Packaging apparatus

A packaging apparatus including a base to pivotable attachment to one or more spindles and rigid attachment to a cutting cabinet and a control device to more efficiently automate the process of wrapping an article with a web material is disclosed. The cutting cabinet includes a pneumatically powered, rotating blade carried by a cylinder positioned on an air cylinder within the cutting cabinet, permitting the blade to displace vertically almost the entire longitudinal length of the cabinet. A pair of powered rollers are also positioned within the cutting cabinet so that the web material may be fed from the larger supply stored on the spindle into the cutting cabinet in a predetermined manner as dictated by the control device so that a predetermined length of web material may be distributed and used to package an article, regardless of whether subsequent articles are the same size or not.

FIELD OF THE INVENTION

The invention herein pertains to packaging equipment and particularly pertains to a wrapping machine for housing and dispersing a web material, typically but not exclusively rolls of paper, and especially of single-face corrugated substrate.

Wrapping machines that deploy a web material around an article for the purpose of packaging the article for shipping or transportation are known in the art. These types of machines are often grouped into at least two separate types. The first type is a continuous wrapping machine which, as its name suggests, releases a continuous supply of web material that is either mechanically or manually affixed around the article, often with a separation device in the form of a blade or knife used to remove the estimated necessary length of web material from the total supply. The second type of machine is engaged, either electronically or manually, to repetitively produce a uniform length of web material that is then either mechanically or manually affixed around the article, again with the assistance of a separation device as described above. These prior art machines suffer from a number of shortcomings which should be clear even to the lay observer, but perhaps the most important inadequacy is shared. These devices have no scalable solution to the variables inherent in the manufacturing process. Despite speed controls, both machines produce web material as expected until shut off, either continuously or in a repetitive manner, and adjustments to the amount of web material dispersed are costly and labor-intensive. This problem is particularly acute in manufacturing settings where the size and shape of the article to be wrapped may vary from one dispersal event to the next. For example, the custom cabinet industry is growing rapidly at the present time, as homeowners seek to refurbish dated residential spaces with updated fixtures. Given the high cost of shipping cabinets completely enclosed in sturdy cardboard boxes, it is more desirable to enclose and reinforce the cabinet ends, and wrap the intervening space with a less robust, and therefore lighter, material. However, even within a single order, the size and shape of the cabinets being wrapped may vary greatly, upsetting the business efficiency of the drop-ship business model.

Thus, in view of the problems and disadvantages associated with prior art devices, the present invention was conceived and one of its objectives is to provide a packaging apparatus that carries and deploys one or more types of web material.

It is another objective of the present invention to provide a packaging apparatus that includes a base section, a separation station, and an electronic control device.

It is still another objective of the present invention to provide a packaging apparatus that has two or more spindles for distributing a web material defined by single-face corrugated sheet.

It is yet another objective of the present invention to provide a packaging apparatus with a pneumatically powered, rotating blade electronically controlled by the control device.

It is a further objective of the present invention to provide a control device with computation logic configured to calculate the appropriate desired length of web material to distribute to adequately wrap an article.

It is still a further objective of the present invention to provide a packaging apparatus that is efficient to manufacture and install as well as easy to use.

It is yet a further objective of the present invention to provide a method of packaging an article including the steps of providing a packaging apparatus with a base, a pair of web material-dispensing spindles, and an electronic control device, programming the control device with software to distribute a predetermined length of web material selected from a group of predetermined web material lengths, and cutting the web material for manual or mechanical packaging of an article.

It is another objective of the present invention to provide a packaging apparatus with a plurality of spindles for distributing selectively predetermined single-face corrugated sheets of different widths coupled with computation logic to dissect the web material in a multiplicity of lengths to bestow upon the apparatus a greater range of operational flexibility.

SUMMARY OF THE INVENTION

The aforesaid and other objectives are realized by providing a packaging apparatus including a generally square base formed by tubular members that serves as a platform for one or more spindles that are rotatably mounted to the base with a fixed pin and clevis attachment and a displacing pin and clevis attachment. The one or more spindles are laterally offset relative to the middle of the square base, making room for a separation station in the form of a cutting cabinet formed by vertical tubular supports and housing a rotating blade. The circular knife blade is held within a pneumatically powered cylinder that travels vertically within the cutting cabinet. One or more feed rolls are mechanically attached to a motor housed proximate the apparatus and vertically oriented within the cutting cabinet to pass a web material stored on the one or more spindles through large and small material guides and position the material to be cut by the rotating blade. A control device is in electronic communication with both the rotating blade and the feed rolls, and includes electronic instructions operatively present within the control device to receive user input designating the article to be packaged, distribute the appropriate length of web material from the spindle, and cut the predetermined length of web material with the knife blade, thus freeing the appropriate amount of web material to package the article as desired. A method of packaging an article including the steps of providing a packaging apparatus as described above, programming the control device with software to distribute a predetermined length of web material selected from a group of predetermined web material lengths, and cutting the web material for manual or mechanical packaging of an article is also provided.

For a better understanding of the invention and its operation, turning now to the drawings,FIGS. 1-5display a preferred embodiment of packaging apparatus10, which includes base11, one or more spindles12, and cutting cabinet13in electronic communication with control device14. As shown more clearly inFIG. 1, the preferred embodiment of base11defines a generally square shape and is formed by a plurality of metallic tubular base members15. Each corner of base11preferably includes foot16which may be formed from the same tubular construction as tubular base members15and extends downwardly therefrom to create a structural stable platform on which to mount spindles12, cutting cabinet13, and control device14. Although not shown in the figures, an embodiment of foot16may include an adjustable feature to assist in the leveling of packaging apparatus10, particularly useful in unfinished or unleveled manufacturing spaces. Further, base11also supports frame26that is formed from one or more tubular frame members27in a generally rectangular shape that extends vertically in a perpendicular orientation relative to base11.

A preferred embodiment of base11includes metallic cross-members17, defining the same tubular cross-section as base members15, one that extends generally perpendicularly from approximately a mid-point of a first base member15and connects to approximately a mid-point of a second base member15, preferably the opposing base member15that is oriented in parallel relationship to the first base member15. Preferred base11includes at least four (4) cross-members17that join within the periphery of base11, bestowing added structural stability to base11, but it should be understood that the number, length and orientation of cross-members17are not intended to be limiting, and more or less cross-members17may be deployed within base11, and the orientation of said cross-members17may vary as well. While base members15and cross-members17may be affixed by adhesives, mechanical fasteners, or the like, the preferred method of attachment of respective base members15and cross-members17is welding.

In addition to the structural support features, base11also serves as the mounting substrate for cutting cabinet13, control device14, and the attachment of one or more spindles12. As demonstrated inFIGS. 1 and 2, preferred packaging apparatus10includes one or more, and preferably two (2) pivotable spindles12that rotate from a first, more vertical position (FIG. 1) to a second, more angular position (FIG. 2) to aid in the unloading and loading of web material18. Each spindle12preferably includes axle19attached to shield20which in turn is carried by tubular post21formed in the same manner as base members15and cross-members17. Tubular post21is pivotably attached to base11, and more particularly to at least one cross-member17, by virtue of one or more clevises. Each spindle12preferably includes one fixed clevis22and one displacing clevis23, each configured (i.e. sized and shaped) to receive a portion of tubular post21, in addition to pins24, between the respective ears. Clevis22is considered “fixed” to the extent that pin24rotates, but does not vertically or laterally displace, while clevis23is considered “displacing” in that pin24laterally or longitudinally, but preferably both laterally and longitudinally relative to base11, displaces within longitudinal slot25when spindle12moves from the first position to the second position as illustrated inFIGS. 1 and 2.

As demonstrated schematically inFIG. 3and illustrated inFIGS. 4 and 5with cover plate30removed, cutting cabinet13is a web material separation station whereby web material18is unspooled or otherwise removed from spindles12as will be described in further detail below and separated from the larger web material supply based on one or more predetermined variables, usually length, for use in the packaging of a given article such as a cabinet (not shown). As demonstrated more clearly inFIGS. 4-5, cutting cabinet13is defined by a generally rectangular housing28defined by a plurality of stanchions29and preferably including one or more cover plates30joined at opposing ends by respective plates36,36′ to protect the interior components of cutting cabinet13. The primary function of cutting cabinet13as described above is served by one or more blades31carried by air motor32that travels the substantial vertically longitudinal length of cutting cabinet13during a cutting event. Preferably, blade31is a rotating, circular knife blade disposed within a pneumatically powered air motor32in communication with motor33via air cylinder34(FIG. 3) and associated attachment hardware (i.e. hoses, couplings, fasteners, and the like) as would be understood in the art. Other cutting members such as electric blades, hydraulic blades, and the like should also be construed as within the scope of packaging apparatus10. When fully assembled, air cylinder34extends vertically nearly the entire height of cutting cabinet13, granting travel to cylinder32and blade31a tremendous distance relative to the prior art and permitting packaging apparatus10to accommodate web material18of significant length and width as dictated by the size and shape of the article to be packaged.

Web material18is fed from spindles12through cutting cabinet13by virtue of one or more cylindrical rollers35. For the purposes of this disclosure, the term “web material” is intended to encompass, though not be limited to, paper, foam, plastic, and film, but preferably refers to single-face corrugated substrate, which is viewed as structurally inferior to a conventional cardboard box and thus is highly disfavored in the packaging industry. Further, web material may also include secondary substrates combined with the aforementioned materials, such as a plastic lining adhered to the corrugated side of the single-face corrugated described above. Preferably, at least one pair of rollers35are oriented vertically and positioned abutting the rear of, and parallel to the longitudinal length of cutting cabinet13. This positioning and orientation places rollers35in close proximity to the supply of web material18, reducing the likelihood of damage to web material18during operation of packaging apparatus10. One of cylindrical rollers35includes a drive-shaft (not shown) in mechanical engagement with motor33via gear box56at a first end, and both rollers35include gear37for enmeshed engagement at the opposing end. In this manner, a single motor33can engage multiple rollers35without the need for additional mechanical engagements. Although not shown in the figures, preferred packaging apparatus10also includes a biasing member, for example a spring, that biases respective rollers35together, such that once web material18is fed through said rollers, a certain degree of tension is placed on the web such that it does not fall out of engagement with rollers35and damage said web.

Preferred packaging apparatus10may also include one or more large paper guides38alone or in combination with one or more small paper guides39, as best shown inFIG. 1. Both large paper guides38and small paper guides39are formed from elongated portions of metal and define an angular shape somewhat similar to the shape of an L. When installed along the longitudinal length of cutting cabinet13, large paper guides38and small paper guides39ensure that web material18passes without complication from spindle12into cutting cabinet13. More preferably, small paper guide39is installed more proximal to rollers35while large paper guide38is installed more distal to rollers35, defining channel40to pass web material18therethrough after being cut within cutting cabinet13by blade31, in addition to providing clearance space for blade31and cylinder32.

The operation of packaging apparatus10is controlled primarily through the electronic operation of control device14. In a preferred embodiment of packaging apparatus10, control device14is in the nature of a control panel with touch screen41for manual engagement by a user, housing42containing circuitry and electronic storage (identified schematically in dotted fashion)43, power cord46to provide power to control device14, connection wires44to establish electronic communication with motor33, gear box56, and power button45to engage and disengage the operation of packaging apparatus10. Additionally, electronic instructions in the form of computer software, computer code, or the like, are stored in or on circuitry and electronic storage43to govern the operation of packaging apparatus10, particularly the engagement of motor33and gear box56with roller35and the activation of blade cylinder32carrying blade31within cutting cabinet13. These instructions embody the logic of receiving specific dimensions for articles to be wrapped (i.e. programming), calculating the necessary run time of rollers35necessary to feed one or more predetermined lengths of web material18from spindle12into cutting cabinet13, adjusting for any intervening distance, communication of activation signals for blade cylinder32and associated blade31, and therefore distribution of a length of web material18that adequately wraps around an article in a timely manner and without significant surplusage. Additionally, the electronic instructions may be configured for specific actions and data storage to produce multiple predetermined lengths of web material18, as well as incorporating all the specific actions to take place at the push of a single button. For example, screen41may display a variety of pre-programmed article designations (icons, lists, product numbers, or the like) for selection by a user. In one or more alternate embodiments, control device14may be configured to accept inputs to engage the stored data and specific actions associated with a given article by non-manual (that is to say, other than manual entry) methods, such as by detection of one or more predetermined variables (i.e. height, weight, color, etc.) by an electronic sensor, scanning of a barcode from a label by a barcode scanner, or other predetermined input methods as may be now known in the art.

An alternate embodiment, packaging apparatus100, is illustrated inFIGS. 6 and 7. Packaging apparatus100includes base11, one or more spindles112,112′ and cutting cabinet113(cover plates30and paper guides38,39removed) in electronic communication with control device14, similar to packaging apparatus10. At least one, and preferably two of spindles112are of the pivotable nature previously described above, but packaging apparatus100may also include one or more spindles112′ which are fixed in the upright orientation. This combination of fixed and pivotable spindle structures may be advantageous for packaging apparatus100, as it may better accommodate rolls of web material18defined by different widths, basis weight, or other web-related structural variables as would be understood in the art. As demonstrated inFIGS. 6-7and described in further detail below, packaging apparatus100preferably includes a total of four spindles112,112′, both fixed and pivotable species, to permit a wide range of operational flexibility. In this configuration, the fixed spindles112′ would be appropriate for smaller, narrower, or lighter webs18that could be mounted on spindles112′ by hand, while spindles112would be better suited to accommodate larger, wider, or heavier rolls of web material18. By way of example, one configuration of web materials could include web species eighteen inches (45.72 cm), thirty inches (76.20 cm), thirty-four and a fourth inches (86.99 cm), and forty-two inches (106.68 cm) wide.

An embodiment of packaging apparatus100includes a power supply, preferably a motored power supply, and more preferably an electric-powered motor such as electric motor133, providing rotational energy to transmission assembly134and ultimately driving powered rollers151. Transmission assembly includes at least one gear136, but preferably includes at least one gear136and associated axle137for each powered roller151. In a similar manner, cabinet rollers135include a power supply, preferably electric motor133′ (similar in most respects to electric motor133) that provides rotational energy to transmission assembly134′, which in turn may power one or both rollers135. Transmission assembly134′ also preferably includes a counter (sometimes referred to as an encoder), such that the exact rotation of rollers135may be known and recorded. This information can be monitored by control device14to ensure precise use of web18during use. Additionally, or in the alternative, packaging apparatus100may further include valve assembly140, preferably positioned proximate control device14, for the management of various air flows used by packaging apparatus100. As demonstrated more clearly inFIG. 8, valve assembly140(illustrated with house partially removed) includes one or more valve bodies141, and preferably includes one valve body for each pre-feed assembly150as well as a valve body141for the functionality of cabinet113.

As shown more clearly in the top plan schematic view ofFIG. 7, packaging apparatus100includes one or more pre-feed assemblies150, each which includes powered roller151pivotably attached to mount152by rod153, including electric motor133and driven by transmission assembly136positioned about base11. As web material18is spooled off of axle19, it is routed towards pre-feed assembly150via guide154. Web material18enters a longitudinally extending channel, whereby at least the outboard surface of web18is exposed. In an embodiment of packaging apparatus100, roller151is in a constant state of counterclockwise rotation, and engaging the outboard surface of web material18is performed by rotating rod153on or off web18as desired. In an alternate embodiment of packaging apparatus100, roller151does not commence counterclockwise rotation until an electronic signal is received from control device14, at which time roller151begins rotation, or rod153is rotated until roller151contacts the outboard surface of web18, and rotation of roller151begins thereafter. As roller151engages web18, it is moved in the direction of cabinet113. As demonstrated inFIG. 7, various species of web18may move in separate channels, divided by respective guides154, or they move in an aggregated central channel, but either embodiment ends in cabinet113. To better facilitate the travel of web18, particularly to prevent wrinkling or rolling within the channels divided by guides154, blocks of material (not shown) may be inserted to keep web18on a linear path.

Unlike cabinet13described previously, cabinet rollers135are positioned in the “front” of cabinet113, that is to say more distal relative to spindles112,112′ and more proximal to the article to be wrapped (not shown). This is possible due to the pre-feed assemblies150as described above. More specifically, the dispensing process begins as an article enters the packaging zone and a user inputs or selects the appropriate measurements or icon from the control device14, and the corresponding pre-feed assembly150responds by engaging and driving the respective web18through the cutting area and received by main feed rollers135, where web18is detected by sensor device155(for example an optical “eye” sensor). This detection by sensor device155generates one or more action responses from packaging apparatus100, including the rotation of pre-feed roller151away from the web18and the termination of rotation by pre-fed assembly150. The main feed roller135commence rotation, engaging web18and feeding and measuring web18by virtue of an encoder connected to transmission134, which transmits the information to control box14. When web material18reaches the predetermined length as programmed into control box14and selected by the user, rollers135stop rotating and air cylinder34is activated by instructions from control box14which directs blade31to progress (i.e. descend or ascend) through web18, cutting the material to the requested length. Preferably, a signal is sent by control device14to pre-feed rollers151to retract web material18back away from blade31, for example a small distance back into the feed channel such as two inches, to permit the next segment of web material18to pass through the cutting station of cabinet113without fouling the other lines of web material18. Feed rollers135carry the separated length of web material18exterior of the cutting cabinet, for example through a slot similar to channel40as described above, where it can be retrieved manually and placed around an article to be packaged. In an alternate embodiment, a sensing device detects an input, for example an electronic scanner device detects an optical input such as a barcode or the like, and communicates the information via a wired or wireless network (not shown) to control device14for a similar cutting action via blade31.