U.S. patent application number 12/996578 was filed with the patent office on 2011-06-16 for deaeration system and method for flexible packages.
Invention is credited to Andre Albert, Guillaume Lessard, Steve Michaud.
Application Number | 20110138745 12/996578 |
Document ID | / |
Family ID | 41397685 |
Filed Date | 2011-06-16 |
United States Patent
Application |
20110138745 |
Kind Code |
A1 |
Albert; Andre ; et
al. |
June 16, 2011 |
DEAERATION SYSTEM AND METHOD FOR FLEXIBLE PACKAGES
Abstract
System for allowing removal of air from the interior of flexible
packages, in which material can be found, including a conveyor
transporting and supporting the bottom of the flexible packages or
package, a second sub-system holding the top part of the package
and an air extraction system. The package is raised vertically
while being displaced along the conveyor. Removing the air from the
packages before closing them results in a flat and straight flap,
while reducing the distance between the product and the sealed or
sewn joint. The process is accomplished through a continuous
displacement of the package. These advantages result in packing
material savings. A method for allowing removal of air is also
disclosed.
Inventors: |
Albert; Andre; (Quebec,
CA) ; Michaud; Steve; (Quebec, CA) ; Lessard;
Guillaume; (Quebec, CA) |
Family ID: |
41397685 |
Appl. No.: |
12/996578 |
Filed: |
June 4, 2009 |
PCT Filed: |
June 4, 2009 |
PCT NO: |
PCT/CA09/00785 |
371 Date: |
February 22, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61058805 |
Jun 4, 2008 |
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Current U.S.
Class: |
53/408 ;
53/79 |
Current CPC
Class: |
B65B 43/26 20130101;
B65B 31/041 20130101; B65B 31/046 20130101 |
Class at
Publication: |
53/408 ;
53/79 |
International
Class: |
B65B 31/00 20060101
B65B031/00 |
Claims
1-9. (canceled)
10. A system for removal of air from an interior of a flexible
package before sealing thereof, the system comprising: a lower
conveyor sub-system for continuously displacing the package along a
length of the system; an upper driving sub-system holding
continuously an upper part of the package, keeping the upper part
closed along a length of its displacement, said upper driving
sub-system comprising at least one perforated belt bag-opening
sub-system comprising: at least one pair of adjacent guiding
structures, each guiding structure having a profile surface facing
a corresponding profile surface of the opposite guiding structure;
a plurality of driving belts, each belt circulating around a
corresponding guiding structure of the at least one pair of guiding
structures, each of said belts following a path along the
corresponding profile of the guiding structure on which the driving
belt is travelling; a pulley system for driving displacement of the
plurality of driving belts around the guiding structures; and a
belt sub-system vacuum source applying vacuum behind the belts,
said at least one bag-opening sub-system spreading partially open
the upper part of the package at a specific location along the
length of the system when passing between the profile surfaces of
adjacent guiding structures, said upper driving sub-system being
synchronized with the lower conveyor sub-system; and a deaeration
port located above the bag-opening sub-system allowing removal of
air from the interior of the package when the package is positioned
under the port.
11. The system according to claim 10, wherein a distance between a
top surface of the lower conveyor sub-system and the upper driving
sub-system decreases along the length of the system to remove
vertical tension from the upper part of the package.
12. The system according to claim 10, wherein the bag-opening
sub-system repositions the package and allows passage of a certain
quantity of air.
13. The system according to claim 10, wherein each of the guiding
structures is a block comprising a concave surface.
14. A method for removing air from an interior of a flexible
package before sealing thereof, comprising the following steps: a)
providing a system for removal of air comprising: a lower conveyor
sub-system for continuously displacing the package along a length
of the system; an upper driving sub-system holding continuously an
upper part of the package, keeping the upper part closed along a
length of its displacement, said upper driving sub-system
comprising at least one perforated belt bag-opening sub-system
comprising: at least one pair of adjacent guiding structures, each
guiding structure having a profile surface facing a corresponding
profile surface of the opposite guiding structure; a plurality of
driving belts, each belt circulating around a corresponding guiding
structure of the at least one pair of guiding structures, each of
said belts following a path along the corresponding profile of the
guiding structure on which the driving belt is travelling; a pulley
system for driving displacement of the plurality of driving belts
around the guiding structures; a belt sub-system vacuum source
applying vacuum behind the belts, said at least one bag-opening
sub-system spreading partially open the upper part of the package
at a specific location along the length of the system when passing
between the profile surfaces of adjacent guiding structures, said
upper driving sub-system being synchronized with the lower conveyor
sub-system; and a deaeration port located above the bag-opening
sub-system allowing removal of air from the interior of the package
when the package is positioned under the port, b) displacing
continuously the package along a horizontal direction, using the
low conveyor sub-system; b) maintaining continuously an upper part
of the package closed along a length of its displacement, using the
upper driving sub-system; c) partially opening the upper part of
the package at a specific location along the length of the system,
using said bag-opening sub-system; and d) removing air from the
interior of the package when the package is positioned, at said
specific location, using the deaeration port.
15. The method according to claim 14, further comprising the step
of decreasing, along the length of the displacement, a distance
between the lower conveyor sub-system and the upper driving
sub-system to remove vertical tension from the upper part of the
package.
16. The method according to claim 15, wherein each of the guiding
structures is a block comprising a concave surface.
17. A system for removing air from an interior of a flexible
package before sealing thereof, comprising: displacement means for
continuously displacing the package along a horizontal direction
while supporting a bottom of the package and holding an upper part
of the package at all times; raising means for raising the bottom
of the package along a distance of travel of the package to reduce
vertical tension within the package; and opening means for opening
a portion of the upper part of the package, said opening means
comprising: at least one pair of guiding structures, each guiding
structure having a profile surface facing a corresponding profile
surface of the opposite guiding structure; a plurality of driving
belts, each belt circulating around a corresponding guiding
structure of the at least one pair of guiding structures, each of
said belts following a path along the corresponding profile of the
guiding structure on which the driving belt is travelling; a pulley
system for driving displacement of the plurality of driving belts
around the guiding structures; and a belt sub-system vacuum source
applying vacuum behind the belts, said bag-opening sub-system
spreading partially open the upper part of the package at a
specific location along the length of the system when passing
between the profile surfaces of adjacent guiding structures, while
maintaining displacement of the package; and a deaeration port
located above the opening means allowing removal of air from the
interior of the package when the package is positioned under the
port.
Description
RELATED APPLICATIONS
[0001] This application is the U.S. National Phase under 35 U.S.C.
.sctn.371 of International Application No. PCT/CA2009/000785, filed
on Jun. 4, 2009, which in turn claims the benefit of U.S.
Provisional Application No. 61/058,805, filed on Jun. 4, 2008, the
disclosures of which Applications are incorporated by reference
herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to packaging
systems. More particularly, the present invention relates to a
deaeration system for flexible packages and a method associated
thereto.
BACKGROUND OF THE INVENTION
[0003] Several different types of products are packaged typically
in flexible packages. After filling of the packages, in order to
reduce the overall volume of the package; it is often desired to
remove air remaining within the package before sealing thereof.
Removing the air from the packages before closing them results in a
flat and straight flap (upper part of the package above the
product). Then, it is possible for the closing system belts to be
closer to the product. Therefore, it is possible to reduce the
distance between the product and the sealed or sewn joint. By
reducing this distance, the freeboard (distance between the upper
part of the package and the product level when the package is full)
is also reduced. The required length of empty bags is consequently
reduced, which result in packing material savings (economic and
ecological savings).
[0004] The invention described in U.S. Pat. No. 7,316,102 involves
an apparatus for extracting air from within flexible packages. The
package is displaced along a conveyor system and has air removed
therefrom under a hood which is linked to a subsequent closing
mechanism.
[0005] However, flexible packaging customers still have several
requirements that are not completely satisfied with existing
deaeration systems, including: [0006] Reducing a warehouse bursting
packages problem; [0007] Reducing the amount of air in packages;
[0008] Maintaining current productivity, reliability and quality;
[0009] Using the smallest footprint possible (ex.: providing 7 feet
maximum length available for the footprint); [0010] Providing
flexible package sizes (from 13'' to 20''); and [0011] Using less
freeboard.
[0012] Consequently, there is still presently a need for a
deaeration system and associated method which offers superior
results in terms of the efficiency of the removal of air from the
flexible package and addresses the above requirements.
SUMMARY OF THE INVENTION
[0013] The present invention addresses at least one of the
above-mentioned needs.
[0014] More particularly, the present invention provides a system
for removal of air from an interior of a flexible package before
closure thereof, the system comprising: [0015] a lower conveyor
sub-system for continuously displacing the package along a length
of the system; [0016] an upper driving sub-system holding
continuously an upper part of the package, keeping the upper part
closed along a length of its displacement, said upper driving
sub-system comprising at least one perforated belt bag-opening
sub-system comprising: [0017] at least one pair of adjacent guiding
structures, each guiding structure having a profile surface facing
a corresponding profile surface of the opposite guiding structure;
[0018] a plurality of driving belts, each belt circulating around a
corresponding guiding structure of the at least one pair of guiding
structures, each of said belts following a path along the
corresponding profile of the guiding structure on which the driving
belt is travelling; [0019] a pulley system for driving displacement
of the plurality of driving belts around the guiding structures;
and [0020] a belt sub-system vacuum source applying vacuum behind
the belts, said at least one bag-opening sub-system spreading
partially open the upper part of the package at a specific location
along the length of the system when passing between the profile
surfaces of adjacent guiding structures, said upper driving
sub-system being synchronized with the lower conveyor sub-system;
[0021] and [0022] a deaeration port located above the bag-opening
sub-system allowing removal of air from the interior of the package
when the package is positioned under the port.
[0023] Preferably, the lower conveyor sub-system has a profile or
shape that allows the package to increase in height sufficiently to
remove vertical tension from the top of the package.
[0024] Preferably, the bag-opening sub-system has a shape that
allows the upper part of the package to be partially opened by a
vacuum source connected to bag-opening sub-system.
[0025] Preferably, the air removal section displaces the package
through a perforated belt system or any other equivalent system
allowing repositioning of the package and allowing passage of a
certain quantity of air.
[0026] Preferably, the air removal section opens a portion (in the
upper part) of the package. In this section, the upper sides of the
package are maintained against the driving belts to spread it out,
partially opening the package. In fact, a source of vacuum applied
behind the perforated belts, a pulley desynchronisation and a
curved block or guiding structure constrain the two belts to follow
a curved path (opposite of one another).
[0027] The present invention also provides a method for removing
air from the interior of flexible packages before closure thereof,
comprising the following steps: [0028] a) providing a system for
removal of air comprising: [0029] a lower conveyor sub-system for
continuously displacing the package along a length of the system;
[0030] an upper driving sub-system holding continuously an upper
part of the package, keeping the upper part closed along a length
of its displacement, said upper driving sub-system comprising at
least one perforated belt bag-opening sub-system comprising: [0031]
at least one pair of adjacent guiding structures, each guiding
structure having a profile surface facing a corresponding profile
surface of the opposite guiding structure; [0032] a plurality of
driving belts, each belt circulating around a corresponding guiding
structure of the at least one pair of guiding structures, each of
said belts following a path along the corresponding profile of the
guiding structure on which the driving belt is travelling; [0033] a
pulley system for driving displacement of the plurality of driving
belts around the guiding structures; [0034] a belt sub-system
vacuum source applying vacuum behind the belts, said at least one
bag-opening sub-system spreading partially open the upper part of
the package at a specific location along the length of the system
when passing between the profile surfaces of adjacent guiding
structures, said upper driving sub-system being synchronized with
the lower conveyor sub-system; [0035] and [0036] a deaeration port
located above the bag-opening sub-system allowing removal of air
from the interior of the package when the package is positioned
under the port, [0037] b) displacing continuously the package along
a horizontal direction, using the low conveyor sub-system; [0038]
c) maintaining continuously an upper part of the package closed
along a length of its displacement, using the upper driving
sub-system; [0039] d) partially opening the upper part of the
package at a specific location along the length of the system,
using said bag-opening sub-system; and [0040] e) removing air from
the interior of the package when the package is positioned, at said
specific location, using the deaeration port.
[0041] According to the present invention, there is also provided a
system for removing air from an interior of a flexible package
before closure thereof, comprising: [0042] displacement means for
continuously displacing the package along a horizontal direction
while supporting a bottom of the package and holding an upper part
of the package at all times; [0043] raising means for raising the
bottom of the package along a distance of travel of the package to
reduce vertical tension within the package; and [0044] opening
means for opening a portion of the upper part of the package, said
opening means comprising: [0045] at least one pair of guiding
structures, each guiding structure having a profile surface facing
a corresponding profile surface of the opposite guiding structure;
[0046] a plurality of driving belts, each belt circulating around a
corresponding guiding structure of the at least one pair of guiding
structures, each of said belts following a path along the
corresponding profile of the guiding structure on which the driving
belt is travelling; [0047] a pulley system for driving displacement
of the plurality of driving belts around the guiding structures;
and [0048] a belt sub-system vacuum source applying vacuum behind
the belts, said bag-opening sub-system spreading partially open the
upper part of the package at a specific location along the length
of the system when passing between the profile surfaces of adjacent
guiding structures, while maintaining displacement of the package;
[0049] and [0050] a deaeration port located above the opening means
allowing removal of air from the interior of the package when the
package is positioned under the port.
[0051] The system according to the present invention offers the
following advantages: [0052] Capability of staying in control of
the top of package [0053] Keeping current packaging machine
configuration [0054] Capability of being added at the exit of
machine [0055] Capability to remove air "in-line" (continuously)
with up to 150 fpm linear speed [0056] Keeping high level of
reliability [0057] Preventing air entrance into the package (after
air extraction and prior to sealing) [0058] Package shape
conditioning after sealing
[0059] A non-restrictive description of preferred embodiments of
the invention will now be given with reference to the appended
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] FIG. 1 is a side view of the system according to a preferred
embodiment of the present invention;
[0061] FIG. 2 is another side view of the system shown in FIG. 1
with the packages removed and the upper housing installed;
[0062] FIG. 3 is another side view of the system shown in FIG. 2
with the upper housing removed;
[0063] FIG. 4 is a another side view of the system according to a
preferred embodiment of the present invention;
[0064] FIG. 5 is a side close-up view of the upper driving system
shown in FIG. 4;
[0065] FIGS. 6A and 6B are top and side-cut views respectively of
an aluminium block or guiding structure and associated hardware
from FIG. 4;
[0066] FIG. 7 is a detailed side view of the upper driving system
(air removal section) shown in FIG. 5;
[0067] FIG. 8 is another side close-up view of the upper driving
system shown in FIG. 4;
[0068] FIG. 9 is a side view of the system shown in FIG. 4, during
its operation with packages, illustrating different work
stations;
[0069] FIG. 10 is a top view of part of the upper driving system
shown in FIG. 4;
[0070] FIGS. 11a and 11b are front views of the interaction of a
package with a system according to another preferred embodiment of
the present invention, showing lower and upper positions of the
package;
[0071] FIGS. 12a to 12c are side views of the interaction of a
package with a system according to another preferred embodiment of
the present invention, as the package travels along the conveyor
system;
[0072] FIGS. 13a and 13b are perspective views of the interaction
of a package with the system shown in FIG. 11, before and after
removal of air;
[0073] FIGS. 14a to 14d are perspective views of the interaction of
a package with the system shown in FIG. 11, illustrating air
extraction, vacuum shutdown and maintaining of the condition of the
package after extraction.
[0074] FIGS. 15A to 15C are side, top and front views respectively
of the system shown in FIG. 1 with the upper housing and associated
support structure installed.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0075] As shown in FIGS. 1 to 3 and 15A to 15C, a deaeration system
10 for flexible packages 12 according to the present invention is
shown. The system comprises a lower conveyor sub-system 14. The
system 10 also has an upper driving system 16 maintaining
continuously the upper part of the package 12 closed along a
significant length of its displacement. The upper driving system 16
comprises one or several bag-opening sub-systems, preferably
connected to a vacuum source 18, that allows opening of the
flexible package at a specific location when the package travels
along the upper driving system 16 and on the lower conveyor system
14. The system also comprises a deaeration port 20 located above
the upper driving system 16 connected to the vacuum source 18 that
allows removal of air from the interior of the package 12 when the
package is positioned under the deaeration port 20 by the upper
driving system 16 and the lower conveyor system 14, under the
bag-opening sub-system.
[0076] In the present application, it is to be understood that the
deaeration port can be an aspiration port, a dedusting port, a
vacuum port, a system connected to a vacuum source or any other
equivalent system known to the person of skill in the art which is
capable of removing air or substances from the package.
[0077] As better shown in FIG. 4, the lower conveyor 14 includes a
steel frame 30, conveyor rollers 32 and a conveyor belt 34. The
conveyor belt is driven by a motor 36 at a constant linear velocity
in order to displace the package towards the closing or sealing
systems located downstream. The steel frame has a shape 38 that
allows the conveyor belt and the package to rise along a certain
height while translating along the system.
[0078] As better shown in FIG. 5, the system 40 controlling the
upper part of the package has three sections, 42,44,46. The first
42 and third 46 sections are made of aluminum blocks or guiding
structures, pulleys and belts. The upper part of the package is
maintained closed through pressure exerted by the belts on the
package. The belts are driven by a motor 48 at the same linear
velocity as the lower conveyor belt.
[0079] As better shown in FIGS. 6A and 6B and 7, the mid-section of
the system 44 includes aluminum blocks or guiding structures 50
having a special shape, perforated belts 52, pulleys 54 and various
other pieces of hardware. On each side of the system, a tube 56
connected to a high debit ventilator removes the air through an
opening in the aluminum blocks or guiding structures and through
the perforated belt.
[0080] As better shown in FIG. 8, the vacuum removal system 18 is a
deaeration port 60 located above the upper section. This port is
connected to a high flow ventilator 62 for removal of the air.
[0081] Explanation of the Operation of the System
[0082] The package arrives from the packaging system with a certain
quantity of air inside thereof, in addition to the packaged
product. The product reaches a certain height within the package.
The upper part of the package which is not filled is designated as
the freeboard. During removal of air from the package, the sides of
the freeboard approach one to another. Raising the package using
the shape of the bottom conveyor will result in loose freeboard.
Once an amount of play (loose) is given to the freeboard, the
package enters into the deaeration module. The blocks or guiding
structures in the deaeration section have a special internal
curvature. The belts are assembled in a manner such that there is a
greater length on the side on which the belts face each other to
follow the curvature. Moreover, the source of vacuum produced by
the high flow ventilator which removes the air from behind the
belts constrains the belts to follow the curvature of the block or
guiding structure. Finally, as the belts are perforated, a certain
quantity of air passes through them so that the upper sides of the
package are constrained to follow the belt and curvature of the
block or guiding structure.
[0083] In FIG. 9, the package can be seen along three different
stations along the system. The steps presented below are shown on
the figure. [0084] A. Module receives packages from packaging
machine. [0085] B. Bottom of the package is raised prior to vacuum
extraction. [0086] C. Top of package is forced to open and air is
extracted from package. [0087] D. Package exits towards the
sealer.
[0088] In FIG. 10, the air removal section of the system is seen
from above. The two blocks or guiding structures facing each other
can be seen, as well as the package along three different positions
during its displacement through the system. The package is
represented through bold lines and the hash marks represent the
opening through which air is removed from the inside of the
package.
[0089] FIGS. 11 to 14 illustrate various aspects of the system
during operation.
[0090] FIGS. 11a and 11b show lower and upper positions of the
package along the conveyor illustrating how tension is removed from
the top of the package once it is lifted.
[0091] FIGS. 12a to 12c are side views of the package as it travels
along the conveyor system. In this example, the slope is 3 inches
over 2 feet, preferably at 150 fpm.
[0092] FIGS. 13a and 13b illustrate the package before and after
removal of air.
[0093] FIGS. 14a to 14d are perspective views of the interaction of
a package with the system shown in FIG. 11, illustrating air
extraction, vacuum shutdown and maintenance of the condition of the
package after extraction of air.
[0094] Preferably, the present invention offers the following
performance parameters: [0095] Linear speeds up to 150 fpm [0096]
Adjustable to bag sizes (conveyor height) [0097] No additional
freeboard required (to hold the package while filling it) [0098]
Maximum footprint length of 7 feet [0099] Air removal time
estimated at 0.4 second [0100] No air entrance into the package
(after air extraction and prior to sealing)
[0101] According to the present invention, there is also provided a
method removing air from an interior of a flexible package before
closure thereof, comprising the following steps: [0102] a)
displacing the package along a horizontal direction; [0103] b)
maintaining continuously an upper part of the package closed along
a significant length of its displacement; [0104] c) partially
opening the upper part of the package at a specific location along
the length of the system; and [0105] d) removing air from the
interior of the package when the package is positioned, at said
specific location.
[0106] Preferably, the method further comprises the step of
decreasing, along the length of the displacement, a distance
between a means for displacing the package in step a) placed under
the package and a means for maintaining the package closed in step
b) to remove vertical tension from the upper part of the
package.
[0107] A package, after going through the above-described
deaeration system or method, can then be sealed or closed using any
sealing or closing system known in the art.
[0108] Differences with Respect to the Prior Art
[0109] As described in U.S. Pat. No. 7,316,102, packages must go
through the hood (see 1.sup.st paragraph of the summary of the
invention . . . "vacuum extraction hood through which the packages
are conveyed"), whereas, in the present invention, the hood is
replaced by a deaeration port and the package passes under the
port.
[0110] As described in U.S. Pat. No. 7,316,102, the open package
goes through the hood and it is gradually closed by the belts
facing each other and located in the upper part. In the present
invention, the package is closed when it arrives at the air removal
section (the package is held by the upper driving system belts) and
it is partially opened. In fact, a portion of it stays closed while
it is still held by the belts. This partial opening is done while
the package is moving forward.
[0111] With the system presented in U.S. Pat. 7,316,102, the upper
part of the bag is not held before and during air extraction. On
the contrary, in the present invention; the upper part of the
package is continuously held, even during air extraction, ensuring
an exact positioning of the upper part of the bag, thus ensuring a
constant transfer to the closing system and an increase in the
closing system reliability and quality of the finished product.
[0112] In the invention described in U.S. Pat. No. 7,316,102, the
upper part of the package is not held before the end of air
extraction; whereas in the present invention, the upper part of the
bag is continuously held. The distance between the conveyor which
supports the lower part of the package and the belts supporting the
upper parts of the package is adjustable. Consequently, it is
possible to control tensions exerted to the sides of the package
when the air is extracted from it. Since the distance between the
conveyor supporting the lower part of the package and the belts
holding the upper part of the package is controlled, the condition
(behaviour) of the flap is also controlled and the distance between
the closing system and the product level into the bag is decreased
which reduces the freeboard required.
[0113] In U.S. Pat. No. 7,316,102, air extraction is made through a
big hood maintained at a negative pressure. Air is drawn up
everywhere around several packages at the same time. Loss of
efficiency is obvious and should be certainly quantifiable. In the
present invention, air extraction is made through an aspiration
port. The dimension of the air aspiration end is smaller than the
upper part of the packages from which air is extracted. This small
end, located very near the upper part of the package offers more
efficiency (and increased performance).
[0114] Moreover, the system described in U.S. Pat. No. 7,316,102
has a voluminous hood that makes the system more burdensome, even
cumbersome or bulky. The present invention has a small deaeration
port allowing a realization of the same functions more efficiently
while keeping the system dimension to its minimum.
[0115] Although the present invention has been explained
hereinabove by way of preferred embodiments thereof, it should be
pointed out that any modifications to these preferred embodiments
within the scope of the appended claims are not deemed to alter or
change the nature and scope of the present invention.
* * * * *