Abstract:
The disclosure relates to a method and apparatus for compressing woven material or other compressible material, such as, but not limited to, a comforter set or bedding set. The bedding set or other woven material is placed into a reclosable storage bag through the open bottom thereof. The bag is compressed by a compression apparatus and the open bottom of the storage bag is sealed shut. The result is a package with reduced volume, which reduces shipping and display costs, and is more aesthetically attractive to the consumer.

Description:
BACKGROUND OF THE DISCLOSURE 
       [0001]    This application claims priority under 35 U.S.C. §119(e) of provisional patent application Ser. No. 61/359,133, filed on Jun. 28, 2010; provisional application Ser. No. 61/304,734, filed on Feb. 15, 2010, the contents of all of which are hereby incorporated by reference in their entirety. Additionally, this application is a continuation-in-part of application Ser. Nos. 12/823,823 and 12/823,331, both filed Jun. 25, 2010 and both claiming priority under 35 U.S.C. §119(e) of said provisional patent application Ser. No. 61/304,734, filed on Feb. 15, 2010, the contents of all of which are hereby incorporated by reference in their entirety. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present disclosure relates to a form fill and seal method and apparatus for producing compact shipping for woven fabric articles or compressible materials, such as, but not limited to, bedding materials. 
       DESCRIPTION OF THE PRIOR ART 
       [0003]    In the prior art, it is well known to package woven fabric articles or compressible materials, such as bedding material, in a package or bag made from polymeric or similar material. However, the resulting packaging can be bulky which increases transportation, storage and display costs throughout the chain of commerce. Similarly, a consumer may be less prone to buy an unwieldy package. 
         [0004]    The storage of polymeric bag within a box is disclosed in U.S. Pat. No. 7,588,160, entitled “Combined Storage Apparatus”, issued on Sep. 15, 2009 to Chen. 
         [0005]    While the embodiments disclosed in parent application Ser. Nos. 12/823,823 and 12/823,331, both filed Jun. 25, 2010 and entitled “Method and Apparatus for Compressing and Holding in Compression Woven Fabric Articles” have been satisfactory for their intended purposes, further improvements are desired, such as increasing the manufacturing speed and possibly increasing the automation of the method and apparatus. 
       SUMMARY AND OBJECTS OF THE DISCLOSURE 
       [0006]    It is therefore an object of the present disclosure to provide further improvements in a method and apparatus for compressing woven fabric articles or compressible materials, such as, but not limited to, bedding materials, in order to provide a compact and aesthetically pleasing package. These improvements may include increasing the manufacturing speed and possible increasing the automation of the method and apparatus. 
         [0007]    This and other objects are attained by the present disclosure by providing a method and apparatus wherein a series of plastic storage bags with open bottoms are provided. The plastic storage bags are typically of the type with a reclosable zipper (but may be a plain closure or a non-reclosable closure, such as with a hard seal sealing the top edges of the front and rear walls together), and typically provided in a successive chain configuration, a stacked configuration, a wicketed configuration or a similar configuration. The compressible materials are placed into an open bottom of a plastic storage bag. The compressible material and plastic storage bag are compressed, typically with a pneumatic or hydraulic apparatus. After the compression step has been performed, the bottom is sealed closed thereby retaining the package in its compressed state. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawings, wherein: 
           [0009]      FIG. 1  is a perspective view of an embodiment of the compression apparatus of the present disclosure, implementing the compression step in the vertical direction. 
           [0010]      FIG. 2  is a perspective view of a stack of open bottom zippered packages or bags in a wicketed configuration. 
           [0011]      FIG. 3  is a plan view of an embodiment for providing packages or bags from a wicketed stack in a vertical direction to a compression device which implements compression in the horizontal direction. 
           [0012]      FIG. 4  is a side or cross-sectional view of a blanket or similar compressible material with the package or bag and positioned within the compression apparatus prior to compression in the horizontal direction. 
           [0013]      FIG. 5  is a side or cross-sectional view of a blanket or similar compressible material with the package or bag, after the compression step in the horizontal direction has been performed by the compression apparatus, with the seal jaws preparing to form the seal in the package or bag. 
           [0014]      FIG. 6  is a perspective view of an embodiment for providing packages or bags from a wicketed stack in a horizontal direction to a compression device which implements compression in the horizontal direction. 
           [0015]      FIG. 7  illustrates a chain of inverted packages or bags with the open bottoms facing upwardly. 
           [0016]      FIG. 8  illustrates a chain of inverted packages being removed from a container, filled with compressible goods and sealed shut. 
           [0017]      FIG. 9  illustrates a chain of packages being removed from a container, and configured into a horizontal configuration, in anticipation of subsequent filling, compressing and sealing. 
           [0018]      FIG. 10  illustrates the extrusion of zipper profiles onto a film for the production of the packages or bags used in an embodiment of the present disclosure. 
           [0019]      FIG. 11  illustrates the folding of the film to join the profiles of the zipper. 
           [0020]      FIG. 12  illustrates the folded film with cross-seals, thereby forming the open bottom bags of an embodiment of the present disclosure. 
           [0021]      FIG. 13  is a perspective view of an embodiment of the present disclosure. configured as a horizontal compression fill rotary seal apparatus. 
           [0022]      FIG. 14  is a perspective view of an embodiment of the present disclosure, configured as a horizontal funnel fill seal apparatus. 
           [0023]      FIG. 15  is a perspective view of an embodiment of the present disclosure, configured as a horizontal funnel fill seal apparatus with ninety degrees to the feed conveyors. 
           [0024]      FIG. 16  is a perspective view of an embodiment of the present disclosure, configured as a horizontal pre-compression filling apparatus with sealing station with in-line conveyors. 
           [0025]      FIG. 17  is a perspective view of an embodiment of the present disclosure, configured as a horizontal funnel filling open zipper apparatus. 
           [0026]      FIG. 18  is a perspective view of an embodiment of the present disclosure, configured as a horizontal compression index loading apparatus. 
           [0027]      FIG. 19  is a perspective view of a pre-compression inserter device which is adaptable to at least the illustrated embodiments of  FIGS. 13 ,  16  and  18 . 
           [0028]      FIG. 20  is a perspective view of a final compression and sealing device which is adaptable to at least the illustrated embodiments of  FIGS. 13 ,  14 ,  15 ,  16 ,  17  and  18 . 
           [0029]      FIGS. 21A-C  form a series of perspective views showing a compression device for various illustrated embodiments of the present disclosure. 
           [0030]      FIG. 22  is a perspective view illustrating an apparatus of the present disclosure, using guide rails to guide and open the packages or bags. 
           [0031]      FIG. 23  further illustrates the use of guide rails, in combination with packages or bags with perforations for the removal of a portion of the packages or bag. 
           [0032]      FIG. 24  further illustrates the use of guide rails to open the packages or bags. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0033]    Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that  FIG. 1  is a perspective view of pressing apparatus  10  of the present disclosure. The apparatus of  FIG. 1  was disclosed in the above-referenced parent applications of the present application. Pressing or compression apparatus  10  includes a frame  12 , typically made from metal, which further includes a ground-engaging rectangular base  14 , upright vertical elements  16  at the corners, and an upper horizontal portion  18 . Tray  20  is positioned on rectangular base  14 . Tray  20  typically includes an extended floor  21  which can serve as a feeding ramp. Tray  20  further typically includes first and second side elements  22 ,  24  which are inwardly and outwardly adjustable to accommodate different sizes of packages and may be configured as being movable. Tray  20  further typically includes rear element  25 . Rear element  25  may be hinged to provide further access to storage bag  104  (described hereinafter) and to allow the storage bag  104  (including compressible material  102 ) to be pushed out of the rear of pressing or compression apparatus  10 . The use of first and second side elements  22 ,  24 , along with rear element  25 , allows the storage bag  104  (including compressible material  102 ) to be compressed into a controlled shape, with the contents typically remaining very flat and smooth. Additionally, different shapes for the resulting product may be achieved by placing elements into different configurations. 
         [0034]    Compression arm  30  reciprocates vertically toward and away from tray  20 . Compression arm  30  includes flat compression plate  32  (typically sixteen by sixteen inches for applications involving bedding materials) which moves toward and away from tray  20  and impinge against the storage bag  104 , with compressible material  102  contained therewithin. The compression plate  32  provides a compression surface and is connected by first and second horizontal cross-beams  34 ,  36  which are, in turn, connected to respective first and second vertical guide rods  38 ,  40  which are engaged by respective first and second guide apertures  39 ,  41  and thereby constrained to vertical motion. Vertical drive rod  37  is connected between pneumatic drive  48  and compression plate  32 . Pneumatic drive  48  thereby moves compression plate  32  vertically and applies a force to compression plate  32 , thereby causing a compression force to be exerted across the area of compression plate. It has been found that a force of at least 2.5 to 3.5 pounds per square inch typically is required for sufficient compression of most compressible materials, such as, but not limited to, woven textile or cloth, particularly those frequently used for bedding materials. 
         [0035]    While  FIG. 1  illustrates the compression taking place in a vertical direction. Other embodiments may implement compression in the horizontal direction. Additionally, in all of the illustrated embodiments, while not illustrated, a small amount of vacuum may be applied during compression in order improve the appearance of the compressed material. 
         [0036]      FIG. 2  illustrates a stack  200  of storage bags  104 . Sealable storage bags  104  include front and rear walls  106 ,  108 , typically of transparent polymeric material, with an airtight or leak-resistant reclosable zipper  110  at a top or first end thereof, with first and second interlocking profiles  112 ,  114  which can be selectively opened (separated) or closed (interlocked) by movement of an optional slider (not shown). The stack  200  is typically provided with the first and second interlocking profiles  112 ,  114  interlocked with each other. A pre-activated peel seal  115  may be provided on the product side of zipper  110  to further insure the air-tight characteristics of the top of the storage bag  104 . While not shown in  FIG. 2 , one of the front and rear walls  106 ,  108  may include a reclosable air valve with an open position which allows air to pass freely therethrough and a closed position which provides an airtight or leak-resistant configuration. As shown in  FIG. 2 , sealable storage bags  104  are initially provided with an open bottom (or opening)  120  at a second end thereof, with rear wall  108  including a supporting portion  122  below a perforated or otherwise tearable line  124 . The supporting portion  122  includes first and second apertures  126 ,  128  which align with like first and second apertures  126 ,  128  of successive storage bags  104 , thereby allowing respective first and second pins  130 ,  132  to pass therethrough, resulting in what is known to those skilled in the art as a wicketed configuration. This allows the storage bags  104  to be provided from the stack  200  by tearing along perforated or otherwise tearable lines  124 , thereby typically resulting in front and rear walls  106 ,  108  of substantial equal length. Storage bags  104  may be provided in different ways, such as, but not limited to, in a stack free of connection with each other, or in a chain-type configuration wherein the sides of subsequent storage bags are connected to each other. 
         [0037]      FIGS. 3 ,  4  and  5  illustrate a sequence of compressing and sealing package  104  with compressible material  102  therewithin. Individual storage bags  104  are taken from wicketed stack  200 . Compressible material  102 , such as, but not limited to, a comforter set, is placed into an inverted storage bag  104  (with the first and second interlocking profiles  112 ,  114  interlocked with each other) through the upwardly facing open bottom  120  thereof, and dropped, typically by gravity, between compression plate  32  and fixed vertical wall  14 ′ of horizontally oriented compression apparatus  10 . The storage bag  104  and the compressible material  102  are then compressed horizontally between compression plate  32  and fixed vertical wall  14 ′ as shown in  FIG. 5 . As further shown in  FIG. 5 , then first and second seal bars  50 ,  52  engage and seal the lower edges of front and rear walls  106 ,  108 , thereby forming a bottom air-tight seal  140  so as to maintain the compressible material  102  in a compressed state within the air-tight storage bag  104 . The compression plate  32  may then be retracted to the position shown in  FIG. 3  and lower hinged plate  25 ′ lowered so as to allow the storage bag  104 , with compressible material  102  therein, to drop from the compression apparatus. 
         [0038]    Compressible material  102  may further include, but is not limited to, comforters, pillows, blankets, quilts, bedspreads, mattress pads, bath towels beach towels. dish towels, kitchen towels, toilet lid and tank covers, bath accessories, bedding accessories, sleeping bags, duffel bags, toys, apparel, fabrics, cotton batting, and fill materials (such as polyester fill). 
         [0039]    In the embodiment shown in  FIG. 6 , the stack  200  of storage bags  104  is provided in a wicketed configuration, and in a vertical orientation. The orientation can further be considered to be inverted in that the open bottoms  120  are facing upwardly. The swing arm  300  is configured to swing through a range of 180 degrees and, by using a vacuum or similar device, takes a single storage bag  104  from stack  200  and moves the storage bag  104  in a generally horizontal direction to horizontally oriented compression apparatus  10 , as accessed through hinged side door  60 . A process similar to that shown in  FIG. 5  is then typically used to insert the compressible material  102  into storage bag  104  and form the bottom seal. 
         [0040]      FIG. 7  illustrates a connected chain of inverted storage bags  104 , with the open bottoms  120  facing upwardly. The inverted storage bags  104  are connected to adjacent inverted storage bags  104  by their respective edges. The downward facing tops of the storage bags  104  include reclosable zippers  110 , but the reclosable zippers may be replaced with non-vacuum laminate film. 
         [0041]      FIG. 8  illustrates a connected chain of inverted storage bags  104 , wherein the storage bags  104  are stored in a horizontal configuration in stack  200  and subsequently mounted on spreader rails  410 ,  412  (typically by passing spreader rails  410 ,  412  through respective loops formed in front and rear walls  106 ,  108 ) and conveyed in a vertical configuration. As the spreader rails  410 ,  412  engage the front and rear walls  106 ,  108 , respectively, increasing the distance between spreader rails  410 ,  412  can serve to spread apart the opening of the storage bag  104 . 
         [0042]      FIG. 9  is similar to  FIG. 8 , but the storage bags  104  are conveyed in a horizontal configuration on table  404 . 
         [0043]    As shown in  FIGS. 10 ,  11  and  12 , the first and second zipper profiles  112 ,  114  can be extruded on a single sheet of web which is folded to align the zipper profiles  112 ,  114  with each other, and further to form front and rear walls  106 ,  108 . Cross seals  117  are formed to provide the separate storage bags  104  as shown in  FIG. 12  Cross seal  117 ′ illustrates an incomplete cut in the cross seal, thereby allowing a chain to be formed by successive storage bags  104 . 
         [0044]      FIG. 13  illustrates an embodiment of form fill seal (FFS) apparatus  500  with horizontal pre-compression ninety degrees rotate seal capability. Chain linked open-bottom storage bags  104  are indexed horizontally while lying flat and guided by the zipper profiles  112 ,  114 . The compressible material  102  is also indexed along parallel to the storage bag movement. At the fill station  502 , the compressible material  102  enters the pre-compression inserter device  504  (see  FIG. 19 ) and is compressed between platens  507 ,  509  and pushed by automated pusher arm  520  into the open bag which is between the platens  508 ,  510  of the final compression and sealing device  506  (see  FIG. 20 ). The platens  508 ,  510  complete the compression, the storage bag  104  is rotated ninety degrees about a vertical axis, and sealer  512  (similar to the seal bars  50 ,  52  of  FIGS. 3 and 5 ) seals the open bottom of storage bag  104 . 
         [0045]      FIG. 14  illustrates an embodiment of form fill seal (FFS) apparatus  500  with a horizontal funnel filling sealing station with in-line conveyors. Chain-linked open-bottom storage bags  104  are indexed horizontally while lying flat and guided by the zipper profiles  112 ,  114 . The compressible material  102  is likewise indexed parallel to the movement of the storage bags  104 . At the fill station  502 , the compressible material  102  is pushed through a sizing funnel  516  by plate  511 , thereby performing preliminary compression, and into the opened storage bag  104  that is placed between two horizontal conveyor belts  513 ,  515  that are aligned in the same direction as the movement of the compressible material  102  and the storage bag  104 . The conveyor belts  513 ,  515  are angled together, so that when they index, the conveyor belts  513 ,  515  continue to compress the storage bag  104  to expel the excess air. The almost fully compressed filled storage bag  104  continues to index in the same direction into a final compression and sealing device  506  (see  FIG. 20 ) which further compresses and seals the storage bag  104 . Final compression and sealing device  506  may include side containment walls  518  which assist with the final sizing of storage bag  104 . 
         [0046]      FIG. 15  illustrates an embodiment of form fill seal apparatus  500  with a horizontal funnel filling sealing station with ninety degrees to feed conveyor. Chain-linked open bottom storage bags  104  are indexed horizontally while lying flat and guided by the zipper profiles  112 ,  114 . The compressible material  102  is also indexed parallel to the storage bag movement. At the fill station  502 , the compressible material  102  is pushed through a sizing funnel  516  by plate  511  and into the opened storage bag that is placed between two horizontal conveyor belts  513 ,  515  that are aligned perpendicular to the direction of the movement of the storage bag  104  and the compressible material  102 . Similar to the embodiment of  FIG. 14 , the conveyor belts are angled together, so that when they index, the conveyor belts continue to compress the storage bag  104  to expel the compressed air. The almost fully compressed filled storage bag  104  continues to index in the same direction into a final compression and sealing device  506  (see  FIG. 20 ) which further compresses and seals the storage bag  104 . Final compression and sealing device  506  may include side containment walls  518  which assist with the final sizing of storage bag  104 . 
         [0047]      FIG. 16  illustrates an embodiment of form fill seal apparatus  500  with horizontal pre-compression with a sealing station in line with the conveyors. Chain-linked open bottom storage bags  104  are indexed horizontally while lying flat and guided by the zipper profiles  112 ,  114 . The compressible material  102  is indexed along parallel to the storage bag movement. At the fill station  502 , the compressible material  102  enters the pre-compression inserter device  504  (see  FIG. 19 ) is compressed between platens  507 ,  509 . While plates  507 ,  509  are in the compressed position, the pre-compression insertor device  504  moves perpendicularly to the bag motion into the open bottom of the storage bag  104 . An automated pusher arm pushes  520  the filled partially compressed storage bag  104  from the platens  507 ,  509  and between the two horizontal conveyor belts  513 ,  515  that are aligned in the same direction as the movement of the compressible material  102  and the storage bag  104 . The conveyor belts  513 ,  515  are angled together, so that when they index, the conveyor belts  513 ,  515  continue to compress the storage bag  104  to expel the excess air. The almost fully compressed filled storage bag  104  continues to index in the same direction into a final compression and sealing device  506  (see  FIG. 20 ) which further compresses and seals the storage bag  104 . Final compression and sealing device  506  may include side containment walls  518  which assist with the final sizing of storage bag  104 . 
         [0048]      FIG. 17  illustrates an embodiment of form fill seal apparatus  500  with horizontal funnel filling through an open zipper. Chain-linked open-bottom storage bags  104  are indexed horizontally while lying flat. The compressible material  102  is likewise indexed parallel to the movement of the storage bags  104 . At the fill station  502 , the compressible material  102  is pushed through a sizing funnel  516  by plate  511 , through the opened zipper profiles  112 ,  114  and the opened storage bag  104  that is placed between two horizontal conveyor belts  513 ,  515  that are aligned in the same direction as the movement of the compressible material  102  and the storage bag  104 . The conveyor belts  513 ,  515  are angled together, so that when they index, the conveyor belts  513 ,  515  continue to compress the storage bag  104  to expel the excess air. The almost fully compressed filled storage bag  104  continues to index in the same direction into a final compression and sealing device  506  (see  FIG. 20 ) which further compresses and closes the zipper profiles  112 ,  114  of the storage bag  104 . Final compression and sealing device  506  may include side containment walls  518  which assist with the final sizing of storage bag  104 . 
         [0049]      FIG. 18  illustrates an optional loading device with horizontal compression and index loading. Compressible material  102  loaded onto an indexing feeding device which is configured as conveyor belt  540  with partitions  542  spaced at package-width intervals. This apparatus further includes pre-compression inserter device  504  (see  FIG. 19 ) and final compression and sealing device  506  (see  FIG. 20 ) as previously described. 
         [0050]      FIG. 19  illustrates the pre-compression inserter device  504  which is incorporated into the previously described embodiments of  FIGS. 13 ,  16  and  18 . Platens  507  and  509  are used to grasp and initially or preliminarily compress compressible material  102 . Compressible material  102  is then urged out of device  504  by automated pusher arm  520  (with a pusher plate) into the open storage bag  104 . 
         [0051]      FIG. 20  illustrates the final compression and sealing device  506  which is incorporated into the previously described embodiments of  FIGS. 13-16 ,  18  and  19 . After the final compression of compressible material  102  with storage bag  104  (with an open bottom) is performed between platens  508 ,  510 , the device  506  can, depending upon the requirements of the specific embodiment, rotate 90 degrees about a vertical axis in order to present the open bottom film-to-film section to the sealer  512 . 
         [0052]      FIGS. 21A-21C  show a further improvement to final compression and sealing device  506  wherein side plates  522 ,  524  are provided. A similar back plate (not shown) may also be provided. The movable side plate  522 ,  524  pivot inwardly from both sides toward the storage bag  104 . As they pivot inwardly, they can also slide upwardly to allow for clearance as the top platen  508  compresses the storage bag  104 . The side plates  522 ,  524  function as constraints to compress the open bottom bag symmetrically, squeezing from both sides simultaneously rather than from just on side, or, only from the top. This provides increased uniformity in the control of the compression of the storage bag containing compressible material  102 , thereby, in some applications, perhaps producing a more aesthetically pleasing, less wrinkled product. 
         [0053]      FIGS. 22-24  illustrate how spreader rails  410 ,  412  can be attached to front and rear walls  106 ,  108  of storage bag  104 , thereby allowing the increasing of distance between spreader rails  410 ,  412  to open the storage bag  104  as desired. Additionally, as shown in  FIG. 24 , spreader rails  410 ,  412  may be hollow with radially oriented apertures  414  in order to allow compressed air to be injected into spreader rails  410 ,  412 , thereby reducing friction between the spreader rails  410 ,  412  and the front and rear walls  106 ,  108  of storage bag  104 , thereby enabling the rapid movement of the storage bags  104  along spreader rails  410 ,  412 . 
         [0054]    The resulting storage bags  104 , with the compressed material  102  sealed therewithin, can be sold within a retail establishment, and may include the configuration disclosed in parent application Ser. Nos. 12/823,823 and 12/823,331. 
         [0055]    Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.