Patent Publication Number: US-2010127112-A1

Title: Apparatus And Method For Dispensing A Deformable Web

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the priority benefit of Aquarius, Netherlands Patent Application No. NL 2002241, filed on Nov. 21, 2008, entitled “Apparatus And Method For Dispensing A Deformable Web,” the contents of which are expressly incorporated herein by reference in their entirety, including any references therein. 
     FIELD OF THE INVENTION 
     The invention relates to an apparatus for dispensing a deformable web. 
     BACKGROUND 
     Such an apparatus is known per se from the prior art. See, e.g., WO2005/102677. The web creased by the disclosed prior art apparatus is used, for instance, as filler. More particularly the filler is used, for instance, as a cushion material to fill up packages. 
     SUMMARY OF THE INVENTION 
     Disadvantages of known apparatuses, such as those described in WO2005/102677, are that they are relatively slow, sizeable, noisy and susceptible to a number of problems. The present invention contemplates an improved apparatus that addresses these problems. 
     According to an aspect of the invention, the improved apparatus is characterized by the features of claim  1 . In particular, the invention is embodied in an apparatus for dispensing a deformable web that advantageously comprises a (preferably) cylinder-shaped transport element rotatable under the influence of a drive, and a web guide disposed opposite thereto, the transport element and the web guide being arranged to cooperate, for the purpose of transport and deformation of the web. 
     According to a first aspect, the drive is completely integrated into the transport element. In this way, a web can be dispensed particularly fast, and thereby deformed, for instance folded and/or creased. In addition, the present apparatus is relatively durable and can be manufactured from few components. The number of components moving during use can be limited to a minimum. 
     Furthermore, an aspect of the invention provides for use of a cylinder-shaped transport element. With such a shape, high dispensing speeds can be achieved in a reliable manner. In particular the cylinder-shaped transport element can engage the web over a relatively large contact surface. An embodiment is particularly advantageous where both a cylinder-shaped transport element and a drive integrated therein are provided. 
     If the drive is completely integrated into the transport element, then a particularly compact apparatus can be obtained, for instance, without projecting parts. Moreover, use of a separate transmission can be avoided, so that an extra durable, easy-to-maintain and energy-efficient apparatus is achieved. The drive can, for instance, comprise a tube motor. 
     An outside of the transport element is advantageously provided with friction enhancing projections. The projections (e.g., relatively blunt studs) ensure high web throughput speeds and bring about web deformation (e.g., folding and/or crumpling) during web feed-through. 
     At least the outside of the transport element is manufactured from friction enhancing material. The outside, in a particular embodiment, is a resilient friction enhancing material such as rubber. 
     According to a further aspect of particular embodiments, the apparatus is provided with a housing. The housing is arranged to hold a web to be dispensed. The housing is then preferably provided with an inner space that is substantially closed off from an environment and arranged to fully enclose a web to be dispensed. Thus, the housing properly protects the web to be dispensed from unwanted ambient influences such as, for example, moisture or manipulation. Moreover, the housing affords safety to bystanders during use of the apparatus. It is then further preferred that the housing be provided with at least one transparent wall through which, for example, the contents (web to be dispensed) are visible for the purpose of inspection. 
     A particularly advantageous embodiment of the apparatus includes a number of walls (for instance a front wall, rear wall, and sidewalls extending therebetween) that are provided with wall parts obliquely converging towards one other and extending to a web dispensing area. During use, inner sides of the wall parts may already provide for a web guidance, and/or a web deformation. In addition, in this way, a stable apparatus can be obtained, having a relatively high stiffness and strength, utilizing relatively lightweight wall materials. Such walls can, for example, be made of plastic, Plexiglas, glass, or the like, such as, for instance, from plastic plate material. The invention is not limited to the above-mentioned materials. Other options include use of walls manufactured, for instance, from metal, an alloy, wood and/or the like. 
     A particularly compact, relatively low-noise apparatus is obtained when the housing is provided with an upper edge which surrounds a web passage, the housing being preferably provided with a cover structure which holds the transport element and the web guide, and preferably the drive, at a level above the upper edge. 
     Preferably, the transport element and the drive during operation are situated in or under the cover structure and at least under an upper wall of the apparatus defined by the cover structure. 
     A preferred embodiment comprises an apparatus designed to draw a web from a stationary web roll and dispense it. The apparatus may, in particular, include a support to support a side of the web roll. Moreover, such a support can provide stability to the apparatus, whether or not the apparatus is utilizing a web roll mass carried by the support. A weight of the web roll may for instance be active centrally on the apparatus during use. 
     The present invention furthermore concerns an advantageous method for dispensing a web, utilizing an apparatus according to the invention, wherein a web roll and the apparatus are disposed stationarily with respect to each other, wherein a web end of the stationary web roll is passed along the transport element and the web guide, wherein the drive imparts rotation to the transport element for dispensing the web. Preferably, a roll holder provided with the web roll is provided, with the roll holder being opened and brought into a position cooperating with the apparatus, to load the apparatus with the web roll. 
     The present invention furthermore concerns an advantageous method for dispensing a web, for instance utilizing an apparatus according to the invention, wherein a rotating cylinder-shaped web transport element and a stationary web guide cooperate with each other to deform, and further discharge, a web passed between them. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further advantageous elaborations of the invention are described in the appended claims. Presently, the invention will be further elucidated on the basis of exemplary embodiments and the drawing. In the drawing: 
         FIG. 1  shows a perspective drawing of a first exemplary embodiment of the invention; 
         FIG. 2  shows a side elevational view of the example shown in  FIG. 1 ; 
         FIG. 3  shows a front elevational view of the example shown in  FIG. 1 ; 
         FIG. 4  shows a top plan view of the example shown in  FIG. 1 ; 
         FIG. 5  shows a perspective drawing of a second exemplary embodiment of the invention; and 
         FIG. 6  shows a detail of the second example, in a vertical section. 
     
    
    
     The same or corresponding features in this application are designated with the same or corresponding reference signs. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows an example of an apparatus  1  for dispensing a deformable web. The web W to be deformed in the example is manufactured from paper, and is creasable and foldable. The dispensed web can for instance have utility as dunnage, for instance a cushion material, to fill up packages. 
     The apparatus  1  is provided with a housing  10 , arranged to hold the web W to be dispensed. The present housing  10  includes an inner space which can be substantially closed off from an environment. The housing  10  is arranged to fully enclose the web W to be dispensed, for instance, to increase safety of use of the apparatus and to protect the web W. In this example, the housing  10  can receive the web W in a rolled-up condition, as a paper roll R. 
     The housing  10  is manufactured wholly from plastic, and preferably with substantially closed walls  10   a,    10   b,    10   c,    10   d,    10   e  having a thickness of less than 1 cm, so that a relatively lightweight apparatus  1  can be obtained. By the use of a space that during use is substantially closed off (by a housing  10 ) from an environment, to hold paper web W to be dispensed, the apparatus  1  can operate, in a relatively low-noise manner, at high web dispensing speeds. 
     The housing  10  may include a front wall  10   a,  rear wall  10   b,  and opposite sidewalls  10   c,    10   d  extending therebetween. The walls  10   a,    10   b ,  10   c,    10   d  in this case are provided with tapering wall parts  10   at ,  10   bt ,  10   ct ,  10   dt  extending towards an upper edge TR situated at a web dispensing area. The upper edge TR of the housing  10  (comprising upper edges of the tapering wall parts) surrounds a web passage. 
     The paper roll R, during use, extends between the walls  10   a,    10   b,    10   c ,  10   d,  on the bottom  10   e  and below the (horizontal) level of the tapering wall parts  10   at ,  10   bt ,  10   ct ,  10   dt.    
     The bottom  10   e  forms a support for supporting a side of the web roll R, in particular such that a centerline of the web roll R extends at right angles to a centerline of the transport element  5  already mentioned. In the example, web W during use is unwound from a radially inner part of the roll R (i.e., the roll R is unwound from the inside to the outside). 
     A roll supporting face defined by the bottom  10   e  is for instance larger than a web passage defined by the apparatus, situated opposite that support  10   e,  near a transport element  5  discussed further hereinafter. 
     The tapering wall parts  10   at ,  10   bt ,  10   ct ,  10   dt  provide a (truncated) pyramid-shaped top of the housing, whose (preferably smooth) inner side is configured to guide the paper web W from the roll R to transport element  5  and guide  11 , via the passage surrounded by the upper edge R. The top of the housing can already pre-form, at least gather, the web W. Further, the apparatus  1  can thus engage web W from rolls of different dimensions, allowing relatively high dispensing speeds to be achieved in a reliable manner, both during web unwinding from relatively central locations in the inner space and when web W is being pulled from locations close to the walls  10   a,    10   b,    10   c,    10   d  out of the inner space. 
     Preferably, the housing  10  is provided with at least one transparent wall. Each of the walls  10   a,    10   b,    10   c,    10   d  may, for instance, be of transparent design. In addition, one or more wall may, for instance, be lightproof. In the example, at least one of the walls, viz. the front wall  10   a , inclusive of a respective tapering part  10   at , is of transparent design. As a result, both the web roll R, and transport of the web W between roll R and the upper edge of the housing  10 , are well visible from an environment during use. The housing  10  may include a cover structure  51 ,  52 , which holds a transport element  5  and a web guide  11  at a level above the upper edge of the housing  10 . In this exemplary embodiment, during operation the transport element  5  and the drive  6  (with a cover closed) are situated wholly in a space surrounded by the cover structure, under a top wall  52  of the apparatus defined by the cover structure. 
     The housing  10  is provided, for example, with an access closable by a wall. In such example, the housing  10  includes an access closable by a pivotable front wall  10   a  (door). The front wall  10   a  is coupled to a sidewall  10   d  by hinges (see also  FIG. 5 ). The Figs. provided herewith show a closed position of the front wall  10   a.  In an opened, outwardly pivoted position thereof, the inner space surrounded by housing  10  is accessible, for example, to insert a web roll R and to draw web W from the roll and bring it to the cover  51 ,  52 , in order to be taken over by the transport element  5 . Preferably, the whole wall  10   a,  hence inclusive of a respective tapering upper part  10   at , forms a movable component to close the access (see also  FIG. 5 ). The apparatus  1  may, for example, include a retaining device  71 ,  72  to keep the front wall  10   a  in a closed position. In the exemplary embodiment, the retaining device is provided with a permanent magnet  71  (for example arranged on a sidewall  10   c ) which engages a metal strip  72  (in this case arranged on the door  10   a ) in a closed position of the door. 
     The apparatus  1  shown in  FIGS. 1-4  is of particularly compact and robust construction, and to this end advantageously includes a cylinder-shaped transport element  5  (having an outside of substantially circular cross section) rotatable under the influence of a drive and a web guide  11  disposed opposite thereto. In particular, the apparatus  1  is not provided with gears that would potentially deform the web. Nor does the apparatus  1  include separate gears to transmit rotation of an external motor shaft to web transport means. This form of the transport element  5  contributes to durability, reliability and a low noise level. The transport element  5  and the web guide  11  are arranged to cooperate, for the purpose of transport and deformation of the web W (laid along them). 
     The drive  7  in the exemplary embodiment, is fully integrated into the transport element  5  and is preferably a tube motor  7 —the transport element  5  being a (cylinder-shaped) tube  5  driven by that motor  7 . 
     The guide of the first example is a cylinder-shaped counter roller  11  rotatable about a respective axis. Rotation axes of the roller  11  and transport element  5  are parallel with respect to each other. 
     The outside of the transport element  5  is preferably uninterrupted, closed, and preferably wholly manufactured from friction enhancing material. Such material is, in particular, resilient friction enhancing material such as rubber. In this way, the transport element  5  provides a good grip on the paper. The outside of the counter roller  11  also includes friction enhancing material. 
     The web guide  11  is movable from the web guide position moved to the transport element  5 , shown in  FIGS. 2-4 , to a release position moved away from the transport element  5  (shown in  FIG. 1 ), and vice versa. 
     The present apparatus comprises a web dispensing head. In particular the apparatus includes a cover structure  51 ,  52  as mentioned, provided with a first cover part  51 , attached to the upper side of the housing  10 , and a second cover part  52  which is movable (in particular pivotable) relative to the first cover part  52 . 
     One cover part (in the example the first cover part  51 ) includes the drive  7  with transport element  5 , and the other cover part (in the example the second cover part  52 ) includes the rotatable (itself non-driven) guide  11 . In a closed position of the cover  51 ,  52 , the cover preferably constitutes a substantially closed covering of the top of the housing  10 , and of the transport element with motor  5 ,  6  and rotatable guide  11  held by the cover  51 ,  52 . As a result, the cover  51 ,  52  provides a good reduction of acoustic transmission to control broadcast of noise coming from the apparatus. Optionally, the apparatus includes, on an inside thereof, sound-absorbing material—e.g., acoustic foam or the like (not shown)—to achieve further noise reduction. As follows from the Figs., the cover parts  51 ,  52  may provided on an inside thereof with for instance wall parts  51   a,    52   a,  which—viewed in front view—partly overlap rearwardly situated rotatable components  5 ,  11 . The latter wall parts  51   a,    52   a  bound a web dispensing gap with the cover  51 ,  52  closed. Sidewalls, a top wall and rear wall of the cover  51 ,  52  are preferably wholly closed, with the cover closed. 
     In the position of the cover parts  51 ,  52  when moved away from each other, guide  11  and transport element  5  are moved apart, such that web W can be passed between them (see,  FIG. 1 ). Thereupon, cover parts  51 ,  52  can be brought into the position moved towards each other, such that the web W is clamped between guide  11  and transport element  5 , to be engaged by guide  11  and transport element  5  and to be discharged from the housing  10  at high speed. 
     Preferably, the apparatus  1  includes a locking means, for instance releasable closing elements  53 , to lock the cover parts  51 ,  52  in the position moved towards each other. 
     Further, the apparatus (for instance cover  51 ,  52 ) advantageously includes spring means, arranged to spring-mount the web guide  11 , and in particular to push the guide  11  under the influence of spring force in the direction of the transport element  5  (i.e. in a radial direction of the guide  11 ). The spring suspension of the counter roller  11  can provide a particular pressure, to transport the paper W. In this way, a particularly reliable operation of the apparatus can be achieved, and jamming of web W in the cover  51 ,  52  can be avoided. Furthermore, the spring means of the web guide  11  can bring about a proper web engagement between web guide  11  and driving tube  5 , and also reduce noise during operation. 
     The present apparatus  1 , when in use, draws web W from a stationary web roll R, folds it and dispenses it. The apparatus includes only one transport element  5 , drivable by a drive  7 , to transport and deform the web. Preferably, the apparatus dispenses the web W at a speed of more than 100 meters per minute. More particularly the web W is dispensed at a speed of more than 150 meters per minute, and even more particularly the web W is dispensed at a speed of at least 200 meters per minute. 
     As  FIGS. 1-4  illustratively depict, the apparatus  1  during use can dispense web W, with the web roll R and the apparatus  1  being disposed stationarily with respect to each other. A web end of the stationary web roll R (with cover  51 ,  52  open) is passed along the transport element  5  and the web guide  11 . The drive  7  imparts rotation to the transport element  5  for dispensing the web W. 
     Folded web W dispensed by the apparatus has for instance a tubular shape including at least two longitudinal folds (see  FIGS. 1 ,  3 ). A web W dispensed over a particular length is removed from a remaining web part—e.g., torn off, cut off or the like. To this end, the apparatus  1  optionally includes tearing or cutting means (e.g., a saw tooth strip) which, for example, is arranged on or near the head  51 ,  52 . 
     The example shown in  FIGS. 5-6  differs from the first example in that the web guide comprises a stationarily disposed guide element  111 . In this case, an outside of the transport element  105  and an inside of the web guide  111  extending opposite thereto bound a deformation zone of a circular segment-shaped cross section (see  FIG. 6 ). The second example is designed in particular to crease the web W. Also, this example provides a fold in the web W as represented in the figures. 
     The rotatable transport element  105  is disposed on or near the upper end of the housing  110  and, in particular, connected via the drive and two rigid coupling pieces  161  to a (in this case truncated pyramid-shaped) cover part  151  of the housing  110 . 
     The rotatable transport element  105  extends between an inside of the web guide  111  on one side and a web accommodation space defined by the housing on the other side. In this example, the web guide  111  comprises an integral component of the housing, and in particular is integrated with a rear wall  110 B of the housing  110 . 
     In this example, an outside of the transport element  105  includes friction enhancing projections  106 . The projections  106  preferably meet one or more of the following features, and more preferably each of the following features: 
     1. the projections  106  are studs, having a diameter in the range of circa 0.5-5 cm; 
     2. a thickness of each of the projections measured in radial direction is greater than 0.2 cm; 
     3. a thickness of each of the projections  106  measured in a radial direction is at least equal to or greater than a radial distance measured between an outer surface of the rotatable element  105  and the web guide  111 ; 
     4. a neighbor distance between the studs is in the range of circa 1-10 cm; and 
     5. the transport element is provided with more than 10 projections  106 , and for example fewer than 50 projections  106 . 
     The operation of the second example comprises cooperation between the rotating cylinder-shaped web transport element  105  and a stationary web guide  11 , to crease and further discharge the web W passed therebetween. Here, the projections  106 , preferably stud-shaped, bring about crumpling during transport, along with a proper engagement of a paper web W. This example too can achieve high web discharge speeds, and is reliable, compact, low-noise and durable. 
     To those skilled in the art, it will be clear that the invention is not limited to the exemplary embodiments described. Various changes are possible within the framework of the invention as set forth in the following claims.