U.S. patent application number 11/094826 was filed with the patent office on 2006-10-05 for adjustable infeed bed for packaging apparatus.
This patent application is currently assigned to Sealed Air Corporation. Invention is credited to Eric A. Kane, Laurence B. Sperry.
Application Number | 20060218884 11/094826 |
Document ID | / |
Family ID | 36576062 |
Filed Date | 2006-10-05 |
United States Patent
Application |
20060218884 |
Kind Code |
A1 |
Sperry; Laurence B. ; et
al. |
October 5, 2006 |
Adjustable infeed bed for packaging apparatus
Abstract
An apparatus for packaging an object, the apparatus having an
adjustable infeed bed to center the object before a nipping
operation. The packaging apparatus includes a pair of opposing
rollers and an adjustable infeed bed. The pair of opposing rollers
pushes together sheets of packaging material against each other and
the object or product to be package. In order to accommodate
objects of various heights, the infeed bed is adjustable so as to
line up the center of the object to the center of the rollers. To
determine the proper adjustment to the infeed bed, the packaging
apparatus may also include a height detector for measuring a height
dimension for an object.
Inventors: |
Sperry; Laurence B.;
(Boston, MA) ; Kane; Eric A.; (Lynn, MA) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Sealed Air Corporation
|
Family ID: |
36576062 |
Appl. No.: |
11/094826 |
Filed: |
March 30, 2005 |
Current U.S.
Class: |
53/450 ; 53/504;
53/553 |
Current CPC
Class: |
B65B 9/02 20130101; B65B
49/06 20130101; B65B 51/12 20130101 |
Class at
Publication: |
053/450 ;
053/553; 053/504 |
International
Class: |
B65B 9/02 20060101
B65B009/02; B65B 57/10 20060101 B65B057/10 |
Claims
1. An apparatus for packaging an object, comprising: a pair of
opposing rollers forming a nip arranged to receive a pair of
opposing packaging material sheets with an object disposed
therebetween, the rollers exerting pressure on the sheets to adhere
the sheets to each other around said object so as to form a
package; a height detector configured to measure a height of the
object; and an adjustable infeed bed upstream of the nip for
supporting the object, said infeed bed being adjustable in position
in a height direction of the object based on the height measured by
the height detector so that the object is approximately centered to
the opposing rollers.
2. The apparatus of claim 1, wherein the adjustable infeed bed has
an upstream end and a downstream end and the downstream end is
adjustable relative to the opposing rollers.
3. The apparatus of claim 2, wherein both the upstream end and
downstream end are adjustable relative to the opposing rollers.
4. The apparatus of claim 1, wherein the adjustable infeed bed
includes a conveying belt for advancing the object toward the
opposing rollers.
5. The apparatus of claim 1, wherein the adjustable infeed bed has
at least two positions for centering the object relative to the
rollers.
6. The apparatus of claim 1, wherein the adjustable infeed bed has
a range of positions for centering the object relative to the
rollers.
7. The apparatus of claim 1, wherein the adjustable infeed bed
includes an upper surface for supporting one of the packaging
material sheets and the sheet supports and advances the object
toward the rollers.
8. The apparatus of claim 1, wherein each of the rollers includes a
resiliently complaint roller portion that is deformed by the object
between the packaging material sheets, the resiliently complaint
roller portion tending to return to its undeformed shape thereby
exerting pressure on the packaging material sheets to closely
conform to the object.
9. An apparatus for packaging an object, comprising: a pair of
opposing rollers forming a nip therebetween, a web supply system
for supplying a pair of generally opposing web portions of flexible
packaging material into the nip so that an object to be packaged
when placed between the web portions is passed through the nip
along with the web portions, the web portions having sealing
material for sealing the web portions together; a height detector
configured to measure a height of the object; and an adjustable
infeed bed for supporting the object as the object is advanced to
the rollers, said infeed bed being adjustable relative to the
rollers based on the height measured by the height detector so that
the object is aligned to the rollers.
10. The apparatus of claim 9, wherein the adjustable infeed bed
includes a downstream end, an upstream end, and at least one
actuator for adjusting the position of the downstream end relative
to the rollers.
11. The apparatus of claim 10, wherein the adjustable infeed bed
includes at least one actuator for adjusting the upstream end
relative to the rollers.
12. A method for packaging an object comprising: advancing a pair
of packaging material sheets in opposing relation toward a nip
defined between two opposing rollers, with an object disposed
between the sheets; measuring a height of the object with a height
detector and producing a height measurement; adjusting a position
of the object in a height direction thereof based on the
measurement from the height detector; and advancing the sheets and
object through the nip so as to seal the packaging material
together around the object.
13. A method of packaging an object comprising: placing an object
to be packaged on an infeed bed; measuring the height of the object
with a height detector; sending a signal from the height detector
to a controller and activating one or more actuators to adjust the
infeed bed based on the signal sent to the controller so that a
center of the object is substantially aligned with a nip between a
pair of opposing rollers; and advancing the object and two portions
of packaging material through the nip between the opposing rollers
and enclosing the object between the portions to form a
package.
14. The method of claim 13 further comprising: severing the package
from the rest of the packaging material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to U.S. patent application Ser. No.
10/237,507 filed on Sep. 9, 2002, currently pending.
FIELD OF INVENTION
[0002] The present invention relates to machines and methods for
packaging objects using flexible or semi-flexible sheet materials,
wherein an object is disposed between two portions of sheet
material and the two portions are sealed together about the
periphery of the object to form a package.
BACKGROUND OF THE INVENTION
[0003] Flexible packaging has long been used to package products
such as books, compact discs, cassette tapes, and a host of other
types of objects to provide protection when shipping or mailing the
objects, and in some cases to hermetically seal the objects from
the outside environment. Web-handling machines have been developed
to automate the process of packaging objects in flexible packaging
materials. Dual-web machines bring a pair of webs into generally
parallel confronting relation with each other and feed a product,
or a group of products, between the webs. Longitudinal or side
seals are then effected to seal the webs together along their side
edges, and transverse or cross seals are similarly made ahead of
and behind the packaged product(s), thus forming a package
containing the product(s). The package is severed from the
remainder of the webs to complete the process. Single-web machines
work similarly, except a single web is either supplied to the
machine as a C-fold, or a flat web is manipulated and folded into a
C-fold configuration, the objects to be packaged are inserted
between the two opposing portions of the C-folded web, and one
longitudinal seal and two cross seals are formed.
[0004] Single-web machines typically include a longitudinal seal
device such as a pair of rollers or the like forming a nip through
which the overlying longitudinal edges of the opposing web portions
pass to effect a longitudinal seal on one side of the package.
Dual-web machines include a similar longitudinal seal device
through which the opposite longitudinal edges of the web portions
pass to effect an opposite longitudinal seal. The longitudinal seal
devices can apply pressure alone where cold seal materials are
employed, or can apply pressure and heat in the case of heat-seal
materials. The longitudinal seal devices are spaced apart by a
distance corresponding to the width of the web material. Typically
this distance is fixed, such that the machine is able to handle
only one width of material.
[0005] With conventional machines, a problem that frequently arises
is that the packaged object is not centered between the pair of
rollers or the like that form the nip in the thickness direction of
the object, i.e., in a direction normal to the surfaces of the web
portions. If the object is offset in the thickness direction toward
one roller, the frequent result is that the overlying longitudinal
edges of the web portions are not properly aligned with each other;
the edge (or both edges in the case of a dual-web machine) of the
web portion toward which the object is offset tends to be pulled
transversely inward toward the longitudinal centerline of the web
portion because the web portion must curve outward to a greater
extent than the other web portion. This results in package edges
that are unsightly.
[0006] Another problem with many types of flexible packaging
machines of the above-noted type is that the web materials tend to
become wrinkled as a result of being forced to bend and curve
around the contour of the object being packaged. In some cases, no
attempt is made to eliminate the wrinkling, and the result is that
packages are made that are not very aesthetically pleasing. The
problem tends to become worse as the height or thickness of the
packaged object increases, since the web material is forced to
curve and bend to a greater extent. Furthermore, different types of
web materials behave differently with respect to wrinkling.
Therefore, the conventional machines are not well suited to
packaging a variety of objects of different thicknesses, sizes, and
shapes, since a machine set-up that may minimize wrinkling for one
object configuration and/or one type of web material may not work
well for a different object configuration and/or different web
material.
[0007] In light of the above considerations, a more versatile
packaging machine and method are needed, able to handle various
object configurations, including varying heights.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention addresses the above needs and achieves
other advantages by providing an apparatus for packaging an object,
with an adjustable infeed bed to center the object before a nipping
operation. In general, the apparatus includes a pair of opposing
rollers that form a nip, an adjustable infeed bed, and a height
detector. Two opposing packaging material sheets are passed through
the nip with an object disposed therebetween, and the sheets of
packaging material are sealed together around the object to form a
package. The infeed bed receives an object to be packaged and feeds
it into the nip between the sheets. The infeed bed is adjustable
for centering the object in its height direction relative to the
nip based on the measurement from the height detector.
[0009] In other aspects of the present invention, the adjustable
infeed bed may have an upstream end and downstream end. In some
embodiments, the downstream end is adjustable relative to the
opposing rollers, while in other embodiments, both the downstream
and upstream ends are adjustable to the rollers. The apparatus may
further include at least one actuator such as a pneumatic cylinder,
hydraulic cylinder, electric motor or the like for adjusting the
infeed bed. The infeed bed may have at least two positions for
centering the object between the rollers. In one embodiment, the
adjustable infeed bed may include a conveying belt for advancing
the object toward the opposing rollers. Alternatively, the
adjustable infeed bed may include an upper surface arranged to
support one of the packaging material sheets in such a manner that
the sheet supports and advances the object toward the rollers.
[0010] In at least one embodiment, each roller includes a
resiliently compliant roller portion that is deformed by the object
between the packaging material sheets. The resiliently compliant
roller portion has a tendency to return to its undeformed shape.
This tendency exerts pressure on the packaging material to closely
conform to the object being packaged.
[0011] In another embodiment, the present invention provides an
apparatus for packaging an object. The apparatus includes a pair of
opposing rollers, a web supply system, and an adjustable infeed
bed. The rollers together form a nip. The web supply system
supplies a pair of generally opposing web portions of flexible
packaging materials into the nip, so that an object placed between
the web portions passes through the nip along with the web
portions. The facing surfaces of the web portions have a sealing
material for sealing the web portions together as the portions pass
through the nip and form a package around the object. The
adjustable infeed bed is for advancing the object to the rollers so
that the object is fed into the nip between the web portions. The
position of the infeed bed relative to the rollers is adjustable in
order to adjust the position of the object relative to the nip in a
height direction of the object.
[0012] The infeed bed has a downstream end and an upstream end. In
one embodiment, the infeed bed includes at least one actuator such
as a pneumatic cylinder or the like for adjusting the position of
the downstream end relative to the rollers. In other embodiments,
the infeed bed may further include at least one actuator, such as a
pneumatic cylinder or the like for adjusting the upstream end
relative to the rollers. Also, the apparatus may further comprise a
height detector for measuring the height of the object to determine
the proper adjustment to the infeed bed.
[0013] According to another embodiment of the invention, a method
is provided for packaging an object or product. The method includes
advancing a pair of packaging material sheets along two paths that
converge into and through a nip formed by two opposing rollers,
determining a dimension of an object to be packaged in a height
direction, centering the object relative to the nip in the height
direction, feeding the centered object in the nip between the two
packaging material sheets, and sealing the sheets together around
the object. The method may also include measuring the height of the
object with a height detector.
[0014] In yet another embodiment of the invention, a method of
packaging an object includes placing the object on an infeed bed,
adjusting the position of the infeed bed so that a center of the
object in a height direction thereof is substantially aligned with
a nip formed by a pair of opposing rollers, advancing the object
along the infeed bed to the opposing rollers and between two
portions of a packaging material, and advancing the object and the
portions through the nip and enclosing the object between the
portions to form a package. The method may also include measuring
the height of the object. For example, the height may be determined
with a height detector. Furthermore, the method may include a step
of sending a signal from the height detector to a controller and
activating one or more pneumatic cylinders or the like to adjust
the infeed bed based on the signal sent to the controller.
[0015] The present invention has several advantages. The adjustable
infeed bed allows the packaging to accommodate objects of various
heights. More specifically, the infeed bed aligns or centers each
object relative to the rollers based on the object's height. The
centering results in a more symmetric and aesthetic package and
reduces any stress variances within the package. Also, the height
detector can provide the necessary information to set the infeed
bed in an automatic fashion.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0016] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0017] FIG. 1 is a side view of a packaging apparatus in accordance
with one embodiment of the invention, partially broken away to
display the adjustable infeed bed;
[0018] FIG. 2 is a side view of the packaging apparatus as shown in
FIG. 1 with the adjustable infeed bed in a comparatively lower
position for a taller object than in FIG. 1;
[0019] FIG. 3 is a perspective view of the downstream end of the
infeed bed according to one embodiment of the present
invention;
[0020] FIG. 4 is a cross-section view the infeed bed taken along
line 4-4 of FIG. 3;
[0021] FIG. 5 is another cross-section view of the packaging
apparatus taken along line 5-5 of FIG. 1; and
[0022] FIG. 6 is yet another cross-section of the packaging
apparatus taken along line 6-6 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present inventions now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some but not all embodiments of the inventions are shown. Indeed,
these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0024] A packaging apparatus 20 in accordance with one embodiment
of the invention is shown in FIGS. 1 and 2. The apparatus 20 is of
the dual-web type for advancing a first or upper web 22 and a
second or lower web 24 in generally parallel opposing relation with
a product P disposed between the webs 22, 24 and sealing the webs
22, 24 together to capture the product P therebetween. The
packaging apparatus 20 includes a main frame having a plurality of
spaced vertical support columns. More specifically, the main frame
has three pairs of vertical columns 26, 28, 30. Each pair 26, 28,
30 has a column on one side of a longitudinal axis of the apparatus
20, and a corresponding support column on the opposite side of the
longitudinal axis. One or more transverse members are rigidly
connected between each pair of support columns 26, 28, 30. Upper
and lower longitudinal members 32 are rigidly connected between the
support columns of 26 and 28 on the same side of the longitudinal
axis. The frame also includes a pair of upper longitudinal members
48. The upper ends of the vertical support columns 26, 28, 30 on
one side of the longitudinal axis rigidly connect to one of the
upper longitudinal members 48, as shown in FIGS. 1 and 2.
Similarly, the upper ends of the vertical support columns 26, 28,
30 on the other side of the longitudinal axis rigidly connect to
the other upper longitudinal member which is not visible in the
drawings. As described in more detailed below, an infeed bed 40 is
positioned between two pairs of the vertical support columns 28,
30.
[0025] The upstream columns 26 support web mounts 52, 54 that
respectively support supply rolls of the webs 22, 24 in a rotatable
manner. The upper web 22 is drawn from its supply roll and advanced
over a guide 56 supported between the two upper longitudinal
members 48 then over and around a guide 57 also supported between
the upper longitudinal members 48 and spaced longitudinally
downstream from the first guide 56, then downward to a guide 58
supported between the columns 30 and then toward a pair of rollers
70, 72 discussed in more detail below.
[0026] The lower web 24 is drawn from its supply roll and advanced
over a lower guide 60 supported between columns 28 then under a
downstream guide and web tensioner 61 pivotally supported by
columns 30 then under and around a guide 62 supported by columns
30, then around a guide 63 also supported by columns 30 and then
toward the pair of rollers 70.
[0027] In general, according to the illustrated embodiments the
lower web 24 traverses a path under the infeed bed 40 and then
toward and into the pair of rollers 70, 72. However in an
alternative embodiment, not shown, the path of the lower web 24 may
proceed over, rather than under, the infeed bed 40. More
specifically, the lower web 24 can advance along a general planar
upper surface 66 of the infeed bed 40.
[0028] As shown in FIGS. 1 and 2 and as stated above, the apparatus
20 includes a pair of rollers 70, 72 that are rotatably mounted in
the main frame at a downstream end thereof. The rollers 70, 72 form
a nip through which the webs 22, 24 are advanced with the product P
to be packaged disposed therebetween. As best seen in FIG. 6, one
or both of the rollers 70, 72 comprises a resiliently deformable
material at least over a medial portion 85 of the roller's length,
such that the passage of the product P through the nip deforms the
roller(s) 70, 72 and the restoring force of the resiliently
deformable material presses the webs 22, 24 toward each other so
that the packaging material from the webs 22, 24 conforms closely
to the product P and helps to push out the air that otherwise would
be trapped between the product and material. The webs 22, 24
advantageously have cold seal or cohesive material on their facing
surfaces such that the application of pressure by the rollers 70,
72 causes the webs 22, 24 to adhere to each other but not to the
product P. The end portions 87 of each of the rollers 70, 72
advantageously comprise a generally non-deformable or substantially
less-deformable material for firmly gripping the opposite edge
portions of the webs 22, 24. As seen in FIGS. 1 and 2, the rollers
70, 72 advantageously are rotatably driven for advancing the webs
22, 24 through the apparatus 20, thus comprising a web drive
system. Alternatively, a separate web drive system can be employed
if desired.
[0029] As best seen in FIGS. 1 and 2, the apparatus 20 may also
have a housing 74 to shield or cover the rollers 70, 72. The
housing 74 preferably is pivotable relative to the main frame about
hinges (not shown) for access to internal parts of the machine when
required for maintenance and the like.
[0030] As mentioned above, the infeed bed 40 has a generally planar
upper surface 66. This surface 66 supports a conveying mechanism
for advancing the product P to be packaged to the rollers 70, 72.
For example, the conveying mechanism may be a conveyor belt 89 that
rotates around the infeed bed 40, as best seen in FIG. 3. More
specifically the conveyor belt 89 rotates around a general
perimeter of the infeed bed 40. The belt 89 is driven by a motor 91
that drives one of four belt guides 92 proximate to each corner of
the infeed bed 40. The belt 89 may also have a series of dividers
or pushers 93 that extend generally perpendicular to the belt 89.
The pushers 93 facilitate the advancement of the product or
products P along the belt 89.
[0031] Alternatively, in embodiments where the lower web 24 runs
along the upper surface 66 of the infeed bed 40, the lower web 22
will function as a conveyor and advance the product P to the
rollers 70, 72. The product P may be placed on the conveying
mechanism either manually by an operator or automatically by
another conveyor belt (not shown) that leads to the infeed bed
40.
[0032] Preferably, the center of the product P in its height
direction is aligned with the nip formed by the rollers 70, 72.
This facilitates a more symmetric package, reduces misalignment
between the edges of the two webs 22, 24, and reduces any stress
variation within the packaging material. Advantageously, the
position or orientation of the infeed bed 40, and more specifically
the upper surface 66, is adjustable relative to the rollers 70, 72.
The position or orientation of the upper surface 66 is adjusted so
that the center the product P in the height direction is aligned or
lined up with the nip between the rollers 70, 72. This
adjustability allows for the packaging apparatus 20 to accommodate
a variety of products P of differing heights.
[0033] In order to determine the proper adjustment to the upper
surface 66, the apparatus 20 may also have a height detector 76 for
measuring the height of the product P. Based on the height of the
product P, the proper adjustment to the upper surface 66 may be
determined. The height detector 76 can comprise various types of
devices, including but not limited to an optical distance-measuring
device such as a laser distance-measuring device. The height
detector 76 is preferably mounted above the infeed bed 40 and is
positioned and aimed down onto the upper surface 66, as illustrated
in FIGS. 1 and 2.
[0034] Adjusting the upper surface 66 can be accomplished in
several ways. For example purposes only, and not as a limitation,
the adjusting of the upper surface 66 may be accomplished by one or
more hydraulic or pneumatic cylinders controlled by suitable fluid
valves. Alternatively, an electric motor driving a suitable
mechanism (e.g. gears, chains, etc.) may be used. One skilled in
the art would appreciate that various methods and structures are
available to adjust the upper surface 66, including examples not
mentioned herein.
[0035] In the illustrated embodiment, the infeed bed 40 is adjusted
by two pairs of pneumatic cylinders 80 (only one is visible in FIG.
1 and 2) and 82 (as shown in FIG. 3). More specifically one pair 80
is located at the upstream end of the infeed bed 40 and the other
pair 82 is located at the downstream end of the infeed bed 40. FIG.
1 illustrates the pneumatic cylinders 80 and 82 having adjusted the
infeed bed 40 to a raised position for a relatively thin product P.
Alternatively, FIG. 2 illustrates the pneumatic cylinders 80 and 82
having adjusted the infeed bed 40 to a lowered position for a
relatively thick product P.
[0036] In particular, as shown in FIG. 5, each pneumatic cylinder
80, 82 is rigidly attached between one of the vertical columns 28,
30 of the main frame and rigidly attached to the infeed bed 40.
Also each cylinder 80 and 82 is slidably attached to a guide rail,
for example see the pair of rails 83 in FIG. 5. The guide rails are
supported by a corresponding vertical column for additional
support. The position of the infeed bed 40 is adjusted by the
extending or retracting the cylinders 80 and 82.
[0037] In some embodiments, the position of the entire upper
surface 66 may be adjusted according to the height of the product
P. Alternatively, in other embodiments, an upstream end of the
upper surface 66 may be fixed and serve as a pivot point about
which the infeed bed 40 pivots to adjust a downstream end of the
upper surface 66.
[0038] The apparatus 20 may also include a controller 88 comprising
a microprocessor. The controller 88 is programmed to control the
various motors and actuators of the apparatus 20 that effect
movement of the moving parts such that the movements are properly
synchronized with respect to determining the height of the product
P, adjusting the infeed bed 40, and advancing the web of materials
22, 24 and the product P to and through the rollers 70,72.
[0039] The operation of the apparatus 20 is now explained with
primary reference to FIGS. 1 and 2. Rolls of upper and lower webs
22, 24 are mounted in the web mounts 52, 54, respectively. The
upper web 22 is threaded through the machine by advancing the web
over and around the guides 56, 57, 58 and then through the nip
between rollers 70, 72. The lower web 24 is threaded by advancing
the web under and around the guides 60, 61, 62, 63 and then through
the nip. To begin a packaging sequence, a product P is placed on
the conveying mechanism on the upper surface 66. A cycle start
button is pressed, which causes the controller 88 to execute a
series of operations as follows: the controller 88 causes the
height detector 76 to measure the height of the product P, the
signal from the detector 76 is relayed back to the controller, and
based on the height of the product P, the controller 88 activates
the various motors or actuators to cause the infeed bed 66 to be
adjusted, if necessary, in order to center the product P to the nip
between the rollers 70, 72 before the product P is advanced into
the nip. Either simultaneously with the adjusting of the infeed bed
40 or after the adjustment is completed, the controller 88 causes
the various motors to drive the rollers 70, 72 to advance the webs
22, 24 and the product P up to and through the nip to produce a
package, which is cut off by the cutoff device 98 and conveyed by
an out-feed conveyor 100 to the machine discharge. The process
generally as described above is repeated for each subsequent
package.
[0040] The present invention has several advantages. The adjustable
infeed bed 40 allows the packaging of objects or products P of
various heights in a consistent manner. More specifically, the
infeed bed 40 substantially aligns or centers each object relative
to the rollers 70, 72 based on the object's height. The centering
produces a more symmetric and aesthetic package and reduces any
stress variances within the package. The height detector 76 can
provide the necessary information to set the infeed bed 40
properly.
[0041] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *