Information
-
Patent Grant
-
6640520
-
Patent Number
6,640,520
-
Date Filed
Monday, October 22, 200122 years ago
-
Date Issued
Tuesday, November 4, 200320 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Kim; Eugene
- Harmon; Christopher R
Agents
- Wood, Herron & Evans, L.L.P.
-
CPC
-
US Classifications
Field of Search
US
- 053 430
- 053 118
- 053 114
- 242 5753
- 242 5716
- 242 571
-
International Classifications
-
Abstract
An apparatus and method for roll packing a variety of compressible materials including a radially collapsible mandrel for easy removal of the roll packed material without tearing or telescoping of the material. The apparatus further includes an adjustable compression roller for setting the amount of compression in the rolled material and a roll handling device that facilitates removal of finished rolls from the apparatus. In one embodiment of the invention, a packing material dispenser supplies packing material to the in-fed compressible material as it is wound upon the mandrel.
Description
FIELD OF THE INVENTION
This invention relates to the packaging of compressible materials such as foam and spring assemblies used in the manufacture of mattresses and the like, and is more particularly directed to an apparatus for packaging such compressible materials into a roll.
BACKGROUND OF THE INVENTION
Conventional packaging and transportation of compressible materials such as finished mattresses, as well as foam or spring assemblies used in the manufacture of mattress products, generally involves handling of the materials in an uncompressed state. As such, the shipping and storage of the materials requires much more space than would be required if the materials were provided in a compressed state. To improve the efficiency of shipping and storage, foam mattress cores have been packaged in a compressed state by flattening the foam and sealing it in an evacuated bag. See, for example, U.S. Pat. No. 4,711,067 to Magni. This method of packaging foam cores, however, is not useful in packaging spring assemblies. In addition, storage and transportation efficiencies of the foam could be further improved by packaging the flattened cores into a tight roll.
Roll packing generally involves winding-up a desired material to form a roll and then securing the roll to prevent uncoiling of the roll during handling. In the case of compressible materials such as mattresses and foam or spring cores, it is often desired to compress the materials during the roll packing process to obtain a more dense and compact roll. Various devices have been used to achieve compression of roll packed materials. U.S. Pat. No. 3,927,504 to Forrister discloses an apparatus for rolling resilient foamed sheet material without the use of a mandrel. This machine is not useful for packaging spring assemblies and does not have the capability to package multiple units of a compressible material into a large roll. The device further does not provide for packaging a compressible material with a barrier layer between successive turns of the roll, which barrier layer is desirable to prevent adhesion between successive layers of foam.
Some roll packing systems further include a mandrel for facilitating the winding of the material. For example, U.S. Pat. No. 2,114,008 to Wunderlich discloses a spring packing machine having a radially collapsible arbor for use in roll packing spring assemblies. A barrier layer between successive turns of the roll keeps the spring assemblies separate and permits easy removal of a single assembly from the roll. However, this machine is not useful for roll packing foam material due to the presence of a pressure bar
50
, between belt
15
and the collapsible arbor, which would tend to snag a compressed foam as it passed beneath. The disclosed machine also has other drawbacks. For example, to remove a finished roll, the arbor must be removed from the machine and collars must be adjusted to collapse the arbor so that the roll can be taken off the arbor. The arbor must then be replaced in the machine before another roll can be formed. Operation of the machine is thus very labor intensive and ergonomically inefficient.
There is thus a need for a simple apparatus capable of roll packing multiple units of various compressible materials, such as foam mattress cores, mattress spring assemblies, and finished mattress products and which is ergonomically efficient and is capable of providing a barrier layer between successive turns of a formed roll.
SUMMARY OF THE INVENTION
The present invention provides a simple machine for roll packing a variety of compressible materials such as foam cores, spring assemblies, and fiber materials used in the manufacture of mattress products, as well as finished mattresses themselves. The machine has a radially collapsible mandrel that permits finished roll packed materials to be easily removed from the machine by sliding the roll off of the mandrel. This radially collapsible mandrel permits rolled materials to be removed without any telescoping or tearing of the materials which is usually caused by binding of the roll packed material on the mandrel. The machine of the present invention is especially useful in roll packing foam materials which are highly susceptible to binding against a mandrel. The simplicity of design of the machine of the present invention further permits use in roll packing practically any compressible material, even materials as diverse as coiled spring assemblies for mattresses and foam cores.
In accordance with the present invention, an apparatus is provided having a radially collapsible mandrel for winding compressible materials to be roll packed. A feed table is provided upstream of the mandrel to support and direct the compressible material to the mandrel. A packing material dispenser is further provided proximate the mandrel to feed packing material to the mandrel with the compressible material. A compression roller associated with the mandrel is used to compress in-fed compressible materials between the compression roller and the mandrel as the material is being wound upon the mandrel. The compression roller is adjustable to vary the spacing between the mandrel and the compression roller so that the amount of compression for the in-fed materials can be varied accordingly. In one exemplary embodiment, a pneumatic cylinder is used to adjust the position of the compression roller relative to the mandrel. The mandrel is driven at one end by a driving mechanism including, for example, a motor and a gearbox, and has a bearing plate at the opposite end. The bearing plate is movable away from the end of the mandrel so that a finished roll of material can be easily pushed off of the mandrel after it has been collapsed. In another exemplary embodiment, the apparatus includes a stripper bar associated with the mandrel to facilitate the removal of finished rolls from the mandrel, and further includes a roll handler for receiving the finished roll as it is pushed off the mandrel.
In further accordance with the present invention, a method for roll packing various compressible materials includes the steps of providing a collapsible mandrel and a compression roller, directing in-fed compressible materials between the mandrel and compression roller, adjusting the spacing between the mandrel and compression roller, winding the compressible material around the mandrel, stopping the mandrel when a desired amount of in-fed material has been wound upon the mandrel, collapsing the mandrel, and removing the roll packed material from the mandrel. A method for roll packing foam materials, in particular, in accordance with the present invention is disclosed in U.S. patent application Ser. No. 09/986,227, entitled “Method for Roll Packing Foam Cores,” filed on even date herewith, assigned to the assignee of this application, and incorporated by reference herein in its entirety.
Accordingly, the invention provides a simple apparatus and method for roll packing a variety of compressible materials and which has a collapsible mandrel that facilitates the easy removal of finished rolls without tearing, telescoping, or otherwise damaging the roll packed material. These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
FIG. 1
is a perspective view showing a roll packing apparatus according to the principles of the present invention;
FIG. 2
shows detail of the mandrel and compression roller of the apparatus of
FIG. 1
, where an in-fed material is being compressed between the mandrel and compression roller;
FIG. 3
shows a cross-sectional view of the mandrel of the present invention, taken along line
3
—
3
, showing the collapsed state of the mandrel in solid lines and the expanded state of the mandrel in dashed lines;
FIG. 4A
is a partial side-view of the apparatus of
FIG. 1
, depicting the start of a winding operation with an expanded mandrel;
FIG. 4B
shows the partial side-view of the apparatus of
FIG. 1
, depicting a partially wound roll on the expanded mandrel;
FIG. 4C
shows the partial side-view of the apparatus of
FIG. 1
, depicting a fully wound roll and the mandrel in its collapsed state.
DETAILED DESCRIPTION
An apparatus and method are provided for roll packing compressible materials in a simple and efficient manner without damaging the materials, and wherein the materials can be stored and shipped in a compact state. The present invention may be described and understood by a description of an exemplary apparatus.
With reference to
FIG. 1
, there is shown an illustration of one embodiment of roll packing apparatus
10
incorporating the principles of the present invention. The apparatus
10
includes a collapsible mandrel
12
for receiving in-fed materials
14
and winding them into a roll. The mandrel
12
is fixed to a shaft
16
that is driven at a first end
18
by a driving mechanism, for example motor
20
and gearbox
22
connected to the shaft
16
. The invention further includes a compression roller
24
, which is located proximate the mandrel
12
and which is fixed to a compression roller shaft
26
that is substantially parallel to the mandrel shaft
16
. Thus, the rotational axis of mandrel
12
is substantially parallel to the rotational axis of compression roller
24
. The compression roller
24
is adjustable such as by means of an actuator
28
fixed to the roller shaft
26
whereby the spacing
30
(see
FIG. 2
) between the compression roller
24
and the mandrel
12
may be adjusted to vary or maintain the amount of compression on the in-fed materials
14
. A feed table
32
located upstream of the mandrel
12
and compression roller
24
directs in-fed compressible materials
14
between the mandrel
12
and compression roller
24
as the material
14
is wound upon the mandrel
12
. In one example of the present invention, not shown, the feed table
32
includes a jig plate to ensure proper alignment of the in-fed materials
14
with respect to the mandrel
12
and compression roller
24
. A disc brake
34
may be attached to the roller shaft
26
to control rotation of the compression roller
24
.
The apparatus
10
further includes a packing material dispenser
36
which supplies packing material
38
, such as paper, plastic or fiber material, to a surface
40
of the in-fed compressible materials
14
as they are fed through the mandrel
12
and compression roller
24
. The packing material is then wound with the compressed in-fed material to create a barrier layer between successive turns of the rolled material. In this manner, the barrier layer protects successive layers of in-fed material such as foam and prevents adhesion of the successive layers. The packing material dispenser
36
may further include a guide roller
42
, pinch rollers
44
,
46
, and a tension roller
48
to aid in directing packing material
38
to the in-fed compressible material
14
and also to maintain proper tension and alignment of the packing material
38
.
A bearing plate
50
is located at a second end
52
of the mandrel shaft
16
, opposite the drive motor
20
, and is movable to expose an end of the mandrel
12
so that a finished roll of material
54
may be removed from the mandrel
12
. The invention further includes a roll handler
58
for facilitating easy removal of the finished rolls
54
. In the exemplary embodiment of
FIG. 1
, the roll handler
58
is a trough-shaped cradle that is pivotally connected to a support (not shown) and can be placed in a first position near the end of the mandrel
12
for receiving a finished roll of material
54
. A stripper bar
60
associated with the mandrel
12
aids in removing a finished roll
54
from the collapsed mandrel
12
onto the roll handler
58
. The roll handler
58
may then be placed in a second position (shown in phantom) to permit operators to subsequently remove the roll
54
from the machine
10
.
As depicted more fully in
FIGS. 2 and 3
, the collapsible mandrel
12
may include a series of elongated plates
62
attached to the mandrel shaft
16
and positioned about the shaft
16
in an overlapping arrangement to create a substantially tubular surface
64
along the length of the shaft
16
. The plates
62
are slidably connected to the shaft
16
and may move toward or away from the shaft
16
along radially extending paths
66
to increase or decrease the diameter
67
of the tubular surface
64
formed by the overlapping plates
62
. Rods
68
connected to each plate
62
engage a cam
70
attached to the shaft
16
, whereby rotational operation of the cam
70
causes the plates
62
to move either toward or away from the shaft
16
to correspondingly collapse or expand the mandrel diameter
67
.
Referring to
FIGS. 4A-4C
, the method of the present invention, as it relates to operation of the exemplary apparatus
10
of
FIGS. 1-3
, will be described. The spacing
30
between the mandrel
12
and compression roller
24
is adjusted to provide a desired amount of compression in the in-fed compressible material
14
. Packing material
38
from the packing material dispenser
36
is fed through the guide roller
42
, pinch rollers
44
,
46
, and tension roller
48
and then directed between the compression roller
24
and mandrel
12
while the mandrel
12
is turned to wind an initial length of packing material
38
upon the mandrel
12
, as depicted in FIG.
4
A. In-fed compressible material
14
, which is supported on feed table
32
, is directed between the mandrel
12
and compression roller
24
. The motor
20
(
FIG. 1
) is started and the mandrel
12
rotates to wind up the in-fed compressible material
14
and packing material
38
as it is compressed between the mandrel
12
and compression roller
24
. The actuator
28
(
FIG. 1
) attached to the compression roller shaft
26
may be operated to vary the spacing
30
between the mandrel
12
and compression roller
24
as the roll
54
gets bigger, as can be seen in
FIG. 4B
, to maintain uniform compression in the roll
54
. When a sufficient amount of compressible material
14
has been wound upon the mandrel
12
, the motor
20
is stopped. The finished roll
54
is secured, for example, with tape, straps, or other suitable material, and bearing plate
50
(
FIG. 1
) is moved to expose an end of the mandrel
12
. The mandrel
12
is then collapsed, as depicted in
FIG. 4C
, so that the finished roll
54
may be removed from the mandrel
12
under the operation of the stripper bar
60
(FIG.
1
). The stripper bar
60
pushes the finished roll
54
into the roll handler
58
(
FIG. 1
) and the roll handler
58
then pivots to a second position so that operators can maneuver the finished roll
54
away from the machine
10
.
While the present invention has been illustrated by the description of an embodiment thereof, and while the embodiment has been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of applicant's general inventive concept.
Claims
- 1. An apparatus for roll packing compressible material, comprising:an elongated, radially collapsible mandrel, the mandrel having a rotational axis along its length, whereby material may be wound upon the mandrel by rotating the mandrel, the mandrel having an adjustable diameter; a compression roller operatively associated with said mandrel and having a rotational axis substantially parallel to the rotational axis of the mandrel, the compression roller being adjustable to vary its spacing relative to the mandrel, whereby in-fed material may be compressed between the compression roller and the mandrel as it is being wound upon the mandrel; a drive mechanism operatively connected to a first end of the mandrel to turn the mandrel about its rotational axis; a packing material dispenser proximate the mandrel for receiving and dispensing packing material to the compressible material as it is being wound upon the mandrel; a support bearing located at a second end of the mandrel, opposite the first end, the support bearing being moveable to expose the second end of the mandrel to allow removal of a roll of material from the mandrel; and a stripper bar proximate the mandrel and configured to engage a roll of material on the mandrel and push the material toward the second end and off of the mandrel.
- 2. The apparatus of claim 1, further including a disk brake operatively connected to the compression roller to control the rotation of the compression roller about its rotational axis.
- 3. The apparatus of claim 1, further including a pneumatic cylinder operatively connected to the compression roller to adjust the position of the compression roller relative to the mandrel and thereby control the spacing between the mandrel and the compression roller.
- 4. The apparatus of claim 1, further including at least one feed roller associated with the packing material dispenser to provide even tension on the packing material and to direct the packing material from the dispenser to the in-fed compressible material as it is being wound upon the mandrel.
- 5. The apparatus of claim 1, further including a feed table upstream of the mandrel for supporting the compressible material and directing the compressible material between the mandrel and compression roller.
- 6. The apparatus of claim 5, wherein the feed table includes a jig plate for aligning the mandrel relative to the mandrel.
- 7. The apparatus of claim 1, further including a roll handler proximate the second end of the mandrel and configured to receive a roll of material from the mandrel and reposition the roll relative to the apparatus for subsequent processing.
- 8. An apparatus for roll packing compressible material, comprising:an elongated, radially adjustable mandrel having a rotational axis along its length, the mandrel including a shaft, a plurality of elongated, overlapping plates movably connected to the shaft and radially disposed about the shaft to form a substantially tubular surface, and a cam fixed to the shaft and configured to move the plates toward or away from the shaft along paths extending radially from the shaft; a compression roller operatively associated with said mandrel and having a rotational axis substantially parallel to the rotational axis of the mandrel, the compression roller being adjustable to vary its spacing relative to the mandrel, whereby in-fed material may be compressed between the compression roller and the mandrel as it is being wound upon the mandrel; a drive mechanism operatively connected to a first end of the mandrel to turn the mandrel about its rotational axis; a packing material dispenser proximate the mandrel for receiving and dispensing packing material to the compressible material as it is being wound upon the mandrel; a feed table upstream of the mandrel for supporting the compressible material and directing the compressible material between the mandrel and compression roller; a support bearing located at a second end of the mandrel, opposite the first end, the support bearing moveable to expose the second end of the mandrel to allow removal of a roll of material from the mandrel; a stripper bar proximate the mandrel and configured to engage a roll of material on the mandrel and push the material toward the second end and off of the mandrel; and a roll handler proximate the second end of the mandrel and configured to receive a roll of material from the mandrel and reposition the roll relative to the apparatus for subsequent processing.
- 9. The apparatus of claim 8 wherein the feed table includes a jig plate for aligning the material relative to the mandrel.
- 10. The apparatus of claim 8 further including a disk brake operatively connected to the compression roller to control the rotation of the compression roller about its rotational axis.
- 11. The apparatus of claim 8 further including a pneumatic cylinder operatively connected to the compression roller to adjust the position of the compression roller relative to the mandrel and thereby control the spacing between the mandrel and the compression roller.
- 12. The apparatus of claim 8 further including at least one feed roller associated with the packing material dispenser to provide even tension on the packing material and to direct the packing material from the dispenser to the in-fed compressible material as it is being wound upon the mandrel.
- 13. The apparatus of claim 8 wherein the roll handler is an elongated, trough-shaped cradle pivotally mounted at a first end to a support, whereby the cradle may be placed in a first position to be substantially aligned with the mandrel to receive a finished roll from the second end of the mandrel, and whereby the cradle may be pivoted to a second position to permit subsequent handling of the finished roll.
- 14. A method of roll packing a compressible material in a roll packing machine having a radially collapsible mandrel, a compression roller proximate the mandrel and adjustable to vary the spacing therebetween, a stripper bar, a roll handler proximate the mandrel, and a packing material dispenser, the method comprising the steps of:providing the mandrel in a non-collapsed position; adjusting the spacing between the compression roller and the mandrel to obtain a desired compression of the compressible material; winding packing material from the packing material dispenser onto the mandrel; directing compressible material between the mandrel and the compression roller such that compressible material can be wound upon the mandrel by rotating the mandrel; rotating the mandrel to wind the compressible material onto the mandrel; applying packing material to the compressible material as it is wound upon the mandrel; stopping rotation of the mandrel when a desired quantity of compressible material has been wound onto the mandrel; collapsing the mandrel; positioning the roller handler at an end of the mandrel: pushing the finished roll off of the mandrel and into the roll handler using the stripper bar.
- 15. The method of claim 14 further including the step of securing the roll of compressible material, prior to removal from the mandrel, to prevent unrolling.
- 16. An apparatus for roll packing compressible mattress material, the apparatus comprising:an elongated, radially collapsible mandrel supported by at least one support bearing, the mandrel having a rotational axis along its length, whereby mattress material may be wound upon the mandrel by rotating the mandrel, wherein the outer surface is adjustable to increase or decrease an outer diameter of the mandrel; means for adjusting the amount of compression of the compressible mattress material as it is being wound upon the mandrel; means for directing compressible mattress material between the mandrel and the compressing means so that the compressed mattress material may be wound upon the mandrel; means for dispensing and applying packing material to successive layers of the compressible mattress material as it is wound upon the mandrel; and means for removing the roll of compressible mattress material from the collapsed mandrel.
- 17. An apparatus for roll packing a compressible material in a roll packing machine having a radially collapsible mandrel, a compression roller proximate the mandrel and adjustable to vary the spacing therebetween, and a packing material dispenser, the apparatus comprising:means for providing the mandrel in a non-collapsed position supported by at least one support bearing; means for adjusting the spacing between the compression roller and the mandrel to obtain a desired compression of the compressible material; means for directing compressible material between the mandrel and the compression roller such that compressible material can be wound upon the mandrel by rotating the mandrel; means for rotating the mandrel to wind the compressible material onto the mandrel; means for applying packing material to the compressible material as it is wound upon the mandrel; means for stopping rotation of the mandrel when a desired quantity of compressible material has been wound onto the mandrel; means for collapsing the mandrel to release the roll from the mandrel; and means for removing the roll of compressible material from the mandrel.
- 18. The apparatus of claim 7, wherein the roll handler is an elongated, through-shaped cradle pivotally mounted at a first end to support, whereby the cradle may be placed in a first position to be substantially aligned with the mandrel to receive a finished roll from the second end of the mandrel, and whereby the cradle may be pivoted to a second position to permit subsequent handling of the finished roll.
US Referenced Citations (28)