The present disclosure relates generally to a vertical form, fill and seal (VFFS) machine, and in particular to a VFFS machine operating continuously while applying a reclosable fastener to a package, together with a method of forming reclosable packages on the continuous VFFS machine.
Form, fill and seal bag machines are configured to form packages of different shapes and sizes. Typically, the machine, in sequence, forms a tube from a roll of film and fills the tube with a product, for example a food product. A cross seal mechanism sequentially makes a cross seal, which simultaneously forms a top seal of one bag and a bottom seal of an immediately adjacent bag, such that the latter bag may be filled with the product. The cross seal is then cut to separate the bags.
Typically, form, fill and seal machines may run intermittently, wherein the formed bag is momentarily stopped for sealing and/or cutting, or continuously, wherein the sealing jaws and cutting knife travel with the formed bag to form the seal and separate the bags. In some applications, reclosable fasteners are applied to the bag. The reclosable fasteners may be applied in the machine or transverse directions, typically on intermittent machines.
The present invention is defined by the following claims, and nothing in this section should be considered to be a limitation on those claims.
In one aspect, one embodiment of a form, fill and seal machine for making a reclosable package includes a reclosable fastener handling assembly. The reclosable fastener handling assembly includes a flattening device, a feed device and a feedback sensor. The flattening device is reciprocally moveable in a machine direction, wherein the flattening device is configured to move with a reclosable fastener material and successively flatten the reclosable fastener material at spaced apart locations. The reclosable fastener feed device is configured to move the reclosable fastener material in the machine direction. The feedback sensor is configured to measure a characteristic of the reclosable fastener material, such as the slack, position, force and/or tension of the reclosable fastener material, downstream of the reclosable fastener feed device and provide an input to the reclosable fastener feed device, wherein the reclosable fastener feed device adjusts the speed of the movement, or length/feed amount, of the reclosable fastener material in response to the input from the feedback sensor. A forming tube is disposed downstream of the feedback sensor, and is configured to receive a film and form a film tube. A vertical seal assembly is disposed adjacent the forming tube and is positionally fixed in the machine direction. The vertical seal assembly is configured to continuously seal the film tube and reclosable fastener material. A sealing jaw assembly is disposed downstream of the vertical seal assembly. The sealing jaw assembly includes a pair of sealing jaws reciprocally moveable in a machine direction. The pair of sealing jaws is configured to move with the film tube and fastener material. The sealing jaws are movable toward and away from each other in a transverse direction and are configured to form a transverse seal on the film tube and fastener material in alignment with the spaced apart locations of flattened reclosable fastener material.
In another aspect, one embodiment of a form, fill and seal machine includes a forming tube configured to receive a film and form a film tube, a vertical seal assembly disposed adjacent the forming tube, wherein the vertical seal assembly is configured to continuously seal the film tube, and a tear notch applicator positioned downstream of the vertical seal assembly. The tear notch applicator is positionally fixed in the machine direction and is configured to intermittently apply a plurality of slits spaced apart in the machine direction to the continuously moving film tube.
In another aspect, one embodiment of a method of forming a package with a reclosable fastener includes moving a reclosable fastener material continuously in a machine direction with a feed device, moving a flattening device with the moving reclosable fastener material in the machine direction, flattening a portion of the reclosable fastener material with the flattening device, measuring a characteristic of the reclosable fastener material, such as the slack, position, force and/or tension of the reclosable fastener material, downstream of the feed device and providing an input to the feed device from the sensor, adjusting a speed of the feed device, or length/feed amount of the reclosable fastener material exiting therefrom, in response to the input from the sensor, forming a film tube on a forming tube downstream of the feedback sensor, continuously sealing the film tube and reclosable fastener material with a vertical seal assembly disposed adjacent the forming tube, wherein the vertical seal assembly is positionally fixed in the machine direction, moving a pair of sealing jaws in the machine direction downstream of the vertical seal assembly, and forming a transverse seal across the film tube and fastener material in alignment with the flattened portions of the reclosable fastener material.
In yet another aspect, one embodiment of a method of forming a tear notch in a film tube includes continuously forming a film tube on a forming tube, continuously sealing the film tube with a vertical seal assembly disposed adjacent the forming tube, wherein the vertical seal assembly is positionally fixed in the machine direction, and intermittently applying a slit to the continuously moving film tube.
In another aspect, a vertical seal assembly includes a first pair of first heater bars extending in a longitudinal direction, with the first heater bars being spaced apart in a lateral direction and defining a first gap therebetween. A second pair of second heater bars extends in the longitudinal direction, with the second heater bars being spaced apart in the lateral direction and defining a second gap therebetween. A first pair of first actuators are coupled respectively to the first pair of first heater bars, wherein the first actuators are each moveable in the lateral direction such that the first gap may be increased or decreased. A second pair of second actuators are coupled respectively to the second pair of second heater bars, wherein the second actuators are each moveable in the lateral direction such that the second gap may be increased or decreased. The first and second pairs of actuators are independently moveable, such that the first and second gaps may independently adjusted.
The various embodiments of the form, fill and seal machines, and methods for the use thereof, provide significant advantages over other form, fill and seal machines, and components used therein. For example and without limitation, the disclosed form, fill and seal machine provides for a continuous bag forming operation incorporating a reclosable fastener. Running a continuous operation provides a substantially higher output of bags, while allowing the film to travel at a lower speed. The lower film speed in turn eliminates dynamic loading of the film, and avoids skipping and other disruptions. The tear notch applicator, positionally fixed in the machine direction, also allows for a continuous bag forming operation, without the need to move the knife, or other film separator, with the film/bag as it progresses through the machine.
The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The various preferred embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
It should be understood that the term “plurality,” as used herein, means two or more. The terms “longitudinal” and “machine” as used herein means of or relating to length or the lengthwise direction 30, and refers to the direction of film 4, film tube 12 or reclosable fastener material 40 movement through a form, fill and seal machine. In this way, it should be understood that portions of the reclosable fastener material may be positioned at different angles and/or orientations relative to other portions of the reclosable fastener material upstream or downstream therefrom at any one time during the bag forming process, but with the various portions all travelling in the longitudinal or machine direction. Likewise, the film 4 and reclosable fastener material 40 may travel along separate “machine” direction paths before being joined at the vertical seal assembly. The terms “downstream” and “upstream” refer to the relative position of the film and/or reclosable fastener material as they travel from a supply roll to the final bag formation, with a component lying “upstream” from a reference point being closer to the supply roll in the process and a component lying “downstream” from the reference point being closer to the final bag formation. The terms “lateral” and “transverse” as used herein, means situated on, directed toward or running from side to side, and refers to a direction transverse to the machine direction movement of the film and reclosable fastener material through a form, fill and seal machine.
The term “coupled” means connected to or engaged with whether directly or indirectly, for example with an intervening member, and does not require the engagement to be fixed or permanent, although it may be fixed or permanent (or integral), and includes both mechanical and electrical connection. The terms “first,” “second,” and so on, as used herein are not meant to be assigned to a particular component so designated, but rather are simply referring to such components in the numerical order as addressed, meaning that a component designated as “first” may later be a “second” such component, depending on the order in which it is referred. For example, a “first” set of heating bars may be later referred to as a “second” set of heating bars depending on the order in which they are referred. It should also be understood that designation of “first” and “second” does not necessarily mean that the two components or values so designated are different, meaning for example a first set may be the same as a second set, with each simply being applicable to separate but identical components.
U.S. Pat. Nos. 5,715,656, 5,752,370 and 8,539,741, and U.S. Pub. No. 2017/0113,823, assigned to Triangle Package Machinery Company, the same Assignee as the present application, disclose various components of form, fill and seal machines, the entirety of which patents and publication are hereby incorporated herein by reference.
Form, Fill and Seal Machine:
Referring to
Reclosable Fastener Material Handling Assembly
Referring to
The roll 102 of reclosable fastener material is mounted on a shaft connected to a variable frequency drive VFD unwind motor 108. The reclosable fastener material moves past a detection sensor 110, which confirms that the reclosable fastener material is present, and passes over a fixed pulley roller 112. The reclosable fastener material then passes through an assembly of dancing rollers 114, which can move up and down on a slide 118. The dancing rollers 114 apply a constant tension to the reclosable fastener material 40 as determined and set by the weight of the assembly. An unwind roller sensor 116 is configured as a distance or proximity sensor that detects the position of the moveable dancing rollers 114, or target portion 120 coupled thereto, as shown in
Referring to
An encoder 140 positioned downstream of the flattening device 124 monitors the speed and position of the reclosable fastener material 40. Using feedback from the encoder 140, a controller, e.g. a programmable logic controller (PLC), matches the speed of the flattening device 124 with the speed of the reclosable fastener material, with the flattening device 124 clamping to the moving reclosable fastener material by actuating the cylinder 130, flattening (e.g., welds or crushes) the reclosable fastener material, un-clamping from the moving reclosable fastener material, and returning in an upstream direction for the next cycle. This motion profile is similar to the motion profile used by the jaw assembly to seal and cut each bag as the film moves continuously down the forming tube as disclosed below. After the reclosable fastener material is flattened or crushed at spaced apart locations, the control system identifies and controls the locations of the flattened portions 150 so that the flattened portions eventually align with the bag cutoff downstream in the machine and process as shown in
After passing by or through the encoder 140, the reclosable fastener material travels by or through a reclosable fastener feed device 160, which is configured to move the reclosable fastener material in the machine direction 30. In one embodiment, the reclosable fastener feed device includes a pair of spaced apart pinch belts 162 (continuous loops) driven by a servo motor 165, with the belts 162 engaging opposite sides of the reclosable fastener material 40, maintaining positive control of the reclosable fastener material, and propelling the reclosable fastener material 40 forward in the machine direction 30. In other embodiments, the reclosable fastener material feed device may include spaced apart rollers, spaced apart vacuum belts, or combinations thereof.
Downstream of the feed device, a feedback sensor 164 measures a characteristic of the reclosable fastener material, including for example and without limitation the slack, position, force and/or tension of the reclosable fastener material. In one embodiment, the feedback sensor 164 is configured as a slack sensor that measures the slack of the reclosable fastener material. In other embodiments, the feedback sensor may be configured as, or may include, the encoder 140, or may be configured as a tension sensor or other sensor, or combinations of the aforementioned sensors. In one embodiment, the reclosable fastener material 40 travels below and is engaged by a dancer plate 166 coupled to and supported by two pairs of links 168, 170. The dancer plate 166 moves up or down in response to the tension (or slack) of the reclosable fastener material 40, with the sensor 164 measuring the distance (D2) between the sensor 164 and the dancer plate 166, which defines a target portion for the sensor 164. The position of the target portion, or plate 166, provides an input to the feedback (slack) sensor 164, which in turn provides an output communicated to the reclosable fastener feed device 160, or controller (PLC) associated therewith, as a sensor input. In response, the controller and the servo motor driving the reclosable fastener feed device 160 makes small corrections to maintain a consistent slack in the reclosable fastener material. For example, the reclosable fastener feed device adjusts the speed of the movement, or length/feed amount, of the reclosable fastener material in response to the input from the feedback sensor. This has the effect of maintaining the reclosable fastener material 40 at a consistent tension as it passes through the remaining downstream systems.
Vertical Seal Assembly
Referring to
A first pair of first actuators 196, 198 are coupled respectively to the first pair of first heater bars 182, 184, wherein the first actuators are each moveable in the lateral direction such that the first gap (G1) may be increased or decreased. A second pair of second actuators 200, 202 are coupled respectively to the second pair of second heater bars 192, 194, wherein the second actuators are each moveable in the lateral direction 32 such that the second gap (G2) may be increased or decreased. The first and second pairs of actuators are independently moveable, such that the first and second gaps may independently adjusted. The heater bars are coupled to brackets 208, 210 that are supported by ball bearing slides 214 that move along rails 212 coupled to the frame 2.
A guide blade 204 is positioned between the second set of heater bars 192, 194 and is inserted between the two mounting flanges 106 of the reclosable fastener material so as to prevent those flanges from being sealed to each other. Rather, an outer surface of one of the mounting flanges 106 is sealed to an inner surface of one of the film tube edges 174 to form a seal 260, and an outer surface of the other mounting flange is sealed to an inner surface of the other edge 174 of the film tube to form another seal 260. As shown in
As mentioned, the sets of heater bars are positionally fixed in the machine direction 30. In addition, the heater bars 180, 190 are positionally fixed in the transverse or lateral direction 32 as well, such that the sets of heaters remain engaged with the opposite outer surfaces of the film edges 174 during operation (i.e., the heaters do not cycle open and closed). However, when the machine is stopped, or is not operating, the sets of heater bars 192, 194, 182, 184 are moved away from each other with the actuators 196, 198, 200, 202 in the transverse or lateral direction 32 so that the heater bars are not in contact with, and do not damage, the film tube or reclosable fastener material.
In one embodiment, the vertical seal assembly includes four heating elements 220, which are each 3 mm (0.12 inches) in diameter in one embodiment. Each heating element is mounted in a heat transfer channel, or seal bar 182, 184, 192, 194, which expands the heating surface area exposed to the film. The seal bar may be made one-piece, with a hole drilled in it for receiving the heating element, or the seal bar may be made two-piece, which are pressed together with the heating element sandwiched between the two pieces. In other embodiments, the seal bar may be made of more than two pieces. In one embodiment, the channel, or seal bar, has an outer heating surface that bears against the film with a width of about 9.5 mm (0.38 inches). In some embodiments, the width may be smaller or larger, for example 0.25 to 1.00 inches. The seal bars may be 6 to 12 inches in length, and are 10 inches in one embodiment. Each heat transfer channel, or seal bar, has ridges or flanges that slide into and mount with a corresponding interlocking portion formed in a separator bar 222, made for example of glass filled plastic, as shown in
In other embodiments, the vertical seal(s) may be formed by pressurized hot air applied to the sides of the film tube to seal the edges of the film tube and to seal the reclosable fastener material to the film tube. In this embodiment, friction between the vertical seal assembly and the film tube would be greatly reduced or eliminated.
The connection of the support brackets 224 to the ball bearing slides 214 moveably supports the heater bars on the rails 212 supported by the frame. This allows the heater bars 182, 184, 192, 194 to be individually engaged and disengaged with the film by actuating air cylinders 196, 198, 200, 202 to move the heater bars in the transverse or lateral direction 32. In one embodiment, the first pair of actuators includes a pair of upper air cylinders 196, 198 controlling the movement of the first set of heater bars 182, 184 applying the vertical seal to the film tube, while the second pair of actuators includes a pair of lower cylinders 200, 202 controlling the movement of the second set of heater bars 192, 194 applying the seal between the film tube and the reclosable fastener material. Each cylinder has an adjustment device 230, for example a grippable nut disposed laterally outwardly, which allows an operator to adjust the engagement distance between the heaters of the first set and the heaters of the second set. For example, the operator may adjust the heater sets to create a small gap (G1 or G2) for the film or reclosable fastener material to pass through.
The first and second sets of heater bars, which are positionally fixed in the machine direction, are heated by way of the heating element 220 and transfer heat to the film tube so as to attach the reclosable fastener material to the film tube, and the edges of the film tube, while the reclosable fastener material and film tube are travelling continuously together through the vertical seal assembly.
Mounting the seal bars (heat transfer channels) in/on the high temperature plastic separator bars 222, together with the individual actuators, provides for independent positioning of all four heater bars 182, 184, 192, 194, and makes it convenient and practical to fit several heaters in a small space. Each heating element 220 is associated with its own thermocouple, such that the temperature of each heating element 220 may be independently selected and controlled for each heater bar.
One or more springs 211 (see
Tear Notch Applicator
After the film tube 12, with the reclosable fastener material 40 attached thereto so as to define a composite film tube, exits the vertical seal assembly 10, the composite film tube passes a tear notch applicator 250. The tear notch applicator is optional, meaning it does not have to be deployed when manufacturing certain kinds of bags. The tear notch applicator 250 includes a knife 266 that makes a small slit 262 in the composite film tube in the longitudinal machine direction. The slits 262 is positioned between the reclosable fastener material seal 260 and the edge seal 172. The knife 266 is mounted on a slide assembly 268 that moves in the transverse lateral direction 32. The tear notch applicator 250 is positionally fixed in the machine direction, meaning the tear notch applicator is not moveable in the machine/longitudinal direction during the normal operation of the machine, but may or may not be adjusted in such a direction when the machine is not operating. A controller times the actuation of the knife 266 such that the slit 262 is made in the composite film tube at a location where the slit 262 is intersected by a knife 280 making a transverse cut to separate the bags, with a portion of the slit 262 defining a tear notch 264 at each end of the bag as shown in
The tear notch applicator includes a linear servo motor 270, which momentarily positions the knife 266 in the film path at a time coordinated with the sealing jaw motion, such that the tear notch 264 is located at the bag cutoff line. In one embodiment, the knife 266 moves in and out in about 66 milliseconds, which is the total time from when the knife starts moving toward the film until it returns to the starting position. The knife is in the film path for about 20 milliseconds in one embodiment, wherein a 0.25 inch slide is made with the film moving at 12 inches per second. Depending on the film speed and desired length of the tear notch, the knife may be in the film path for 10 to 100 milliseconds.
Below the tear notch applicator, a driven pulley system, or vertical seal pull assembly 290, pinches the film tube and reclosable fastener material, pulling the film tube and reclosable fastener material in the machine direction, e.g., downwardly in the vertical machine. The pulling action provides tension within the vertical seal assembly 10, which helps the reclosable fastener material attach consistently to the film tube. Without tension, the reclosable fastener material, or film edges, may drag against the vertical seal bars or guide blade, causing the film or reclosable fastener material to bunch up and perhaps require a machine reset.
Sealing Jaw Assembly:
Downstream of the vertical seal pull assembly, the attached reclosable fastener material and film tube travel together as a composite film tube. The composite film tube travels through a sealing jaw assembly between a pair of sealing jaws, which match speed with the composite film tube traveling downstream in the machine direction, clamp the composite film tube to form a transverse seal across the composite film tube as the sealing jaws travel with the composite film tube, cut the film tube and reclosable fastener material at a specified repeat location, open and release the composite film tube, and return in the upstream direction for the next cycle.
Referring to
The jaws 20 are configured with a sealing device and a film separation device. The sealing device is mounted to one of the jaws between upper and lower grippers. The sealing device, in one embodiment, has a length equal to or greater than the width of the composite film tube 12. The sealing device may be configured as a heat seal bar, an ultrasonic sealing device or other suitable sealing device. In one embodiment, the sealing device is configured as an insert, which is secured to the carriage with a quick-release mechanism, including for example and without limitation removable pins. The film separation device is mounted to at least one of the jaws between the upper and lower grippers. The film separation device, in one embodiment, has a length equal to or greater than the width of the composite film tube 12. The film separation device is configured in one embodiment as a cutting device, such as a knife, secured to one of the opposing carriages. It should be understood that the film separation device can include other types of cutting devices including without limitation air and water jets, hot wire, die, shear, ultrasonic devices, and/or combinations thereof, positioned between the upper and lower grippers. In one embodiment, the film separation device is secured to the jaw with a quick-release mechanism, including for example and without limitation removable pins. The film separation device is laterally moveable relative to the jaw with an actuation cylinder from a cutting position to a retracted position.
In operation, and with reference to
In one embodiment, the jaws 20 have top and bottom sealing surfaces, with a film separation device, configured as a knife in one embodiment, located between the top and bottom surfaces. The film separation device fires through the film after the seal is made. The grippers may maintain a grip on the film as the film separation device is actuated in one embodiment. In an alternative embodiment, the jaws 20 may open a slight distance, for example about 10-15 mm, and move at a different velocity relative to the film tube 12 until the film separation device is aligned with the seal and the sealing device is moved out of alignment with the seal, whereinafter the the jaws 20 are then closed again. With the upper and lower grippers again gripping the film tube 12, the film separation device is actuated, for example by moving the cutting device laterally to thereby cut the film tube across the seal. Alternatively, the jaws can be closed with an extended knife so as to make the cut while moving with the film, preferably proximate the longitudinal centerline of the seal.
The film tube is filled with product 14 after a first lower seal is made and before a next upper seal is formed as shown in
For the entire system to operate in a continuous manner, the servo motion, including the reclosable fastener feed VFD unwind system, the flattening device, the reclosable fastener feed device, the tear notch applicator, and the sealing jaw position, are coordinated by one or more PLC (programmable logic controller) as shown for example in
Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 62/509,472, filed May 22, 2017 and entitled “Continuous Vertical Form, Fill and Seal Machine and Method for Making Reclosable Packages,” the entire disclosure of which is hereby incorporated herein by reference.
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