Patent Application
20130092716
An apparatus for processing a line of material is disclosed. More particularly, an apparatus for assisting a user in tearing the line of material at a desired point therealong is disclosed.
In the context of paper-based protective packaging, rolls of paper sheet are crumpled to produce the dunnage. Most commonly, this type of dunnage is created by running a generally continuous strip of paper into a dunnage conversion machine that converts a compact supply of stock material, such as a roll or stack of paper, into a lower density dunnage material. The continuous strip of crumpled sheet material may be cut into desired lengths to effectively fill void space within a container holding a product. The dunnage material may be produced on an as needed basis for a packer. Examples of cushioning product machines that feed a paper sheet from an innermost location of a roll are described in U.S. Patent Publication Nos. 2008/0076653 and 2008/0261794. Another example of a cushioning product machine is described in U.S. Patent Publication No. 2009/0026306.
At a selected point along the processed line of material, a user may wish to sever the line so as to separate the line into two or more portions. Existing processing systems require the user to pull the line against a cutting member in order to sever a portion therefrom. Such pulling requires the user to exert a force against the line.
It would therefore be desirable to employ a line processing apparatus and system with a tear-assist apparatus. In particular, it would be desirable to employ an apparatus that lessens the force required of a user to sever a processed line of material at a desired point.
One embodiment includes a system for processing a line of material along a path and a tear-assist apparatus. The tear-assist comprising a driving portion that drives the line of material along the path, a sensing unit that detects pulling of the line of material in a first direction along the path away from the driving portion, and a cutting member for cutting the line of material. The sensing unit can be associated with the driving portion such that upon detecting movement of the line in the first direction, the sensing unit causes the driving portion to drive the line of material in a second direction along the path for drawing the line of material against the cutting member to cut the line of material. In another configuration, when the sensing unit detects the movement in the first direction, the sensing unit can cause the driving portion to drive the line of material in the second direction sufficiently for severing the portion of the line of material. The driving portion can also be configured to drive the line of material in the first direction along the path to dispense the material.
In yet other configurations, the system can further have a converting station that includes the driving portion and is operable in the first direction for converting supply material into low-density dunnage and moving the dunnage in a dispensing direction along a material path. The cutting member can cut the dunnage when the driving member draws the material thereagainst.
In another embodiment of the dunnage converting apparatus, the converting apparatus can have a converting station that is operable in a converting direction for converting supply material into low-density dunnage and moving the dunnage in a dispensing direction along a material path. The converting apparatus can also have a cutting member that divides the path and the dunnage therein into an outfeed portion between the converting station and the cutting member and a severable portion beyond the cutting member from the converting station. The dunnage converting apparatus can also have a sensing unit configured to detect a pulling of the dunnage severable portion of the path against the cutting member. The converting station can also be operable in a reverse direction for pulling the dunnage against the cutting member to cause the cutting member to cut the dunnage when the dunnage severable portion is pulled against the cutting member at an angle to the outfeed portion. The sensing unit can also be operably associated with the converting station for causing the converting station to operate in the reverse direction upon detecting the pulling.
In another embodiment, the converting station of the can include a drum and a pressing portion that presses against the drum on an opposite side of the path therefrom to engage the material, and the drum can be driven in the converting and reverse directions. The pressing portion can also include a roller biased against the drum.
In yet another apparatus of claim 5, wherein the converting station is configured to operate in the reverse direction sufficiently to sever the dunnage in the severable portion of the path. The cutting member can also have a blade that extends laterally next to the path. In other embodiments, the cutting member can be disposed on a single lateral side of the path.
In another embodiment, the path can be bent at the cutting member such that the outfeed and severable portions are out of alignment. The sensor can also be configured for detecting the resultant force of the dunnage in the bent path against the cutting member. In one embodiment, the sensing unit can detect a force against the cutting member to detect the pulling of the dunnage. The force against the cutting member that is detected by the sensing unit can be in a direction laterally away from the dunnage path. In other embodiments, the cutting member can comprise a movable blade, and the sensor can detect displacement of the blade away from the path.
In yet another embodiment, the force detected by the sensing unit can result from pulling on the severable portion of the dunnage in a direction such that the path is bent at the cutting member so that the outfeed and severable portions are out of alignment.
In another embodiment, the sensing unit can detect the pulling of the dunnage by detecting movement of the material in the converting station in the dispensing direction caused by an external force. In other configurations, the converting station can include a rotating member that drives the material in the dispensing direction while the converting station converts the material into dunnage, and the sensing unit can detect the pulling of the dunnage by detecting movement of the rotating member caused by an external force.
In other embodiments, the cutting member can be connected to the converting station, such that a movement of the driving portion in the reverse direction causes a corresponding movement of the cutting member into the dunnage in the path.
In another embodiment, the dunnage converting apparatus can have a converting station that can be operable in a converting direction for converting supply material into low-density dunnage and moving the dunnage in a dispensing direction along a material path and a cutting member that can be disposed on a single lateral side of the material path. The cutting member can divide the path and dunnage therein into an outfeed portion between the converting station and the cutting member, and a severable portion beyond the cutting member from the converting station. The converting station can be operable in a reverse direction for pulling the dunnage against the cutting member to cause the cutting member to cut the dunnage when the dunnage in the severable portion is pulled against the cutting member at an angle to the outfeed portion.
In another embodiment, the converting station can have a drum and a pressing portion that presses against the drum on an opposite side of the path therefrom to engage the material. The drum can be driven in the converting and reverse directions. The pressing portion can also comprise a roller biased against the drum. The converting apparatus can also have a sensing unit configured to detect a pulling of the dunnage in the severable portion of the path against the cutting member. The sensing unit can be operably associated with the converting station for causing the converting station to operate in the reverse direction upon detecting the pulling. In other configurations, the converting station can operate in the reverse direction sufficiently to sever the dunnage in the severable portion of the path.
A method for processing a line of material can include converting supply material into low-density dunnage and moving the dunnage in a dispensing direction along a material path, detecting a pulling of the dunnage at a severable portion of the path against a cutting member, and responding to said detection by pulling the dunnage against the cutting member in a reverse direction, thereby causing the cutting member to cut the dunnage when the dunnage in the severable portion is pulled against the cutting member at an angle to the outfeed portion. Additional advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
An apparatus for processing a line of material is disclosed. More particularly, an apparatus for assisting a user in tearing the line of material at a desired point therealong is disclosed. The present disclosure is generally applicable to systems and apparatus where supply material, preferably being a line of material, is processed. In an example system, the line of material originates from a source repository, where the line of material is stored in a roll (whether drawn from inside or outside the roll), a wind, a fan-folded source, or any other form. In one embodiment, the line of material can be perforated. The line of material is then processed, which can include driving the line of material in a first direction, which can be a dispensing direction. In one example system, the line of material is fed from the repository through a drive roller in a dispensing direction, which is further discussed below, so as to dispense the line of material in said direction. The supply material can also be other types of protective packaging including other dunnage and void fill materials, and inflatable packaging pillows. A particular application of the apparatus described herein is the processing of dunnage material for packaging. Other applications can also be used, including lines of other paper or fiber-based materials in sheet form, lines of wound fiber material such as ropes or thread, and lines of thermoplastic materials such as a web of plastic material usable to form pillow packaging material.
With reference to
In one configuration, the system 10 can include a support portion for supporting the station and an inlet guide 12 for guiding the sheet material into the system 10. As shown in
Preferably, the system 10 also includes an actuator for driving the line of material 19. In the preferred embodiment, the actuator is an automatic or electric motor 11 or other motive device. The motor 11 is connected to a power source, such as an outlet via a power cord, and may be arranged and configured for driving the system 10. The motor 11 may be part of a drive portion, and the drive portion may include a transmission portion for transferring power from the motor 11. Alternatively, a direct drive may be used. The motor 11 may be arranged in a housing and may be secured to a first side of the central housing. The transmission may be contained within the central housing and may be operably connected to a drive shaft of the motor 11 and a drive portion thereby transferring motor 11 power.
During operation of the preferred embodiment, the motor 11 dispenses the line of material 19 by driving it in a dispensing direction, depicted as arrows “B” in
In one embodiment, the system 10 includes a pressing portion that can also include a pressing member such as a roller, multiple rollers, or other similar elements. The rollers 14 may be supported via a bearing or other substantially frictionless device positioned on an axis shaft arranged along the axis of the rollers 14. Alternatively, the rollers can be powered and driven. The rollers 14 may have a circumferential pressing surface arranged in tangential contact with the surface of the drum 17. That is, for example, the distance between the drive shaft or rotational axis of the drum 17 and the axis shaft of the rollers 14 may be substantially equal to the sum of the radii of the drum 17 and the rollers 14. The rollers 14 may be relatively wide such as ¼ to ½ the width of the drum and may have a diameter similar to the diameter of the drum, for example.
In some embodiments, the roller 14 may have an approximately 2 inch diameter and an approximately 2 inch width. In some embodiments, the drum 17 may have an approximately 4-5 inch diameter 94 and an approximately 4 inch width. Other diameters of the rollers may also be provided. The roller diameter may be sufficiently large to control the incoming material stream. That is, for example, when the high speed incoming stream diverges from the longitudinal direction, portions of the stream may contact an exposed surface of the rollers, which may pull the diverging portion down onto the drum and help crush and crease the resulting bunching material. In the preferred embodiment, the motor 11 is connected to a cylindrical driving drum 17, which is caused to rotate by the motor 11. This embodiment can also include one or more drum guides 16 arranged on axial ends thereof in a lateral position relative to the feed direction. The drum guides 16 may help to guide the sheet material toward the center of the drum 17. The drum guide 16 may be operably connected to the drum 17 to rotate freely with or without the drum 17. As such, the drum guide 16 may be supported off of the drive shaft of the drum 17 via a bearing or other isolating element for allowing the drum guide 16 to rotate relative to the drum 17. In addition, the drum guide 16 may be isolated from the axial side of the drum 17 by an additional space, bearing, or other isolation element for minimizing the transfer of rotational motion from the drum 17 to the guide 16. In other embodiments, the outer drum guide 16 may be supported via a bearing off of the outer axial side of the drum 17 rather than off of the drive shaft, for example. While a drum 17 connected with an actuator 11 is disclosed in this embodiment as the driving portion for driving the line of material in the dispensing direction, it will be appreciated that other feed methods are possible, such as an automated motor.
Referring to
For example, the pressing portion 13, which can include a pressing member 13, can be disposed about a pivot axis such that, ignoring gravitational force, the pressing portion 13 is substantially free to pivot in a direction tending to separating the rollers 14 from the drum 17 about the pivot point. To resist this substantially free rotation, the pressing portion 14 can be secured in position by a position control system configured to maintain the rollers 14 in tangential contact with the drum 17, unless or until a sufficient separation force is applied, and hold the rollers 14 in a released position, once released. As such, when the material 19 passes between the drum 17 and the roller 14, the position control system can resist separation between the pressing portion 13 and the drum 17 thereby pressing the stream of sheet material and converting it into a low-density dunnage. When the rollers 14 are released due to a jam or other release causing force, the position control system can hold the rollers 14 in a released position allowing the jam to be cleared and preventing damage to the machine, jammed material, or human extremities, for example.
The position control system can include one or more biasing elements arranged and configured to maintain the position of the pressing portion 13 unless or until a separation force is applied. In the exemplary embodiment, the one or more biasing element can include a magnetic biasing element 196, as disclosed in U.S. Publication 2012/0165172. The magnetic biasing element 196, shown in
Once in the pressing portion 13 is released, the magnets in the release hold element can function to hold the pressing portion 13 in the released condition. In one configuration, the force it takes to release the pressing portion 13 can be greater than the force required to place the pressing portion 13 back into an engaged position. This releasing mechanism can be advantageous to situations in which the user incorrectly positions the sticker on the supply unit, for example, and the supply units and sticker causes the converting station 102 to jam. In such situation, once the release force is reached due to the jam, the pressing portion 13 can release to a release position allowing for the user to easily remove the jam and preventing damage to the converting station 102.
In the preferred embodiment, the system further includes a tear-assist apparatus to facilitate the tearing or severing of the line of material 19. The tear assist facilitates moving the line of material in a direction opposite the pulling direction and toward the supply side 61 of the converting station 102, i.e. the reverse direction. Referring to
Preferably, the cutting member 15 can be curved downward so as to provide a guide for the material in the outfeed portion of the path as it exits the system. Preferably, the cutting member 15 is curved at an angle similar to the curve of the drum 17, but other curvature angles could be used. It should be noted that the cutting member 15 is not limited to cutting the material using a sharp blade, but is can include a member that causes breaking, tearing, slicing, or other methods of severing the line of material 19. The cutting member 15 can also be configured to fully or partially sever the line of material 19.
Preferably the tear-assist apparatus comprises a single cutting member 15 that engages the line 19. The cutting member 15 can be is disposed on a single lateral side of the material path. In the preferred embodiment, it is disposed below the drum 17, and substantially along the material path. As shown in
The cutting member 15 of
The cutting member 15 can also include a finger guard 22, as shown in
In operation, the user feeds a desired length of the line 19 at the supply side 60 of the converting station 102 which is then moved in a dispensing direction by the operation of the motor 11 and dispensed at the outfeed side 61. The drum 17 turns in coordination therewith, and the line 19 is fed out of the machine until a desired length has been reached. At this point, the operator stops the motor 11, and dispensing movement of the line 19 stops. The user then pulls on the line 19 in a “D” direction that is downward and in the outward direction from the supply side 60 so as to engage the line with the cutting member 15. Direction “D” is defined as the direction tangent to the drum 17, preferably at 90° to the axis of the drum which is illustrated as line 191 in
As an illustrative example shown in
The user pulls at the severable portion 24 of the line of material 19 in an outward direction from the supply side 60, which is illustrated as line 191 in
In the preferred embodiment, the reverse movement of the line of material 19 and the pull of the line 19 in a direction outward from the supply side 60 cooperatively engages the line 19 with the cutting edge 20 such that the line partially or fully severs. In other embodiment, the cutting edge 20 sufficiently catches the line of material 19, for example caused by teeth or another element, such that the force of the reverse movement and the resistance caused by the cutting edge 20 causes the line of material 19 to partially or fully sever. For example, in some configurations the teeth at the cutting edge 20 catches or engages the line of material 19 by partially piercing through the material 19 at the pointed tip of the teeth. In other configurations, for example when the cutting edge 20 has no teeth, the cutting member catches and engages the line of material 19 as the line 19 is pulled in the reverse direction, for example causing it to tear. In some embodiments, sufficient force needs to be applied to the severable portion 24 by the user in order to catch the cutting edge 20 with the line of material 19. In some configurations, the reverse movement on the line of material 19 may be sufficient to partially tear the line 19 or completely tear the line 19. In one embodiment, the reverse movement pulls a slightly distance such that the line 19 creates a weakened area or a partial tear. In other embodiments, the reverse movement pulls the line of material 19 sufficiently enough to cause the line 19 to tear.
In other embodiments of the cutting member 15, the member can be a bar that sufficiently engages the line of material 19 such that both the force of the user pulling in one direction and the force of the tear assist pulling the line of material 19 in a reverse direction cooperatively partially or fully tears. It should be appreciated, however, that a cutting member does not need to be present, for example where the line is perforated, the tear-assist can function to assist the user to sever the line at the perforation.
In one embodiment of the tear assist apparatus, the reverse movement of the line can be caused by an actuator, or preferably a motor 11. In this embodiment, the drum 17 can rotate in a reverse direction (depicted as direction “A”) to cause the line 19 to move in the reverse direction toward the supply side of the converting station 102. In one embodiment, as the drum 17 rotates in reverse, a portion of the converted line of material 19 can be reversed back under the pressing members.
Preferably, the drum 17 is connected to the motor 11, which is the same motor 11 that moves the line of material 19 in the dispensing direction. In an another configuration, there are multiple actuators where one moves the line of material 19 in a dispensing direction and the another separate actuator moves the line of material in a reverse direction. Alternatively, one or more other drums may be used, which may be connected to one or more other actuators, to cause reverse movement. In one embodiment, the reverse movement is caused by a spring or other mechanical member.
The sensor is configured to detect parameters reflective of the user pulling the severable portion of the dunnage out from the device and against the blade. In this embodiment, the sensor is configured to detect the current induced in the motor 11 by the dunnage pulling the motor 11 in a forward direction. Upon detecting the minimum current, which is reflective of the a minimum speed and/or distance of the dunnage being pulled out of the machine that is commenced of a user pulling by hand. Thereby activating the motor in reverse. Preferably, the user will pull the severable portion at an angle against the blade at a force about at least ½ lb, more preferably the force is about at least 1 lb, and most preferably, the force is about at least 2 lbs. Preferably, the force is about at most 10 lbs, and more preferably the triggering force is about at most 4 lbs.
In an embodiment, the sensing unit is configured to detect parameters reflective of a pulling initiated only by the user, and not from another part of the device or due to residual motion of the converting station 102. Thus, while the converting station 102 is in operation, the motion of the driving portion, dispensing of the line of material 19, or other motions will not cause the sensing unit to trigger the tear assist apparatus.
In one embodiment of the sensing unit, when the appropriate trigger force is applied to the line of material 19, the sensing unit sends a signal to the driving portion to initiate a short rotational movement in the direction opposite the dispensing direction, thereby causing the line 19 to be pulled in a reverse direction. As discussed above, this reverse motion and the pulling by the user cooperatively engages the line of material 19 with the cutter 15 causing the line of material 19 to partially or fully tear or sever. The tear-assist thereby assists the user in tearing the line. In one embodiment, this short reverse impulse causes the line 19 to engage more directly with the cutting edge 20 of the cutting member 15, and as such assists the user in tearing or severing the line 19. The cutting edge 20 sufficiently catches the line of material 19 such that the reverse pull caused by the driving portion provides a tear-assist force, and decreases the force required by the user pull in order to sever the line 19.
In some embodiments, the reverse rotational pulse initiated by the motor 11 may be less than a millisecond in duration, or less than 10 milliseconds in duration, or less than 100 seconds in duration. In some embodiments, the line 19 may be pulled along the material path opposite the dispensing direction toward the supply side of the converting station by at least about 0.25 inches, 0.5 inches, 1 inch, 2 inches, or 5 inches, or more during the cutting operation. In the preferred embodiment, the line 19 is pulled into the opposite direction toward the supply side at a sufficient distance, preferably about ½ inch to an inch, such that the converted line of material 19 is not pulled so far toward the supply side that it disengages with the converting station 102, and thus requiring the material 19 to be reloaded onto the converting station 102.
In another embodiment, the sensing unit detects the pulling motion by the sensing of electric current or voltage in the motor 11 while not in operation. For example, as the user pull the line 19, the drum 17 is caused to rotate, which in turn causes the motor to rotate. This rotation of the motor 11 induces an electric current therein, which may be detected by the sensing unit. At this point, the sensing unit causes the motor to operate, as discussed above, in the direction opposite the dispensing direction. In an alternate embodiment, pull motion is detected by the sensing unit using mechanical members, for example a switch or button or like member is engaged and caused to be moved when the line 19 is pulled, such movement being detectible by the sensing unit.
As discussed above, in the preferred embodiment, the supply material is a line of material 19, such as preferably a line of sheet material. The sheet material preferably has a basis weight of about at least 20 lbs to about at most 100 lbs. Preferably, the line of material 19 comprises paper stock stored in a high-density configuration having a first longitudinal end and a second longitudinal end, that is later converted into a low-density configuration. In the preferred embodiment, the line of material 19 is a ribbon of sheet material that is stored as coreless rolls, as shown in
The sheet of material may be made of a single ply or multiple plies of material. Where multi-ply material is used, a layer can include multiple plies. It is also appreciated that other types of material can be used, such as pulp-based virgin and recycled papers, newsprint, cellulose and starch compositions, and poly or synthetic material, of suitable thickness, weight, and dimensions.
In one embodiment, as shown in
Preferably, as the material 19 is being fed into the converting station 102 as a coiled stream. It is appreciated, however, that the material may not be oriented as a coil, but in alternative embodiments, could be folded, crumpled, flat without any coil, fold, or crumple, or could have other similar configurations. The preferred width 30 of the material being fed through the converting station 102 is about at least 1″, more preferably about at least 2″, and most preferably about at least 4″. The preferred width 30 of the material being fed through the converting station 102 is about up to 30″, and more preferably about up to 10″. The preferred dimensions of the material being fed through the converting station 102 is about at least ½″ thick. The preferred dimension of the material being fed through the converting station 102 is about up to 3″ thick, and more preferably about up to 2″ thick.
As shown in
The sensor 38 in this embodiment can be configured to detect parameters reflective of the user pulling the severable portion 24 of the dunnage out from the device and against the cutting member. In this embodiment, the sensor is configured to detect the displacement, for example the rotation of the cutting member about its pivot, that changes the state of the sensor, such as a switch. For example, as the cutting member 15 is pivoted downward, the lever 36 is released or lifted from the trigger button 40. Upon detecting the minimum displacement of the cutting member, which is reflective of a user pulling by hand, the motor is activated causing reverse movement on the line of material 19. Preferably the force required to displace the cutting member is about at least ½ lb, more preferably the force is about at least 1 lb, and most preferably, the force is about at least 2 lbs. Preferably, the force is about at most 10 lbs, and more preferably the triggering force is about at most 4 lbs. As discussed above, this reverse movement and the force 52 applied by the user 50 cooperatively causes the line of material 19 to engage the cutting edge 20 and fully or partially tear or sever the line of material 19. Preferably there is a predetermined distance between the stop 34 and the sensor 38. This predetermined distance prevents the cutting member 15 from being pulled too far outwardly away from the supply side.
An illustrative flowchart of a method for operating the tear-assist application is depicted in
With respect to any of the embodiments above, as shown in
The controller 1000 may also include a computer-accessible medium (e.g., as described herein above, a storage device such as a hard disk, floppy disk, memory stick, CD-ROM, RAM, ROM, etc., or a collection thereof) can be provided (e.g., in communication with a processing arrangement). The computer-accessible medium can contain executable instructions thereon. In addition or alternatively, a storage arrangement can be provided separately from the computer-accessible medium, which can provide the instructions to the processing arrangement so as to configure the processing arrangement to execute certain exemplary procedures, processes and methods, as described herein above, for example.
Any and all references specifically identified in the specification of the present application are expressly incorporated herein in their entirety by reference thereto. The term “about,” as used herein, should generally be understood to refer to both the corresponding number and a range of numbers. Moreover, all numerical ranges herein should be understood to include each whole integer within the range.
While illustrative embodiments of the invention are disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the features for the various embodiments can be used in other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention.
The present application claims priority from U.S. patent application Ser. No. 61/537,021 filed Sep. 20, 2011, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61537021 | Sep 2011 | US |
