SYSTEMS AND METHODS FOR AIR PILLOW CONVEYANCE AND SEPARATION

An inflatable packaging system includes an inflatable cushioning supply and a conveyance module. The conveyance module includes a sliding conveyor, a fixed conveyor, a belt-drive, and an encoder. The sliding conveyor is adjustable, relative to the fixed conveyor, such that a space between the sliding conveyor and the fixed conveyor is adjustable. The belt-drive displaces the inflatable cushioning supply through the space between the sliding conveyor and the fixed conveyor. The encoder is coupled to the belt-drive.

FIELD

The present disclosure relates generally to systems and methods for the conveyance and separation of inflatable packaging materials. More specifically, this disclosure relates to systems and methods for the conveyance and separation of air pillows, including measurement, conveyance, and separation of pre-determined lengths of air pillows for efficient packing and void fill.

BACKGROUND

Systems and methods implementing inflatable packaging materials, such as rows or strands of air pillows, often require the operator to manually start/stop conveyance of the packaging materials. Namely, an operator initiates conveyance, such that inflatable packaging material is formed and subsequently discharged into a box or container; the inflatable packaging material is used as cushioning or void fill, protecting contents within the box or container. At some point during this conveyance process, the box or container includes sufficient inflatable packaging material. The operator then ceases conveyance and manually tears off an individual air pillow from a particular row or strand via a pre-defined perforation.

While this process generally provides for controlled conveyance of air pillows, it does not afford the operator with precise measurement capabilities as the air pillows are being formed and conveyed. The operator does not know how many air pillows have been conveyed, or the total length of an individual row or strand as it is being conveyed. This lack of information typically results in over-conveyance and, hence, waste. Too many air pillows are formed, conveyed, and thus discarded. Measurement of air pillow conveyance becomes all the more difficult when the particular geometry of the air pillow changes between packaging applications. For example, a first box may require larger air pillows, whereas a second box may require smaller air pillows. Thus, any conveyance measurement systems must be dynamically adjustable to accommodate varying size air pillows on an application-by-application basis.

Improved systems and methods for conveying, measuring, and separating inflatable packaging, such as air pillows, are therefore needed.

SUMMARY

The systems and methods for conveying, measuring, and separating inflatable packaging disclosed herein improve on current packaging technology by implementing a conveyor that dynamically measures the total length or quantity of air pillows that are dispensed, as they are being dispensed. The systems herein may also automatically dispense predetermined lengths or volumes of inflatable packaging. Predetermined lengths or volumes may be manually input, by an operator, or automatically determined, by an upstream vision, void sensing, or other similar data analysis system. Predetermined lengths or volumes may also be calculated based on a known carton size and known carton contents. Via a powered separator assembly, the systems and methods herein provide for both automated control and improved tearing of air pillow strands in a controlled fashion, improving overall ease of use. A single inflator and dispensing device, via the systems herein, may advantageously provide inflated packaging to a distribution system that is servicing multiple pack stations.

In light of the disclosure herein, and without limiting the scope of the invention in any way, in a first aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, an inflatable packaging system includes an inflatable cushioning supply and a conveyance module. The conveyance module includes a sliding conveyor, a fixed conveyor, a belt-drive, and an encoder. The sliding conveyor is adjustable, relative to the fixed conveyor, such that a space between the sliding conveyor and the fixed conveyor is adjustable. The belt-drive displaces the inflatable cushioning supply through the space between the sliding conveyor and the fixed conveyor. The encoder is coupled to the belt-drive.

In a second aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system calculates a total length of inflatable cushioning supply that is displaced through the conveyance module.

In a third aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system calculates a total quantity of inflatable cushioning supply that is displaced through the conveyance module.

In a fourth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the inflatable cushioning supply is a strand of air pillows.

In a fifth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the conveyance module further includes a separator assembly.

In a sixth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly is configured to tear the inflatable cushioning supply at a perforation zone.

In a seventh aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly tears the inflatable cushioning supply at the perforation zone by reversing the belt-drive.

In an eighth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly tears the inflatable cushioning supply at the perforation zone by over-driving the belt-drive.

In a ninth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly tears the inflatable cushioning supply at the perforation zone by over-driving and reversing the belt-drive.

In a tenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly partially tears the inflatable cushioning supply at the perforation zone, such that the inflatable cushioning supply is configured for manual tearing via an operator.

In an eleventh aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly includes a plurality of hinged doors.

In a twelfth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system further includes a proximity sensor.

In a thirteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system further includes a spring. The spring is configured for biasing the sliding conveyor and the fixed conveyor towards one another.

In a fourteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, an inflatable packaging system includes a strand of air pillows, a conveyance module, and a separator assembly. The conveyance module includes a sliding conveyor, a fixed conveyor, a belt-drive, and an encoder. The separator assembly is configured to tear the strand of air pillows at a perforation zone.

In a fifteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the sliding conveyor is adjustable, relative to the fixed conveyor, such that a space between the sliding conveyor and the fixed conveyor is adjustable.

In a sixteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the belt-drive displaces the strand of air pillows through the space between the sliding conveyor and the fixed conveyor. The encoder is coupled to the belt-drive.

In a seventeenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system calculates a total length or quantity of the strand of air pillows that is displaced through the conveyance module.

In an eighteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the separator assembly tears the inflatable cushioning supply at the perforation zone by reversing the belt-drive.

In a nineteenth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system further includes a proximity sensor.

In a twentieth aspect of the present disclosure, which may be combined with any other aspect listed herein unless specified otherwise, the system further includes a spring. The spring is configured for biasing the sliding conveyor and the fixed conveyor towards one another.

DETAILED DESCRIPTION

With reference to the Figures,FIGS.1A and1Billustrate side views of an inflatable packaging system100, which includes an inflation module102and a conveyance module104. Generally the inflation module102is configured to inflate rolled film106(e.g., from an integrated roller at the inflation module102), and subsequently seal the rolled film106after inflation, such that the rolled film106is transformed into inflatable packaging (discussed in greater detail herein). For example, an individual portion of the rolled film is inflated and sealed to form an air pillow. A plurality of these individual portions are coupled to one another, prior to inflation, such that inflation module102is configured to inflate strands or rows of air pillows. In an embodiment, the strands of air pillows include perforations, between each of the inflated air pillows, such that the total length of an air pillow is adjustable by an operator (e.g., via tearing at the perforation).

Once inflated, the strands of air pillows are disposed into an integrated hopper108, which is typically located below the inflation module102. In an embodiment, the integrated hopper108includes an accumulation sensor, for example, to identify when the integrated hopper108is full or near-full of a strand of air pillows. It should be appreciated that the integrated hopper108is an optional accessory.

The inflatable packaging system100further includes the conveyance module104. For example, conveyance module104may include an entry chute110and a dispenser head112. The strand of air pillows (post-inflation) is received by the entry chute110, and passes through the dispenser head112. The dispenser head112is configured to dispense the strand of air pillows for an operator (e.g., into a partially filled crate, into an empty crate for filling, into the operator's hands for manual filling, or into integrated hopper108). As disclosed in greater detail herein, dispenser head112includes a number of additional features, including sensors (e.g., for calculating the length of the strand of air pillows) and control features (e.g., for automated separation of the strand of air pillows at a specific perforation).

As illustrated inFIGS.1A and1, each of the inflation module102and the conveyance module104are disposed on an adjustable height stand114. In an embodiment, height-adjustment accommodates a variety of air pillow sizes, integrated hopper sizes, and crate sizes for final filling. Inflatable packaging system100may further include a bracket or base, with or without wheels for improved portability.

FIGS.2A to2Billustrate side views of the inflatable packaging system100, with additional detail regarding conveyance module104. Namely, conveyance module104may include one or more switches, such as a feed switch, to power conveyance module104. The dispenser head112of conveyance module104includes an opposing pair of driven conveyors.

Specifically, as illustrated byFIG.2B, dispenser head112includes fixed conveyor118and sliding conveyor120. A strand of inflated air pillows122is disposed between fixed conveyor118and sliding conveyor120. In an embodiment, each of fixed conveyor118and sliding conveyor120are belt-driven, such that each driven conveyor118,120includes an input roller at a top side of dispenser head112, an output roller at a bottom side of dispenser head112, and a conveyor belt disposed around an exterior of the input roller and the output roller. Specifically, for example, fixed conveyor118includes input roller124and output roller126; a belt is disposed around these respective rollers124,126and is driven by said rollers. Similarly, for example, sliding conveyor120includes input roller128and output roller130; a belt is disposed around these respective rollers128,130and is driven by said rollers.

In an alternate embodiment, the driven conveyors118,120are roller driven conveyors, such that each driven conveyor in the pair includes an input roller and an output roller and a number of additional rollers, but no conveyor belt.

Generally, one or more of the rollers are powered by an electric motor. In an embodiment, each of the input rollers124,128is powered by an individual electric motor. For example, fixed conveyor118includes a first electric motor powering input roller124. Similarly, sliding conveyor120includes a second electric motor for powering input roller128.

The strand of air pillows122is configured to be conveyed, through the conveyance module104, via the pair of driven conveyors. For example, the input rollers124,128are driven, which drive belts contacting either side of the strand of air pillows122, such that the strand of air pillows122is conveyed through the dispenser head112from the input roller side to the output roller side.

At the output roller side of the dispenser head112, the conveyance module104further includes a separator assembly132. In an embodiment, separator assembly132is configured for controlled separation of the strand of air pillows122at a perforation zone. Separator assembly132is described in greater detail herein with respect toFIGS.4A to4BandFIG.5.

As shown byFIG.2B, the pair of driven conveyors includes a fixed conveyor118and a sliding conveyor120. Namely, by incorporating a sliding conveyor120, dispenser head112is customizable, to accommodate a variety of sizes and widths of air pillows. In an embodiment, width-adjustment (as described in greater detail herein) is automatically adjusted via a controller. For example, the pair of driven conveyors118,120may be adjusted to convey varying widths of air pillows and, additionally, adjusted to convey flat or deflated material without interruption or operator input.

With reference toFIG.2BandFIG.3C, dispenser head112includes a linear bearing134(e.g., plain or circular) and a linear shaft136or guide, such that sliding conveyor120is configured to translate towards and away from fixed conveyor118, to adjust the width between fixed conveyor118and sliding conveyor120. Linear shafting and related bearings ensure that the two conveyors are maintained in a parallel orientation to one another while simultaneously minimizing the force required to open and close the opposing conveyors relative to one another.

In an embodiment, dispenser head112further includes one or more springs138coupled to each of fixed conveyor118and sliding conveyor120; the springs ensure that these components are generally biased in a “closed” or “narrow” configuration. In an embodiment, linear actuators may be used to apply biasing force in place of, or in addition to, springs.

In an embodiment, dispenser head112is tilted on an angle, such that gravity biases the sliding conveyor120“toward” the fixed conveyor118, ensuring that these components are generally biased in a “closed” or “narrow” configuration (not illustrated); in this particular embodiment, biasing force can be mechanically adjusted by modifying the weight of sliding conveyor120and/or the angle of tilt of the conveyors118,120.

In an alternate embodiment, fixed conveyor1118and sliding conveyor120are arranged horizontally (e.g., 90-degrees relative to the orientation illustrated inFIG.2B), and further include compression springs to limit any compressive load due to gravity.

As noted previously, dispenser head112includes a number of additional features, including sensors (e.g., for calculating the length of the strand of air pillows).FIGS.3A to3Cillustrate side views of the conveyance module104, depicting some of these features.

In an embodiment, dispenser head112includes a conveyor proximity sensor140. For example, as discussed above, dispenser head112is customizable, to accommodate a variety of sizes and widths of air pillows. Conveyor proximity sensor140may be configured to measure the distance between sliding conveyor120and fixed conveyor118, and subsequently communicate this distance to a controller and/or display for the operator. Alternatively, conveyor proximity sensor140may be configured to measure whether any distance exists between sliding conveyor120and fixed conveyor118(e.g., open or closed configuration), and subsequently communicate this information to a controller and/or display for the operator.

In an embodiment, dispenser head112includes an optical sensor142(e.g., an optical encoder) configured to measure the total length of the strand of air pillows122that is conveyed through the dispenser head112. In a related embodiment, dispenser head112uses the width of an individual air pillow and the total length of the air pillow strand to determine the total number of air pillows in an individual strand. Optical sensor142may communicate with a controller and/or display. In an embodiment, the operator enters a desired length of a strand of air pillows, such that the dispenser head112conveys air pillows until the controller determines that the dispenser head112has dispensed the desired length, via the optical sensor142. Alternatively, the operator enters a desired number of air pillows air pillows, such that the dispenser head112conveys air pillows until the controller determines that the dispenser head112has dispensed the desired number of air pillows via the optical sensor142.

In an embodiment, dispenser head112includes an encoder assembly144directly or indirectly coupled to a drive belt. As previously noted, the input rollers124,128are driven, which drive belts contacting either side of the strand of air pillows122, such that the strand of air pillows122is conveyed through the dispenser head112from the input roller side to the output roller side via the drive belts. The encoder assembly144is thus configured to measure the rotation of the drive belt, and associate that belt-rotation with an overall output length of a strand of air pillows that is conveyed through the dispenser head112. Encoder assembly144may communicate with a controller and/or display. In an embodiment, the operator enters a desired length of a strand of air pillows, such that the dispenser head112conveys air pillows until it determines it has reached the desired length via the encoder assembly144.

In any of the embodiments described above, it should be appreciated that, at some point, the dispenser head112achieves the desired length of a strand of air pillows. When this occurs, the strand of air pillows must be separated or “torn” at the intended perforation location to conclude the particular strand of air pillows. As noted previously, dispenser head112may include control features (e.g., for automated separation of the strand of air pillows at a specific perforation).

Specifically,FIGS.4A to4BandFIG.5illustrate perspective and side views of the separator assembly132. Separator assembly132includes a pair of followers146, which are opposed rotating surfaces that are pivotably configured between an “open” position (e.g., to permit the strand of air pillows to be dispensed) and a “closed” positon (e.g., to restrict the strand of air pillows from being dispensed). The pair of followers146are mounted on pins and are disposed in an outwardly-angled configuration, to readily permit a strand of air pillows to pass through the pair of followers (e.g., during dispensing) without damaging the strand of air pillows.

In an embodiment, the pair of followers146trace the contour of the strand of air pillows. For example, the pair of followers may be configured to detect mechanical deflection (e.g., deflection outward as a pillow passes and deflection inward between two pillows), such that the pair of followers146identifies specifically when a perforation zone is disposed between the pair of followers.

At the instance where the inflatable packaging system100determines that it has dispensed the desired length of the strand of air pillows122, the dispenser head112stops conveyance (e.g., when the perforation zone is disposed between the pair of followers146), and the dispenser head112subsequently “reverses” conveyance over a short distance. Specifically, while the pair of followers146are disposed to readily permit the strand of air pillows122to pass through the pair of followers146outwardly (e.g., during dispensing), the pair of followers146are angled such that air pillows are not capable of being “withdrawn” back into the dispenser head112. Therefore, when the dispenser head112reverses conveyance, the strand of air pillows122is pulled against the pair of followers146, and torn at the perforation zone via the pair of followers146. The strand of air pillows then drops into an empty crate or into the operator's hands.

While separation is described herein with respect to reversing (e.g., reversing the belt drive to tear the inflatable cushioning supply at the perforation zone via the separator assembly132), it should be appreciated that other types of belt drive control may, likewise, cause separation to occur. For example, in a different example embodiment, over-driving the belt drive (e.g., an increased forward speed) causes perforation to occur. Similarly, in another different example embodiment, separation may be caused by simultaneously over-driving and reversing the belt drive (e.g., increased forward speed on one belt while simultaneous reversing of another belt).

In an embodiment, each of the pair of followers146includes a generally triangular surface area, such that a separation zone148is formed at the vertex of the generally triangular surface area. The pair of followers146are specifically shaped such that there is a large surface area in contact with the air pillow during forward/dispensing motion, and minimal contact with the air pillow during the reverse/separation motion. This specific geometric configuration lowers the overall stress on the air pillow material during a rapid feed and maximizes the stress on a short, centered portion of the perforation during the separation process.

Via the separation process explained above, a generally triangular surface area ensures that the perforation zone tearing of a particular air pillow begins in the middle of a perforation line. This advantageously ensures that the total reverse distance to achieve complete tearing is reduced (e.g., approximately half the width of a strand of air pillows) by tearing the perforation in both directions from the center. Separating from the center of the perforation, rather than the edge, thus reduces the force required and also reduces the distance required to ensure complete separation, allowing for a compact conveyor design and requiring less overhead space.

In an embodiment, each of the generally triangular surface areas includes a beveled or rounded vertex, to ensure tearing while reducing the risk of puncturing an individual air pillow.

In an embodiment, the pair of followers146are mechanically controlled between the “open” position (e.g., to permit the strand of air pillows to be dispensed) and the “closed” positon (e.g., to restrict the strand of air pillows from being dispensed). For example, as illustrated byFIG.5, separator assembly132may include a mechanical linkage150, coupled to a solenoid actuator152. The solenoid actuator152may be used to displace and/or lock the mechanical linkage150in the closed position, preventing the inflated article from forcing the pair of followers146open when running the dispenser head112in the reverse direction. In this example, it is not necessary for the pair of followers146to touch when disposed in the closed position. Rather, a small gap is permissible so long as the gap will not permit the inflated article to pass thru the pair of followers146during reversing. In an embodiment, a grip, such as silicone, or other mechanical feature may be added to the pair of followers146(e.g., at the vertex of the generally triangular surface area) to hold the material and improve tearing during perforation.

In an alternative embodiment, illustrated byFIGS.6A to6B, the pair of followers146are mechanically controlled between the “open” position (e.g., to permit the strand of air pillows to be dispensed) and the “closed” positon (e.g., to restrict the strand of air pillows from being dispensed) via a rotatable cam154and associated mechanical linkage156. When the cam154rotates (driven by a motor158), the mechanical linkage156may be “locked” in the closed or open position (as generally discussed above).