HEAT-SEAL COOLERS FOR PACKAGING SYSTEMS AND RELATED SYSTEMS, KITS, METHODS AND ASSEMBLIES

FIELD OF THE INVENTION

The present invention relates to packaging apparatus with heat-seal devices.

BACKGROUND OF THE INVENTION

Conventionally, in the production of consumer goods such as, for example, meat or other food products, the food is fed (typically pumped) or stuffed into a casing in a manner that allows the casing to fill with a desired amount of the product. As is well-known, the casings can be a slug-type natural or artificial casing that unwinds, advances, stretches and/or pulls to form the elongate casing over the desired product. Another type of casing is a heat-sealed tubular casing formed by seaming together long edges of a thin sheet of flexible material, typically elastomeric and/or polymeric material via an adhesive. U.S. Pat. Nos. 5,085,036 and 5,203,760 describe examples of automated substantially continuous-feed devices suitable for forming sheet material or flat roll stock into tubular film casings.

Rotating multi-clipper platform systems, such as the Rota-Clip® high speed packaging system by Tipper Tie, Apex, N.C., have been used with heat-seal devices to produce a series of chubs or clipped packages of product. See, e.g., U.S. Pat. Nos. 4,821,485; 5,020,298; 5,259,168; 5,471,815; 5,644,896 and 8,006,463. The contents of the above referenced patents are hereby incorporated by reference as if recited in full herein.

As is well known, the heat-seal seam is typically cooled so that when heated product fills the tube, which can occur close in time to the formation of the heat-seal, the seam will stay intact. In the past, chilled air blown on the seam has been used to solve this problem but chilled air systems may not be effective enough to reliably solve the problem. Water sprayed at the seam has also been used to dissipate heat/cool the seam. However, spraying water introduces the potential for water to get into operational components such as film drive motors and/or a vacuum film drive and/or water may undesirably collect or pool on the floor under and/or around the packaging machine.

SUMMARY OF EMBODIMENTS OF THE INVENTION

Embodiments of the invention provide a heat-seal cooler with a (typically, static) liquid applicator pad fed by a reservoir of liquid (e.g., water) that contacts the heated seal to apply a film of liquid (e.g., water) while minimizing dripping.

In some embodiments, the seal cooler may be used with a packaging system with a rotating table holding a plurality of circumferentially spaced apart clippers.

Some embodiments are directed to heat-seal cooler assemblies. The assemblies include a reservoir body comprising at least one liquid inlet in fluid communication with at least one liquid cavity, and at least one holding compartment with an open space with an outer facing open perimeter. The reservoir body also includes a partition extending between the at least one liquid cavity and the holding compartment. The partition is configured to distribute liquid from the liquid cavity over a longitudinally extending length of the holding compartment. The assemblies also include a valve in fluid communication with the at least one liquid inlet of the reservoir body.

The heat-seal cooler assemblies can include an applicator pad held in the holding compartment so that an outer surface thereof extends a distance below the holding compartment outside bounds of the reservoir body.

The valve can be attached to the reservoir body.

The reservoir body can have a length of between 3-10 inches.

The heat-seal cooler assemblies can include a liquid flow conduit attached to a valve and a liquid supply.

The applicator pad can have an elongate configuration with a planar exposed surface that contacts heat-sealed film.

The applicator pad can be rectangular with a length dimension greater than a height and a width dimension.

The reservoir body can have an elongate shape. The partition can include a plurality of longitudinally spaced apart apertures.

The applicator pad can have an elongate polygonal shape and can include felt and/or sponge material.

The holding compartment can have sidewalls that taper outward below the partition and longitudinally extending spaced apart shoulders that are sized and configured to releasably hold a compressible applicator pad therein.

The heat-seal cooler assemblies can include a mounting assembly configured to mount the reservoir body to a frame of a packaging system over a product horn so that the reservoir body is closely spaced apart above the product horn and is optionally able to float in a vertical direction to thereby accommodate uneven product horns.

Other embodiments are directed to packaging systems. The packaging systems can include a rotating platform having a vertical column and plurality of circumferentially spaced apart clippers mounted to the rotating platform. The platform is configured to concurrently mount the plurality of clippers in respective circumferentially spaced apart clipper stations. The packaging systems also include a heat-seal cooler holding an applicator pad with an exposed surface positioned adjacent and over a product horn so that the exposed surface of the applicator pad contacts heat-sealed film to thereby apply liquid to cool the heat-sealed film as the heat-sealed film travels toward the clippers.

The heat-seal cooler can include a reservoir body with at least one liquid inlet in fluid communication with an external valve. The reservoir body can have at least one liquid cavity that is configured to hold liquid and at least one holding compartment with an open space that holds the applicator pad. The reservoir body can also include a partition extending between the at least one liquid cavity and the holding compartment. The partition can be configured to distribute liquid from the liquid cavity over a longitudinally extending length of the holding compartment.

The valve can be attached to the reservoir body.

The applicator pad can be elongate with a length of between 3-10 inches.

The packaging systems can include a liquid flow valve attached to a reservoir body of the heat seal cooler and a liquid flow conduit extending to a liquid supply.

The applicator pad can be rectangular with a length dimension greater than a height and a width dimension. The applicator pad an include felt and/or a sponge material.

The reservoir body can have an elongate shape and a partition extending between the holding compartment and the at least one liquid cavity. The partition can include a plurality of longitudinally spaced apart apertures.

The holding compartment can have sidewalls that taper outward below the partition and can also include longitudinally extending spaced apart shoulders that are sized and configured to compress the applicator pad therein.

The packaging systems can include a mounting assembly configured to mount the reservoir body to a frame of the packaging system over a product horn so that the reservoir body is closely spaced apart above the product horn and is optionally able to float in a vertical direction to thereby accommodate uneven product horns.

The packaging systems can include an adhesive heat-seal module with a stationary-mounted extruder in communication with a hopper of bulk adhesive and an adhesive flow path supplying heated adhesive to an adhesive dispensing applicator that then dispenses the heated adhesive to film formed into a tubular shape using a forming collar residing upstream of the adhesive dispensing applicator. The applicator pad can reside downstream of the adhesive applicator a distance of between 0.1 inches and 6 inches.

The packaging systems can include a liquid supply conduit attached to a valve in fluid communication with the heat seal cooler and to a water liquid supply. The systems can include a controller that closes the valve when film is not being produced.

Still other embodiments are directed to retrofit kits for a multi-clipper rotating packaging system. The kits include a reservoir body comprising at least one liquid inlet in fluid communication with at least one liquid cavity. The reservoir body also includes a partition extending between the at least one liquid cavity and the holding compartment. The partition can include at least one aperture that is configured to distribute liquid from the liquid cavity over a longitudinally extending length of the holding compartment. The kits also include at least one compressible applicator pad configured to be releasably held by the reservoir body in the holding compartment so that an outer surface thereof extends a distance below the holding compartment outside bounds of the reservoir body.

The kits can include a valve attached to the reservoir body in fluid communication with the at least one liquid inlet of the reservoir body.

The applicator pad can be porous and can have a length of between 3-10 inches.

The kits can include a conduit adapted to attach to the valve and a liquid supply.

The applicator pad can have an elongate configuration with an exposed surface that contacts heat-sealed film when held in the reservoir body.

The applicator pad can be rectangular with a length dimension greater than a height and a width dimension.

The reservoir body can have an elongate shape. The partition can include a plurality of longitudinally spaced apart apertures.

The applicator pad can have an elongate shape and comprises felt or sponge material.

The kits can include a mounting assembly configured to mount the reservoir body to a frame of a packaging system over a product horn so that the reservoir body is closely spaced apart above the product horn.

The mounting assembly and/or applicator pad can be configured to be able to float in a vertical direction to thereby accommodate uneven product horns.

Still other aspects of the invention are directed to computer program products for operating a packaging system with a rotating table having a plurality of circumferentially spaced apart clippers thereon in communication with a forming collar and product horn to form flat stock into generally tubular film using a heat-seal module. The computer program product includes a non-transitory computer readable storage medium having computer readable program code embodied in the medium. The computer-readable program code including computer readable program code configured to open and close at least one meter-in flow valve in fluid communication with a liquid reservoir holding an applicator pad under a partition that distributes liquid over a length of the applicator pad when heat-seal film production is ongoing.

Other aspects of the system are directed to packaging systems. The packaging systems include: a product horn having a forming collar thereon and a roll of flat sheet stock in communication with the forming collar and the product horn. The system is configured to form the sheet stock in situ into a substantially tubular shape with open overlapping long edges about the product horn. The system also includes a hot adhesive supply source in communication with an adhesive applicator. The adhesive applicator applies heated adhesive to seal film held on the product horn into a tubular shape. The system also includes a heat-seal cooler with a reservoir body holding an applicator pad proximate to, but downstream of, the adhesive applicator. The reservoir body comprises at least one liquid inlet, and at least one holding compartment with the applicator pad held therein. The reservoir body also includes a partition extending between the at least one liquid cavity and the holding compartment. The partition is configured to distribute liquid from the liquid cavity over a longitudinally extending length of the applicator pad in the holding compartment to thereby wet the pad so that the pad can contact and apply moisture or liquid to a seam of the heat-seal film. The system also includes a valve in fluid communication with the at least one liquid inlet of the reservoir body and a liquid flow path comprising a conduit attached to the valve and extending to a liquid supply.

Still other embodiments are directed to methods of cooling a heat-seal of a container material. The methods include: forming a length of flat roll-stock packaging material into a tubular shape; heat-sealing a seam of the tubular shaped packaging material; contacting the heat-sealed seam with an applicator pad comprising liquid as the tubular packaging material is continuously pulled thereunder at a production rate; and applying liquid from the applicator pad to the heat-sealed seam in response to the contacting step to thereby cool the seam as the heat-sealed seam travels away from the applicator pad.

The flat roll-stock can be film.

The heat-sealing can be carried out using hot-melt adhesive applied to the seam at a temperature between 200 degrees C. and 300 degrees C.

The applicator pad can be held in a reservoir body under a partition with spaced apart apertures and the applicator pad faces downward to contact the heat-sealed seam of the packaging material.

The methods can also include flowing liquid into the reservoir body at a sufficient rate to apply a pressure that allows the applicator pad to apply the liquid in a dripless manner at film drive speeds of between about 100-330 feet/minute.

The applicator pad can be positioned above at least one film drive belt, axially in line with a product horn.

In some embodiments, a liquid (e.g., water) supply can be attached to a distribution block with an applicator material (e.g., a wicking or wetting material such as felt and/or a sponge). The liquid can wick, migrate or flow through the applicator material which rests on top of the film. This new device lays down a thin layer of water on top of the seam, and is carried away from the glue seal module towards the clippers. The contact-cooler can be configured so that no water drips around or near the film drive motors or vacuum belts. The applicator pad can be configured to “float” or have some resilience to accommodate different size horns and/or so that it can conform to the film and horn, as the horn may not be exactly level and configuring the cooler to float a little can be useful.

The seal cooler can be positioned above the product horn.

The seal cooler can be positioned adjacent the adhesive applicator above the film drive belts.

In some embodiments, the liquid delivered to the distribution block can be controlled by at least one valve so that liquid is only flowing when film is being made. When the valve is closed to stop the liquid flow, the applicator pad can retain the liquid therein without dripping to provide a drip-less contact cooler for a seal generated by a heat-seal module.

Some embodiments are directed to packaging machines that include a plurality of clippers held on a rotating table, an adhesive or glue dispenser residing upstream of the rotating table, and a roller module with a roller held adjacent the adhesive or glue dispenser nozzle.

The roller module can include a bracket that holds the roller.

The roller module can include an actuator cylinder with a leg that can extend and retract the roller.

The roller module can include first and second bracket members with the actuator leg attached to the second member and with roller attached to the first member under the actuator leg.

The roller module can include a spring held between the first and second members adjacent the roller.

The roller module can include a third bracket member residing above the first and second bracket members and a rod attached to the second and third bracket members parallel to the actuator leg.

The roller module can include a mounting assembly with an upper bracket member residing above first and second lower bracket members. The upper bracket member can hold the cylinder so that the actuator leg extends down to attach to the second bracket member with the roller held by the first bracket member so as to be closely spaced apart above a product horn.

The packaging machine can include an automated film lifter that can extend and retract to lift film residing adjacent and upstream of the dispenser.

The packaging machine can include a heat-seal cooler assembly residing between the rotating table and the roller module. The heat-seal cooler assembly can include a reservoir body that can have at least one liquid inlet and at least one holding compartment with a wall surrounding an outer facing open space. The heat-seal cooler assembly can also include a pad held in the holding compartment so that an outer surface thereof extends a distance outside of the wall surrounding the holding compartment.

Yet other embodiments are directed to packaging machines with a plurality of clippers held on a rotating table and a heat-seal cooler assembly residing upstream of the rotating table. The heat-seal cooler assembly can include a reservoir body comprising at least one liquid inlet and at least one holding compartment with a wall and having an outer facing open space and a pad held in the holding compartment so that an outer surface thereof extends a distance outside of the wall surrounding the holding compartment.

The wall may surround or partially surround the outer facing open space.

The packaging machine can include a valve in fluid communication with the reservoir body. The valve can optionally be attached to the reservoir body.

The reservoir body can be rectangular and has a length of between 3-10 inches.

The reservoir body can have a height greater that its lateral width and can have a length that is greater than its height.

The packaging machine can comprise a liquid flow conduit attached to the valve and a liquid supply.

The pad can have an elongate, horizontal orientation with the outer surface adapted to contact heat-sealed film.

The pad can be a felt pad or comprise felt that forms an outer surface thereof.

The reservoir body and/or pad can be rectangular with a length dimension that is larger than a width dimension.

The pad can have between 20-40 Shore A durometer hardness.

The pad can be held with an upper body portion thereof compressed inward in the reservoir body holding compartment.

The pad can comprise felt and can have a felt grade rating of F3, F5 or F7.

The pad can reside adjacent (and downstream of) a roller so that the roller resides within 0.25 inches and three inches of an adjacent end of the (applicator) pad.

Although described above with respect to method aspects of embodiments of the present invention, it will be understood that these features may also be embodied as systems, sub-systems, modules and/or computer program products. It is noted that aspects of the invention described with respect to one embodiment, may be incorporated in a different embodiment although not specifically described relative thereto. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination. Applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to be able to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner. These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front view of an exemplary heat-seal module according to embodiments of the present invention.

FIG. 1B is an enlarged view of part of the module shown in FIG. 1A.

FIG. 1C is a front view of another exemplary heat-seal module according to embodiments of the present invention.

FIG. 1D is a front perspective view of a machine with a heat-seal module similar to the machine shown in FIG. 1C, according to embodiments of the present invention.

FIG. 1E is a partial top, front perspective view of the machine shown in FIG. 1D, according to embodiments of the present invention.

FIG. 2 is a side perspective view of an exemplary heat-seal cooler over a heat-seal seam of film and product horn according to embodiments of the present invention.

FIG. 3A is a front perspective view of a packaging system with a multi-clipper rotational platform with a heat seal module that can incorporate a heat-seal cooler such as shown in FIG. 1A according to embodiments of the present invention.

FIG. 3B is a side perspective view of an exemplary heat seal module that can incorporate a heat-seal cooler such as that shown in FIG. 1A according to embodiments of the present invention.

FIG. 4A is a side perspective view of a reservoir body (e.g., applicator mount) according to embodiments of the present invention.

FIG. 4B is a front view of the reservoir body shown in FIG. 4A.

FIG. 4C is a bottom view of the reservoir body shown in FIG. 4A.

FIG. 4D is an end view of the reservoir body shown in FIG. 4A

FIG. 5 is a cross-sectional view taken along lines 5-5 in FIG. 4B.

FIG. 6 is a cross-sectional view taken along lines 6-6 in FIG. 4D.

FIG. 7A is a greatly enlarged, partial end perspective view of the reservoir body shown in FIG. 4A.

FIG. 7B is a greatly enlarged, partial end perspective view of the reservoir body shown in FIG. 7A illustrating an exemplary applicator pre and post assembly to the reservoir body according to some embodiments of the present invention.

FIG. 8 is an exploded view of an exemplary embodiment of a mounting assembly for a heat seal cooler according to embodiments of the present invention.

FIG. 9 is a front, side perspective view of another embodiment of a reservoir body for a heat-seal cooler according to embodiments of the present invention.

FIG. 10A is a front view of the reservoir body shown in FIG. 9.

FIG. 10B is a bottom view of the reservoir body shown in FIG. 10A.

FIG. 10C is an end view of the reservoir body shown in FIG. 10A.

FIG. 11 is a cross-sectional view taken along line 11-11 in FIG. 10A.

FIG. 12 is a cross-sectional view taken along line 12-12 in FIG. 10C.

FIG. 13A is a side perspective, section view of a reservoir body with pad for heat seal cooling according to some embodiments of the present invention.

FIG. 13B is a front, perspective view of the reservoir body shown in FIG. 13A mounted to a mounting bracket according to embodiments of the present invention.

FIG. 13C is a side perspective view of the reservoir body and mounting bracket in cooperating alignment with a horn and heat seal module according to embodiments of the present invention.

FIG. 14A is a side perspective view of another embodiment of a heat-seal seam cooler according to embodiments of the present invention.

FIG. 14B is a partially exploded view of the assembly shown in FIG. 14A.

FIG. 14C is a partially exploded view of an exemplary glue nozzle assembly according to embodiments of the present invention.

FIG. 14D is another partially exploded view of the glue nozzle assembly shown in FIG. 14C.

FIG. 15 is a schematic illustration of a heat-seal cooler system according to embodiments of the present invention.

FIG. 16 is a schematic illustration of another embodiment of a heat-seal cooler system according to embodiments of the present invention.

FIG. 17A is a schematic illustration of another embodiment of a heat-seal cooler system according to embodiments of the present invention.

FIG. 17B is a schematic illustration of yet another embodiment of a heat-seal cooler system according to embodiments of the present invention.

FIG. 18 is a front view of a heat-band seal module with a heat-seal cooler according to embodiments of the present invention.

FIG. 19 is a block diagram of a data processing system according to embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. Features described with respect to one embodiment may be used alone or with another embodiment although not specifically described with respect to that other embodiment.

In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations unless specified otherwise. The terms “FIG.” and “Fig.” are used interchangeably with the word “Figure” in the application and/or drawings. In addition, the sequence of operations (or steps) is not limited to the order presented in the claims unless specifically indicated otherwise. Where used, the terms “attached”, “connected”, “contacting”, “coupling” and the like, can mean either directly or indirectly, unless stated otherwise. The term “concurrently” means that the operations are carried out substantially simultaneously.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

The term “frame” means a generally skeletal structure used to support one or more assemblies, modules and/or components. The frame can be a floor mount frame.

The term “automated” means that operations can be carried out substantially without manual assistance, typically using programmatically directed control systems and electrical and/or mechanical devices. The term semi-automatic means that operator input or assistance may be used but that most operations are carried out automatically using electromechanical devices and programmatically directed control systems.

The term “about” means that the numerical value can vary by +/−20%.

In the description of embodiments of the present invention that follows, certain terms are employed to refer to the positional relationship of certain structures relative to other structures. As used herein, the term “front” or “forward” and derivatives thereof refer to the general or primary direction that the filler or product travels in a production line to form an encased product; this term is intended to be synonymous with the term “downstream,” which is often used in manufacturing or material flow environments to indicate that certain material traveling or being acted upon is farther along in that process than other material. Conversely, the terms “rearward” and “upstream” and derivatives thereof refer to the directions opposite, respectively, the forward and downstream directions.

The terms “adhesive” or “glue” means a material that when applied to a seam or overlying edge portions of a covering or casing material can adhere the edges to seal the product (typically in a substantially tubular or elongate shape). The seal is typically strong and is able to withstand desired pressures. For food products, the adhesive can be food grade, e.g., biocompatible. Examples of suitable adhesives include, but are not limited to, polymers such as melted HDPE (high density polyethylene).

Embodiments of the present invention are particularly suitable for cooperating with apparatus for producing encased products with clippers to apply clips to seal products held in the casings. The product may be a linked chain of elongated extruded product held in a casing. The casing or covering can be any suitable material or materials (edible or inedible, natural or synthetic) such as, but not limited to, collagen, cellulose, elastomeric, polymeric and/or plastic casing. The term “film” refers to a thin flexible sheet of covering material. The film can comprise foil or a foil laminate. When used with food products, the film, casing or covering should be food-compatible.

Referring now to the figures, exemplary heat-seal modules 100 are shown in FIGS. 1A, 1B, 1C, 1D and 1E. As shown, the heat-seal module 100 can include an adhesive system 30 with an associated (heated) adhesive flow path 30f that provides hot-melt or other heated adhesive to the adhesive applicator 39, e.g., nozzle or other dispensing member (FIG. 3A), a casing (i.e., film) drive assembly 40 (omitted from FIGS. 1A and 1B, shown in FIGS. 1C-1E, 3A and 3B), and a heat-seal cooler 125 positioned about an end portion 52e of a product horn 52, downstream of a forming collar 50. The heat-seal module 100 can include a Human Machine Interface (HMI) with a controller 10c and a display 10d for allowing a user to select certain operating parameters and/or review operational status and the like. To be clear, the term “module” when used with respect to the phrase “heat-seal” refers to a physical sub-assembly of a packaging system that seals flat stock for encasing a product, typically the heat-seal module seals the film or other casing material into a tubular shape. The term “module” when used with respect to a data processing system (see FIG. 19, for example) refers to computer executable program code for implementing specified logical functions.

As shown in FIGS. 1A, 1B, 13C, 14C and 14D, the heat-seal cooler 125 can reside downstream of the film drive assembly 40 and within a distance D of between about 0.1 inches to about 6 inches from the drive belts 221b, 222b (FIG. 3B). In some embodiments, as shown in FIG. 1C and 1E, the heat-seal cooler 125 can reside above the belts 221b, 222b, in line with the horn 52 and a short distance downstream of the adhesive applicator 39 (FIG. 3B), typically positioned to reside within about 0. 10 inches to about 6 inches from the applicator 39 more typically between about 0.25 inches and 3 inches.

In the embodiments shown in FIGS. 1C, 1D, 1E. 13C, 14C and 14D, for example, the seam cooler 125 can be located further upstream, closer to where the film overlap is sealed, i.e., adjacent the nozzle 39. This arrangement would be unsatisfactory with a “spray” type seam cooler as the excess water would get into the vacuum belts 221b, 222b. Advantageously, the new seam cooler 125 can be a “dripless” contact type cooler and the liquid coolant does not enter the vacuum drive system 40 (either none at all or a di minimis amount).

It is noted that while an adhesive heat-seal module 100 is shown, the heat-seal cooler 125 may be useful in other packaging systems including those that use heat, e.g., a heat-band 140 (FIG. 18), to seal the flat film without requiring application of an adhesive.

As shown in FIGS. 1A-1E, 2 and 13C, the heat-seal cooler 125 can include an applicator pad 130 that contacts a formed heat-seal 62 of film 60 as the film travels (is pulled) over the product horn 52. The heat-seal cooler 125 can comprise a reservoir body 132 with at least one cavity 132c that comprises a liquid coolant, e.g., water. The cavity 132c is in fluid communication with the applicator pad 130. The at least one cavity 132c feeds the liquid to the applicator pad 130. The applicator pad 130 has an external exposed surface 130e that contacts the heat-seal seam or area of the film 62 (FIG. 2). In use, the applicator pad 130 can contact the film and wipe liquid onto the heat-seal 62. The contact can apply a thin layer of liquid to avoid dripping the liquid from the applicator pad onto the floor under the applicator pad 130 or onto the film drive 40 or motor(s) thereof. Thus, the heat-seal cooler 125 is not required to be configured as a closed loop circulating coolant system.

In some embodiments, the liquid (e.g., water) reservoir body 132 is in fluid communication with a meter-in valve 135 and a supply flow line 137 (FIG. 2) to a liquid supply/liquid source 200 (FIG. 15).

FIG. 1E illustrates that the heat-seal module 100 and/or associated packaging machine can include an air piloted valve 1135 to control liquid supplied to the pad 130. The valve 1135 may be “ON” continuously or substantially continuously (e.g., 90% of the time that film production is in progress) when the pad 130 is applying coolant liquid to the seam 62. In some embodiments, the air piloted valve 1135 to control valve 135. The air piloted valve 1135, where used, can be cycled ON/OFF for defined times to create a flow for the liquid supplied to the cavity 132c, then to the pad 130 held by the reservoir body 132. The cycle may have a longer ON than OFF duration, equal ON/OFF periods or longer OFF than on periods. The cycling may be used to reduce liquid flow for slower speed film production runs. The controller 10c (e.g., PLC) can activate a pneumatic valve in the packaging machine, such as in a pneumatic box/control box that can pilot the valve 1135. A small liquid (e.g., water) supply line can be split from the liquid used for cooling a glue extruder jacket or other component, feature and/or region of the packaging device.

The applicator pad 130 can be held by the reservoir body 132. The applicator pad 130 can comprise a wicking or wetting material such as felt and/or a sponge material as described further below. Thus, the (coolant) liquid for the heat-seal can wick, migrate or flow through the applicator material which rests on/against the film. The heat-seal cooler 125 can dispense, wipe or lay down a thin layer of liquid (e.g., water) on top of the seam as the film travels past the heat-seal cooler 125 and the thin layer of liquid is carried away from the heat-seal (e.g., glue seal) module 100 and may be evaporated by the time the film reaches a clipper or other closure device. In some embodiments, the liquid-cooled heat-seal travels toward one or more clippers 22 (FIG. 3A). The contact-cooler 125 can be configured so that no water drips around or near the film drive system 40, e.g., the film drive motors and/or vacuum belts.

A controlled volume of liquid can be maintained in the reservoir cavity 132c. The volume may change over time or remain substantially constant. The at least one reservoir cavity 132c can be sized and configured to maintain a sufficient flow and/or migration of liquid coolant (e.g., water) through the applicator pad 130. As long as there is sufficient liquid volume, the density/porosity of the applicator pad 130 and the flow control valve 135 can control the liquid applied to the heat-seal film. In some embodiments, dense but porous material is used for the applicator pad 130 because for long wear and/or satisfactory performance characteristics.

The applicator pad 130 and/or reservoir body 132 can be configured to “float” or have some resilience to accommodate different size horns and/or so that it can conform to contact the film against the horn, as the horn 52 may not be precisely level.

The heat-seal cooler 125 can be attached to a frame 10f of the heat-seal module or other support member of the packaging system, using a mounting assembly 150. The mounting assembly 150 and associated components (heat seal cooler 125) can be provided as a retrofit kit as well as incorporated as features of OEM heat-module systems.

As shown in FIGS. 1B, 1C and 2, for example, the at least one cavity 132c of the reservoir body 132 can be in fluid communication with a meter-in flow valve 135 for adjusting flow rate and/or turning the liquid flow from the supply line 137 ON and OFF.

In the exemplary embodiment shown in FIGS. 1A, 3A and 3B, the flow path 30f has a substantially horizontal first portion associated with the (horizontal) extruder 33, which merges into a curvilinear portion associated with a conduit, pipe or hose 36 that travels up, then down to the adhesive applicator 39. The extruder 33 can be stationary and horizontally oriented in fluid communication with a hopper 31. The conduit, pipe or hose 36 can have a lower end proximate the adhesive applicator 39 that is able to move substantially vertically between about 3-6 inches, typically between about 4-5 inches (down for application or dispensing of the adhesive and up in a rest configuration). The heat seal module 100 with the fluid adhesive delivery system 30 can optionally include at least four separately controllable heat zones, shown as “A, B, C, D” in FIG. 3B. Individual control allows the system 10 to electronically monitor and to set different (or the same) temperatures at each zone A-D. Other extruder/adhesive systems and different flow paths may be used. The adhesive applicator 39 can be configured to emit a plurality of strips of adhesive onto the surface of the film/covering, typically three strips.

In some embodiments, as shown in FIGS. 1C and 13C, the adhesive system 30 can include a hopper 31 positioned above a horizontal extruder 33 with a flow path 30f that extends to the applicator 39. The horizontally extending extruder 33 can be oriented to extend perpendicular to the horn 52 as shown. A lifter 41 may be positioned upstream and adjacent to the applicator 39 (e.g., dispensing nozzle).

As shown in FIGS. 1A, 1D, 3A, 3B and 13C, the system 10 includes a heat seal module 100 with a vertically oriented hopper 31 that holds bulk adhesive material, typically in solid pellet, crystal or granule form. The adhesive pellets can comprise a polymer such as, for example, HDPE. The hopper 31 feeds the raw material to a horizontally extending screw extruder 33 that includes a barrel in communication with a screw auger. As shown, the extruder 33 is stationary and fixed in position. The barrel includes at least one heater, typically two internal heaters, to melt the pellets or other source adhesive material into a flowable form.

As shown in FIGS. 13B, 13C and 14A-14D, for example, a roller module 44 with a downwardly extending roller 43, typically a spring-loaded roller 43, can be positioned adjacent the dispenser 39, downstream thereof, to press against the seam 62 after the adhesive has been applied. Typically, as shown, the roller 43 is positioned before the heat-seal cooler 125, e.g., between the dispensing nozzle 39 and the heat seal cooler 125, such as 0.25-two inches from the dispenser 39 and between 0.25 inches and three inches of the closest end of the pad 130. The roller 43 can apply pressure to the seam 62 (FIG. 2) immediately after the adhesive (glue) is applied to facilitate a strong, flat seal. The roller module 44 can include a fluid (typically pneumatic) cylinder 47 with an actuator leg 47l to move it into operative position. The roller module 44 can include at least one downwardly extending spring 46 that can reside downstream of the roller 43 and that can apply a force unrelated to the air pressure force, typically a force smaller than the force applied by the cylinder 47.

The roller module 44 can include first and second bracket members 144b, 144u with the actuator leg 47l attached to the second member 144u and with roller 43 attached only to the first member 144b, under the actuator leg 47l.

The roller module 44 (i.e., roller assembly) can have a mounting assembly 144 that can include first, second and third brackets 144b, 144u, 47m. The lower or first bracket 144b can hold the roller 43. A coil spring 46 can be held between the first and second bracket members 144b, 144u, adjacent the roller 43. The upper or third bracket member 47m can reside above the first and second bracket members 144b, 144u. A rod 247 can be attached to the second and third bracket members 144u, 47m, and extend parallel to the actuator leg 47l. The lower or first bracket member 144b can hold the roller 43 to be closely spaced apart above a product horn 52.

The fluid flow system can comprise a pressure sensor that senses the pressure in the extruder barrel. The pressure limit can be configured to ensure that the downstream pipe or hose is not over-pressured; typically the pressure limit is set to about 1500 psi and the system 10 and/or the adhesive system 30 can be automatically shut down if this pressure is exceeded. A suitable commercially available extruder is a ¾ inch screw extruder from Killion Extruders, located in Cedar Grove, N.J. A keyway or groove can be bored or formed into the inner diameter of the extruder feed section (at about “6:00 o'clock” opposite the infeed of the hopper) to promote flowability of the pellets into the extruder 33 without over driving the motor. Further details of a packaging system and en exemplary hot-melt seal system can be bound in U.S. Pat. No. 8,006,463, the contents of which are hereby incorporated by reference as if recited in full herein.

As shown in FIGS. 1A, 1B, 1C, 1D2, 3A and 3B, and as is well known to those of skill in the art, the packaging system 10 and/or heat-seal module 100 can include a forming collar 50 that is configured to form sealed (seamed) substantially tubular casings from an elastomeric and/or polymeric sheet and/or planar roll stock that is then stuffed or filled with flowable product. More typically, the roll stock is an elastomeric and/or polymeric sheet that is relatively thin. The roll stock can be flat sheet stock of a flexible film that can be formed in situ into a continuous length of heat-sealed and/or otherwise joined or seamed tubular casing. The forming can be carried out substantially automatically and continuously over a desired interval (typically between at least about 45-60 minutes, depending on the size of the length of the roll stock).

The heat-seal can be performed using a hot-melt flowable material, such as a polymer, as the adhesive that seals two layers together to form a seam that connects the two long edges/edge portions to form a tubular body from flat roll stock. The seaming can use additional and/or other suitable sealing means, including, for example, a heat-seal band, ultrasonic, light (ultraviolet or other desired wavelength), chemical, mechanical and/or other sealing means. The seam can be a flat seam, a fin seam, or other overlapping and/or abutting joint configuration, but is typically formed with one long edge 62 of the casing 60 overlapping the other as shown, for example, in FIG. 2. The adhesive can be heated to or above the melt point, typically between about 200-300 degrees Celsius to promote the flow of the adhesive. The adhesive can be discharged from the adhesive applicator 30 onto to the film at a temperature that is between about 200-300 degrees Celsius.

The encased elongated or tubular product can be an elongated food product, such as a meat product. Exemplary meat products include, but are not limited to, strands of meat (that may comprise pepperoni, poultry, and/or beef or other desired meat), and processed meat products including whole or partial meat mixtures, including sausages, hotdogs, and the like. Other embodiments of the present invention may be directed to seal other types of food (such as cheese) or other product in film or other casing materials. Examples of other products include powders such as granular materials including grain, sugar, sand, explosives and the like or other flowable materials including wet pet food (similar to that held conventionally in cans) or other powder, granular, solid, semi-solid or gelatinous materials. The product may be a packaged in any suitable industry including food, aquaculture, agriculture, environment, chemical, explosives, or other applications.

FIGS. 1A and 3A illustrate tension feedback members 70 that communicate with the filled tensioned casing/product (not shown). One member is configured to translate outwardly from a pivoting arm in response to excess tension, which exerts force against the respective member, causing the film speed, the adhesive extrusion speed, and/or adhesion delivery to increase. In operation, the downstream member of the members 70 is configured to communicate with a position sensor to provide the feedback to the controller to allow the controller to adjust the operational parameters. FIGS. 1A and 3A illustrate that the tension feedback members 70 can reside above an end portion of a discharge feed support surface 55.

FIGS. 3A and 3B illustrate an exemplary packaging system 10 with a rotating platform or table 20 holding multiple clippers that can include the heat-seal module 100 is shown. Although shown as including (typically dual) clippers 22, not all need be operational during a packaging operation (e.g., alternating ones can be deactivated), or the table 20 may include other numbers of clippers 22, typically between 10-14. Rota-Clip® packaging systems are available from Tipper Tie, Apex, N.C. As shown in FIGS. 3A and 3B, the rotating platform 20 can have a table top 21 with circumferentially spaced apart clippers 22 (typically double clippers). The number of clippers 22 used in combination with the circumference of the table 20, and/or the radially adjusted position of the clippers 22 on the table 20 can allow for different lengths of end product to be produced. For example, for the same clipper radial positions, one operation using all 12 (twelve) clippers 22 can produce a six-inch product and if every other clipper 22 is deactivated, up to a 36 inch product can be used. Larger sizes can be achieved using alternate configurations.

As shown in FIG. 3A, the system 10 can include miniature ball valves 22v, typically one for each clipper 22 in communication with a pneumatic control that automatically controls the activation and deactivation of the respective clipper 22 based on the system (HMI/PLC) controller 10c. As with conventional rotating platform clippers, in operation, the sealed filled tubular covering is clipped under the platform table surface. The system 10 can be configured a touchscreen input on the HMI (human/machine interface) display 10d. This user-selectable input can tell the rear and front vacuum belt drives 221, 222 of the film drive assembly 40, to open or close, and can automate various control functions. After the film 60 is in position, the machine/system 10 is ready for operational position, whereby the vacuum belt drives 221, 222 should be closed so that the vacuum belts 221b, 222b abut up against the film 60, clamping the film 60 between the horn 52 and the belts 221b, 222b. This can be done pneumatically with air cylinders which are associated with the vacuum belt drives 221, 222. A belt driven by an electric motor can drive both vacuum belt drives 221, 222. The film drive assembly 40 can have an adjustment wheel 225 which can move both of the vacuum belt drives 221, 222 (together) toward the front or back of the machine. This action allows the front and back vacuum belt drives to be aligned substantially equidistant to the horn 52. Once they are equal in distance from the horn 52, an input on the touchscreen 10d (FIG. 1A) can be used to electronically open or close the vacuum drives 221, 222. The opening and closing are typically simultaneous. It is noted that, while vacuum film drives are shown by way of example for moving the film through or past the heat-seal module 100, other film drives may be used.

Referring to FIG. 3A, two air lines 22a can run down the center column 12 for each clipper station 22s. One line is the main air line for the trigger valve underneath the sprocket. The second air line allows the clipper gate of the respective clipper 22 to close. It can also have an inline shut off valve 22v installed in the tubing. If this is used, it shuts off the air to the gate cylinder on that individual clipper. If the gate does not close, the clipper will not “fire” (send down the punch or fire the knife). The reason behind turning off a clipper is to run a longer product than the normal length of product (e.g., chub) that each clipper can handle. For example, if clipper #1 is on, clipper #2 is off, and clipper #3 is on, the product length becomes the distance from the #1 clipper to the #3 clipper.

The system 10 can operate at a rate that is either about 300 pieces/minute or a maximum of about 300 feet of film/minute, whichever comes first. To further explain the term “whichever comes first”: the speed of the overall machine can be determined in feet of film/minute produced. The smaller length and smaller diameter products can sometimes pump faster than large ones. For example, an 8 inch long×1 inch diameter piece or “chub” of product can be pumped and produced faster than a 18 inch long chub×3 inch in diameter. Embodiments of the present invention can produce 300 pieces/minute as long as they are 12 inch and under. Pump speeds can vary for each facility. In some embodiments, the system 10 can produce between about 100 feet to about 400 feet of film/minute, such as about 300 feet of film/minute.

The rotating platform 20 has a vertical support 12 (also described as a column or leg) which is in communication with the main drive system 20d that rotates the platform and clippers at the desired speed (and can automatically vary the speed depending on production requirements/inputs). The air supply lines that connect to the various clippers can travel down the column 12 to an air supply. The system 10 can include a single common main air supply that can be diverted to feed all of the clippers. Alternatively, each or groups of the clippers may have a dedicated discrete air supply. Each clipper 22 can include on-board air supply conduits/lines with valves that releasably connect to the air supply lines on the column 12.

The system 10 can include a Siemens variable frequency drive and integral safety system, including, for example, a Siemens Step7300 Processor with Integral Safety Systems, including a Siemens touch screen, motor drives and safety modules. The touch screen can include a series of iconic and/or pictorial image display of user-activated or status indicating features for various components, e.g., adhesive nozzle down, pump “on or off' and the like. The electric motors can be explosion-proof TECO motors that can be mounted outside the electrical box to reduce or eliminate cooling issues. The system can include automatic positioning of vacuum belt drives. The system 10 can be Ethernet ready for remote access via VPN and may also be PROFIBUS ready, foreign language supported.

In some embodiments, the system 10 can be configured to operate with an automated synchronized drive control system that may use a single virtual axis for ramp-up to maximum operational speed that synchronizes the covering (e.g., film) drive, the adhesive extruder drive and the rotating table drive (using the Siemens or a similar variable frequency drive system). Each drive system can operate at a selected (variable or constant) speed. The film and extrusion drive can operate to provide sealed tubular covering at any desired speed, including between about 10-400 feet per minute, typically between about 150-300 feet/min; more typically, the machine can operate at an operating speed of about 300 feet/minute.

Referring now to FIGS. 4A-4C, 5, 6, 7A and 7B, one example of a reservoir body 132 of the heat-seal cooler 125 is shown. In this embodiment, the reservoir body 132 has outer walls surrounding at least one elongate internal liquid cavity 132c in fluid communication with a liquid inlet 132i. The liquid inlet 132i is shown medially located through a top wall but can be located at other positions. The liquid inlet 132i can be provided as a single inlet or a plurality of inlets.

The reservoir body 132 can also include an interior longitudinally extending partition or wall 132w that is positioned between the liquid cavity 132c and a holding compartment 133 for the applicator pad 130. The interior partition or wall 132w can be configured to provide a distribution of liquid over at least a major portion of a length of the pad 130 and in any event a longer length than direct flow to the pad from the typically single inlet 132i. The liquid transfer paths provided by the distribution pattern of the apertures in the reser{acute over (v)}oir cavity 132 to the applicator pad in the holding compartment 133. As shown, the partition 132w has at least one aperture 132a extending therethrough to define a liquid exit path for the liquid held in the at least one cavity 132c to feed the pad 130 in the open region 133 holding the applicator pad 130.

The applicator pad 130 can be a consumable component that can be replaced by an operator/user at desired intervals. The applicator pad 130 can be releasably held in the holding compartment 133 of the reservoir body 132.

As shown, the reservoir body 132 has a unitary/single member configuration to provide the reservoir liquid cavity 132c, partition 132w and holding compartment 133. However, the reservoir body 132 can alternatively be configured as separate cooperating members such as stackable cooperating members to provide the noted components.

FIG. 5 illustrates that the sidewalls 133w of the holding compartment 133 can angle outward an angle β between about 10-20 degrees, typically between about 12-14 degrees. The angle β can be, for example, about 10 degrees, about 11 degrees, about 12 degrees about 13 degrees, about 14 degrees, about 15 degrees, about 16 degrees, about 17 degrees, about 18 degrees, about 19 degrees and about 20 degrees, in some embodiments. The upper shoulder of the holding compartment 133s can angle down to reside at an angle a from the side wall 133w that can be between about 50 to about 80 degrees, typically between about 60 and 80 degrees, and more typically between about 65 and 75 degrees such as about 68-70 degrees, in some embodiments.

The applicator pad 130 can have a shape that is compressed when held in the reservoir body 132 compared to its natural self-supporting shape (without any force applied) outside the reservoir body. FIG. 7B shows the applicator pad 130 in a natural self-supporting three dimensional “block-like” shape 130n outside the reservoir body 132 and the compressed shape 130c inside the reservoir body 132. The applicator pad 130 can occupy most or all of the volume of the open compartment 133 so that liquid coolant (e.g., water) can only exit the reservoir body 132 through the applicator pad 130. The applicator pad 130 can extend a distance “d” outside the compartment 133. The holding compartment 133 can have longitudinally extending tapered sidewalls 133w and shoulders 133s that can concurrently apply compression forces Fc to the applicator pad 130.

The reservoir body 132 can have an open compartment 133 that releasably holds the applicator pad 130 while allowing one side (e.g., a bottom in the orientation shown in FIGS. 1A and 1B) of the applicator pad 130 to extend outward a distance “d” from the reservoir body 132 to form the external pad contact surface 130e. The distance “d” can be between 10-80%, typically between 10-50%, of a height of the applicator pad 130. The distance “d” can be between about 0.1 inches and about 1 inch, but other distance values may be used. In some embodiments the applicator pad 130 can have a height that is between about 1 inch and 2 inches, and a width that is less than the height, typically by about 20% to 60% less, such as about 25%, about 30%, about 30%, about 40%, about 45%, and about 50% less. In some embodiments, the width is about 0.5 inches. In some particular embodiments, the height of the pad 130 can be about 1 inch with about ⅝ inch in the holding compartment 133 and about ⅜ inch exposed/extending out the bottom of the reservoir body 132, 132′.

As shown in FIG. 4C and 6, the at least one aperture 132a can be a plurality of longitudinally spaced apart apertures 132a in a single line, laterally centered. However, the apertures 132a can be provided in other arrangements such as in a plurality of lines, in neighboring lines with adjacent apertures offset from each other, in different lines. The apertures 132a are shown as regularly spaced apart, typically by between about 0.3 to about 0.75 inches, but may be irregularly spaced apart (not shown).

The at least one aperture 132a can be smaller than the at least one liquid inlet 132i. For example, the liquid inlet 132i can have a diameter that is between 0.20 and 0.16 inches and the at least one aperture 132a can have a diameter or maximal width dimension that is between 0.10 and 0.13 inches. The at least one aperture 132a can have a maximal width/length dimension (e.g., diameter) of between 0.10 inches to 0.13 inches, in some particular embodiments. Although shown in FIG. 4C as circular, the apertures 132a can have other shapes including slits 132s (FIG. 7A) in one or more of a transverse, angled or longitudinally extending orientation.

The number of apertures 132a can vary, typically between 1-100, more typically between 5-50. In the embodiments shown in FIGS. 4C and 13A, the reservoir body 132° comprises eleven apertures 132a, shown as arranged in a straight line (but offset designs may be used).

Referring to FIG. 5, the reservoir body 132 can hold the internal liquid cavity 132c above the holding compartment 133. The holding compartment 133 can have sidewalls that taper out widen toward the lower end, typically at an angle that is between 10-20 degrees from vertical. The holding compartment 133 can have an upper portion with shoulders 133s that can have an outer edge that can grip against the applicator pad 130, when held therein in a compressed shape.

As shown in FIGS. 7A and 7B, for example, the shoulders 133s can extend inwardly and taper upward and face each other across the holding compartment to define sharp pinch points/surfaces for the applicator pad 130. The applicator pad 130 can be held in the holding compartment 133 to have a wider top and bottom configuration relative to the upwardly/downwardly extending shape of the compressed pad between the exposed lower surface 130e and the top 130t.

As shown in FIGS. 1A and 1B, the applicator pad 130 can face down out of the reservoir body 132, in some embodiments. However, in other embodiments, the reservoir body 132 can be held upside down from this orientation or sideways to position the applicator pad 130 at other positions, typically corresponding to the location of the heat-seal weld/seam.

The reservoir body 132, 132′ can be an elongate body or have a length between 3-10 inches, such as about 3 inches, about 3.5 inches, about 4 inches, about 4.5 inches, about 5 inches, about 5.5 inches, about 6 inches, about 6.5 inches, about 7 inches, about 7.5 inches, about 8 inches, about 8.5 inches, about 9 inches, about 9.5 inches and about 10 inches.

The pad 130 can have a substantially block-like shape and in some embodiments, may be configured as an elongate rectangular body as shown in an exploded view in FIG. 8. The applicator pad 130 can have a height dimension that is greater than its width dimension. In some embodiments, the applicator pad 130 can have a width (outside the reservoir body 132) that is between about 0. 3 inches and 1 inch, such as about 0.4 inches, about 0.5 inches, about 0.6 inches, about 0.7 inches and about 0.9 inches, for example. The applicator pad 130 can have a height that is between about 0.4 to about 0.7 inches. The applicator pad 130 can have a length that is between about 3-10 inches such as about 3 inches, about 3.5 inches, about 4 inches, about 4.5 inches, about 5 inches, about 5.5 inches, about 6 inches, about 6.5 inches, about 7 inches, about 7.5 inches, about 8 inches, about 8.5 inches, about 9 inches, about 9.5 inches and about 10 inches.

The applicator pad 130 can have other shapes, typically, but optionally, with a planar film-contact surface 130e. The film contact surface 130e can alternatively have a curved shape that has a radius of curvature corresponding to the underlying product horn. The applicator pad 130 can have a cross-sectional shape that is a “T” shape, a triangular shape, or a polygonal shape such as a pentagon or octagon and the like.

The applicator pad 130 can comprise a deformable, porous material or materials, such as felt, foam and/or a sponge material. Where the applicator pad 130 comprises a sponge material, the sponge can be synthetic or natural and should be able to withstand temperatures of about 200-250 degrees Celsius (or even up to about 320 degrees C., in some embodiments) without undue degradation for a suitable operating period such as at least one shift (6-8 hours).

The applicator pad 130 can comprise a felt. Felt can be synthetic or natural. The felt can have a high percentage of wool, typically between about 95%-100%. Wool fiber has a resilient cortex encased in a rigid jacket covered with microscopic barbs, or scales. With heat, moisture and pounding, the fibers relax, curl and interlock in all directions. With increased hammering and pounding, the fibers can be compressed or hardened into a tight dense mass. The resulting product can be firm and compact while still retaining a degree of resilience. 100% wool felt is divided into two broad classifications, SAE Felt and Technical Felt. Density, which relates to hardness, determines major property differences. Felt density can be determined as conventional and known to those of skill in the art. For example, felt density can be determined by weighing a 36″×36″×1″ sample., if a 36″×36″×1″ felt sheet weighs 20 lbs., it is referred to as “20-lb. felt.”

In some embodiments, the applicator pad 130 can comprise felt which can have between 10-40 lbs/square yard density. In some embodiments, the applicator pad 130 can have a felt density of between 10-20 lbs/square yard.

In some particular embodiments, the applicator pad 130 can comprise a felt with a density of about 10 lbs/square yard to about 20 lbs/square yard with about 80%, 85%, 90% or 95% or greater wool content.

The felt can be synthetic and/or natural felt. The felt can be sheet felt, which is a dense, pressed wool product. The felt can comprise needle punched felt, which refers to felt that is made by vertically needling fibers together to achieve a desired thickness and density. Needled felt is commonly made from wool, synthetic and other re-processed fibers. When viewing a cross-section of needled punched felt, the fibers lay vertically, as opposed to pressed felt, where the fibers lay horizontally. Needle punched wool felt normally contains a lower percentage of wool as compared to SAE wool felts

The applicator pad 130 can have between a 20-40 Shore A hardness, more typically between 20-35 Shore A durometer hardness, such as about 20, about 25, about 30 or about 35 Shore A hardness.

In some embodiments, for sponge/foam material, the applicator pad 130 can have between a 70-86 Shore 00 hardness, typically between about 76-83 Shore 00 hardness.

The applicator pad 130 can have between about a 100-600 (minimum) psi tensile strength, such as a (min) tensile strength that is about 150 psi, about 200 psi, about 250 psi, about 300 psi, about 350 psi, about 400 psi, about 450 psi, about 500 psi, about 550 psi and about 600 psi.

In some embodiments, the applicator pad 130 can comprise felt having a Felt grade rating of F3 (Felt Grade), F5 or F7.

In some embodiments, the felt can be F3 with a density of about 15.6 lbs./square yard at 1″ thick, durometer hardness Shore A 35, and rated (min) tensile strength of 400 psi. In some embodiments, the felt can be F5 with a density at about 12.2 lbs./square yard at 1″ thick, durometer hardness Shore A 25 and a rated tensile strength (min) of 400 psi. In some embodiments, the felt can be F7, with a density at about 12.2 lbs./square yard at 1″ thick, durometer hardness Shore A 25, and rated (min) tensile strength 250 psi.

The applicator pad 130 can be wetted by the liquid in the reservoir cavity 132c to a degree that allows the applicator pad 130 to apply the liquid to the heat-seal of the film in a dripless manner. The term “dripless” means that after at least one hour of operation of the heat-seal cooler with the heat-seal module 100 (FIG. 1A) in a normal film production mode and normal fluid supply volume/rate to the cooler 125, no liquid accumulation or pooling from the heat-seal cooler 125 is found on adjacent components of the floor. During normal operation, the liquid (e.g., water) can be visually seen as a film or light layer of moisture that is carried way with the movement of the film progressing downstream of the heat-seal cooler 125. The term “dripless” also means that when liquid pressure from a flowing liquid supply is removed from the reservoir body 132, 132′, liquid does not continue to flow or drip from the applicator pad 130, even when the reservoir body is oriented so that the pad 130 is vertical and exposed, above the horn 52.

FIG. 8 illustrates an exemplary mounting assembly 150 for mounting the heat-seal cooler 125 to a heat-seal module 100 of a packaging machine 10. The mounting assembly 150 includes a reservoir-body holding bracket 155 that holds the reservoir body 132 in a vertically adjustable manner. As shown, the bracket 155 can be attached to a slide plate 156 held by a bracket 158 with rails 159. The frame bracket with rails 158 can be stationary and attached to a frame of the heat-seal module 100 and/or packaging system 10. A plunger-style lock pin 152 can extend through the mounting bracket 155 to engage to frame bracket 158 to lock the mounting bracket 155 at a suitable height. Other mounting configurations may be used.

The mounting bracket 150 can float relative to the product horn 52 to some degree so that the applicator pad 130 can conform to the film and horn 52 as the horn 52 may not be exactly level.

A meter-in flow control valve 135 can be held by the reservoir body 132. A “tee” fitting 136 can be sealably attached to the inlet 132i to provide a connection for a flow conduit 137 (FIG. 2) and the meter-in flow valve 135.

FIGS. 9, 10A-10C, 11 and 12 illustrate another embodiment of a reservoir body 132′ for a heat-seal cooler 125. In this embodiment, the reservoir body 132′ has mounting ears 160 with slots 161 for vertical height adjustment when mounting to the packaging system/heat-seal module 100. Shoulder bolts 170 (FIG. 9) can extend through the slots 161 so that it is allowed to float.

FIGS. 13A-13C illustrate a similar embodiment to that shown in FIGS. 9, 1A-10C, 11 and 12. The reservoir body 132 can be held by a mounting bracket 150′ that is attached to the frame or housing of the packaging machine 10. The mounting bracket 150′ can hold a gas cylinder 147 that can direct the actuator leg 147l to move up and down on vertical slide arms 149 to position the pad 130 held by the reservoir body 132. The reservoir body 132 can include at least one in-flow valve 135.

FIGS. 14A and 14B illustrate an embodiments similar to that shown in FIGS. 9 and 13C. In this embodiment, the reservoir body 132 (i.e., holder of the pad which may optionally be or comprise a felt pad) can be held by a mounting bracket 150″ that has a first seam cooler holding segment 125b and can also include an adjacent roller bracket segment 44b. The mounting bracket 150′ can be a unitary plate with a first planar wall 150w₁that merges into an adjacent recessed planar wall 150w₂that resides a lateral distance recessed or inward from a centerline of the product horn 50.

The bracket 150″ can hold an air operated valve 135′ and a valve flow control meter 135f in fluid communication with the fitting 136′ for the inlet port 132i of the reservoir 132′. The heat seal cooler assembly can include a water supply split off member 200c that connects to the valve 135′ and to a water supply line/flow path from a water source 200 (FIG. 15), such as a water supply from the extruder water jacket or from before the extruder water jacket that also supplies the water jacket of the extruder (not shown).

FIGS. 14C and 14C illustrate an exemplary glue nozzle assembly 100a that can optionally be provided as a retrofit kit and/or that can be attached during a new manufacture of a packaging machine. The assembly 100a can include a nozzle and roller support 126. The bracket 150″ can attach to the support 126 to hold the roller assembly 44 and the heat seam cooler 125 downstream of the applicator nozzle 39 and film hook/lifter 41.

The nozzle 39 can be held by a heater block assembly 139 and can reside between the hook/lifter 41 and the roller assembly 44 with roller 43.

The roller assembly 44 can include upper and lower blocks 144u, 144b attached to the roller cylinder mount 47m also holding the cylinder 47. The lower block 144b can hold the wheel 43 via a pin (e.g., laterally extending shaft) 178.

The nozzle 39 can extend inwardly (across/on an opposing side of a longitudinally extending centerline of the product horn) to face the seal cooler 125 (FIG. 14D).

The assembly 100a can include a glue nozzle position assembly 246 with a laterally extending rod 246r that can reside laterally across from the lifter/hook 41 before the nozzle 30, typically aligned with or longitudinally offset from the lifter 41 by between 0.1inches and 1 inch. The lifter 41 and glue nozzle 39 can be aligned vertically, e.g., reside at a common height position during operation.

In some embodiments, there can be between about a 3inch to about a 4 inch offset between the 246r adjustment rod and the 126 plate because of the space for the linkage at the end of the adjustment rod 246r.

The adjustment rod 246r can have a length between about 1 foot to about 2 feet, such as about 18 inches, in some embodiments. The rod 246r can be sufficiently long to reach out to an outer edge of the frame, to be in a position that's easy for an operator to access to make adjustments.

The glue nozzle position assembly 246 can allow for lateral adjustment by rotating the knob 246k. The glue nozzle position assembly 246 can include upper and lower glue nozzle guides 341u, 341b that can slide on rails/shafts 342. A vertically oriented cylinder 241 can raise and lower the glue nozzle position assembly 246.

The nozzle can be held by a nozzle subassembly 239 with a glue nozzle guard 239g. The glue nozzle 39 can be held by a glue nozzle block 139, which may comprise a heater element. The nozzle subassembly includes a port/fitting 239f for connecting to conduit associated with an extruder 33 (FIG. 13C, for example) for providing the glue. The block 139 can be attached to the nozzle and roller support 126.

A hook actuation cylinder 141 can pivot the hook/lifter 41 to lift one of the seam edges to allow the nozzle 39 to apply glue/adhesive. The actuation cylinder 141 can be oriented horizontally as shown. The hook 41 can include an aperture 41a that allows a shoulder bolt 159 to attach to a fixed threaded nut 103 which can cooperate with and/or provide the pivot for the hook (film lifter) 41.

The glue nozzle assembly 100a can include a clevis 111 attached to a bracket 122 that is held by the cross support 126 to cooperate with the cylinder 241 (typically above and in-line with the cylinder 241 in the configuration/orientation shown in FIG. 14C) so that the glue nozzle assembly 100a can travel up and down, lift and lower, the glue nozzle 39 vertically.

It is noted that while FIGS. 8, 9 and 13A, illustrate exemplary reservoir bodies 132 as a single (unitary) body, the reservoir body can be provided as a set of attached or spaced apart reservoir bodies as can the pad 130.

The applicator pad 130 can be a single unitary pad or may be provided as a plurality of pads, stacked vertically and/or arranged longitudinally in contact or closely spaced apart from one another by 1-10 mm, for example.

FIG. 15 is a schematic illustration of an example of a heat-seal cooler control circuit 100c. The circuit 100c can be configured to control the ON/OFF or flow rate of liquid into the reservoir body 132, 132′ from a liquid supply 200. The liquid supply 200 can be any suitable liquid such as water. The liquid can be non-volatile and/or non-hazardous. For food-based production, the water can be clean and suitable for use in a food production facility.

The flow rates into the reservoir 132, 132′ from the liquid supply 200 can vary for a respective heat-seal cooler 125, typically depending at least in part on film production speed. Film speed can be used to select an appropriate flow rate to provide the amount of liquid supply which can adequately cool the heat-seal seam. Predefined correlations of film speed based on glue usage and/or film property may be provided (e.g., as a computer database look up chart) to automatically provide a liquid flow rate suitable for reliable cooling during operation.

The liquid in the reservoir 132, 132′ can be at ambient temperature and is not required to be cooled. The controller 10c can be configured to automatically shut the valve 135 in fluid communication with the supply of liquid to the reservoir 200 to “OFF” when film is not being produced and can be configured to automatically open the valve to ON when film is being produced, based on a triggering event or user input to a start production mode on the display 10d, for example. A user can also manually close the valve 135. The automated operation may inhibit liquid pooling or dripping when film production ceases, for example.

The liquid flow rate into the reservoir body 132, 132′ during production may, in some particular embodiments, be between about 1 ml/min and about 3500 ml/min, and may, in some embodiments be between about 100 ml/min and about 3000 ml/min. The flow rate can be a continuous “drip” or slow rate and/or may be successive short ON/OFF cycles or faster flow rates, at rates/fills sufficient to keep the reservoir at a desired liquid capacity without overfilling to maintain a desired pressure without forcing undue amounts of liquid into through the applicator pad 130 and/or into the holding compartment 133 with the applicator pad 130.

Upon start-up, per shift, for example, the controller 10c can direct liquid to flow into the reservoir body 132, 132′ to pre-fill to a defined level or volume so that once film is being produced, the heat-seal cooler 125 is active with the applicator pad 130 sufficiently wet to be able to apply liquid to the heat-seal film. The controller 10d can be configured to prevent film seal until the heat-seal cooler is ready for active operation with sufficient liquid in the reservoir cavity and/or the applicator pad pre-filled/exposed with sufficient liquid to provide the heat-seal cooling.

Sensors can be used to confirm that a liquid level in the reservoir body is proper and/or to confirm the applicator pad 130 is in proper position or sufficiently wet. For example, a “blank” substrate with a liquid sensor can be placed on the horn 52 under the applicator pad 130 and the controller 10c can monitor the sensor to then allow/start film production or activate the heat-seal module, for example. In other embodiments, the liquid sensor can be placed in the applicator pad itself above the exposed surface 130e or in the sidewall 133s of the holding compartment 133.

While not wishing to be bound by any particular film rate or liquid flow rate, an example of a calculation of one flow rate for about a 300 ft/min operational mode is discussed below.

Thermo-property of Nova Sclair 2714: Softening point: 119° C.; Melt Temperature: 170-280 C. (mean glue applied temp 200° C).

Instant cool down temp: 150° C. Cool temp AT=200−150=50° C.
Sclair glue temp usage: p/n 99-0936 2-hole nozzle hole size: 0.036″Φ×2
Cross section A=0.657 mm²
Film speed={tilde over (v)} (this case, 300 ft/min)
Glue usage speed in ml/min=0.657/100×{tilde over (v)} ×30.48
If film speed equals 300 ft/min, glue usage=60 ml/min (single hole)
Total glue usage=60×2=120 ml/min or 0.4×{tilde over (v)} (feet/min)
Cp reference Water Cp=1 Kcal/kg ° C. HDPE Cp=0.55 Kcal/kg
Water flow calculation:
Thermo equilibrium when Water Cp=HDPE Cp
Therefore, water flow=ΔT×HDPE Cp×Mass of 2714=50×0.55×120=3300 ml/min or about 3.3 liter/min.

FIG. 15 also illustrates a timing diagram that may be used by the controller 10c to synchronize or time operation of components of the heat-seal cooler system, e.g., the valve 135 ON/OFF based on film production ON/OFF or START/STOP.

FIG. 16 illustrates that the control circuit 100c can have a common or shared liquid supply 200 that can be used to supply liquid to the reservoir 132, 132′ and to a glue extruder (housing) 33 for cooling both using a T-flow path from the liquid supply 200. The liquid flow path can include a control valve 235 for automated ON/OFF and/or flow control operation.

FIGS. 17A and 17B illustrate a series of reservoir bodies 132 can be used in lieu of a unitary body 132, 132′ as discussed above. FIG. 17A illustrates a single inlet control valve can be used for each respective inlet 132i. FIG. 17B illustrates each may have a separate flow control valve 135. FIG. 17B also illustrates that the respective reservoir bodies may be mounted together via a slide bar 333 or other attachment configuration, for example. Although not shown, a plurality of adjacent applicator pads 130 may be held by a respective reservoir body 132, 132′.

FIG. 18 illustrates the heat-seal cooler 125 used with a different packaging system 10′ that has a heat-band seal assembly 140 according to embodiments of the present invention. For more details of this type of system, see, U.S. Patent Application Publication Ser. No. 2015/0119218, the contents of which are hereby incorporated by reference as if recited in full herein.

FIG. 19 is a block diagram of exemplary embodiments of data processing systems that illustrates systems, methods, and computer program products in accordance with embodiments of the present invention. The processor 410 communicates with the memory 414 via an address/data bus 448. The processor 410 can be any commercially available or custom microprocessor. The memory 414 is representative of the overall hierarchy of memory devices containing the software and data used to implement the functionality of the data processing system. The memory 414 can include, but is not limited to, the following types of devices: cache, ROM, PROM, EPROM, EEPROM, flash memory, SRAM, and DRAM.

As shown in FIG. 19, the memory 414 may include several categories of software and data used in the data processing system 405: the operating system 452; the application programs 454; the input/output (I/O) device drivers 458; the Automated Liquid ON/OFF Control Module 450 that can synchronize liquid flow into the reservoir with film production; and data 456.

The data 456 may include a look-up chart of different “recipes” as well as the associated drive speeds, clipper and table position set-up information, and the like, corresponding to particular or target products for one or more producers. The data 456 may a synchronized drive module for synchronizing the drive speeds of the different cooperating systems, e.g., film drive system, the table rotation drive system, the extruding speed, pump speed, and the like. The speed of the film/covering 60 or rotation speed of the table 20 and the like can be adjusted based on real-time feedback of the operative status of the machine such as from the tension/force feedback from the dancer arm discussed above with respect to FIG. 3A. Selection of all, groups and/or individual clippers 22 can be automated based on the “recipe” to activate or deactivate certain clippers at different (typically alternating) clipper stations, e.g., stations 1-12.

As will be appreciated by those of skill in the art, the operating system 452 may be any operating system suitable for use with a data processing system, such as OS/2, AIX, DOS, OS/390 or System390 from International Business Machines Corporation, Armonk, N.Y., Windows CE, Windows NT, Windows95, Windows98 or Windows2000 from Microsoft Corporation, Redmond, Wash., Unix or Linux or FreeBSD, Palm OS from Palm, Inc., Mac OS from Apple Computer, LabView, or proprietary operating systems. The I/O device drivers 458 typically include software routines accessed through the operating system 452 by the application programs 454 to communicate with devices such as I/O data port(s), data storage 456 and certain memory 414 components. The application programs 454 are illustrative of the programs that implement the various features of the data processing system 405 and preferably include at least one application which supports operations according to embodiments of the present invention. Finally, the data 456 represents the static and dynamic data used by the application programs 454, the operating system 452, the I/O device drivers 458, and other software programs that may reside in the memory 414.

While the present invention is illustrated, for example, with reference to the Module 450 being an application program in FIG. 19, as will be appreciated by those of skill in the art, other configurations may also be utilized while still benefiting from the teachings of the present invention. For example, the Module 450 may also be incorporated into the operating system 452, the I/O device drivers 458 or other such logical division of the data processing system 405. Thus, the present invention should not be construed as limited to the configuration of FIG. 19, which is intended to encompass any configuration capable of carrying out the operations described herein.

The I/O data port can be used to transfer information between the data processing system 405 and the downstream clippers or another computer system or a network (e.g., the Internet or Ethernet) or to other devices controlled by the processor. These components may be conventional components such as those used in many conventional data processing systems which may be configured in accordance with the present invention to operate as described herein.

While the present invention is illustrated, for example, with reference to particular divisions of programs, functions and memories, the present invention should not be construed as limited to such logical divisions. Thus, the present invention should not be construed as limited to the configuration of FIG. 19 but is intended to encompass any configuration capable of carrying out the operations described herein.

The operation and sequence of events and can be controlled by a programmable logic controller (PLC). The operational mode and certain input parameters or machine controls can be selected or controlled by an operator input using a Human Machine Interface (HMI) to communicate with the controller as is well known to those of skill in the art.

The block diagram illustrates the architecture, functionality, and operation of possible implementations of embodiments of the present invention. In this regard, each block in the flow charts or block diagrams represents a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. In the claims, means-plus-function clauses, where used, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.

	Number	Date	Country
	62182006	Jun 2015	US
	62234994	Sep 2015	US

HEAT-SEAL COOLERS FOR PACKAGING SYSTEMS AND RELATED SYSTEMS, KITS, METHODS AND ASSEMBLIES

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