Patent Publication Number: US-11027512-B2

Title: Forming of vacuum bag packaging

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This is a divisional of U.S. patent application Ser. No. 14/558,082, titled “Forming of Vacuum Bag Packaging” and filed on Dec. 2, 2014, which claims the benefit of and priority to U.S. Provisional Patent Application No. 61/911,288, filed Dec. 3, 2013, the entire contents of each of the foregoing are hereby incorporated by reference herein. 
    
    
     BACKGROUND 
     The present disclosure relates to packaging materials and, more particularly, to the forming of certain types of packaging materials to a desired shape. U.S. Pat. No. 6,085,909 (“the &#39;909 patent”) and U.S. Pat. No. 8,011,511 (“the &#39;511 patent”) disclose reusable flexible packaging pads comprising sealed bags that are filled with foam beads and/or other resilient filler materials. During manufacturing, the bags are filled with beads, compressed, and then sealed such that the pressure on the inside of the sealed bag is less than ambient or atmospheric pressure. The bag is therefore compressed upon the filler materials and renders the filler materials non-free flowing. The resultant vacuum bag packaging has the simultaneous properties of “handling rigidity,” whereby the packaging maintains its shape during routine handling, and formability, whereby the packaging can be molded or formed around a part or component during packaging, and will thereafter maintain the molded or formed shape and protect the packaged part or component. The entire contents of both the &#39;909 patent and the &#39;511 patent are hereby incorporated by reference herein. 
     SUMMARY 
     In some aspects, a system is provided for forming a packaging material to a desired configuration. The system includes a forming chamber configured to receive the packaging material, a vacuum system fluidly communicating with the forming chamber and operable to establish a vacuum within the forming chamber, and a forming die positioned within the forming chamber. An actuator is operable to urge the packaging material and the forming die into engagement with one another while the vacuum system maintains the vacuum within the forming chamber. 
     The forming chamber may include a body and a closure sealingly engageable with the body and moveable between an open configuration for placement of the packaging material into the forming chamber and a closed configuration in which the forming chamber is sealed such that the vacuum system is operable to establish the vacuum within the forming chamber. The actuator may include a rod that extends from a location outside the forming chamber to a location inside the forming chamber. The actuator may also include a pressing member located inside the forming chamber for urging the packaging material and the forming die into engagement with one another. The vacuum system may include a first vacuum fitting in a first portion of the forming chamber and a second vacuum fitting in a second portion of the forming chamber. The first vacuum fitting and the second vacuum fitting may be controllable independently from one another. The forming die may include a vent opening providing fluid communication between the vacuum system and the forming chamber. 
     In other aspects, a method is provided for forming a packaging material to a desired configuration. The method includes placing the packaging material into a forming chamber at ambient pressure, applying a vacuum to the forming chamber, thereby expanding the packaging material, urging the expanded packaging material and a forming die into engagement with one another, thereby forming the expanded packaging material into a shape at least partially corresponding to the forming die, and returning the forming chamber to ambient pressure. 
     The expanding packaging material and the forming die may be maintained in engagement while the forming chamber is returned to ambient pressure. The expanded packaging material may delimit the forming chamber into a first portion and a second portion. Returning the forming chamber to ambient pressure may include returning the first portion of the forming chamber to ambient pressure before returning the second portion of the forming chamber to ambient pressure. The forming chamber may include a first vacuum fitting and a second vacuum fitting, and returning the forming chamber to ambient pressure may include controlling the first and second vacuum fittings independently from one another. Returning the forming chamber to ambient pressure may compress the packaging material such that the packaging material maintains the shape at least partially corresponding to the forming die. The packaging material may include an unbound filler material surrounded by a sealed membrane having an internal pressure less than ambient pressure such that the membrane compresses the filler material to a non-free flowing state. Applying the vacuum to the forming chamber and expanding the packaging may render the filler material substantially free flowing. Urging the expanded packaging material and the forming die into engagement with one another may cause at least some of the substantially free flowing filler material to flow around and assume the shape at least partially corresponding to the forming die. 
     In still other aspects a method is provided for forming packaging material to a desired configuration. The packaging material includes an unbound filler material surrounded by a sealed membrane having an internal pressure less than an ambient pressure such that the membrane compresses the filler material into a non-free flowing state. The method includes expanding the membrane by subjecting the packaging material to a vacuum, engaging the packaging material with a forming die while the membrane is expanded, and removing the vacuum. 
     After engaging the packaging material with the forming die, a first portion of the packaging material may be adjacent the forming die and a second portion of the packaging material may be spaced from the forming die, and removing the vacuum may include removing the vacuum applied to the first portion of the packaging material after removing the vacuum applied to the second portion of the packaging material. Subjecting the packaging material to a vacuum may include placing the packaging material into a forming chamber. Engaging the packaging material with a forming die may include operating an actuator to urge the packaging material into engagement with the forming die. The membrane may remain sealed throughout the steps of expanding, engaging, and removing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vacuum bag packaging material that may be formed into various shapes in accordance with the present teachings. 
         FIG. 2  is a section view of the vacuum bag packaging material taken along line  2 - 2  of  FIG. 1 . 
         FIG. 3  is a perspective view of a forming machine for the vacuum bag packaging material of  FIG. 1 . 
         FIG. 4  is a perspective view of the forming machine of  FIG. 3  with a clamping arm in a raised position. 
         FIG. 5  is a perspective view of the forming machine of  FIG. 3  with the clamping arm in a raised and open position that affords access to a forming chamber. 
         FIG. 6  is a perspective view of the forming machine of  FIG. 3  with the clamping arm in a closed and raised position. 
         FIG. 7  is a perspective view of the forming machine of  FIG. 3  with the clamping arm in a closed and lowered position. 
         FIG. 8  is a section view taken along line  8 - 8  of  FIG. 7  and showing the forming machine with the clamping arm in the closed and lowered position with a vacuum bag packaging material inserted into the sealed forming chamber. 
         FIG. 9  is a section view similar to  FIG. 8  and showing the vacuum bag packaging material in an expanded configuration due to establishing a vacuum within the forming chamber. 
         FIG. 10  is a section view similar to  FIG. 8  and showing an actuator in a lowered position that presses the vacuum bag packaging material against a forming die. 
         FIG. 11  is a perspective view of the vacuum bag packaging material after being formed in accordance with the present teachings. 
     
    
    
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
     Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
       FIGS. 1 and 2  illustrate a packaging material  10  formed in accordance with the teachings of the &#39;909 and &#39;511 patents identified in the Background. In the illustrated configuration the packaging material is in the form of a flat board or sheet, which renders the packaging material relatively easy to store and transport. As shown in  FIG. 2 , an outer membrane  12  surrounds a filler material  14 . As discussed above, because the pressure inside the membrane  12  is less than the ambient pressure, the membrane  12  compresses the filler material  14  and renders the filler material “non-free flowing,” which is to say the packaging material  10  maintains its shape (e.g., generally flat) during normal handling. The packaging material  10  may, however, be formed into various shapes and configurations, for example, by manually folding and pressing the packaging material into a container, and then pressing or folding a product to be packaged into the material. In so doing, the pressure applied during insertion of the packaging material  10  into the container and during the pressing of the product into the material  10  can cause the filler material  14 , to a limited extent, to conform around the product or to the container. This process can be somewhat inefficient and of limited effectiveness due to the substantial friction between the individual particles of filler material  14 , and because the outer membrane  12  maintains a constant compressive force against the filler material. As a result, such forming may be limited to those circumstances where the product being packaged is relatively rigid and durable. Furthermore, the degree to which the packaging material  10  conforms to the specific shape and contour of the container and the product being packaged can be fairly limited. 
     Referring now to  FIGS. 3-10 , an exemplary forming system  16  is provided that is operable to form the packaging material  10  into desired shapes and contours by subjecting the exterior of the packaging material  10  to vacuum and pressing the packaging material  10  into or against a forming device, such as a forming die and/or a forming chamber. By subjecting the packaging material  10  to a vacuum, the membrane  12  expands such that the filler material  14  is able to move more freely within the membrane  12 . When the expanded packaging material  10  is pressed into or against a forming device, the filler material  14  may flow into or around the forming device and may assume a shape that closely matches the shape of the forming device. The vacuum may be removed while the packaging material  10  is engaged with the forming device. As the packaging material  10  is subjected to ambient pressure, the membrane  12  once again compresses the filler material  14  and the filler material  14 , having assumed a shape corresponding to the shape of the forming device, reassumes a non-free flowing state. The formed packaging material  10  may then be removed from the forming device and thereafter holds the shape imparted by the forming device during normal handling and use. The packaging material may then be used to package and protect the product for which it was formed. 
     Although a wide variety of uses are possible, the processes discussed herein are particularly well suited for the formation of end caps and similar packaging materials where the packaging material does not necessarily surround the entire product. Regardless of the particular use, after the packaging material  10  has been formed and used to pack and/or ship a particular product, the previously-formed packaging material  10  may be reformed into a different shape and reused to package a different product. For example, after the packaging material  10  has been formed and used a first time, the forming process discussed herein may be performed a second time and the packaging material  10  may be formed into a different shape for packaging a different product. This process may be repeated over and over, generally so long as the membrane  12  remains intact and is able to maintain the lower-than-ambient pressure on the interior of the packaging material  10 . 
     The illustrated forming system  16  includes a base  20 , a control system  22  mounted to one side of the base  20 , a forming chamber  24  mounted generally in the center of the base  20 , and a pivot arm assembly  28  mounted to another side of the base  20  and operable to open and close the forming chamber  24 . The illustrated forming chamber  24  includes a cylindrical body  32  with a lower end  36  sealingly coupled to the base  20  and an upper end  40  that defines an upper opening  44 . The forming chamber  24  also includes a closure or lid  48  that is coupled to the pivot arm assembly  28  and is sealingly engageable with the upper opening  44  to seal the forming chamber  24 . 
     The pivot arm assembly  28  includes a pivot arm  52  having a first end  53  moveably coupled to the base  20  by way of a telescoping support post  56 , and a second end  54  supporting an actuator  55  on one side of the pivot arm and the lid  48  on the other. The support post  56  is configured to allow both pivotal and translational (e.g., up and down) movement of the pivot arm  52  during operation, for reasons discussed further below. The first end  53  of the pivot arm  52  is provided with a curved slot  60  that receives a portion of a detent latch assembly  64 . The latch assembly  64  is operable to raise and lower the pivot arm  52  with respect to the base  20 , while the curved slot  60  allows the pivot arm  52  to pivot relative to the latch assembly  64 . As best seen in  FIGS. 8-10 , the actuator  55  includes a rod  68  that extends through the pivot arm  52  and through the lid  48 . A pressing member or ram in the form of a generally circular plate  72  is coupled to the end of the rod  68  and is moveable therewith during operation of the actuator  55 . In the illustrated configurations, clearance is provided between the outer edges of the plate  72  and the inner walls of the forming chamber  24  such that the plate  72  does not delimit or pneumatically divide the chamber  24 . 
     The forming system  16  also includes a forming die  76  that, in the illustrated configuration, is fixed to the base and positioned at the lower end  36  of the forming chamber  24 . The illustrated forming die  76  is a generally rectangular prism with rectangular projection along one end, and is selected to approximate the shape of one end of a printer toner cartridge. It should be appreciated, however, that the forming die  76  can be made in substantially any shape to correspond to substantially any product that is desired to be packaged within the formed packaging material  10 . 
     A lower portion of the illustrated forming die  76  is provided with a vent opening  80  that provides fluid communication between the forming chamber  24  and a lower or first vacuum fitting  84  ( FIGS. 8-10 ) associated with a lower portion of the forming chamber  24 . An upper or second vacuum fitting  88  is mounted on the pivot arm  52  and communicates and is associated with an upper portion of the forming chamber  24  by way of openings provided in the pivot arm  52  and the lid  48 . Each vacuum fitting  84 ,  88  fluidly communicates with a vacuum system including a vacuum source  89  ( FIG. 8 ) and suitable fluid control devices  90  (e.g., pressure regulators, control valves, and the like) capable of independently controlling the amount of vacuum applied to each fitting  84 ,  88 . In some configurations, each fitting  84 ,  88  may be provided with its own vacuum source  89 . In some methods of operation, the ability to maintain a vacuum in the vicinity of the forming die  76  while eliminating the vacuum in the upper portion of the forming chamber  24  may improve the degree to which the packaging material  10  conforms to the forming die  76  during a forming operation, which may result in improved packaging characteristics for the finished product. Although the illustrated configuration includes a single vent opening  80  in the form of a slot at the bottom of the forming die  76 , a plurality of vent openings may also be provided by forming holes or other passageways throughout the forming die  76  to achieve a desired vacuum profile. 
     The control system  22  electrically communicates with system components such as the actuator  55 , the vacuum source  89 , the fluid control devices  90 , and any other actuators or electrically operated or controlled devices that might be incorporated into the system  16 . The control system  22  may include a user interface  92  ( FIG. 3 ), one or more processors, memory, switches, relays, and other hardware, and may be operable to define and execute software programs for operating the system  16 . The control system  22  may send commands and receive inputs used to control the system  16 . For example, the system  16  may include sensors, such as micro switches and vacuum sensors, that inform the control system  22  of the status of the system components and of the vacuum level or levels within the forming chamber  24 . 
     To operate the illustrated system  16 , a user manipulates the latch assembly  64  to raise the pivot arm  52  ( FIG. 4 ) such that the lid  48  and the plate  72  are raised above the upper opening  44  of the forming chamber  24 . The latch assembly  64  includes a first detent mechanism that holds the pivot arm  52  in the raised position until the latch assembly  64  is once again manipulated by a user. With the pivot arm  52  raised, the pivot arm  52  is pivoted about the support post  56  to expose the upper opening  44  of the forming chamber  24  ( FIG. 5 ). A packaging material  10  to be formed may then be inserted into the forming chamber  24  through the upper opening  44  and the pivot arm  52  may be pivoted such that the lid  48  is again positioned over the upper opening  44  ( FIG. 6 ). The latch assembly  64  may then be operated to lower the lid  48  and to move the lid  48  into sealing engagement with the upper end  40  of the body  32  of the forming chamber  24  ( FIG. 7 ). The latch assembly  64  includes a second detent mechanism that holds the lid  48  in secure, sealed engagement with the body  32  of the forming chamber  24 . In other embodiments, movement and operation of the pivot arm  52  may be automated using suitable actuators, and may be controlled by the control system  22 . 
     With the packaging material  10  positioned in the sealed forming chamber  24  ( FIG. 8 ), formation of the packaging material  10  may commence. The control system  22  operates the vacuum system to establish a reduced pressure or vacuum at the lower and upper vacuum fittings  84 ,  88 . The vacuum may be established substantially simultaneously, or one of the fittings  84 ,  88  may be subjected to the vacuum before the other fitting, depending on the specifics of a particular operation. As a vacuum is formed in the forming chamber  24 , the pressure on the outside of the packaging material  10  becomes equal to, and eventually becomes less than, the internal pressure of the packaging material  10  as determined during the original manufacturing of the packaging material  10 . As the pressure in the forming chamber  24  becomes less than the internal pressure of the packaging material  10 , the membrane  12  begins to expand and the filler material  14  is able to more readily flow within the expanded membrane ( FIG. 9 ). 
     In some configurations, the pressure in the forming chamber  24  is reduced to a value that is at least about 4 psi less than ambient pressure. In other configurations, the pressure in the forming chamber  24  is reduced to a value that is at least about 6 psi less than ambient pressure. In still other configurations, the pressure in the forming chamber  24  is reduced to a value that is at least about 8 psi less than ambient pressure. In some configurations, the pressure in the forming chamber is reduced to a value that is about 8.8 psi less than ambient pressure. 
     While maintaining the desired level of vacuum in the forming chamber  24 , the actuator  55  is activated to lower the circular plate  72  and press the expanded packaging material  10  against the forming die  76  ( FIG. 10 ). In one method of operation, as the actuator  55  presses the packaging material  10  against the forming die  76 , the vacuum fittings  84 ,  88  are returned to a non-reduced pressure, such as ambient pressure, for example by venting the fittings  84 ,  88  to the atmosphere. As a result, the pressure on the outside of the membrane  12  is raised to a level above the pressure on the inside of the membrane  12 , and the membrane  12  once again compresses down upon the filler material  14  to rigidify the packaging material  10  by rendering the filler material non-free flowing. The combination of forces applied by the actuator  55  and by the change in pressure in the forming chamber  24  causes the packaging material  10  to compress upon and closely form around the forming die  76 . After the forming chamber  24  is returned to atmospheric pressure, the actuator  55  can be operated to lift the plate  72  away from the formed packaging material and the pivot arm  52  can be operated to expose the upper opening  44 . The formed packaging material  10  can then be removed from the forming chamber. When the formed packaging material  10  is removed, it is once again in a non-free flowing state and, in the illustrated configuration, defines a cavity  94  having a shape corresponding to the shape of the forming die  76  ( FIG. 11 ). 
     In some configurations, the packaging material  10  may expand to such an extent that, when the forming chamber  24  attains a sufficient vacuum, the membrane  12  engages the inner wall of the forming chamber  24  around the entire circumference of the forming chamber  24 . As a result, the expanded packaging material  10  may at least partially seal or otherwise delimit the upper portion of the forming chamber  24  from the lower portion of the forming chamber  24 . In such instances, another method of operation may be utilized to manage independently the upper and lower pressure zones that may be created within the forming chamber  24  by the expanded packaging material. For example, with the vacuum established in the forming chamber  24  and packaging material  10  expanded, the actuator  55  is activated to lower the circular plate  72  and press the expanded packaging material  10  against the forming die  76 . Substantially simultaneously with or shortly after actuation of the actuator  55 , the upper vacuum fitting  88  is returned to a non-reduced pressure (e.g., ambient), while the lower vacuum fitting  84  is maintained at the reduced pressure. With ambient pressure on the upper portion of the packaging material  10  and reduced pressure on the lower portion of the packaging material  10 , the lower or inner portion of the packaging material is firmly urged into engagement with the forming die  76 . Once the actuator  55  has completed its stroke and pressed the packaging material  10  fully against the forming die  76 , the lower vacuum fitting  84  is returned to a non-reduced pressure (e.g., ambient), which allows the formed packaging material  10  to be removed from the forming die  76 . 
     Although not illustrated in the exemplary embodiment, movement and operation of the pivot arm  52  or another opening and sealing mechanism for the forming chamber  24  may be automated by way of one or more additional actuators. Such additional actuators may be controlled by the control system  22  in sequence with operation of the actuator  55  and operation of the vacuum system to increase or decrease the vacuum level to the lower and upper vacuum fittings  84 ,  88 . In addition, a pick and place robot or other automated manipulator, which may also be controlled by the control system  22 , may be used to position the pre-formed packaging material  10  in the forming chamber  24  and to remove the formed packaging material  10  from the forming chamber  24 . 
     In other alternative embodiments, the forming die  76  may be moveable within the forming chamber  24 , and/or the forming chamber  24  may be provided with multiple fixed and/or moveable forming dies  76  to attain a desired configuration of finished product. For example, a fixed forming die may be provided in the bottom of the forming chamber  24  and moveable dies may be provided in the sides of the chamber and may move inwardly as the packaging material  10  is pressed onto the fixed forming die, resulting in a formed packaging material  10  having three distinct cavities. It should also be appreciated that the shape and configuration of the forming chamber  24  may be selected to produce a desired finished geometry of the formed packaging material  10 . For example, while the illustrated embodiment shows a generally cylindrical forming chamber  24 , an alternative forming chamber  24  may have a generally rectangular cross section. The cross section of the forming chamber  24  may be selected to substantially correspond to the dimensions of a box into which the finished packaging material  10  is intended to fit. In addition, the forming system  16  may include a plurality of forming chambers  24  each having its own forming die or dies  76  and connected to a common vacuum control system for the simultaneous formation of multiple packaging materials  10 . 
     Although the present teachings have specifically referenced packaging materials of the type identified in the &#39;511 and &#39;909 patents, the present teachings may be applied to substantially any type of packaging where a loose, unbound filler material is surrounded by a sealed membrane having an internal pressure that is lower than ambient pressure such that the filler material is compressed by the membrane to produce a material having handling rigidity. In addition to expanded polystyrene and other expanded foam materials, the filler material may also or alternatively include a variety of reused or recycled materials such as ground rubber, shredded paper or cardboard, shredded or ground plastic materials, textiles, and the like. 
     While specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the disclosure, and the scope of protection is to be commensurate with the scope of the accompanying claims.