Patent Publication Number: US-2022212825-A1

Title: Web packaging machines with variable depth forming

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is divisional of U.S. patent application Ser. No. 16/819,897, filed Mar. 16, 2020, which is a continuation of U.S. application Ser. No. 15/289,604 filed on Oct. 10, 2016, now U.S. Pat. No. 10,625,892, issued Apr. 21, 2020, which claims priority to U.S. Provisional Patent Application Ser. No. 62/241,359 filed Oct. 14, 2015, the disclosures of both of which are incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to web packaging machines for packaging a product between upper and lower webs. 
     BACKGROUND 
     The following patents are incorporated herein by reference in entirety: 
     U.S. Pat. No. 7,490,448 discloses a form-fill-seal web packaging system that includes a pressure monitor at the sealing station to monitor a sealing pressure. A bladderless actuator effects relative movement of dies and applies the sealing pressure. 
     U.S. Pat. No. 7,607,279 discloses a web packaging system that provides easy access and changing of tooling. The changing of tooling thereby changes a product receiving cavity pocket in a lower web. 
     U.S. Pat. No. 8,181,432 discloses a web packaging system that provides easy access and changing of a forming plug tooling. 
     SUMMARY 
     This Summary is provided herein to introduce a selection of concepts that are further described herein below in the Detailed Description. This Summary is not intended to identify key or essential features from the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. 
     In certain examples, a packaging machine for forming a product cavity in a web includes a forming die box that defines a recess into which the product cavity is formed, an insert that is movable in the recess to thereby vary a depth of the recess, and a variable depth mechanism that selectively moves the insert to vary the depth of the recess. 
     In certain examples, a packaging machine for forming a product cavity in a web includes a forming die box that defines a recess into which the product cavity is formed, a die box base that supports the forming die box, and a latching mechanism that selectively moves the forming die box into and between a first position in which the forming die box is spaced apart from the die box base and a second position in which the forming die box is supported by the die box base. 
     In certain examples, a method for forming a product cavity in a web includes providing a forming die box that defines a recess into which the product cavity is formed, positioning an insert in the forming die box such that the insert is axially movable in the recess to thereby vary a depth of the recess, actuating a variable depth mechanism to selectively move the insert to vary the depth of the recess, and then forming the product cavity in the web. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Examples are described with reference to the following drawing figures. The same numbers are used throughout the drawing figures to reference like features and components. 
         FIG. 1  is an example web packaging machine. 
         FIG. 2  is a perspective view of an example forming station of the web packaging machine having a forming die box in a staging position and a guide track assembly in an extended position. 
         FIG. 3  is a perspective view of the forming station of  FIG. 2  having the forming die box in a first position and the guide track assembly in a retracted position. 
         FIG. 4  is an enlarged view of the forming station of  FIG. 2 , the forming die box in the first position. 
         FIG. 5  is an enlarged view of the forming station of  FIG. 2 , the forming die box in a second position. 
         FIG. 6  is a side view of the forming station of  FIG. 2  including a framing assembly movable between a first lowered position and a second forming position, the forming die box and a die box base move axially (as depicted in dashed lines) when the framing assembly moves to the second forming position. 
         FIG. 7  is a cross sectional view of the forming station depicted in  FIG. 2  through a middle of the forming die box, the forming die box is in the second position and a variable depth mechanism extending into an interior vacuum space. 
         FIG. 8  is an enlarged cross sectional view of the forming die box depicted in  FIG. 2  through a recess of the forming die box. 
         FIG. 9  is an example system of the packaging machine. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWING 
     In the present disclosure, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different apparatuses, systems, and methods described herein may be used alone or in combination with other apparatuses, systems, and methods. Various equivalents, alternatives, and modifications are possible within the scope of the appended claims. 
     Packaging machines for packaging food products between two webs of elastic materials are known in the food packaging industry. Often, the packaging machines form a product cavity in at least one of the webs to hold the food product. The product cavity is formed by a forming die box that defines a recess into which the product cavity is formed. The forming die box often must be changed to form and/or accommodate size/dimension requirements for different product cavity sizes. For example, a forming die box having recesses with a 2.0 inch recess depth may be changed with a forming die box having recesses with a 4.0 inch recess depth. The process of changing the forming die box usually requires that the packaging machine be shut down in order for the forming die box to be removed and/or the web to be cut and peeled away. In other examples, the recess depth can be changed by manually inserting or removing plates or blocks into the recess (e.g. a 1.0 inch plate is inserted into the recess of the forming die box to decrease the depth of the product cavity 1.0 inch). 
     Changing the forming die box and/or the recess depth disadvantageously requires operator interaction and shut-downs of the packaging machine which lead to lost packaging time and inefficiencies. The inventor has recognized these problems and has endeavored to provide apparatuses for changing the depth of product cavities formed in a web by a packaging machine. The present disclosure provides apparatuses and methods for allowing simplified, user-friendly, and automated recess depth change for forming die boxes. 
       FIG. 1  depicts an indexing motion packaging machine  2  that includes a web transport conveyor  4  transporting a web  6  of flexible packaging material from upstream to downstream through a series of stations including a forming station  10  that forms at least one product cavity  7  in the web  6 , a loading station  12  that places food product P in the product cavity  7 , and a closing station  14  that closes and/or seals the pocket with another web of flexible packaging material. 
     Referring to  FIGS. 2-3 , the forming station  10  includes a die box base  20  that is fixedly coupled to a frame assembly  30  (further described herein below) of the packaging machine  2 . The die box base  20  includes a perimeteral surface  22  that corresponds to and abuts a perimeteral surface  42  on a forming die box  40  (further described herein below). The die box base  20  also defines at least one hole  24  (see  FIG. 8 ) through which an engagement member  92  (further described herein below) extends. 
     The forming station  10  includes the forming die box  40  which is configured to define at least one recess  44  in the web  6 , into which the product cavity  7  is formed. A bottom surface of the recess  44  and/or the depth of the recess  44  is defined by an insert  60  (further described herein below) which is received in the recess  44 . The forming die box  40  includes a shelf  46  (see  FIG. 8 ) that radially projects into the recess  44  to axially support the insert  60  in the forming die box  40  (i.e. the shelf  46  prevents the insert  60  from falling through the recess  44  and out of the forming die box  40 ). The forming die box  40  also defines the perimeteral surface  42  that corresponds to and abuts the perimeteral surface  22  of the die box base  20 . The number of recesses  44 , the shape of the recess  44 , the depths of the recesses  44 , the recess depths, and/or other dimensions of the recess  44  can vary. In the example depicted in  FIG. 2 , six rectangular recesses  44  are depicted. A handle  48  is coupled to the forming die box  40  to assist the user in moving the forming die box  40 . Reference is made to the incorporated U.S. Pat. No. 7,607,279 for further explanation of movable die boxes. 
     The forming die box  40  is moveable into and out of the forming station  10  by a guide track assembly  70  that is configured to support the forming die box  40 . The guide track assembly  70  allows the forming die box  40  to be moved between a staging position (see  FIG. 2 ) such that the forming die box  40  can be easily removed (e.g. lifted) from the forming station  10  by an operator and a first position (see  FIGS. 3-4 ) in which the forming die box  40  is axially above the die box base  20 . The guide track assembly  70  includes a pair of rails  72  having rollers  74  that reduce friction between the forming die box  40  and the guide track assembly  70  as the forming die box  40  is moved on the guide track assembly  70 . The guide track assembly  70  is movable between a retracted position (see  FIG. 3 ) in which the rails  72  are substantially vertical and adjacent to the frame assembly  30  and an extended position (see  FIG. 2 ) such that the rail members  82  are substantially horizontal and support the forming die box  40  in a staging position (see  FIG. 2 ) which is offset from the packaging machine  2 . When loading the forming die box  40  into the forming station  10 , an operator moves the guide track assembly  70  to the extended position (see  FIG. 2 ) and places the forming die box  40  onto the rails  72 . The operator then pushes the forming die box  40  along the rails  72  into the first position (see  FIG. 3 ). Once the forming die box  40  is in the first position, the operator rotates the guide track assembly  70  back to the retracted position (see  FIGS. 3-4 ). When unloading the forming die box  40  from the forming station  10 , the operator moves the guide track assembly  70  to the extended position and then pulls the forming die box  40  into the staging position (see  FIG. 2 ). The operator can then remove the guide track assembly  70 . Reference is made to the incorporated U.S. Pat. No. 7,607,279 for further details of the guide track assembly  70 . In certain examples, a locking plate  38  (see  FIG. 5 ) secures the forming die box  40  to the die box base  20 . 
     Referring to  FIGS. 4-5 , the forming die box  40  is axially movable within the forming station  10  by a latching mechanism  80  that secures the forming die box  40  to the forming station  10  by moving the forming die box  40  into and out of engagement with the die box base  20 . The latching mechanism  80  moves the forming die box  40  into and between the first position (see  FIGS. 3-4 ) in which the forming die box  40  is spaced apart from the die box base  20  and a second position (see  FIG. 5 ) wherein the forming die box  40  is supported by the die box base  20  (or otherwise mates with or engages with the die box base  20 ). That is, the latching mechanism  80  axially moves the forming die box  40  such that the perimeteral surface  22  of die box base  20  is supported by the perimeteral surface  42  of the forming die box  40 . When the forming die box  40  is in the first position (see  FIGS. 3-4 ), the forming die box  40  is freely laterally movable away from the die box base  20 , and when the forming die box  40  is in the second position (see  FIG. 5 ) the forming die box  40  is supported by the die box base  20 . The forming die box  40  is supported by the die box base  20  in a manner that creates a fluid tight seal and define an interior vacuum space  28  (see  FIG. 8 ) there between, and the fluid tight seal is created when the perimeteral surface  22  of the die box base  20  abuts the perimeteral surface  42  of the forming die box  40 . The forming die box  40  and the die box base  20  cooperate with a cover  26  (see  FIG. 6 ) (described further herein below) positioned above the web  6  at the forming station  10  to create a vacuum in the interior vacuum space  28  and thereby form the product cavity  7  under force of vacuum. In certain examples, a gasket  47  (see  FIG. 8 ) is included along the perimeteral surface  22  of the die box base  20  to create a vacuum tight seal between the forming die box  40  and the die box base  20 . 
     The latching mechanism  80  includes a rail member  82  for axially supporting the forming die box  40  in the first position (see  FIGS. 3-4 ). The rail member  82  includes a sloped surface  84  configured allow the forming die box  40  to slide along the rail member  82  when the forming die box  40  moves between the staging position (see  FIG. 2 ) and the first position (see  FIGS. 3-4 ). The latching mechanism  80  includes an eccentric member  86  that is configured to rotate to thereby move the rail member  82  such that the forming die box  40  moves between the first position (see  FIGS. 3-4 ) and the second position (see  FIG. 5 ). That is, rotation of the eccentric member  86  moves the rail member  82  thereby moving the forming die box  40  into and between the first position (see  FIGS. 3-4 ) and the second position (see  FIG. 5 ). For example, the eccentric member  86  is rotatable in a first direction such that the rail member  82  axially moves downward and the forming die box  40  moves from the first position (see  FIGS. 3-4 ) to the second position (see  FIG. 5 ); and the eccentric member  86  is rotatable in a second direction opposite the first direction such the rail member  82  axially moves upward and the forming die box  40  moves to the from the second position (see  FIG. 5 ) to the first position (see  FIGS. 3-4 ). The shape of the eccentric member  86  can vary. In one example, the eccentric member  86  is a semicircle disk. The latching mechanism  80  includes a handle  88  by which an operator can manually rotate the eccentric member  86 . 
     Once the forming die box  40  is positioned in the second position (see  FIG. 5 ), the packaging machine  2  can form the product cavity  7  in the web  6 . Referring to  FIG. 6 , the forming die box  40  (which is in the second position) and the die box base  20  are supported by a movable base plate or frame assembly  30  which moves during operation of the packaging machine  2 . The frame assembly  30  is movable between a lowered position axially below the web  6  such that the forming die box  40  is axially below the web  6  and the web  6  is allowed to advance; and a forming position such that the forming die box  40  engages the web  6  to thereby form the product cavity  7  in the web  6  (the forming die box  40  is depicted in dash-doubledot-dash line weight in  FIG. 6  when the frame assembly  30  is in the forming position). When the frame assembly  30  is in the forming position, the cover  26  (which is stationary and fixedly mounted to the packaging machine  2  at the forming station  10 ) cooperates with forming die box  40  to create a vacuum in the interior vacuum space  28  and thereby form the product cavity  7  in the web  6 . Vacuum equipment (not shown and known in the prior art) coupled to the die box base  20  creates the vacuum in the interior vacuum space  28  such that the product cavity  7  is formed in the web  6 . The cover  26  optionally includes a plug assist mechanism having a plug member, a heat plate, and/or the like. The frame assembly  30  is moved between the lowered position and the forming position by lift arms  32  that are rotated by an actuator  35  (e.g. a servo motor) and belt  34  (see movement arrows A which depict movement of the lift arms  32  and the belt  34 ). 
     Referring to  FIGS. 7-8 , the inserts  60  received in the forming die box  40  are shown in greater detail. As described above, the bottom surface of the recess  44  is defined by the insert  60  which is received or positioned in the recess  44  such that the insert  60  is axially movable in the recess  44  to thereby vary the depth of the recess  44  or the recess depth. The insert  60  includes a projection  62  that radially extends from the insert  60  to contact the shelf  46  of the forming die box  40  (see  FIG. 8 ) such that the insert  60  is supported in the recess  44  (i.e. the projection  62  of the insert  60  contacts the shelf  46  to prevent the insert  60  from axially moving through the forming die box  40  in one axial direction). The insert  60  includes an upper end  63  and a lower end  64  opposite the lower end  64 , and the projection  62  is located nearer the upper end  63  than the lower end  64  such that the lower end  64  is axially below the shelf  46  of the forming die box  40  when the shelf  46  contacts the projection  62  of the insert  60 . The projection  62  has a curved surface  66  that defines a bottom perimeteral fillet of the recess  44 . The insert  60  can change the shape of the recess  44  and/or the number of the recesses  44  defined in the forming die box  40  (i.e. an insert  60  can fill the entire recess  44  such that the number of product cavities  7  formed by the forming die box  40  is reduced (e.g. a forming die box  40  with six recesses  44  receives two inserts  60  that completely fill two recesses  44  such that the number of product cavities  7  formed by the forming die box  40  is reduced to four)). Further, a variable depth mechanism  90  (described herein) is capable of moving the insert(s)  60  such that the number of product cavities  7  formed by the forming die box  40  is reduced. 
     The forming station  10  includes the variable depth mechanism  90  that moves the insert  60  to thereby vary the depth of the recess  44 . The variable depth mechanism  90  includes at least one engagement member  92  that is slideably received in the hole  24  of the die box base  20 . The engagement member  92  comprises a first end  93  that extends into the interior vacuum space  28  defined by the forming die box  40  and the die box base  20  and a second end  94  opposite the first end  93 . The engagement member  92  contacts the insert  60  to thereby move the insert  60  and vary the depth of the recess  44 . In certain examples, the first end  93  of the engagement member  92  comprises a plate  96  configured to contact the insert  60  and/or multiple inserts  60  received in the recess(es)  44  of the forming die box  40 . In operation, axial movement of the first end  93  of the engagement member  92  causes axial movement of the insert  60 . In certain examples, the engagement member  92  must return to a rest position (see the plate  96  depicted in solid line on  FIG. 7 ) before the forming die box  40  can be moved to the staging position (see  FIG. 2 ) (i.e. the engagement member  92  and/or the plate in an engagement position (see the plate  96  depicted in dashed line on  FIG. 7 ) prevents the forming die box  40  from moving from the first position (see  FIGS. 3-4 ) to the staging position (see  FIG. 2 ), and vise versa). The variable depth mechanism  90  can be adapted for use with any type (e.g. size, shape) of forming die box  40 . 
     The variable depth mechanism  90  includes a drive shaft  98  that is rotatably coupled to the die box base  20  and a platform member  100  that is coupled to the drive shaft  98  and the second end  94  of the engagement member  92 . In one example, the platform member  100  includes screw threads and the drive shaft  98  includes screw threads that mate and/or engage with the screw threads of the platform member  100 . An actuator  104  selectably rotates the drive shaft  98  such that the platform member  100  axially moves along the drive shaft  98  to axially move the insert  60  (e.g. when the drive shaft  98  is rotated by the actuator  104 , the platform member  100  axially moves which causes the engagement member  92  to move). In the example depicted, the actuator  104  is a servo motor which selectively moves a belt  105  to thereby rotate the drive shaft  98 . As the servo motor actuates in a first servomotor direction, the belt  105  moves in a first belt direction causing the drive shaft  98  to rotate in a counterclockwise direction; and when the drive shaft  98  actuates in a second servomotor direction, the belt  105  moves in a second belt direction causing the drive shaft  98  to rotate in a clockwise direction. In certain examples, the drive shaft  98  is rotatably supported by a fixed member assembly  108  that supports and allows rotation of the drive shaft  98 . The fixed member assembly  108  being fixed with respect to the die box base  20 . 
     Referring to  FIG. 9 , the packaging machine  2  includes a controller  120  configured to control the components and devices of the packaging machine  2 , including the components described herein. The controller  120  is configured to control movement of the web  6  via the web transport conveyor  4 ; actuation of the actuator  33  to move the lift arms  32  and the frame assembly  30 , as described above; and/or the actuator  104  of the variable depth mechanism  90 , as described above. The controller  120  is part of a system  118  included with the packaging machine  2 . The system  118  includes a user input device  122  that allows the operator to input information into the system  118  to control the depth of the recess  44  in the forming die box  40 . For example, the operator can input into the user input device  122  a selected recess depth of 3.0 inches such that the controller  120  sends appropriate signals (via wired or wireless communication links  130 ) to the actuator  104  of the variable depth mechanism  90 . The actuator  104  then axially moves the engagement member  92  to axially move the insert  60  within the recess  44  such that the insert  60  defines the depth of the recess  44  at the selected recess depth. 
     The controller  120  includes a processing system  124 , storage system  126 , and software  128 . The processing system  124  loads and executes software  128  from the storage system  126 . When executed by the controller  120 , the software  128  directs the processing system  124  to operate to carry out the methods described herein. 
     It should be understood that one or more software application modules could be provided within the software to carry out the same operation. Similarly, while description as provided herein refers to a controller  120  and a processing system  124 , it is to be recognized that implementations of such systems can be performed using one or more processors, which may be communicatively connected, and such implementations are considered to be within the scope of the description. 
     The processing system  124  can comprise a microprocessor and other circuitry that retrieves and executes software  128  from storage system  126 . Processing system  124  can be implemented within a single processing device but can also be distributed across multiple processing devices or sub-systems that cooperate in existing program instructions. Examples of processing system  124  include general purpose central processing units, applications specific processors, and logic devices, as well as any other type of processing device, combinations of processing devices, or variations thereof. 
     The storage system  126  can comprise any storage media readable by processing system  124 , and capable of storing software  128 . The storage system  126  can include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information, such as computer readable instructions, data structures, program modules, or other data. Storage system  126  can be implemented as a single storage device but may also be implemented across multiple storage devices or sub-systems. Storage system  126  can further include additional elements, such as a controller, capable of communicating with the processing system  124 . 
     Examples of storage media include random access memory, read only memory, magnetic discs, optical discs, flash memory, virtual memory, and non-virtual memory, magnetic sets, magnetic tape, magnetic disc storage or other magnetic storage devices, or any other medium which can be used to storage the desired information and that may be accessed by an instruction execution system, as well as any combination or variation thereof, or any other type of storage medium. In some implementations, the storage media can be a non-transitory storage media. In some implementations, at least a portion of the storage media may be transitory. It should be understood that in no case is the storage media a propagated signal. 
     User input device  122  can include a mouse, a keyboard, a voice input device, a touch input device, a motion input device, and other comparable input devices and associated processing elements capable of receiving user input from a user. Output devices such as a video display or graphical display can display an interface further associated with embodiments of the system and methods as disclosed herein. Speakers, printers, bells and other types of output devices may also be included in the user input device  122 . The user input device  122  may display the system  118  on a display screen, and/or may announce it via a speaker. 
     In certain examples, the forming station  10  includes a sleeve  101  that is coupled to the die box base  20  to support and seal the engagement member  92  with the die box base  20  as it slides in the hole  24  (see  FIGS. 7-8 ). In certain examples, the vacuum cups  102  are coupled to the die box base  20  and configured to create the vacuum in the interior vacuum space  28  (see  FIG. 7 ). 
     In certain examples, a packaging machine for forming a product cavity in a web includes a forming die box that defines a recess into which the product cavity is formed, an insert that is movable in the recess to thereby vary a depth of the recess, and a variable depth mechanism that moves the insert to vary the depth of the recess. The variable depth mechanism includes an engagement member that contacts the insert to thereby move the insert and vary the depth of the recess. A die box base supports the forming die box and defines an interior vacuum space therebetween, and the die box base further defines a hole that slidably receives the engagement member. The engagement member comprises a first end that extends into the interior vacuum space to thereby move the insert and vary the depth of the recess. The engagement member includes a second end opposite the first end. The variable depth mechanism can include a drive shaft, a platform member coupled to the drive shaft and the second end of the engagement member, and an actuator that selectively rotates the drive shaft such that the platform member moves along the drive shaft and the engagement member moves the insert. The variable depth mechanism includes a fixed member assembly that supports and allows rotation of the drive shaft. The fixed member assembly is fixed with respect to the die box base. In certain examples, the actuator is a servo motor. In certain examples, a computer controller controls the servo motor to thereby rotate the drive shaft. 
     In certain examples, a latching mechanism that moves the forming die box into and between a first position in which the forming die box is spaced apart from the die box base and a second position in which the die box base supports the forming die box. When in the first position, the forming die box is freely laterally movable away from the die box base, and when in the second position the forming die box is supported by the die box base. The forming die box has a perimeteral surface, and the die box base has a perimeteral surface that corresponds to and abuts the perimeteral surface of the forming die box in the second position. The latching mechanism has a rail member that supports the forming die box and an eccentric member such that rotation of the eccentric member moves the rail member thereby moving the forming die box into and between the first position and the second position. In certain examples, the latching mechanism has a handle configured to rotate the eccentric member. The forming die box includes a shelf that projects into the recess to support the insert in the forming die box, and the insert has a projection that radially extends from the insert and is supported by the shelf. The insert has an upper end and a lower end opposite the upper end such that the projection is positioned nearer the upper end than the lower end such that the lower end is axially below the shelf of the forming die box when the projection is supported by the shelf. In certain examples, the projection has a curved surface that defines a bottom fillet of the recess. 
     In certain examples, a packaging machine for forming a product cavity in a web includes a forming die box that defines a recess into which the product cavity is formed, a die box base that supports the forming die box, and a latching mechanism that moves the forming die box into and between a first position in which the forming die box is spaced apart from the die box base and a second position in which the forming die box is supported by the die box base. The latching mechanism further comprises an eccentric member such that rotation of the eccentric member moves the forming die box into and between the first position and the second position. The latching mechanism includes a rail member for supporting the forming die box, wherein the rail member axially moves when the eccentric member rotates. 
     In certain examples, a method for forming a product cavity in a web includes providing a forming die box that defines a recess into which the product cavity is formed, positioning an insert in the forming die box such that the insert is axially movable in the recess to thereby vary a depth of the recess, actuating a variable depth mechanism to move the insert to vary the depth of the recess, and forming the product cavity in the web. The method can include rotating a drive shaft that moves a platform member of the variable depth mechanism such that the engagement member moves. 
     In the present description, certain terms have been used for brevity, clearness and understanding. No unnecessary imitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different apparatuses, systems, and methods described herein may be used alone or in combination with other apparatuses, systems, and methods. Various equivalents, alternatives and modifications are possible within the scope of the appended claims.