Patent Grant
10160176
1. Field of the Invention
The present invention generally relates to dispensing inflatable structures, and in particular to dispensing connected inflatable structures using a dispensing device and an associated system and method.
2. Description of Related Art
Inflatable structures constitute an important part of the packaging industry. Inflatable structures are commonly used as cushions to package items, either by wrapping the items in the inflatable structures and placing the wrapped items in a shipping container, or by simply placing one or more inflatable structures inside of a shipping container along with an item to be shipped. The cushions protect the packaged item by absorbing impacts that might otherwise be fully transmitted to the packaged item during transit, and also restrict movement of the packaged item within the container to further reduce the likelihood of damage to the item.
Inflatable packaging has an advantage over non-inflatable packaging in that inflatable packaging may require less raw material to manufacture it. Further, it is known within the art to make inflatable packaging such that it is inflatable on demand. Inflate-on-demand packaging allows the entity using the packaging materials to wait and inflate the packaging materials when needed, such as when shipping an item in a shipping container, as described above. This means that inflate-on-demand packaging materials occupy less space as compared to pre-inflated packaging materials, which makes them easier to store. Additionally, transportation of the packaging materials to the entity using them to package items can be less expensive than it would be if the packaging materials were already inflated because they can be shipped in significantly smaller containers.
Despite the advantages of inflate-on-demand packaging, there is still room for improvement within the art. In this regard, the persons who use the inflatable structures to package items may desire that the inflatable structures be provided to them in a rapid, yet controlled manner during the packaging process. Further, some embodiments of inflatable structures are connected and thus the packaging person may need to separate the inflatable structures at desired intervals. Accordingly, embodiments of the present invention are configured to provide the inflatable containers to persons in a manner which facilitates use of the inflatable structures in packaging and other applications.
These and other advantages are provided by the apparatus, system, and method presented herein. In particular, an operator is provided with a convenient way to receive and remove a desired section of inflatable structures from a plurality of connected inflatable structures. Thereby, for example, use of the inflatable structures in packaging may be simplified and expedited.
In particular, there is herein provided in one embodiment an apparatus configured to dispense a plurality of connected inflatable structures. The apparatus may comprise a dispensing device configured to advance the connected inflatable structures, a motor configured to advance the dispensing device, a sensor configured to detect a pulling force applied to the dispensing device and configured to output a signal corresponding to the pulling force, and a controller configured to receive the signal and output a control signal to direct the motor to advance the dispensing device in response to the signal to thereby dispense the connected inflatable structures.
The apparatus may further comprise a plurality of projections extending from the dispensing device, wherein the projections are configured to engage the connected inflatable structures. The projections may extend a distance from the dispensing device and the distance may vary with an axial position along the dispensing device. Further, the projections may define a U-shape such that the distance defined at a first axial position is less than the distance defined at a second axial position and a third axial position, wherein the first axial position is located between the second axial position and the third axial position. Additionally, in some embodiments the connected inflatable structures may comprise slits.
Also, the apparatus may comprise an input device configured to cause the motor to advance the dispensing device. The input device may be configured to detect an actuation force applied thereto and configured to control a rate at which the motor advances the dispensing device based on the actuation force. Actuation of the input device for a time period greater than a threshold time period may be configured to cause the motor to advance the dispensing device until actuation of the input device ceases. Further, actuation of the input device for a second time period which is less than the threshold time period may be configured to cause the motor to advance the dispensing device to dispense a predetermined number of the connected inflatable structures.
The sensor may in some embodiments comprise a strain gauge. Alternatively or additionally the sensor may comprise a rotary movement sensor configured to detect a rotational movement of the dispensing device and thereby the signal may correspond to the rotational movement. The rotary movement sensor may comprise a Hall Effect sensor in some embodiments, whereas in other embodiments the rotary movement sensor may comprise a back electromotive force sensor. Further, the controller may be configured to direct the motor to advance the dispensing device after a delay period in instances in which the rotational movement, as indicated by the signal, is less than a predetermined threshold. The controller may additionally be configured to direct the motor to advance the dispensing device substantially instantaneously in instances in which the rotational movement, as indicated by the signal, is greater than a predetermined threshold. Also, the controller may be configured to direct the motor to advance the dispensing device to dispense a first predetermined number of the connected inflatable structures in instances in which the rotational movement, as indicated by the signal, is less than a predetermined threshold, and the controller may be configured to direct the dispensing device to dispense a second predetermined number of the connected inflatable structures in instances in which the rotational movement, as indicated by the signal, is greater than the predetermined threshold. In some embodiments the second predetermined number of the connected inflatable structures is greater than the first predetermined number of connected inflatable structures. Further, at least one of the first predetermined number of the connected inflatable structures and the second predetermined number of the connected inflatable structures may be user-selectable.
There is further herein provided a system configured to dispense a plurality of connected inflatable structures. The system may comprise the above-described apparatus and an inflation device configured to inflate the connected inflatable structures. Further, the system may include an accumulation bin, wherein the accumulation bin is positioned downstream of the inflation device and upstream of the apparatus configured to dispense the connected inflatable structures. Further, the system may include a inflatable structure sensor configured to detect the connected inflatable structures positioned downstream of the inflation device and upstream of the apparatus configured to dispense the connected inflatable structures and configured to output a inflatable structure sensor signal indicating whether or not the connected inflatable structures are present, wherein the controller is configured to not direct the motor to advance the dispensing device in instances in which the inflatable structure sensor signal indicates that the connected inflatable structures are not present.
There is further herein provided a method of dispensing a plurality of connected inflatable structures. The method may comprise providing for pulling the connected inflatable structures and thereby applying a pulling force to a dispensing device about which the connected inflatable structures are positioned, detecting the pulling force applied to the dispensing device, and advancing the dispensing device in response to the pulling force to thereby dispense the connected inflatable structures. In some embodiments of the method, the connected inflatable structures may comprise slits.
The method may further comprise delaying advancing the dispensing device for a delay period in instances in which a duration of the pulling force is less than a predetermined threshold. Additionally, the method may comprise advancing the dispensing device substantially instantaneously in instances in which a duration of the pulling force is greater than a predetermined threshold. Also, the method may include dispensing a predetermined number of the connected inflatable structures. Further, the method may comprise dispensing a first predetermined number of the connected inflatable structures in instances in which the duration of the pulling force is less than a predetermined threshold, and dispensing a second predetermined number of the connected inflatable structures in instances in which the duration of the pulling force is greater than the predetermined threshold.
In a further embodiment a system configured to dispense a plurality of connected inflatable structures comprises an apparatus configured to dispense the connected inflatable structures comprising a dispensing device configured to advance the connected inflatable structures, a plurality of projections extending from the dispensing device, wherein the projections are configured to engage the connected inflatable structures, and wherein the projections extend a distance from the dispensing device and wherein the distance varies with an axial position along the dispensing device, and a motor configured to advance the dispensing device. The system may further comprise a controller configured to output a control signal to direct the motor to advance the dispensing device, and an inflation device configured to inflate the connected inflatable structures. The system may also comprise an accumulation bin, wherein the accumulation bin is positioned downstream of the inflation device and upstream of the apparatus configured to dispense the connected inflatable structures. Additionally, in some embodiments the projections define a U-shape such that the distance defined at a first axial position is less than the distance defined at a second axial position and a third axial position, wherein the first axial position is located between the second axial position and the third axial position.
These and other aspects and features of the invention may be better understood with reference to the following description and accompanying drawings.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
With reference to
Returning to the embodiment shown in
In some embodiments the inflatable structures 102 may be provided to the inflation device 110 in an uninflated state. For example, in the illustrated embodiment the inflatable structures 102 are provided to the inflation device 110 in the form of a roll 154 comprising a continuous web of the connected inflatable structures. However, the inflatable structures 102 may be provided to the inflation device 110 in various other forms in other embodiments. For example, the inflatable structures 102 may be provided to the inflation device 110 in the form of a cartridge wherein the inflatable structures are fan-folded on top of one another.
However, the form in which the inflatable structures 102 are provided to the inflation device 110 and the type of inflatable structures themselves may depend upon the type of inflation device selected, or vice versa. In this regard, various embodiments of inflation devices 110 may be employed by the system 100 to inflate the inflatable structures 102. In some embodiments the inflation device 110 may employ inflation-at-a distance techniques to inflate the inflatable structures 102, whereas in other embodiments the inflation device may inflate the inflatable structures by inserting an inflation needle, wand, nozzle, or other similar structure in the inflatable structures. By way of example, various embodiments of inflation devices 110 which may be employed in embodiments of the system 100 are disclosed in U.S. Pat. Nos. 5,942,076; 6,598,373; 6,651,406; 6,804,933; and 7,225,599 and U.S. patent application Ser. Nos. 10/979,583; 11/732,571; 12/256,245; and 12/378,212, which are herein incorporated by reference. However, various other embodiments of the inflation device 110 may be employed by the system 100 as may be understood by one having skill in the art.
Turning now to the apparatus 150 configured to dispense the inflatable structures 102, the apparatus may comprise a dispensing device 156 configured to advance the inflatable structures. The apparatus 150 configured to dispense the inflatable structures 102 may comprise a variety of structures, components, and machines configured to advance the inflatable structures 102 and the motor 158 may comprise a variety of mechanisms configured to provide motion thereto. For example, the dispensing device 156 may comprise two or more wheels which form a nip through which the inflatable structures 102 travel. Thereby, when one or more of the wheels are driven, the dispensing device 156 dispenses the inflatable structures 102.
By way of further example, in the illustrated embodiment the dispensing device 156 comprises a cylindrical member 160 which is configured to be rotated by the motor 158. As will be described below in detail, a controller 162 may output a control signal directing the motor 158 to advance the dispensing device 156 in response to a signal outputted by a sensor. The sensor may in some embodiments be retained within a housing 164 which may also house the motor 158 and a gear train in some embodiments. Further, an alignment member 166 may be positioned upstream of the dispensing device 156 and configured to align the inflatable structures 102 with the dispensing device 156 as they are received from the accumulation bin 152 or directly from the inflation device 110. The dispensing device 156 and/or the alignment member 164 may be attached to the remainder of the apparatus 150 such that they supported on one side in a cantilevered arrangement. By cantilevering the dispensing device 156 and/or the alignment member 164, the loading the inflatable structures 102 though the alignment device and the dispensing device may be simplified and not require disassembly and reassembly. The apparatus 150 may further comprise a plurality of projections 168 extending from the dispensing device 156. The projections 168 may be configured to engage the connected inflatable structures 102 in order to assist in advancing the connected inflatable structures when the motor 158 advances the dispensing device 156.
Details with respect to the dispensing device 156 and the projections 168 are illustrated in
Accordingly, the above-described U-shape and various other configurations may effectively define a variable circumference dispensing device 156 depending upon the axial positions at which the inflatable structures 102 contact the projections 168. In this regard, the dashed lines in
By way of example,
With further regard to the dispensing device 156, as noted above the apparatus 150 configured to dispense the inflatable structures 102 may comprise a sensor which outputs a signal that is used by the controller 162 to determine when to instruct the motor 158 to advance the dispensing device. The sensor (not shown) may be configured to detect a pulling force on the dispensing device 156. The pulling force may be detected in a number of ways. For example, in one embodiment the sensor may comprise a strain gauge which detects strain on the projections 168, which is proportional to the pulling force. For example, strain gauges may couple to each of the projections 168 and detect the strain applied to the projections. In another embodiment the sensor may comprise a rotary movement sensor configured to detect a rotational movement of the dispensing device 156 caused by the pulling force. For example, the rotary movement sensor may comprise an encoder such as a Hall Effect sensor which may be positioned in the housing 164. Further, in some embodiments the rotary movement sensor may comprise a back electromotive force sensor which detects rotation of the motor 158 and outputs a voltage corresponding thereto. The back electromotive force sensor may comprise circuitry in some embodiments which detects the voltage outputted from the motor 158. In some embodiments the circuitry may be embodied in the controller 162, although in other embodiments the circuitry may be embodied elsewhere. The signal outputted by the rotary movement sensor may correspond to the rotational movement of the dispensing device 156. For example, when the inflatable structures 102 are draped over the dispensing device 156 and an operator pulls on the inflatable structures (see, e.g.,
Accordingly, the pulling force may be detected using a variety of methods and sensors which may detect the pulling force indirectly through methods such as detecting movement or more directly by detecting strain created by the pulling force, as described above. Further, although the dispensing device 156 has been described above as comprising cylindrical member 160 with a plurality of projections 168 extending therefrom, various other embodiments of the dispensing device may be employed. For example, the dispensing device may comprise a capstan, belts, conveyors, etcetera in other embodiments. Thus, the embodiments of the dispensing device described herein are provided for example purposes only.
As noted above, the controller 162 may output a control signal directing the motor 158 to advance the dispensing device 156 in response to a signal outputted by the sensor which detects the pulling force. In this regard,
Accordingly, the controller 162 may be configured to advance the dispensing device 156 after a delay period in instances in which the rotational movement, as indicated by the signal, is less than a predetermined threshold, and/or in instances in which a detected strain on the dispensing device lasts for a duration less than a predetermined duration. For example, when the operator 176 tears off the section 102′ of the inflatable structures 102, this may involve a relatively quick pull on the inflatable structures. In order to assist the operator 176 in tearing off the section 102′ of the inflatable structure 102, the dispensing device 156 may comprise a brake or other mechanism which provides resistance to rotation of the dispensing device. However, in some embodiments the motor 158 and/or an associated gear train may provide sufficient resistance so as to enable the operator 176 to tear off the section 102′ of the inflatable structures 102. Also, use of inflatable structures 102 with slits 103 may help the operator separate the inflatable structures by requiring less force to induce the tear and thus assist the controller 162 in determining whether the applied force does or does not result in a tear. Further, the delay period may assist the operator 176 in tearing off the section 102′ of the inflatable structures 102. For example, if the controller 162 were to direct the motor 158 to advance the dispensing device 156 instantly, it may be difficult for the operator 176 to tear the inflatable structures 102 due to the movement of the inflatable structures. However, in other embodiments the controller 162 may direct the motor 158 to rotate substantially instantly in order to provide the inflatable structures 102 to the operator 176 more rapidly.
By rotating the dispensing device 156 after the predetermined delay period, the dispensing device may make the inflatable structures 102 once again accessible to the operator 176 by pulling more of the inflatable structures from the accumulation bin 152. In some embodiments the controller 162 may be configured to direct the motor 158 to advance the dispensing device 156 to dispense a predetermined number of the inflatable structures 102 or to advance the dispensing device for a predetermined period of time in instances in which the rotational movement, as indicated by the signal, is less than the predetermined threshold, or the strain on the dispensing device, as indicated by a signal from a strain gauge lasts for less time than a predetermined duration. Thereby, after tearing off the section 102′ of the inflatable structures 102, the operator 176 may be provided with a desired number of the inflatable structures or a desired length of the inflatable structures.
In some embodiments the controller 162 may be configured to direct the motor 158 to advance the dispensing device 156 to dispense a predetermined number of the inflatable structures 102 or to advance the dispensing device for a predetermined period of time in instances in which the rotational movement, as indicated by the signal, is greater than the predetermined threshold and/or in instances in which the strain on the dispensing device lasts for longer than a predetermined duration. Thereby, by pulling more slowly on the inflatable structures 102, the operator 176 may be provided with a desired number of the inflatable structures or a desired length of the inflatable structures.
In some embodiments the predetermined number (or length) of inflatable structures 102 dispensed when the rotational movement is less than the predetermined threshold and/or when the strain lasts for a period of time less than a predetermined duration (i.e. the first predetermined number of the inflatable structures) may be less than the predetermined number (or length) of inflatable structures dispensed when the rotational movement is greater than the predetermined threshold and/or when the strain lasts for a period of time greater than a predetermined duration (i.e. the second predetermined number of the inflatable structures). In this regard, the operator 176 may desire that a smaller number of the inflatable structures 102 be dispensed after tearing off the section 102′ of the inflatable structures than when pulling on the inflatable structures so as to not tear off a section. However, the first and second predetermined number of inflatable structures may vary in alternate embodiments. For example, the second predetermined number of inflatable structures may be less than or equal to the first predetermined number of inflatable structures. Further, in some embodiments one or both of the first and second predetermined number of inflatable structures may be user-selectable. For example, the operator 176 may select the first and second predetermined number of inflatable structures using the controller 162 in some embodiments.
Further, although the controller is described above as advancing the dispensing device based on detected rotational movement of the dispensing device and/or duration of strain on the dispensing device, various other methods of analyzing the applied pulling force may be employed as would be understood by one having skill in the art. For example, the controller may compare the magnitude of the strain over the time period in which the pulling force is received to a strain pattern. Thereby, for example, a strain pattern which includes a rapid spike in strain magnitude may be interpreted by the controller as a pulling force which tears off of a section of the inflatable structures. Accordingly, the controller may in such instances advance the dispensing device after a delay period as described above. Conversely, a strain pattern involving a relatively constant strain to the dispending device may be interpreted by the controller as a pulling force which does not tear off a section of the inflatable structures. Accordingly, the controller may in such instances advance the dispensing device substantially instantaneously as described above. Further, various other methods of detecting the type of pulling force applied may be employed as may be understood by one having skill in the art.
Additionally, in some embodiments the controller may be configured to learn based on interaction with the operator. For example, after the operator exerts a pulling force on the inflatable structure, the operator may indicate to the controller which type of pulling force was provided (e.g. tearing or not tearing) and/or the operator may indicate how he or she wants the controller to respond (e.g. by delaying advancement for a delay period or advancing the dispensing device substantially instantaneously). Further, the operator may specify the desired number or length or inflatable structures he or she wants to be dispensed based on the inputted pulling force. Accordingly, the controller may provide additional functionality in some embodiments.
As illustrated in
Further, in some embodiments the input device may comprise a bump bar which an operator may actuate, for example by leaning into or pushing against the bump bar using a section of the torso or leg. The bump bar may sense the magnitude of pressure applied by the operator and thereby determine how to dispense the inflatable structures. In some embodiments the bump bar may comprise hydraulic and/or pneumatic components which sense the force applied. The force applied to the bump bar (as may be sensed in terms of pressure) may then determine how to dispense the inflatable structures. For example, less force on the bump bar may cause the dispensing device to dispense the inflatable structures at a relatively slower rate, whereas greater force on the bump bar may cause the dispensing device to dispense the inflatable structures at a relatively faster rate. By way of further example, the speed at which the inflatable structures dispense may be proportional to the force applied to the bump bar. For example, the dispensing speed may linearly increase with increases in the force applied to the bump bar in some embodiments, although other control arrangements may be possible. Thus, the input device may be configured to detect an actuation force applied thereto and configured to control a rate at which the motor advances the dispensing device based on the actuation force.
Thus, as noted above, the controller 162 and in some embodiments the input device 180, may output a signal which directs the motor 158 to advance the dispensing device 156. However, in some instances it may not be desirable for the dispensing device 156 to rotate. For example, as described above, in some embodiments the apparatus 150 configured to dispense the inflatable structures 102 may in some instances be configured to dispense the connected inflatable structures at a rate faster than the inflation device 110 may be able to inflate the connected inflatable structures. As further described above, an accumulation bin 152 may be provided in order to receive and store a buffer quantity of the inflatable structures 102 such that the inflatable structures may substantially always be available to the apparatus 150. However, in some instances the dispensing device 156 may still manage to dispense the inflatable structures 102 at a rate such that most or all of the inflatable structures are removed from the accumulation bin 152. Accordingly, the system 100 may further comprise an inflatable structure sensor 182. The inflatable structure sensor 182 may be configured to detect presence of the inflatable structures 102 positioned downstream of the inflation device 110 and upstream of the apparatus 150 configured to dispense the connected inflatable structures and configured to output a inflatable structure sensor signal indicating whether or not the inflatable structures are present. For example, the inflatable structure sensor 182 may detect whether the inflatable structures 102 are present in the accumulation bin 152. Thereby, the controller 162 may receive the inflatable structure sensor signal from the inflatable structure sensor 182 and not direct the motor 158 to advance the dispensing device 156 in instances in which the inflatable structure sensor signal indicates that the inflatable structures are not present (or present in a quantity less than a predetermined threshold). Thereby, the inflation device 110 may be provided with time to inflate additional inflatable structures 102, or the operator 176 may be provided with an indication that the inflation device is unable to inflate additional inflatable structures, for example, when the roll 154 of the inflatable structures is depleted.
In some embodiments, certain ones of the above-described operations (as illustrated in solid lines in
For example, the method may further comprise delaying advancing the dispensing device for a delay period in instances in which a duration of the pulling force is less than a predetermined threshold at operation 206. Additionally, the method may include advancing the dispensing device substantially instantaneously in instances in which a duration of the pulling force is greater than a predetermined threshold at operation 208. Also, the method may include dispensing a predetermined number of the connected inflatable structures at operation 210. Further, the method may comprise dispensing a first predetermined number of the connected inflatable structures in instances in which the duration of the pulling force is less than a predetermined threshold at operation 212. The method may additionally comprise dispensing a second predetermined number of the connected inflatable structures in instances in which the duration of the pulling force is greater than the predetermined threshold at operation 214.
As noted above, the pulling force may be detected using relatively more and relatively less direct methods. For example, when using a rotary movement sensor, a pulling force may produce a rotational movement of the dispensing device which may be sensed. When the movement is relatively small, the pulling force applied to the dispensing device may be considered to be relatively small at least in terms of the duration of the pulling force applied to the dispensing device. For example, a tearing force may cause a small rotational movement and a strain on the dispensing device that ends relatively quickly due to a section of the inflatable structures tearing off. The actual magnitude of the pulling force applied to the dispensing device may depend on the strength of the connection between the inflatable structures, among other factors. Thus, the determination of whether or not the applied pulling force is greater or less than the predetermined threshold may be based on indirect indicators of the pulling force such as the resulting rotational movement of the dispensing device and/or the duration of strain applied to the dispensing device. Accordingly, the determination of whether the applied pulling force is greater or less than a predetermined threshold using the above described methods may or may not be based directly on the magnitude of the applied pulling force.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application is a continuation of U.S. application Ser. No. 12/886,937, filed on Sep. 21, 2010, which is hereby incorporated herein in its entirety by reference.
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