PACKAGING MACHINE AND PACKAGING METHOD

The present application is based on, and claims priority from JP Application Serial Number 2021-160809, filed Sep. 30, 2021, the disclosure of which is hereby incorporated by reference herein in its entirety.

BACKGROUND
1. Technical Field

Embodiments of the present disclosure relate to a packaging machine and a packaging method.

2. Related Art

A wrapped object manufacturing machine that produces a wrapped object by packaging an object to be wrapped using a wrapping material is known. The manufacturing machine disclosed in JP-A-029270 wraps the object to be wrapped with the wrapping material. The manufacturing machine melts and bonds two surfaces of the wrapping material in a wrapping state to each other. The manufacturing machine wraps the wrapping material around the object to be wrapped. The manufacturing machine wraps the object to be wrapped with the wrapping material formed into a pillowcase-cylindrical shape.

Since the manufacturing machine wraps the wrapping material around the object to be wrapped, the width of the wrapping material used is greater than the perimeter of the object to be wrapped. The installation area of the manufacturing machine is inevitably large because the wrapping material is conveyed inside the manufacturing machine.

SUMMARY

A packaging machine according to a certain aspect of the present disclosure includes: a first supplying unit that supplies a first packaging material; a second supplying unit that supplies a second packaging material; a placing mechanism that places an object to be packaged on the first packaging material supplied by the first supplying unit; a moving mechanism that moves the first packaging material, with the object to be packaged placed on the first packaging material, in a direction along a first axis; a guide member that guides the second packaging material onto the object to be packaged; and a joining mechanism that joins the first packaging material and the second packaging material together, wherein the object to be packaged is packaged using the first packaging material and the second packaging material.

Another aspect of the present disclosure is a packaging method of packaging an object to be packaged using a packaging machine into which a first packaging material and a second packaging material are configured to be loaded, including: placing the object to be packaged on the first packaging material; conveying the first packaging material, with the object to be packaged placed on the first packaging material; guiding the second packaging material onto the object to be packaged; and packaging the object to be packaged by joining the first packaging material and the second packaging material together.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a carton packaging machine.

FIG. 2 is another schematic view of the carton packaging machine.

FIG. 3 is a diagram illustrating the block configuration of the carton packaging machine.

FIG. 4 is a flowchart illustrating the processes of manufacturing a sheet.

FIG. 5 is a diagram illustrating the structure of a first sheet.

FIG. 6 is another diagram illustrating the structure of the first sheet.

FIG. 7 is a diagram illustrating the structure of a packaged object.

FIG. 8 is a flowchart illustrating the processes of packaging a carton.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIGS. 1 and 2 are schematic views of a carton packaging machine 10. The carton packaging machine 10 packages cartons B using a first sheet S1 and a second sheet S2. FIG. 1 is a view of the carton packaging machine 10 from the +X side. FIG. 2 is a view of the carton packaging machine 10 from the +Z side. In FIG. 2, a second roll R2, the second sheet S2, a second supporting roller 31, and a pair of guide rollers 33, which will be described later, are not illustrated. The carton packaging machine 10 is an example of a packaging machine. The carton B is an example of an object to be packaged. The shape of the carton B illustrated in FIGS. 1 and 2 is a rectangular parallelepiped but is not limited thereto. The carton B may have any shape that can be packaged. For example, the carton B may have a cylindrical shape, a hemispherical shape, a plate shape, an indefinite shape, or the like.

Some of the accompanying drawings, including FIG. 1, illustrate an XYZ coordinate system. The X, Y, and Z axes are orthogonal to one another. The X axis is parallel to a plane on which the carton packaging machine 10 is installed. The X axis is an axis orthogonal to a direction in which the cartons B are conveyed by a conveyor belt 15, which will be described later. The direction from the back to the front of the attached sheet of FIG. 1 is the +X direction. The direction from the front to the back of the attached sheet of FIG. 1 is the −X direction. The Y axis is parallel to the plane on which the carton packaging machine 10 is installed. The Y axis is an axis parallel to the direction in which the cartons B are conveyed by the conveyor belt 15. The direction in which the cartons B are conveyed is the +Y direction. The direction opposite of the direction in which the cartons B are conveyed is the −Y direction. The Z axis is perpendicular to the plane on which the carton packaging machine 10 is installed. The direction going vertically up away from the installation plane is the +Z direction. The direction going vertically down toward the installation plane is the −Z direction. The Y axis is an example of a first axis. The +Y direction is an example of a direction along the first axis. The X axis is an example of a second axis.

As illustrated in FIG. 1, the carton packaging machine 10 includes a supporting table 11, which is installed on the installation plane. The supporting table 11 supports the conveyor belt 15. The conveyor belt 15 conveys the first sheet S1, and the cartons B placed on the first sheet S1, in the +Y direction. The conveyor belt 15 has a belt width W in the direction along the X axis. The conveyor belt 15 is an example of a moving mechanism. The mechanism that conveys the cartons B is not limited to the conveyor belt 15. The mechanism that conveys the cartons B may be made up of a plurality of conveyor rollers. The mechanism that conveys the cartons B may be a robot that has at least one arm for gripping the carton B. The mechanism that conveys the cartons B may be configured in any way as long as it is capable of conveying the cartons B in a predetermined direction. The mechanism that conveys the cartons B is an example of a moving mechanism.

The carton packaging machine 10 includes a first supporting roller 21. The first supporting roller 21 supports a first roll R1. The first roll R1 is a roll formed of the first sheet S1. The width of the first sheet S1, of which the first roll R1 is formed, is a first sheet width W1. The first sheet width W1 is either the same as or shorter than the belt width W. The structure of the first sheet S1 will be described later. The first sheet S1 is an example of a first packaging material. The first supporting roller 21 supplies the first sheet S1 to the conveyor belt 15. The first supporting roller 21 is an example of a first supplying unit. The conveyor belt 15 conveys the first sheet S1 supplied therefrom in the +Y direction. The first supporting roller 21 may rotate by being driven by a drive mechanism that is not illustrated. The carton packaging machine 10 illustrated in FIGS. 1 and 2 supplies, as the first sheet S1, a multilayer sheet that includes a binding layer containing a binder.

At a first position P1, the carton packaging machine 10 performs placement of the carton B. Namely, at the first position P1, the carton B is placed onto the first sheet S1 conveyed by the conveyor belt 15. The first position P1 is a carton placement position on the conveyor belt 15. The cartons B are supplied to the conveyor belt 15 by a carton supplying belt 17 illustrated in FIG. 2. As illustrated in FIG. 2, the carton supplying belt 17 conveys the cartons B in the +X direction. The cartons B conveyed by the carton supplying belt 17 are transferred onto the first sheet S1 conveyed by the conveyor belt 15. The carton supplying belt 17 is an example of a placing mechanism.

As illustrated in FIG. 1, the carton packaging machine 10 includes the second supporting roller 31. The second supporting roller 32 supports the second roll R2. The second roll R2 is a roll formed of the second sheet S2. The width of the second sheet S2, of which the second roll R2 is formed, is a second sheet width W2. The second sheet width W2 may be the same as the first sheet width W1. The second sheet width W2 may be different from the first sheet width W1. The second sheet width W2 is either the same as or, preferably, shorter than the belt width W. The structure of the second sheet S2 will be described later. The second sheet S2 is an example of a second packaging material. The second supporting roller 31 unreels the second sheet S2. The second supporting roller 31 may rotate by being driven by a drive mechanism that is not illustrated. The second supporting roller 31 is an example of a second supplying unit. The carton packaging machine 10 illustrated in FIG. 1 supplies, as the second sheet S2, a multilayer sheet that includes a binding layer containing a binder.

The carton packaging machine 10 includes the pair of guide rollers 33. The pair of guide rollers 33 guide, onto the carton B, the second sheet S2 unreeled from the second roll R2. The pair of guide rollers 33 are disposed at a +Z-side position with respect to the conveyor belt 15. The pair of guide rollers 33 may rotate by being driven by a drive mechanism that is not illustrated. By being rotated by the drive mechanism, the pair of guide rollers 33 may cause the second sheet S2 to be unreeled from the second roll R2. The pair of guide rollers 33 constitute an example of a guide member.

The second sheet S2 unreeled therefrom is supplied at a second position P2 onto the carton B conveyed by the conveyor belt 15. The top of the carton B becomes covered by the second sheet S2 at the second position P2. The second position P2 is a second sheet supplying position. The carton B onto which the second sheet S2 has been supplied is conveyed by the conveyor belt 15 to a third position P3.

The carton packaging machine 10 includes a cutter 41. The cutter 41 executes the cutting of the first sheet S1 and the second sheet S2 when the carton B arrives at the third position P3. The cutter 41 is located between the second position P2 and the third position P3. The cutter 41 cuts the first sheet S1 and the second sheet S2 at a −Y-side position with respect to the third position P3. The third position P3 is a cutting execution position. After the cutting of the first sheet S1 and the second sheet S2 by the cutter 41, the carton B, the cut first sheet S1, and the cut second sheet S2 are conveyed to a fourth position P4.

The carton packaging machine 10 includes a first melt bonding mechanism 50. The first melt bonding mechanism 50 joins edge portions of the first sheet S1 and edge portions of the second sheet S2 together by melt bonding. The edge portions of the first sheet S1 mentioned here and the edge portions of the second sheet S2 mentioned here are respective edge portions intersecting with the Y axis. The first melt bonding mechanism 50 includes a first melt bonding member 51 and a second melt bonding member 53. Each of the first melt bonding member 51 and the second melt bonding member 53 has a melt bonding surface that is not illustrated. Each of the melt bonding surface of the first melt bonding member 51 and the melt bonding surface of the second melt bonding member 53 applies heat to the first sheet S1 and the second sheet S2. Each of the first melt bonding member 51 and the second melt bonding member 53 may press the first sheet S1 and the second sheet S2. The first sheet S1 and the second sheet S2 become joined together by melt bonding due to the action of the binder when they are heated. Each of the first melt bonding member 51 and the second melt bonding member 53 joins the first sheet S1 and the second sheet S2 together by melt bonding in the direction along the X axis. The fourth position P4 is a first joining execution position. The first melt bonding mechanism 50 is an example of a joining mechanism. Melt bonding executed by the joining mechanism is an example of joining.

The first melt bonding member 51 is disposed at a −Y-side position of the fourth position P4. The first melt bonding member 51 joins the first sheet S1 and the second sheet S2 together by melt bonding at the −Y-side position with respect to the carton B located at the fourth position P4. The −Y-side edge portion of the first sheet S1 and the −Y-side edge portion of the second sheet S2 become joined together by melt bonding by the first melt bonding member 51 along the X axis. The first melt bonding member 51 is an example of a third joining portion.

The second melt bonding member 53 is disposed at a +Y-side position of the fourth position P4. The second melt bonding member 53 joins the first sheet S1 and the second sheet S2 together by melt bonding at the +Y-side position with respect to the carton B located at the fourth position P4. The +Y-side edge portion of the first sheet S1 and the +Y-side edge portion of the second sheet S2 become joined together by melt bonding by the second melt bonding member 53 along the X axis. The second melt bonding member 53 is an example of a fourth joining portion.

The first melt bonding mechanism 50 includes the first melt bonding member 51, which joins the first sheet S1 and the second sheet S2 together by melt bonding at a position on one side with respect to the carton B on the Y axis, and the second melt bonding member 53, which joins the first sheet S1 and the second sheet S2 together by melt bonding at a position on the other side with respect to the carton B on the Y axis.

The carton packaging machine 10 is able to package the carton B by joining the first sheet S1 and the second sheet S2 at the position on one side and the position on the other side with respect to the carton B on the Y axis. As compared with a structure in which the first sheet S1 alone is wrapped around the carton B in a Y-wrapping direction, the carton packaging machine 10 makes it possible to make the distance between the cartons B shorter. Therefore, the productivity of the carton packaging machine 10 improves.

The first sheet S1 and the second sheet S2 in combination are wrapped around the carton B in a Y-wrapping direction by the joining of the first sheet S1 and the second sheet S2 together by melt bonding. The carton B around which the first sheet S1 and the second sheet S2 in combination have been wrapped in the Y-wrapping direction will be hereinafter referred to as “a half-packaged object in process”. Since the first sheet S1 and the second sheet S2 in combination are wrapped around the carton B, the length in the direction along the Y axis of each of the first sheet S1 and the second sheet S2 may be less than the perimeter of the carton B in the direction along the Y axis. The interval between the second position P2 and the third position P3 may be shorter than one half of the perimeter of the carton B in the direction along the Y axis.

The half-packaged object in process is conveyed from the fourth position P4 to a fifth position P5 by the conveyor belt 15. The carton packaging machine 10 includes a second melt bonding mechanism 60 provided at the fifth position P5. The second melt bonding mechanism 60 joins edge portions of the first sheet S1 and edge portions of the second sheet S2 together by melt bonding. The edge portions of the first sheet S1 mentioned here and the edge portions of the second sheet S2 mentioned here are respective edge portions intersecting with the X axis. The second melt bonding mechanism 60 includes a third melt bonding member 61 and a fourth melt bonding member 63. Each of the third melt bonding member 61 and the fourth melt bonding member 63 has a melt bonding surface that is not illustrated. Each of the melt bonding surface of the third melt bonding member 61 and the melt bonding surface of the fourth melt bonding member 63 applies heat to the first sheet S1 and the second sheet S2. Each of the third melt bonding member 61 and the fourth melt bonding member 63 may press the first sheet S1 and the second sheet S2. The first sheet S1 and the second sheet S2 become joined together by melt bonding due to the action of the binder when they are heated. Each of the third melt bonding member 61 and the fourth melt bonding member 63 joins the first sheet S1 and the second sheet S2 together in the direction along the Y axis. The fifth position P5 is a second joining execution position. The second melt bonding mechanism 60 is an example of the joining mechanism.

The third melt bonding member 61 is disposed at a −X-side position of the fifth position P5. The third melt bonding member 61 joins the first sheet S1 and the second sheet S2 together by melt bonding at the −X-side position with respect to the carton B located at the fifth position P5. The −X-side edge portion of the first sheet S1 and the −X-side edge portion of the second sheet S2 become joined together by melt bonding by the third melt bonding member 61 along the Y axis. The third melt bonding member 61 is an example of a first joining portion.

The fourth melt bonding member 63 is disposed at a +X-side position of the fifth position P5. The fourth melt bonding member 63 joins the first sheet S1 and the second sheet S2 together by melt bonding at the +X-side position with respect to the carton B located at the fifth position P5. The +X-side edge portion of the first sheet S1 and the +X-side edge portion of the second sheet S2 become joined together by melt bonding by the fourth melt bonding member 63 along the Y axis. The fourth melt bonding member 63 is an example of a second joining portion.

The first sheet S1 and the second sheet S2 in combination are wrapped around the carton B in an X-wrapping direction by the joining of the first sheet S1 and the second sheet S2 together. The carton B around which the first sheet S1 and the second sheet S2 in combination have been wrapped in the Y-wrapping direction and in the X-wrapping direction will be hereinafter referred to as “a completely-packaged object in process”. Since the first sheet S1 and the second sheet S2 in combination are wrapped around the carton B, it suffices that the width of each of the first sheet S1 and the second sheet S2 is slightly greater than one half of the perimeter of the carton B in the direction along the X axis. The length in the direction along the X axis of each of the first sheet S1 and the second sheet S2 may be less than the perimeter of the carton B in the direction along the X axis. The belt width W of the conveyor belt 15 supporting the first sheet S1 may be less than the perimeter of the carton B in the direction along the X axis. It is possible to reduce the installation area of the carton packaging machine 10 because it is possible to reduce the first sheet width W1 of the first sheet S1, the second sheet width W2 of the second sheet S2, and the belt width W of the conveyor belt 15.

The second melt bonding mechanism 60 includes the third melt bonding member 61, which joins the first sheet S1 and the second sheet S2 together by melt bonding at a position on one side with respect to the carton B on the X axis intersecting with the Y axis, and the fourth melt bonding member 63, which joins the first sheet S1 and the second sheet S2 together by melt bonding at a position on the other side with respect to the carton B on the X axis.

Having these melt bonding members at the respective two ends of the first sheet S1 and the second sheet S2 in the width direction, the carton packaging machine 10 is able to package the carton B reliably.

A user who operates the carton packaging machine 10 may package the carton B by means of the first sheet S1 and the second sheet S2 without causing either one of the first melt bonding mechanism 50 and the second melt bonding mechanism 60 to operate. If the user causes the second melt bonding mechanism 60 to join the first sheet S1 and the second sheet S2 together by melt bonding without causing the first melt bonding mechanism 50 to operate, the first sheet S1 and the second sheet S2 in combination are wrapped around the carton B in the X-wrapping direction. The carton B around which the first sheet S1 and the second sheet S2 in combination have been wrapped in the X-wrapping direction is a half-packaged object in process. In this case, the half-packaged object in process has an opening at its −Y-side edge portion and an opening at its +Y-side edge portion.

The carton B is packaged by means of the first sheet S1 and the second sheet S2 by joining the first sheet S1 and the second sheet S2 together by melt bonding by either one or both of the first melt bonding mechanism 50 and the second melt bonding mechanism 60. When the first sheet S1 and the second sheet S2 are joined together by melt bonding by both of the first melt bonding mechanism 50 and the second melt bonding mechanism 60, the carton B is packaged hermetically.

The completely-packaged object in process or the half-packaged object in process having been formed by joining the first sheet S1 and the second sheet S2 together by melt bonding at the fifth position P5 is conveyed to a sixth position S6. The completely-packaged object in process or the half-packaged object in process having been conveyed to the sixth position S6 is ejected to the outside of the carton packaging machine 10. The sixth position P6 is a carton ejecting position.

A processing mechanism that performs processing on the completely-packaged object in process or the half-packaged object in process may be provided at the sixth position P6. For example, a print mechanism that is not illustrated is provided thereat. The print mechanism performs printing on the surface of the second sheet S2. The print mechanism prints packaged product delivery address information, information about the product in the carton B, or the like. Alternatively, a cutting mechanism is provided thereat. The cutting mechanism trims the edges of the first sheet S1 and the second sheet S2. By trimming the edges, the cutting mechanism adjusts the shape of the packaged object in process.

The carton packaging machine 10 includes a control unit 70. The control unit 70 is a controller that controls each component of the carton packaging machine 10. The controller includes a central processing unit (CPU), a read only memory (ROM), a random access memory (RAM), and a storage that are not illustrated. The control unit 70 detects detection results from various sensors that are not illustrated, and performs various kinds of control.

A block configuration of the carton packaging machine 10 is illustrated in FIG. 3. The carton packaging machine 10 incudes a first sheet supplying unit 100, a carton supplying unit 110, a second sheet supplying unit 120, a cutting unit 130, a joining unit 140, and a carton ejecting unit 150.

The first sheet supplying unit 100 supplies the first sheet S1. In the carton packaging machine 10 illustrated in FIG. 1, the first supporting roller 21 is an example of the first sheet supplying unit 100. The first sheet supplying unit 100 may have and support the first sheet S1 in the form of the first roll R1 as illustrated in FIG. 1. The first sheet supplying unit 100 may have and support the first sheet S1 in any other form. For example, the first sheet supplying unit 100 may have and support the first sheet S1 in a folded sheet form. If the first sheet supplying unit 100 has and supports the first sheet S1 in a folded sheet form, it includes a sheet feeder mechanism configured to unfold and supply the first sheet S1. The first sheet supplying unit 100 is an example of a first supplying unit.

It is preferable if the first sheet supplying unit 100 has and supports the first sheet S1 in the form of the first roll R1. Since the first sheet S1 formed in the shape of the first roll R1 has not any folded portion, it offers a higher degree of freedom in choosing a cutting position. Therefore, it is easier to adjust the cut length of the first sheet S1 in the direction along the Y axis.

The carton supplying unit 110 supplies the cartons B onto the first sheet S1. The −Z-side surface of the cartons B is covered by the first sheet S1. In the carton packaging machine 10 illustrated in FIG. 2, the carton supplying belt 17 is an example of the carton supplying unit 110. The carton supplying unit 110 is not limited to the carton supplying belt 17 illustrated in FIG. 2. The carton supplying unit 110 may be a robot that has at least one arm for gripping the carton B. The carton supplying unit 110 may be embodied in any specific manner as along as it is configured to place the cartons B on the first sheet S1. The carton supplying unit 110 is an example of a placing mechanism.

The second sheet supplying unit 120 supplies the second sheet S2 to the top of the carton B. In the carton packaging machine 10 illustrated in FIG. 1, the second supporting roller 31 is an example of the second sheet supplying unit 120. The second sheet supplying unit 120 may have and support the second sheet S2 in the form of the second roll R2 as illustrated in FIG. 1. The second sheet supplying unit 120 may have and support the second sheet S2 in any other form. For example, the second sheet supplying unit 120 may have and support the second sheet S2 in a folded sheet form. If the second sheet supplying unit 120 has and supports the second sheet S2 in a folded sheet form, it includes a sheet feeder mechanism configured to unfold and supply the second sheet S2. A part of the second sheet supplying unit 120 is an example of a second supplying unit.

It is preferable if the second sheet supplying unit 120 has and supports the second sheet S2 in the form of the second roll R2. Since the second sheet S2 formed in the shape of the second roll R2 has not any folded portion, it offers a higher degree of freedom in choosing a cutting position. Therefore, it is easier to adjust the cut length of the second sheet S2 in the direction along the Y axis.

The second sheet S2 supplied by the second sheet supplying unit 120 may be the same as the first sheet S1. The second sheet S2 may be different from the first sheet S1. It is preferable if the second sheet S2 is different from the first sheet S1. It is preferable if at least one of the width, thickness, material, or form of the second sheet S2 is different from the width, thickness, material, or form of the first sheet S1. The form is, for example, the shape when the sheet is supported, the layer structure thereof, the surface shape thereof, or the like.

As described above, the first sheet supplying unit 100 is able to supply the first sheet S1 by unreeling it from its roll, and the second sheet supplying unit 120 is able to supply the second sheet S2 by unreeling it from its roll.

Since the carton packaging machine 10 uses the first sheet S1 formed in the shape of the roll and the second sheet S2 formed in the shape of the roll, the degree of freedom in adjusting the length of the first sheet S1 and the length of the second sheet S2 in the direction in which the cartons B are conveyed is high.

The second sheet supplying unit 120 is able to supply the second sheet S2 different from the first sheet S1.

By this means, the carton packaging machine 10 is able to package the carton B while satisfying requirements varying from part to part in terms of strength.

The second sheet supplying unit 120 includes a guide portion. The guide portion guides the second sheet S2 to a position on the +Z-side surface of the carton B. The +Z-side surface of the carton B becomes covered by the second sheet S2 guided by the guide portion. In the carton packaging machine 10 illustrated in FIG. 1, the pair of guide rollers 33 constitute an example of the guide portion. The guide portion is not limited to the pair of guide rollers 33 as long as it is configured to guide the second sheet S2 to the top of the carton B. The guide portion may be a guiding plate. The guide portion is an example of the guide member.

The cutting unit 130 cuts the first sheet S1 and the second sheet S2. In the carton packaging machine 10 illustrated in FIG. 1, the cutter 41 is an example of the cutting unit 130. The cutting unit 130 may be a rotary-blade-type cutter or a guillotine-type cutter. Although a single cutter only is provided as the cutter 41 in FIG. 1, a plurality of cutters may be provided. The cutting unit 130 may include two or more cutting mechanisms. The cutting unit 130 may adjust the width and length of the first sheet S1 and the second sheet S2 that are cut by using the plurality of cutting mechanisms.

The joining unit 140 joins the first sheet S1 and the second sheet S2 together. The joining unit 140 is an example of the joining mechanism. In the carton packaging machine 10 illustrated in FIGS. 1 and 2, the first melt bonding mechanism 50 and the second melt bonding mechanism 60 constitute an example of the joining unit 140. The first sheet S1 after the cutting have four edge portions, namely, the edge portion at the +X-side position, the edge portion at the −X-side position, the edge portion at the +Y-side position, and the edge portion at the −Y-side position with respect to the carton B. The second sheet S2 after the cutting also have four edge portions, namely, the edge portion at the +X-side position, the edge portion at the −X-side position, the edge portion at the +Y-side position, and the edge portion at the −Y-side position with respect to the carton B. The joining unit 140 joins at least two of these four edge portions together. The joining unit 140 packages the carton B by joining two or more edge portions together. The carton B covered by the first sheet S1 and the second sheet S2 joined to each other at their two or three edge portions is a half-packaged object in process. The carton B covered by the first sheet S1 and the second sheet S2 joined to each other at their all four edge portions is a completely-packaged object in process.

The first melt bonding mechanism 50 and the second melt bonding mechanism 60 illustrated in FIG. 1 are configured to join the first sheet S1 and the second sheet S2 together by melt bonding by applying heat to the binder contained in the first sheet S1 and the binder contained in the second sheet S2. However, the joining unit 140 is not limited to such a melt bonding unit. The joining unit 140 may have any other structure as long as it is configured to join the first sheet S1 and the second sheet S2 together. The joining unit 140 may include an adhesive bonding mechanism configured to apply an adhesive and a folding mechanism configured to fold the first sheet S1 and the second sheet S2. The joining unit 140 may include such a folding mechanism and a tape applying mechanism configured to apply an adhesive tape.

It is preferable if the joining unit 140 employs melt bonding. The melt bonding mechanism joins the first sheet S1 and the second sheet S2 together by melt bonding by melting the binder contained in either one or both of the first sheet S1 and the second sheet S2. If such a melt bonding mechanism is used, no mechanism configured to apply an adhesive, etc. is needed. Therefore, it is possible to simplify the structure of the machine. If the joining unit 140 employs melt bonding, either the first sheet S1 or the second sheet S2 contains a binder, or both. The binder acts to join the first sheet S1 or the second sheet S2 together when either heat or pressure is applied, or both.

The joining unit 140 includes a plurality of joining members. The carton packaging machine 10 illustrated in FIG. 1 includes four melt bonding members. The first melt bonding member 51 illustrated in FIG. 1 joins the −Y-side edge portion of the first sheet S1 and the −Y-side edge portion of the second sheet S2 together by melt bonding. The second melt bonding member 53 illustrated in FIG. 1 joins the +Y-side edge portion of the first sheet S1 and the +Y-side edge portion of the second sheet S2 together by melt bonding. The third melt bonding member 61 illustrated in FIG. 2 joins the −X-side edge portion of the first sheet S1 and the −X-side edge portion of the second sheet S2 together by melt bonding. The fourth melt bonding member 63 illustrated in FIG. 2 joins the +X-side edge portion of the first sheet S1 and the +X-side edge portion of the second sheet S2 together by melt bonding.

It is preferable if the number of the melt bonding members included in the joining unit 140 is two or more. It is preferable if the joining unit 140 includes the third melt bonding member 61 and the fourth melt bonding member 63. The carton packaging machine 10 makes it possible to make the belt width W of the conveyor belt 15 configured to convey the first sheet S1 shorter. It is preferable if the joining unit 140 includes the first melt bonding member 51 and the second melt bonding member 53. The carton packaging machine 10 makes it possible to make the distance between the cartons B placed on the conveyor belt 15 shorter.

As illustrated in FIG. 3, in the carton packaging machine 10, the joining unit 140 joins the first sheet S1 and the second sheet S2 together after the cutting unit 130 cuts the first sheet S1 and the second sheet S2. However, the scope of the present disclosure is not limited thereto. The cutting unit 130 may cut the first sheet S1 and the second sheet S2 after the joining unit 140 joins the first sheet S1 and the second sheet S2 together. The carton packaging machine 10 may include an integrated component that is a combination of the cutting unit 130 and the joining unit 140. The carton packaging machine 10 may execute the cutting of the first sheet S1 and the second sheet S2 and the joining of the first sheet S1 and the second sheet S2 simultaneously.

The half-packaged object in process or the completely-packaged object in process having been formed by joining the first sheet S1 and the second sheet S2 together by the joining unit 140 is ejected to the outside of the carton packaging machine 10 by the carton ejecting unit 150. The carton ejecting unit 150 may be a robot that has at least one arm for gripping the packaged object in process, etc. The carton ejecting unit 150 may be a conveying mechanism that conveys the packaged object in process, etc. The carton ejecting unit 150 may keep the packaged object in process, etc. placed on the conveyor belt 15.

As described above, the carton packaging machine 10 includes: the first sheet supplying unit 100 that supplies the first sheet S1; the second sheet supplying unit 120 that supplies the second sheet S2; the carton supplying unit 110 that places the carton B on the first sheet S1 supplied by the first sheet supplying unit 100; the conveyor belt 15 that moves the first sheet S1, with the carton B placed on the first sheet S1, in the +Y direction along the Y axis; the pair of guide rollers 33 that guide the second sheet S2 to the top of the carton B; and the joining unit 140 that joins the first sheet S1 and the second sheet S2 together, wherein the carton B is packaged using the first sheet S1 and the second sheet S2.

The carton packaging machine 10 makes it possible to use the first sheet S1 whose width is less than the perimeter of the carton B and the second sheet S2 whose width is less than the perimeter of the carton B. Therefore, it is possible to reduce the installation area of the carton packaging machine 10.

FIG. 4 is a flowchart illustrating the processes of manufacturing a sheet that is to be used by the carton packaging machine 10. The sheet manufactured through the processes illustrated in FIG. 4 is used as either one or both of the first sheet S1 and the second sheet S2. The processes of manufacturing the sheet in FIG. 4 are executed by a sheet manufacturing machine.

As illustrated in FIG. 4, the processes of manufacturing the sheet include: supplying a raw material in a step S101; performing coarse crushing of the raw material and defibration in a step S103; performing separation of the defibrated material in a step S105; adding a binder and an additive in a step S107; forming a web in a step S109; and processing the web in a step S111.

The process of supplying a raw material in the step S101 is a process of supplying the raw material to the sheet manufacturing machine. The raw material is supplied to the sheet manufacturing machine. The raw material contains cellulose fibers. Examples of the raw material containing cellulose fibers include paper such as waste paper, pulp, pulp sheet, cloth including nonwoven fabric, woven fabric, and the like.

The process of performing coarse crushing of the raw material and defibration in the step S103 is a process of coarse-crushing the supplied raw material and defibrating coarse crushed pieces. The sheet manufacturing machine shreds the raw material into coarse crushed pieces using rotary coarse crushing blades, etc. Each coarse crushed piece has a shredded size of one to a few square centimeters or smaller. The sheet manufacturing machine produces a defibrated material by defibrating the coarse crushed pieces using, for example, an impeller mill. The defibrated material contains fibers contained in the raw material, particles contained in the raw material, and the like. The sheet manufacturing machine performs dry defibration.

The process of performing separation of the defibrated material in the step S105 is a process of screening fibers of predetermined size, among the fibers contained in the defibrated material. In the step S105, among the fibers contained in the defibrated material, those larger than the predetermined size are removed. The sheet manufacturing machine uses a sieve to sift the defibrated material. The defibrated material is sorted into a first screened material that is not larger than the predetermined size and a second screened material that is larger than the predetermined size. The second screened material is returned to the step S103 and undergoes coarse crushing and defibration again. The first screened material having passed the screening in the step S105 is let fall to accumulate on a mesh belt having meshes so as to form a first web thereon. When the first screened material is let fall to accumulate on the mesh belt, particles contained in the first screened material pass through the meshes of the mesh belt. The particles contained in the first screened material are removed. The first web formed thereon is cut into pieces by rotary blades or the like. The sheet manufacturing machine produces fragments by cutting the first web into pieces.

The process of adding a binder and an additive in the step S107 is a process of adding the binder and the additive into the fragments. The binder binds fibers contained in the fragments together. Examples of the binder include natural resin, synthetic resin, natural polymer, and the like. Examples of the natural resin include rosin, dammar, mastic, copal, amber, shellac, dragon's blood, sandarac, colophonium, and the like. Examples of the synthetic resin include AS resin, ABS resin, polypropylene, polyethylene, polyvinyl chloride, polystyrene, acrylic resin, polyester resin, polyethylene terephthalate, polyphenylene ether, polybutylene terephthalate, polyamide, polycarbonate, polyacetal, polyphenylene sulfide, polyetherether ketone, and the like. The natural polymer includes starch. It is preferable if the binder is thermoplastic. The additive is added when there is a need to add desired properties to the sheet that is to be manufactured. Examples of the additive include an organic solvent, a surfactant, a fungicide, a preservative, an antioxidant, an ultraviolet absorber, an oxygen absorber, a flame retardant, a rust inhibitor, a filler, a paper strengthening agent, a pigment, and a dye. The additive may function as a binder that binds fibers together. In the step S107, a mixture of the fragments, the binder, and the additive is formed. The content of the binder in the mixture is 5.0 percent by mass or more and 50.0 percent by mass or less. It is preferable if the content of the binder in the mixture is 7.0 percent by mass or more and 45.0 percent by mass or less. It is more preferable if the content of the binder in the mixture is 10.0 percent by mass or more and 40.0 percent by mass or less.

The process of forming a web in the step S109 is a process of producing a second web by letting the mixture fall and accumulate. The sheet manufacturing machine lets the mixture fall and accumulate on a base sheet. The sheet manufacturing machine produces the second web on the base sheet. The base sheet is made of, for example, nonwoven fabric. The base sheet may be a sheet that was manufactured in advance by the sheet manufacturing machine. The base sheet may be made of a multilayer material including two or more layers. The sheet manufacturing machine may form a second base sheet as another layer on the produced second web. The second base sheet may be the same as the base sheet. The second base sheet may be different from the base sheet.

The process of processing the web in the step S111 is a process of applying heat and pressure to the second web having been formed by accumulation on the base sheet and thereby processing the second web. The second web is processed into a fiber-density-increased layer by being heat-pressed. The density of the fiber-density-increased layer is 0.02 g/cm³or higher and 0.50 g/cm³or lower. It is preferable if the density of the fiber-density-increased layer is 0.03 g/cm³or higher and 0.30 g/cm³or lower. The fiber-density-increased layer may be processed into a desired shape. For example, the sheet manufacturing machine applies a pressing force that differs from part to part when pressing the second web. By applying a pressing force that differs from part to part, the sheet manufacturing machine forms concave portions in and convex portions on the fiber-density-increased layer.

Each of FIGS. 5 and 6 illustrates the structure of the first sheet S1. FIG. 5 is a view, from the +X side, of the first sheet S1 placed on the conveyor belt 15. FIG. 6 is a view, from the +Z side, of the first sheet S1 placed on the conveyor belt 15. The first sheet S1 illustrated in FIGS. 5 and 6 is manufactured through the manufacturing processes illustrated in FIG. 4. The first sheet S1 illustrated in FIGS. 5 and 6 can be used for the carton packaging machine 10. The first sheet S1 illustrated in FIGS. 5 and 6 can be used as the second sheet S2 for the carton packaging machine 10.

The first sheet S1 illustrated in FIG. 5 includes a first base material 201, a first intermediate layer 203, and first cushioning protrusions 205. The first base material 201 is made of, for example, nonwoven fabric. The first intermediate layer 203 and the first cushioning protrusions 205 contain cellulose fibers and a binder. The first intermediate layer 203 and the first cushioning protrusions 205 are made of a first cushioning material. The first intermediate layer 203 and the first cushioning protrusions 205 are formed integrally. The binder contained in the first intermediate layer 203 and the first cushioning protrusions 205 joins the first sheet S1 and the second sheet S2 together when melted by the first melt bonding mechanism 50 and the second melt bonding mechanism 60 illustrated in FIGS. 1 and 2. The first cushioning protrusions 205 are formed by applying a pressing force that differs from part to part when the second web is pressed. The first cushioning protrusions 205 constitute an example of a first cushioning layer. The first cushioning material is an example of a first cushioning medium.

As illustrated in FIG. 6, the first cushioning protrusions 205 are formed on the first intermediate layer 203. The first cushioning protrusion 205 illustrated in FIG. 6 is a protrusion having a quadrangular shape. However, the shape of the first cushioning protrusion 205 is not limited to this example. The first cushioning protrusion 205 may be a hemispherical protrusion. The first cushioning protrusion 205 may be a strip-shaped protrusion. The number of the first cushioning protrusions 205 illustrated in FIG. 6 is forty eight, but is not limited thereto. The number of the first cushioning protrusions 205 may be changed as may be necessary. The first cushioning protrusions 205 function as a cushioning medium for protecting the carton B packaged using the first sheet S1.

The cross-sectional structure of a packaged object is illustrated in FIG. 7. FIG. 7 is a cross-sectional view of a packaged object from the +X side. The packaged object illustrated in FIG. 7 is the carton B packaged using the first sheet S1 and the second sheet S2. The first sheet S1 illustrated in FIG. 7 has the same structure as that of the first sheet S1 illustrated in FIGS. 5 and 6. The second sheet S2 illustrated in FIG. 7 has the same structure as that of the second sheet S2 illustrated in FIGS. 5 and 6.

The second sheet S2 illustrated in FIG. 7 includes a second base material 211, a second intermediate layer 213, and second cushioning protrusions 215. The second base material 211 is made of, for example, nonwoven fabric. The second intermediate layer 213 and the second cushioning protrusions 215 contain cellulose fibers and a binder. The second intermediate layer 213 and the second cushioning protrusions 215 are made of a second cushioning material. The second intermediate layer 213 and the second cushioning protrusions 215 are formed integrally. The second cushioning protrusions 215 constitute an example of a second cushioning layer. The second cushioning material is an example of a second cushioning medium. The binder contained in the second intermediate layer 213 and the second cushioning protrusions 215 joins the first sheet S1 and the second sheet S2 together when melted by the first melt bonding mechanism 50 and the second melt bonding mechanism 60 illustrated in FIGS. 1 and 2. The second cushioning protrusions 215 are formed by applying a pressing force that differs from part to part when the second web is pressed. The second sheet S2 has the second cushioning protrusions 215 in the direction along the X axis. The second cushioning protrusions 215 are arranged in the same manner as the first cushioning protrusions 205 illustrated in FIG. 6.

The second cushioning protrusion 215 of the second sheet S2 illustrated in FIG. 7 is smaller than the first cushioning protrusion 205 of the first sheet S1. The structure of the second sheet S2 is different from that of the first sheet S1. Any of the fibers, the binder, and the additive contained in the second cushioning protrusion 215 may be different from the fibers, the binder, and the additive contained in the first cushioning protrusion 205.

As illustrated in FIG. 7, the first cushioning protrusion 205 of the first sheet S1 and the second cushioning protrusion 215 of the second sheet S2 are joined together by melt bonding by the first melt bonding mechanism 50. The binder contained in the first cushioning protrusion 205, or the binder contained in the second cushioning protrusion 215, joins the first sheet S1 and the second sheet S2 together. The first intermediate layer 203 of the first sheet S1 and the second intermediate layer 213 of the second sheet S2 may be joined together by melt bonding by the first melt bonding mechanism 50. The binder contained in the first intermediate layer 203, or the binder contained in the second intermediate layer 213, joins the first sheet S1 and the second sheet S2 together.

The first cushioning protrusions 205 are in contact with the −Z-side surface, namely, the bottom surface, of the carton B. Being in contact with the bottom surface of the carton B, the first cushioning protrusions 205 function as a cushioning medium for protecting the bottom surface of the carton B. The second cushioning protrusions 215 are in contact with the +Z-side surface, namely, the top surface, of the carton B. Being in contact with the top surface of the carton B, the second cushioning protrusions 215 function as a cushioning medium for protecting the top surface of the carton B. Since the shape of the first cushioning protrusion 205 and the shape of the second cushioning protrusion 215 are different from each other, the capability of absorbing shock applied by an external force differs from part to part.

As illustrated in FIG. 7, the second cushioning protrusions 215 are in contact with the −Y-side side surface and the +Y-side side surface of the carton B. Being in contact with the side surfaces of the carton B, the second cushioning protrusions 215 function as a cushioning medium for protecting the side surfaces of the carton B. In the packaged object illustrated in FIG. 7, the second cushioning protrusions 215 are in contact with the side surfaces of the carton B. However, the structure of the packaged object is not limited to this example. The first cushioning protrusions 205 may be in contact with two side surfaces of the carton B. In this case, the first melt bonding mechanism 50 of the carton packaging machine 10 has a structure for folding the first sheet S1 to bring the first cushioning protrusions 205 into contact with the side surfaces of the carton B.

The cross-sectional structure of the packaged object viewed from the +Y side, though not illustrated, is similar to the structure illustrated in FIG. 7. The second cushioning protrusions 215 are in contact with the −X-side side surface and the +X-side side surface of the carton B. Being in contact with the side surfaces of the carton B, the second cushioning protrusions 215 function as a cushioning medium for protecting the side surfaces of the carton B.

FIG. 8 is a flowchart illustrating the processes of packaging the carton B. The processes illustrated in FIG. 8 are executed by the carton packaging machine 10.

In a step S201, the carton packaging machine 10 supplies the first sheet S1. The first sheet S1 formed in the shape of the first roll R1 can be loaded onto the carton packaging machine 10. The supplied first sheet S1 is conveyed in the +Y direction by the conveyor belt 15.

After supplying the first sheet S1, the carton packaging machine 10 supplies the carton B onto the conveyor belt 15 in a step S203. The carton B is placed on the first sheet S1. The carton supplying belt 17 supplies the carton B onto the first sheet S1. The carton B placed on the first sheet S1 is conveyed in the +Y direction by the conveyor belt 15.

After placing the carton B on the first sheet S1, the carton packaging machine 10 supplies the second sheet S2 to the top of the carton B in a step S205. The second sheet S2 formed in the shape of the second roll R2 can be loaded onto the carton packaging machine 10. Guided by the pair of guide rollers 33, the second sheet S2 is supplied to the top of the carton B.

Though the second sheet S2 may be the same as the first sheet S1, it is preferable if the second sheet S2 is different from the first sheet S1. For example, as illustrated in FIG. 7, it is preferable if the shape of the second cushioning protrusion 215 of the second sheet S2 is different from the shape of the first cushioning protrusion 205 of the first sheet S1.

The thickness of the first sheet S1 and the thickness of the second sheet S2 may be different from each other. For example, the carton packaging machine 10 is able to package the carton B by covering the bottom surface of the carton B by the first sheet S1 having a first thickness and by covering the top surface of the carton B by the second sheet S2 having a second thickness that is less than the first thickness.

It is preferable if the first sheet S1 and the second sheet S2 are different from each other.

The user who operates the carton packaging machine 10 to package the carton B is able to perform packaging suitable for part-by-part conditions of the carton B, for example, suitable for accommodating differences from part to part in required package strength of the carton B.

Though the second cushioning material may be the same as the first cushioning material, it is preferable if the second cushioning material is different from the first cushioning material. It is preferable if one or more of the cellulose fibers, the binder, and the additive contained in the second cushioning material are different from the cellulose fibers, the binder, and the additive contained in the first cushioning material.

For example, the first cushioning material consists of cellulose fibers whose raw material is pulp, and the second cushioning material consists of cellulose fibers whose raw material is waste paper. The carton packaging machine 10 packages the carton B using the first sheet S1 and the second sheet S2 that are different in terms of cellulose-fiber type from each other. The shock-absorbing capability of the bottom surface of the packaged object is different from that of the top surface thereof. The first cushioning material may consist of cellulose fibers whose raw material is wood, and the second cushioning material consists of cellulose fibers whose raw material is a plant. Suitable types of cellulose fibers are chosen for the carton B.

The first cushioning material may contain polyamide resin as the binder. The second cushioning material may contain starch as the binder. The carton packaging machine 10 packages the carton B using the first sheet S1 and the second sheet S2 that are different in terms of binder type from each other. For example, the shock-absorbing capability of the bottom surface of the packaged object is different from that of the top surface thereof. The first cushioning material may contain polyethylene resin as the binder. The second cushioning material may contain AS resin as the binder. By choosing the binder type, the user of the carton packaging machine 10 is able to change the mechanical properties of the first sheet S1 and the second sheet S2. The content of the binder contained in the first cushioning protrusion 205 may be different from the content of the binder contained in the second cushioning protrusion 215.

The first cushioning material contains a paper strengthening agent as the additive. The second cushioning material contains a rust inhibitor as the additive. The carton packaging machine 10 packages the carton B using the first sheet S1 and the second sheet S2 that are different in terms of additive type from each other. For example, the functional properties of the bottom surface of the packaged object are different from those of the top surface thereof. The content of the additive contained in the first cushioning material may be different from the content of the additive contained in the second cushioning material.

The first sheet S1 has the first cushioning protrusions 205 made of the first cushioning material. The second sheet S2 has the second cushioning protrusions 215 made of the second cushioning material different from the first cushioning material.

This structure eliminates the need of manually inserting a cushioning medium between the carton B and the first sheet S1 and manually inserting a cushioning medium between the carton B and the second sheet S2 by the user of the carton packaging machine 10, thereby simplifying the packaging work. Moreover, the user is able to perform packaging satisfying requirements varying from part to part of the carton B in terms of strength.

After supplying the second sheet S2 to the top of the carton B, the carton packaging machine 10 cuts the first sheet S1 and the second sheet S2 in a step S207. The cutter 41 of the carton packaging machine 10 cuts the first sheet S1 and the second sheet S2 at a −Y-side position with respect to the carton B. The cutter 41 cuts the first sheet S1 and the second sheet S2 in a direction intersecting with the Y axis.

After cutting the first sheet S1 and the second sheet S2, the carton packaging machine 10 joins the first sheet S1 and the second sheet S2 together in a step S209. The first melt bonding mechanism 50 of the carton packaging machine 10 joins the first sheet S1 and the second sheet S2 together by melt bonding at a −Y-side position and a +Y-side position with respect to the carton B. The second melt bonding mechanism 60 of the carton packaging machine 10 joins the first sheet S1 and the second sheet S2 together by melt bonding at a −X-side position and a +X-side position with respect to the carton B. The carton packaging machine 10 packages the carton B by joining the first sheet S1 and the second sheet S2 together by melt bonding.

The first sheet S1 and the second sheet S2 are joined together after the cutting of the first sheet S1 and the second sheet S2.

Since the carton packaging machine 10 joins the first sheet S1 and the second sheet S2 together after the cutting of the first sheet S1 and the second sheet S2, the joining of the first sheet S1 and the second sheet S2 is easy.

After joining the first sheet S1 and the second sheet S2 together by melt bonding, the carton packaging machine 10 conveys the packaged carton B to the ejection position in a step S211. The carton B having been conveyed to the ejection position is then ejected therefrom to the outside of the carton packaging machine 10.

As explained above, the packaging method according to an exemplary embodiment is a method of packaging the carton B using the carton packaging machine 10 into which the first sheet S1 and the second sheet S2 are loadable, the method including: placing the carton B on the first sheet S1; conveying the first sheet S1 with the carton B placed thereon; guiding the second sheet S2 to the top of the carton B; and packaging the carton B by joining the first sheet S1 and the second sheet S2 together.

The carton packaging machine 10 makes it possible to use the first sheet S1 whose width is less than the perimeter of the carton B in the direction parallel to the X axis and the second sheet S2 whose width is less than the perimeter of the carton B in the direction parallel to the X axis. Therefore, the degree of freedom in selecting the first sheet S1 and the second sheet S2 increases.

PACKAGING MACHINE AND PACKAGING METHOD

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CPC

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