Patent Publication Number: US-8117806-B2

Title: Vertical bagging machine

Description:
FIELD 
     The present patent application relates to vertical bagging machines and, more particularly, to vertical bagging machines that utilize rolled, flat (i.e., not pre-folded) film stock material. 
     BACKGROUND 
     Bags, particularly bags formed by bagging machines, provide manufacturers and suppliers with an efficient and cost effective means for packaging their goods. As such, various consumer goods are packaged in bags, including food service items (e.g., cups, lids, knives, forks and spoons), do-it-yourself items (e.g., paint rollers, wallpaper rolls, window shades and curtain rods), toys (e.g., footballs), kits (e.g., auto parts, nuts and bolts, puzzle pieces, tie wraps) and various products sold in bulk (e.g., bottle caps). 
     Manufacturers and suppliers seeking to bag their goods typically have three packaging options. As a first option, premade bags may be filled by hand and then sealed. However, hand packing has obvious disadvantages, including high labor cost and low output speed. As a second option, bags may be filled using a horizontal bagging machine. While horizontal bagging machines offer substantial advantages over hand packing, horizontal bagging machines are generally limited to packaging items that are longer than they are wide on the horizontal axis. In particular, horizontal bagging machines typically are not suited to handle irregular shaped objects. Finally, the third option is a vertical bagging machine. 
     Vertical bagging machines, like horizontal bagging machines, may be hand loaded or fully automated. Furthermore, vertical bagging machines typically are supplied with film that travels vertically (i.e., normal to the surface of the earth) around and over the product. The film is then cut and sealed to form the bags around the product. As such, vertical bagging machines have a generally small footprint, but can accommodate items of various sizes (e.g., 2 inches by 2 inches to 24 inches by 65 inches) without the need for re-tooling. 
     Nonetheless, those skilled in the art continue to seek advances in the field of vertical bagging machines. 
     SUMMARY 
     In one aspect, the vertical bagging machine may include a spindle for receiving and supporting a roll of stock material, the spindle defining a spindle axis, wherein the stock material is unwindable from the roll as a sheet, a folding plate defining a folding plate plane that is substantially parallel with the spindle axis, the folding plate including a first edge and a second edge, wherein the first and second edges are generally equal in length and connect at a central peak, a spreader chute including a first guide plate and a second guide plate, the second guide plate being generally parallel with and spaced apart from the first guide plate, wherein the first and second guide plates are substantially perpendicular to the folding plate plane, and first and second folding rollers defining a nip therebetween, the first and second folding rollers being generally parallel with the folding plate plane and disposed between the folding plate and the spreader chute, wherein the sheet is moveable over the central peak, through the nip, and over both the first and second guide plates to define a loading space between the first and second guide plates. 
     In another aspect, the disclosed vertical bagging machine may include a spindle defining a spindle axis, a roll of stock material received over the spindle, wherein the stock material is unwindable from the roll as a flat sheet, a folding plate defining a folding plate plane that is substantially parallel with the spindle axis, the folding plate including a first edge and a second edge, wherein the first edge connects with the second edge at a central peak, first and second folding rollers positioned generally adjacent to the folding plate and being generally parallel with the folding plate plane, the first and second folding rollers defining a nip therebetween, wherein the flat sheet extends over the first edge, the second edge and the central peak and is folded between the nip to define a first folded half and a second folded half, and a spreader chute including a first guide plate and a second guide plate, the second guide plate being generally parallel with and spaced apart from the first guide plate to define a loading space therebetween, each of the first and second guide plates including an inner surface and an outer surface, wherein the first folded half is received over the inner and outer surfaces of the first guide plate, and wherein the second folded half is received over the inner and outer surfaces of the second guide plate. 
     In another aspect, a method for packaging an item may utilize a vertical bagging machine that may include a roll of stock material, a folding plate defining a folding plate plane and including a first edge and a second edge, wherein the first and second edges are generally equal in length and connect at an upwardly pointing central peak, a spreader chute including a first guide plate and a second guide plate, the second guide plate being substantially perpendicular to the folding plate plane and generally parallel with and spaced apart from the first guide plate, wherein each of the first and second guide plates include an inner surface and an outer surface, and first and second folding rollers defining a nip therebetween, the first and second folding rollers being generally parallel with the folding plate plane and disposed between the folding plate and the spreader chute. The method may include the steps of unwinding a sheet from the roll of stock material, passing the sheet over the first edge, the second edge and the central peak of the folding plate such that the central peak initiates a fold line in the sheet, wherein the fold line defines a partially folded sheet having a first folded half and a second folded half, passing the partially folded sheet between the nip of the first and second folding rollers such that the first folded half is opposed to the second folded half to define a folded sheet, passing the first folded half of the folded sheet over the outer surface of the first guide plate of the spreader chute while, simultaneously, passing the second folded half of the folded sheet over the outer surface of the second guide plate of the spreader chute, inverting the sheet over the first and second guide plates such that the first folded half is received over the inner and outer surfaces of the first guide plate and the second folded half is received over the inner and outer surfaces of the second guide plate, thereby defining a loading space between the first and second guide plates, positioning the item in the loading space such that the item is at least partially surrounded by the first folded half and the second folded half, and sealing the first folded half to the second folded half to enclose the item within the sheet. 
     Other aspects of the disclosed vertical bagging machine will become apparent from the following description, the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevational view of one particular aspect of the disclosed vertical bagging machine; 
         FIG. 2  is a side elevational view of the vertical bagging machine of  FIG. 1 , shown with the housing and support structure removed to expose internal components; and 
         FIG. 3  is a front perspective view of the vertical bagging machine of  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
     As shown in  FIG. 1 , one particular aspect of the disclosed vertical bagging machine, generally designated  100 , may include a vertical bagging assembly  10  (shown more fully in  FIGS. 2 and 3 ) supported by a support structure  102 . For example, the support structure may be a cart-like support structure having lockable casters  104  that may facilitate movement and positioning of the vertical bagging machine  100  in the packaging facility. However, those skilled in the art will appreciate that the support structure  102  may also be a stationary support structure without departing from the scope of the present disclosure. 
     Optionally, the support structure  102  may include a housing  106 , such as a cabinet, in which at least a portion of the vertical bagging assembly  10  may be received. The housing  106  may include an access door  108  or the like for providing access to the components of the vertical bagging assembly  10  received in the housing  106 . 
     A control interface  110  may be mounted on the support structure to control the operation of the vertical bagging assembly  10 . For example, the control interface  110  may include an ON/OFF switch, a speed control feature, an emergency shut-off switch, a graphical user interface and the like. 
     Referring now to  FIGS. 2 and 3 , one particular aspect of the vertical bagging assembly  10  of the disclosed vertical bagging machine  100  may include a spindle  12  (having a spindle axis S), a roll  14  of stock material, a dancer roller  16 , an outer roller  18 , an inner roller  20 , a folding plate  22 , first and second vertical folding rollers  24 ,  26 , an adjustable spreader chute  28 , a film puller  30  (shown simply as a block in  FIG. 2 ), and a sealing element  32  (shown only in  FIG. 2 ). Additional rollers may be used to guide the stock material, as will be described below, without departing from the scope of the present disclosure. 
     The folding plate  22  may be generally planar and may include a front face  34  ( FIG. 2 ), a first sheet-receiving edge  36  ( FIG. 3 ) and a second sheet-receiving edge  38  ( FIG. 3 ), wherein the first and second sheet-receiving edges  36 ,  38  may be generally equal in length and may meet at an upwardly pointing central peak  40  ( FIG. 2 ) such that the folding plate  22  may be generally shaped as an isosceles triangle in front view. As shown in  FIG. 1 , the folding plate  22  may be connected to the support structure  102  such that the folding plate  22  is vertical and the plane of the folding plate  22  is generally parallel with the spindle axis S (shown in  FIG. 3 ). 
     The first and second vertical folding rollers  24 ,  26  may be connected to the support structure  102  such that, as shown in  FIGS. 2 and 3 , the first and second vertical folding rollers  24 ,  26  stand vertically and parallel with the plane of the folding plate  22 . Furthermore, the first and second vertical folding rollers  24 ,  26  may be positioned in proximity to each other to define a nip therebetween. 
     The adjustable spreader chute  28  may include a first guide plate  42  that is generally parallel with and spaced apart from a second guide plate  44 , thereby defining a loading space  46  therebetween. The first and second guide plates  42 ,  44  may be secured to the support structure  102  such that the guide plates  42 ,  44  are generally perpendicular to the plane of the folding plate  22  and centered relative to the central peak  40 . In one aspect, each guide plate  42 ,  44  may be generally triangular in side view ( FIG. 2 ) and may include a rear, spreading edge  48  and an angled, film-inverting edge  50 . Optionally, one or both of the guide plates  42 ,  44  may be articulateable relative to each other and the support structure  102  such that the width of the loading space  46  therebetween may be adjusted as necessary. 
     Referring to  FIG. 3 , the film puller  30  may include a motor  52 , a pulley assembly  54 , and opposed belts  56 ,  58 . Rotational power from the motor  52  may be translated into corresponding movement of the opposed belts  56 ,  58  by way of the pulley assembly  54 . The opposed belts  56 ,  58  may define a pinch point (or pinch region) therebetween that grips the sheet  60  and urges the gripped sheet  60  in the direction shown by arrow A, as will be described in greater detail below. 
     The roll  14  of stock material may unwind as a flat, unfolded sheet  60  and may be formed from any appropriate sheet material that may be folded and sealed, whether by heat, adhesives or otherwise, to form a bag. Optionally, the sheet  60  may be pre-printed with various text or graphics. 
     In one particular aspect, the sheet  60  may be a polymeric film such as polyethylene film, polypropylene film, polyvinylchloride film or the like. However, those skilled in the art will appreciate that the sheet  60  may be formed from various materials depending upon the properties desired in the end product. Furthermore, the sheet  60  may be coated with various materials and formulations to impart the sheet  60  with desired properties (e.g., moisture barriers, oxygen barriers and the like). 
     Referring again to  FIGS. 2 and 3 , the roll  14  of stock material may be received over the spindle  12  and may be centered relative to the vertical bagging assembly  10  using arbors (not shown) or the like. In one aspect, the roll  14  of stock material may be positioned on the spindle  12  such that the center line of the sheet  60  is aligned with the central peak  40  of the folding plate  22 . 
     Once the roll  14  of sheet material has been properly aligned with the vertical bagger assembly  10 , the sheet  60  may be unwound from the roll  14 , passed under the dancer roller  16 , then passed up and over the outer roller  18 , and then passed under the inner roller  20 . From the inner roller  20 , the sheet  60  may then pass across the front face  34  of the folding plate  22 , over the central peak  40  and the first and second edges  36 ,  38  of the folding plate  22 , and then through the nip defined by the first and second vertical folding rollers  24 ,  26 . As such, a downwardly open fold  62  may be initiated in the sheet  60  as the center line of the sheet  60  moves over the central peak  40  of the folding plate  22  and through the nip defined by the first and second vertical folding rollers  24 ,  26 . 
     From the first and second vertical folding rollers  24 ,  26 , the folded sheet  60  may pass to the adjustable spreader chute  28  in the direction shown by arrow B. At the adjustable spreader chute  28 , a first folded half  60 A of the sheet  60  may be draped over the outer surface  42 A ( FIG. 2 ) of the first guide plate  42  and a second folded half  60 B of the sheet  60  may be draped over the outer surface  44 A ( FIG. 3 ) of the second guide plate  44 . Then, the center of the sheet  60  (i.e., the portion of the sheet  60  adjacent to the fold line  62 ) may be tucked to the rear of the adjustable spreader chute  28 , as shown in  FIG. 3 , thereby inverting the sheet  60  over the angled, film-inverting edges  50  of the first and second guide plates  42 ,  44 , thereby redirecting the sheet  60  approximately 90 degrees (i.e., the direction that the sheet  60  travels is redirected from the direction shown by arrow B to the direction shown by arrow A). As such, the first folded half  60 A of the sheet  60  is draped over both the outer surface  42 A ( FIG. 2 ) and the inner surface  42 B ( FIG. 3 ) of the first guide plate  42  and the second folded half  60 B of the sheet  60  is draped over both the outer surface  44 A ( FIG. 3 ) and the inner surface  44 B ( FIG. 3 ) of the second guide plate  44 . 
     As the redirected, folded sheet  60  moves vertically downward through the adjustable spreader chute  28  (i.e., in the direction shown by arrow A), the opposed belts  56 ,  58  of the film puller  30  may engage the sheet  60  and may draw the sheet  60  vertically downward through the adjustable spreader chute  28  to define the loading space  46  between the first and second guide plates  42 ,  44 . 
     Referring to  FIG. 2 , the sealing element  32  may be positioned below the loading space  46  of the adjustable spreader chute  28  to engage the redirected, folded sheet  60  and seal the first folded half  60 A of the sheet  60  to the second folded half  60 B of the sheet  60 . The sealing element  32  may employ heat, adhesives, fasteners or the like to form the seal. Optionally, the sealing element  32  may also include a cutting feature such that excess portions  64  of the sheet  60  may be cut away and discarded, as well as to separate individual packages  66  after sealing is complete. Those skilled in the art will appreciate that a cutting feature independent of the sealing element  32  may also be used. 
     In one aspect, the sealing element  32  may be an L-shaped heat sealing element. In another aspect, the sealing element  32  may include a pair of L-shaped heat sealing elements that cooperate to clamp onto and heat seal the folded sheet  60 . The L-shaped heat sealing element  32  (or pair of L-shaped heat sealing elements) may form rectangular packages  66  by forming both a horizontal seal  68 , which defines both upper and lower horizontal edges of the sealed package  66 , and a vertical seal  70 , which defines one of the two vertical edges of the sealed package  66 , per sealing operation. Those skilled in the art will appreciate that the second vertical edge of the sealed package is defined by the fold  62 . 
     Thus, an item  72  to be sealed may be positioned in the loading space  46  of the adjustable spreader chute  28 , thereby surrounding the item  72  with the folded sheet  60  and leaving only two edges unsealed. (The fold  62  and the previously-formed horizontal seal may define the other two edges.) Then, as the film puller  30  draws the sheet  60  vertically downward (i.e., in the direction shown by arrow A), the item  72  is drawn downward and positioned relative to the sealing element  32  such that the sealing element  32  may seal the two previously unsealed edges, thereby forming a sealed package  66 . 
     Still referring to  FIG. 2 , a light curtain  74  may be provided to detect ingress and egress into the loading space  46  of the adjustable spreader chute  28 . Those skilled in the art will appreciate that the ingress and egress detected in the loading space  46  by the light curtain  74  may be a user&#39;s hand/arm depositing an item  72  (i.e., a semi-automatic process), a mechanical arm depositing an item  72 , or simply the item  72  passing the light curtain  74  by, for example, the use of a loading chute (not shown) (i.e., an automatic process). 
     In one aspect, a controller (not shown) may prevent operation of the vertical bagging assembly  10  when the light curtain  74  is broken. In another aspect, the controller may be configured to halt operation when the light curtain  74  is broken and resume operation when the light curtain  74  in not broken, thereby automating or semi-automating the bagging process. For example, when the light curtain  74  is broken, the controller may halt all mechanical functions of the assembly  10 . Then, when the controller determines that the break in the light curtain  74  is no longer present, the controller may assume that an item has been placed into the loading space  46  and, therefore, may instruct the film puller  30  to draw the sheet  60  and item  72  downward to the sealing element  32  and may instruct the sealing element  32  to perform a sealing operation. The process may repeat as the user&#39;s hand is repeatedly placed into the loading space  46  to deposit an item  72  and then removed. 
     The light curtain  74  may include a first light curtain element  76  positioned adjacent to the angled, film-inverting edge  50  of the first guide plate  42  and a second light curtain element (not shown) positioned adjacent to the angled, film-inverting edge  50  of the second guide plate  44 . The first light curtain element  76  may cooperate with the second light curtain element to detect a break in the plane therebetween. As shown in  FIG. 1 , the first  76  and second light curtain elements may be connected to the support structure  102  by a bracket  112  or the like such that the light curtain  74  does not interfere with the sheet  60  as the sheet  60  moves over the first and second guide plates  42 ,  44 . 
     Accordingly, in view of the present disclosure, those skilled in the art will appreciate that a vertical bagging machine may be constructed having a small footprint and easy portability that utilizes flat roll stock material (a cost savings over pre-folded stock), and which automatically (or semi-automatically) cycles with a light curtain mechanism. 
     Although various aspects of the disclosed vertical bagging machine have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application contemplates and includes such modifications and is limited only by the scope of the claims.