packaged in the appropriate place. Additionally, there can be a laser line projected down the center of the table 30 to assist the operator in placing the material in the middle of the table 30. The operator can then press a start button in communication with the controller 50 and the product is advanced on the bottom sheet material BS along the pathway of the package forming system 10. The distance the conveying bottom sheet material BS moves before the product to be packaged encounters the sensor 44, such as the view path of photo eyes, determines the height or thickness of the package estimated by the operator and the table can be automatically adjusted so that the center of the package is on the center of the nip rollers 18 that seal the side of the package.
The distance between the sensor 44 and the cross seal device 20 that separate one package from the next package is a fixed distance that tells the controller 50 when to stop and cut the package in question. As the product continues to advance through the package forming system 10, the sensor 44 can identify the back edge of the package. To get the correct amount of top and bottom sheet materials TS, BS for the package to be formed, the controller 50 adds to the back of the package the same length of bottom sheet material BS as measured from the front of the product after the operator places it on the bottom sheet material BS along the pathway of the package forming system 10 to the position where the sensor 44 takes the reading of the front of the product. This represents the cut line for the back of the package and the front of the next product being packaged.
Also based on the measurement of the table 30 moves up and down to the center line of each of the products being packaged just before each package is about to advance through the side seal nip rollers. Using this method, the controller 50 does not need the length of the product to determine the length of material needed for the package but only the leading and trailing edges of the package.
Referring to
The package forming system 100 can also comprise a frame 106 for supporting the sheet material guide systems 102, 104 and other components of the package forming system 100, including the adjustable support table 110. The frame 106 can comprise outer frame side panels 106A, 106B as well as a plurality of legs 106C that can be directly or indirectly secured to the side panels 106A, 106B. In some embodiments, the frame 106 can also comprise one or more safety guards 106D that can cover components of the package forming system 100 to protect the respective components of the package forming system 100 and reduce the possibility of injury to an operator of the package forming system 100.
The top and bottom sheet material guide systems 102 and 104 can each comprise one or more tension rollers and/or drive rollers for providing the top and bottom sheet materials TS, BS under tension. For example, a roll TS1 of the top sheet material TS can be installed into the top sheet material guide system 102 and the top sheet material TS can be properly placed around the tension rollers and/or between the driver rollers. Similarly, a roll BS1 of the bottom sheet material BS can be installed into the bottom sheet material guide system 104 and the bottom sheet material BS can be properly placed around the tension rollers and/or between the driver rollers as described further below. In some embodiments, the nip rollers 108 can operate as driver rollers for the top and bottom sheet material guide systems 102 and 104 and can pull the top and bottom sheet material TS, BS along the product pathway as explained further below. Other drive rollers (not shown) may be used in additionally or alternatively.
In particular in some embodiments as shown in
The sides of the top and bottom sheet materials TS, BS can be secured between the nips of the two sets of rollers 108 (of which only one set is shown in
The adjustable support table 110 can be movably secured to the frame 106 to allow the adjustable support table 110 to be moved upwardly and downwardly to facilitate accommodation of a wide variety of different sized products that can vary in height and length. The adjustable support table 110 can be secured to the frame 106 in a variety of difference manners and can have difference adjustment mechanisms to allow for movement of the adjustable support table 110 upwardly and downwardly. In some embodiments, as shown in
In the embodiment shown in
The placement gate 112 can have one or more laser guides (not shown) attached thereto. The laser guides can project a laser liner downward on the bottom sheet material BS in the pathway PA to identity where to place the product to be packaged. For example, placement gate 112 can have laser guides attached thereto that provide lateral and longitudinal laser guide lines that provide a centerline and a forward placement lateral line for placement of the product on the bottom sheet material BS.
The table top 114 and inner side panels 118A, 118B can be moved upwardly or downwardly in different manners and by different configurations and mechanisms. In some embodiments, as shown in
In some embodiments, the cam plates 126A, 126B, for example, can have one or more cam slots 126A, 126B therein and one or more cam members, such as cam rollers 121, that extend outward from an outer side of the cam plates 126A, 126B. Similarly, the inner panels 118A, 118B can have one or more cam members, such as cam rollers 123B, that extend inwardly from an inners side of the inner side panels 118A, 118B and one or more cam members, such as cam rollers 123A that extend outwardly from an outer side of the inner side panels 118A, 118B. Additionally, the outer side panels 120A, 120B can have one or more cam slots 127A, 127B and 129A, 129B therein.
In particular in the embodiment shown in
The cam rollers 121 extending outward from each of the cam plates 126A, 126B extend into the horizontal cam slots 127A, 127B so that as the cam plates 126A, 126B are moved, the horizontal cam slots 127A, 127B ensure this movement is a horizontal movement. As the cam plates 126A, 126B move back and forth in a linear horizontal movement, the cam members 123B extending inward from the inner side panels 118A, 118B ride up and down the angled slots 128A, 128B in the cam plates 126A, 126B. Further, as the cam members 123B extending inward from the inner side panels 118A, 118B ride up and down the angled slots 128A, 128B in the cam plates 126A, 126B, the cam members 123A extending outward from the inner side panels 118A, 118B that engage the generally vertical slots in the outer side panels 120A, 120B direct the movement of the table top 114 and inner side panels 118A, 118B in a generally upward direction or downward direction.
To move the cam plates 126A, 126B, for example, as shown in
In particular, the cylinders 125 can be secured to a cross bar 122 that is secured to the cam plates 126A, 126B on a first end and to a cross bar 124 that is secured to the outer side panels 120A, 120B or the outer frame side panels 106A, 106B on a second end. By the cross bar 124 being attached to the outer frame side panels 106A, 106B or to the outer side panels 120A, 120B, which are held stationary by being secured to the outer frame side panels 106A, 106B, the second end of the cylinders 125 are held stationary while the first end of the cylinders 125 secured to the cross bar 122 attached to the cam plates 126A, 126B moves with the cam plates 126A, 126B as the cylinders 125 are activated. The cam plates 126A, 126B can have cross bar grooves, or slots 124A in which the cross bar 124, which is attached to the outer side panels 120A, 120B of the table 110, can reside. As the cylinders 125 move the cam plates 126A, 126B, the cam plates 126A, 126B can slide over the cross bar 124 within the cross bar grooves 124A.
Thus, as the cylinders 125 push the cross bar 122 and the cam plates 126A, 126B attached thereto in one direction and as the cam plates 126A, 126B slide over the cross bar 124 within the cross bar grooves 124A, the cam rollers 121 extending outward from the cam plates 126A, 126B slide horizontally within the horizontal slots 127A, 127B in the outer side panels 120A, 120B while the cam rollers 123B extending inward from the inner side panels 118A, 118B slide downward in the angled slots 128A, 128B and the cam rollers 123A extending outward from the inner side panels 118A, 118B move downwardly within the generally vertical slots in the outer side panels 120A, 120B with the table top 114 and inner side panels 118A, 118B moving downward.
Conversely, as the cylinders 125 pull the cross bar 122 and the cam plates 126A, 126B in the opposite direction, the cam rollers 121 extending outward from the cam plates 126A, 126B slide horizontally within the horizontal slots 127A, 127B in the outer side panels 120A, 120B while the cam rollers 123B extending inward from the inner side panels 118A, 118B slide upward in the angled slots 128A, 128B and the cam rollers 123A extending outward from the inner side panels 118A, 118B move upwardly within the generally vertical slots in the outer side panels 120A, 120B with the table top 114 and inner side panels 118A, 118B moving upward.
As the table top 114 and inner side panels 118A, 118B move upward and downward, the tension rollers 116 attached to the inner side panels 118A, 118B can move upward and downward with the inner side panels 118A, 118B. Further, the outer side panel panels 120A, 120B can comprise tension rollers 117A, 117B secured between the outer inner side panels. Thereby, the tension rollers attached to the inner side panels can move upward and downward with the inner side panels as the table top and inner side panels move upward and downward while the tension rollers attached to the outer side panels remain stationary with the outer side panels as the table top and inner side panels move upward and downward. Such an arrangement of moveable and stationary tension rollers (both sets of tension rollers being capable of rotating about a respective axis) can aid the respective cam members and cam slots in the cam plates, the moveable inner side panels and the outer side panels in maintaining the tension in the bottom sheet material BS without causing a pulling displacement of the sheet material when the table 110 moves upward and a bunching of excess sheet material as the table 110 moves downward.
To maintain the tension in the bottom sheet material BS without causing a pulling displacement of the sheet material when the table 110 moves upward and a bunching of excess sheet material as the table 110 moves downward, the translation of the lateral movements of the cam plates 126A, 126B to the upward and downward movement of the table 110 can be such that the upward and downward movement of the table 110 is at a slight angle off perpendicular. Thus, the cam slots in the outer side panels 120A, 120B can extend vertically at a slight angle off perpendicular. For example, in some embodiments, the cam slots in the outer side panels 120A, 120B can extend vertically at an angle of between about 1° and about 5° off perpendicular. In some embodiments, the cam slots in the outer side panels 120A, 120B can extend vertically at an angle of between about 2° off perpendicular. Thus, in some embodiments, the upward and downward movement of the table 110 can be at an angle of between about 1° and about 5° off perpendicular. In some embodiments, the upward and downward movement of the table 110 can be at an angle of between about 2° off perpendicular. Additionally, some of the tension rollers proximate to the location where the top and bottom sheet materials TS, BS enter between the nip rollers 108 on either side of the top and bottom sheet materials TS, BS can be stationary relative to the table to maintain the proper tensioning in the bottom sheet material BS. The inner side panels 118A, 118B can have angle slots formed therein to accommodate these stationary tension rollers.
Additionally, horizontal slots can be provided in the outer side panels 120A, 120B of the table 110 that can be engaged by outward extending members of the cam plates 126A, 126B. As the cam plates 126A, 126B are moved back and forth, the outward extending members on the cam plates 126A, 126B move within the horizontal slots in the outer side panels 120A, 120B of the table 110 to keep the movement of the cam plates 126A, 126B in a horizontal directional. Thereby, the movement of the cam plates 126A, 126B can be limited to horizontal movement.
For example, as shown in
To aid in ensuring that the bottom sheet material BS does not improperly pull a product being packaged forward or create undesirable slack in the bottom sheet material BS, the package forming system 100 and bottom sheet material guide system 104 can include tension rollers 117A, 117B that are rotatably secured to, for example, the outer side panels 120A, 120B or the outer frame side panels 106A, 106B. In some embodiments as some in
As shown in
Regarding the adjustment of the table 110, the controller 150 can obtain and process information from the sensors, such as a height sensor 162 in some embodiments or one or more sensors 164 that can be used to measurement s distance representative of the length of a bottom sheet material on which the product is placed from a measuring point where the package being formed is to begin to a leading edge LE of the product P, to determine whether the table 110 should be moved upward or downward as described above to position the table 110 such that the centerline of the product aligns properly with the nips of the set of side rollers 108 and the center line of the cross seal device 130. The controller 150 can then communicate with a drive system (not shown) that moves the table 110 up and down to move the table 110 to the desired position at the appropriate time once the product that was measured is placed on the bottom sheet material BS and the table 110.
In some embodiments as shown in
As outlined above, the packaging forming system can operate under a variety of different methods as outlined above. For example, a method of moving a table top of an adjustable table in a packaging forming system can be provided that includes various steps. For instance, the method can comprise providing an adjustable table for use in a packaging forming system. The adjustable table can comprise outer side panels and moveable inner side panels that are moveably connected to the outer side panels. The outer side panels are held stationary relative to the moveable inner side panels. The adjustable table can also comprise a table top secured to the moveable inner side panels. The table top and the inner side panels are configured to move upwardly or downwardly relative to the outer side panels. The method can further comprise moving the moveable inner side panels relative to the outer side panels to move the table top upwardly or downwardly relative to the outer side panels.
In some embodiments of the method, the adjustable table can comprise cam plates movably connected to the moveable inner side panels and the outer side panels. In such embodiments of the method, the step of moving the moveable inner side panels relative to the outer side panels can comprise moving the cam plates the cam plates in a linear horizontal movements to generate a generally upward and downward movement of the table top. In some embodiments of the method, the method also comprises engaging two cam rollers protruding outward from the cam plate from a portion positioned below the inner side panels with horizontal slots in the respective outer side panels so that, during movement of the cam plate, the cam plates are moved in a horizontal movement.
In some embodiments of the method, the method also comprises engaging two angled slots in the cam plate with respective cam rollers that extend inwardly from the respective inner side panels. In such embodiments of the method, the step of moving the moveable inner side panels relative to the outer side panels can comprise moving the cam plate back and forth in a linear horizontal movement so that the cam members extending inward from the inner side panels ride up and down the angled slots in the cam plates.
In some embodiments of the method, each of the inner side panels can comprise two cam rollers that extend outwardly toward the respective outer side panels. The outward extending cam rollers of each of the inner side panels can extend into corresponding cam slots in the outer side panels that extend in a generally vertical direction. In such embodiments of the method, the step of moving the moveable inner side panels relative to the outer side panels can comprise linearly moving the cam plate so that the cam rollers extending inward from the inner side panels ride up or down the angled slots in the cam plates, while the cam members extending outward from the inner side panels that engage the generally vertical slots in the outer side panels direct the movement of the table top and the inner side panels in a generally upward direction or downward direction.
In some embodiments, the table can be constructed with cam plates operated by four (4) air cylinders. The different cylinders can raise and lower the table using the cam plate by varying amounts of distance as desired and designed. For example, a first air cylinder can raise the table about an eighth (⅛) of an inch, a second can raise the conveyor about a quarter (¼) of an inch, the third cylinder can move the table up about a half (½) of an inch, while a fourth cylinder will can raise the table up about one (1) inch. By using these cylinders, the table can move up or down from 0 inches to about 1⅞ inches.
These and other modifications and variations to the present subject matter may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present subject matter, which is more particularly set forth herein above and any appending claims. In addition, it should be understood the aspects of the various embodiments may be interchanged either in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the present subject matter.
The presently disclosed subject matter claims the benefit of U.S. Provisional Patent Application Ser. No. 62/378,432, filed Aug. 23, 2016, the disclosure of which is incorporated herein by reference in its entirety. U.S. patent application Ser. No. 15/684,887, filed Aug. 23, 2017, is also incorporated herein by reference in its entirety.
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