Patent Description:
In recent years, products made from plastic film and machinery to continually produce those products have been developed. These plastic film products typically have sealed seams and zippers to form a reclosable pouch. In some instances, these plastic film products also have pre-printed images. Plastic film processing machinery typically includes tools to cut pouch components from a sheet or tube of plastic film, place zippers, and to weld the pouch components and zippers together.

Certain known film product manufacturing methods use multiple processing stations each equipped with different machinery and associated conveyors to move film products in various stages of completion between those stations. Thus, those known film product manufacturing methods have large footprints in a manufacturing facility to produce finished plastic film products. Further, with certain known film product manufacturing methods the entire film product manufacturing line may need to be stopped to perform maintenance on the multiple pieces of different machinery.

Additionally, while pre-printed film rolls are typically uniform within a single roll, there are often spatial differences between first and second pre-printed rolls even bearing the same images. In others words, the images on the second roll are out of phase (sometimes referred to as "creep") with respect to the first roll. Thus, if a pre-printed film roll is misaligned with respect to the film processing machinery, the pre-printed images will cyclically be cut through. Thus, certain known film product manufacturing methods contemplate stopping and realigning all of the film processing machinery in a film processing station whenever a new pre-printed web of film is introduced to the film processing station.

Therefore, a need exists to develop film product manufacturing methods and associated machinery that take up less space, compensate for differences between pre-printed film rolls, and may be more easily and quickly maintained, repaired, and aligned.

<CIT> describes a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.

<CIT> describes that, if containers to be sealed by means of ultrasound are to be gassed beforehand, the sealing is carried out by making the sonotrode shorter than the container to be sealed and passing it over the container while it is subjected to continuous sound, directly behind or still inside the gassing hood.

<CIT> describes an assembly for packing products, in particular food products, arranged successively and spaced longitudinally apart inside a tube of packing material traveling along a respective longitudinal axis; the assembly has a carriage movable linearly back and forth parallel to the longitudinal axis, a first tool carried by the carriage and movable to perform a first packing operation on the tube, and at least one second tool, which differs from the first tool, is also carried by the carriage, and is movable to perform a second packing operation; and the first and second tool are activated by respective actuating devices, which are carried by the carriage to move together with the carriage.

<CIT> describes a method for continuously forming bags comprising continuous steps of heat-sealing a continuous tubular plastic film, such as a continuously formed inflation tube or the like, widthwise at given positions thereof while the tubular film is being conveyed, cutting sequentially the tubular film along the heat-seals into bag-shaped containers, and conveying the tubular film over a set distance to a following step while the heat-seals of the heatsealed tubular film being press-held and cooled. Also the present invention relates to an apparatus for continuously forming bags for heat-sealing a continuous tubular plastic film, such as a continuously formed inflation tube or the like, widthwise at given positions thereof while the tubular film is being conveyed, and then cutting the tubular film along the heat-seals into bag-shaped containers. The apparatus comprises heat-sealing device for sealing the tubular film including a pair of heat-sealing members which are disposed on one side of a track of conveyance of the tubular film, opposing each other so as to hold the tubular film therebetween, and are movable to and from each other, driving device for driving the heat-sealing device to and from each other, cooling device for cooling the tubular film including a pair of cooling sandwiching members which are supported on a movable member disposed movably in directions of width of the tubular film and conveyance thereof, and intrude inbetween the heat-sealing members to sandwich the heat-seals of the tubular film, and driving device for driving the cooling sandwiching members to and from each other, whereby the tubular film is conveyed by a movement of the movable member to a next step with the those parts of the tubular film at the heat seals held between the cooling sandwiching members.

In one aspect, a system is disclosed, which includes a film processing module, a processor, and memory. The processor and memory are in communication with the film processing module. The processor is configured to dynamically coordinate movement of the film processing module relative to a moving web of film and to perform a function on the web of film with the film processing module.

In another aspect, a film processing module is disclosed, which includes a carriage assembly, a linear actuator, and an upper multi-functional assembly. The carriage assembly is configured to move along a supporting rail. The linear actuator is engaged with the carriage assembly. The upper multi-functional assembly is engaged with the linear actuator to perform a function on a film adjacent to the supporting rail.

In yet another aspect, a method for producing film products is disclosed. The method utilizes a processor to perform the steps of dynamically coordinating movement of a film processing module relative to a moving web of film and instructing the film processing module to perform a function on the web of film.

In a further aspect, a film processing module is disclosed, which includes a carriage assembly, a linear actuator, a base, and an upper multi-functional assembly. The carriage assembly is configured to move along a supporting rail. The linear actuator is engaged with the carriage assembly. The base is engaged with the linear actuator. The upper multi-functional assembly is driveably engaged with the linear actuator to move relative to the base. The upper multi-functional assembly includes a clamping plate to selectively clamp a portion of a film against the base and a cutting mechanism to cut and seal the portion of the film.

In a different aspect, a method for producing sealed film products is disclosed. The method utilizes a processor to perform the steps of moving an upper multi-functional assembly of a film processing module to a ready position relative to a base of the film processing module, moving the film processing module to an aligned location on an oblong supporting rail such that a portion of a film running parallel to the oblong supporting rail is between the upper multi-functional assembly and the base, moving the upper multi-functional assembly toward the base to a clamping position to clamp the film, energizing a cutting mechanism of the upper multi-functional assembly to heat the cutting mechanism, moving the upper multi-functional assembly toward the base to a cutting position to cut the film, moving the upper multi-functional assembly away from the base to an open position, and moving the film processing module to a transfer location on the supporting rail such that a conveyor is between the upper multi-functional assembly and the base.

In yet another aspect, a system is disclosed that includes an oblong supporting rail, a power source and a controller in electrical communication with the supporting rail, and a film processing module moveably engaged with the supporting rail. The film processing module includes a base and an upper multi-functional assembly. The upper multi-functional assembly includes a clamping plate and a cutting mechanism in electrical communication with the power source and the controller to cut and seal film.

As explained herein, the present disclosure provides examples of a film processing station with multiple film processing modules that improve film cutting, shaping, and sealing, e.g., to produce plastic film pouches. The film processing station exhibits a comparatively small footprint to manufacture plastic film products. Additionally, the film processing modules each independently clamp, cut, and seal plastic film into finished products, and transfer the finished products to a waiting conveyor, e.g., for packaging.

As shown in <FIG>, a film processing station <NUM> includes one or more film processing modules <NUM>, a conveyor <NUM>, a supporting rail <NUM>, a bus power source 108a, a rail power source 108b, a bus air source 108c, a main controller 110a, a rail controller 110b, a power and air bus <NUM>, a first transceiver <NUM>, a registration sensor 116a, and a plurality of rail sensors 116b. It should be understood that each film processing module <NUM> is substantially structurally identical to the other film processing modules <NUM>. Thus, multiple film processing modules <NUM> can be used on the supporting rail <NUM> at a given time and the film processing modules <NUM> are interchangeable with one another, without requiring modification to the conveyor <NUM>, the supporting rail <NUM>, the bus power source 108a, the rail power source 108b, the bus air source 108c, the main controller 110a, the rail controller 110b, the power and air bus <NUM>, the first transceiver <NUM>, the registration sensor 116a, and/or the plurality of rail sensors 116b. It is also contemplated that alternative film processing modules structurally different from the illustrated film processing modules <NUM> may be used in conjunction with the supporting rail <NUM> and the film processing modules <NUM>.

Referring to <FIG>, the main controller 110a is in communication with the rail controller 110b, the transceiver <NUM>, the registration sensor 116a, and the rail sensors 116b. The main controller 110a controls the movements of the film processing modules <NUM> along the supporting rail <NUM> via the rail controller 110b. In some embodiments, the main controller 110a and/or the rail controller 110b are remote from the film processing modules <NUM>. The main controller 110a controls the film processing functions of the film processing modules <NUM>, e.g., cutting and sealing, etc., via the transceiver <NUM> and/or the bus <NUM>. The bus <NUM> supplies electrical power and, in some embodiments, compressed air to the film processing modules <NUM> to perform their respective film processing functions. Interactions between the main controller 110a, the rail controller 110b, the transceiver <NUM>, the registration sensor 116a, and the rail sensors 116b, will be explained in greater detail below in conjunction with <FIG>.

With particular reference again to <FIG>, the supporting rail <NUM> forms an oblong circuit with opposing, generally straight, parallel first and second sides <NUM>, <NUM> and opposing first and second rounded ends <NUM>, <NUM>. It is further contemplated that the oblong circuit may be characterized as substantially race-track shaped or may take some other form with both linear and curvilinear segments to form a track. The rail sensors 116b are regularly-spaced along the length of the supporting rail <NUM>. It should be understood that the supporting rail <NUM> is formed of modular panels and thus may be any desired size. The supporting rail <NUM> is in electrical communication with and is powered by the rail power source 108b. The rail power source 108b is controlled by the rail controller 110b. Each of the film processing modules <NUM> is moveably engaged with the supporting rail <NUM>.

It should be appreciated that each of the film processing modules <NUM> are independent of one another. The number of film processing modules <NUM> on the supporting rail <NUM> is based on the length and/or shape of the supporting rail <NUM>. In operation, the rail controller 110b selectively operates all or a subset of the film processing modules <NUM>. Further, in operation, main controller 110a via the rail controller 110b independently controls the movement of each of the film processing modules <NUM> around the supporting rail <NUM>. Additionally, in operation, the controllers 110a, b may control the film processing modules <NUM> to move about the supporting rail <NUM> at varying travel speeds. Thus, the film processing modules <NUM> may approach or move away from one another as they move about the supporting rail <NUM>. In other words, in operation, the controllers 110a, b dynamically coordinate the independent movements of the film processing modules <NUM> about the supporting rail <NUM>. Additionally, where alternative film processing modules are used in conjunction with or in place of the illustrated film processing modules <NUM>, the controllers 110a, b also dynamically coordinate the independent movements of these alternative film processing modules.

With reference again to <FIG>, in the illustrated example, the bus <NUM> is disposed concentrically external to the supporting rail <NUM> to provide the film processing modules <NUM> with electrical power and/or compressed air. It should be appreciated that the bus <NUM> may be placed in any arrangement relative to the supporting rail <NUM> that provides electrical power and/or compressed air to the film processing modules <NUM> as the film processing modules <NUM> move about the supporting rail <NUM>. For example, the film processing modules <NUM> may be arranged to receive electrical power and/or compressed air where the bus <NUM> is concentrically internal to, under, or above the supporting rail <NUM>.

With reference to <FIG>, a web of a film <NUM> is depicted adjacent or otherwise alongside the first side <NUM>. When the film <NUM> is presented to the film processing station <NUM>, the film <NUM> is in tube form or folded. Thus, the film <NUM> has a top layer <NUM> and a bottom layer <NUM> as shown in <FIG>, <FIG>, and <FIG>. In some embodiments, the film <NUM> is provided as a starting material to the film processing station <NUM> from an unwind machine. In other embodiments, the film <NUM> is extruded flat, printed on, folded, and then provided as a starting material to the film processing station <NUM>. In yet other embodiments, zippers are positioned and attached to the film <NUM>, the film <NUM> is folded, and the zippers are closed before the film <NUM> is provided as a starting material to the film processing station <NUM>.

With reference to the embodiment illustrated in <FIG>, the film processing modules <NUM> are adapted to clamp, cut, and seal the film <NUM>. It should be understood and appreciated that alternative film processing modules mounted on the supporting rail <NUM> and used in conjunction with or in place of the film processing modules <NUM> may perform other functions on the film <NUM>. For example, the alternative film processing modules may emboss decorative patterns and/or production information into the film <NUM>, print decorative patterns and/or production information onto the film <NUM>, perforate the film <NUM>, place closure zippers on the film <NUM>, ultrasonically form the film <NUM>, abrade the film <NUM> with sand and/or water jets, melt patterns into the film <NUM>, laser ablate the film <NUM>, remove lip portions of the film <NUM>, add discrete parts to the film <NUM>, cut shapes into the film <NUM>, score the film <NUM>, hot bar seal the film <NUM>, etc. Thus, multiple types of film processing modules may be used together to perform successive in-line functions on the film <NUM>. For example, the film <NUM> may have an image printed on it by a printer film processing module, then be embossed by an embosser film processing module, and then cut into pouches by the illustrated cutting film processing module <NUM>. Alternatively, it is contemplated that multiple types of film processing modules may be used in other manners, e.g., certain modules may remain idle during a first phase of a process and may be active alone or in combination with other modules in a second phase of a process. In fact, it is contemplated that any combination or arrangement of similar or different film processing modules may be used.

With particular reference to <FIG>, the film <NUM> has a plurality of demarcations <NUM>. In some embodiments, the demarcations <NUM> are printed on the film <NUM>. In some embodiments, the demarcations <NUM> are embossed into the film <NUM>. In some embodiments, the demarcations <NUM> are raised features of the film <NUM>. It is contemplated that the demarcations <NUM> may take any form to provide location reference points on the otherwise generally uniform film <NUM>. The registration sensor 116a is disposed adjacent to the film <NUM> to detect the demarcations <NUM>. In the illustrated example, the registration sensor 116a is transverse to the film <NUM>.

Looking again at <FIG>, more specifically, each of the film processing modules <NUM> includes a carriage assembly <NUM> and a forming assembly <NUM>. The carriage assemblies <NUM> are in communication with the supporting rail <NUM>. The carriage assemblies <NUM> each include a supporting bracket <NUM>. The supporting bracket <NUM> is moveably engaged with the supporting rail <NUM>. The carriage assemblies <NUM> each further include position magnets engaged to the supporting bracket <NUM> (not shown). The position magnets actuate the rail sensors 116b in the supporting rail <NUM>. The forming assembly <NUM> is engaged with the supporting bracket <NUM>. It should be understood that the supporting rail <NUM>, the rail power source 108b, the rail sensors 116b, and the carriage assemblies <NUM> may be provided as a complete motion control kit, e.g., an iTrak® system available through Rockwell Automation.

Referring to <FIG> and <FIG>, in addition to the film processing modules <NUM> being selectively operated by the controllers 110a, b, it is contemplated that, in some embodiments, the forming assembly <NUM> is selectively not attached to the carriage assembly <NUM>. Thus, selective ones of the film processing modules <NUM> are reduced to the base carriage assemblies <NUM> and perform no film processing functions. In other words, depending on the film process to be accomplished, the film processing station <NUM> may be outfitted to have "blank" film processing modules <NUM>.

In one embodiment, the carriage assemblies <NUM> each further include one or more rollers, and a motor. The rollers and the motor are engaged to the supporting bracket <NUM>. The rollers are in rolling contact with the supporting rail <NUM>. Thus, the supporting bracket <NUM> is supported by and moveably engaged with the supporting rail <NUM>. Additionally, one or more of the rollers is driven by the motor. Thus, the motors of the carriage assemblies <NUM> are powered by the rail power source 108b and controlled by the main controller 110a via the rail controller 110b and the supporting rail <NUM>. In other words, the motor drives one or more of the rollers to translate the film processing module <NUM> along the supporting rail <NUM>. Movement of the film processing modules <NUM> along the supporting rail <NUM> is controlled via the controllers 110a, b based on signals from the rail sensors 116b in the supporting rail <NUM>.

Alternatively, or in combination with the prior disclosure, the processing modules <NUM> are moved electromagnetically via magnets disposed about the supporting rail <NUM>. Each carriage assembly <NUM> includes a magnetic drive mechanism for movement around the supporting rail <NUM>. Similar to the discussion above, the movement of the film processing modules <NUM> along the supporting rail <NUM> is controlled via the controllers 110a, b based on signals from the rail sensors 116b in the supporting rail <NUM>.

As shown in <FIG> and <FIG>, because the supporting rail <NUM> is a closed circuit, the film processing modules <NUM> travel around the supporting rail <NUM>. As the film processing modules <NUM> travel along the first side <NUM>, the film processing modules <NUM> perform functions on the film <NUM> and deposit cut and sealed film products <NUM> onto the conveyor <NUM>. Further, the film processing modules <NUM> travel along the first rounded end <NUM>, the second side <NUM>, and the second rounded end <NUM> to return to the film <NUM>.

Turning to <FIG>, the forming assembly <NUM> of each of the film processing modules <NUM> includes a frame <NUM>, a base <NUM>, a linear actuator <NUM>, and an upper multi-functional assembly <NUM>. In some embodiments, the forming assembly <NUM> further includes a second transceiver <NUM> and a battery <NUM>. In some embodiments, the forming assembly <NUM> further includes an air controller <NUM> (see <FIG>).

More specifically, and with reference again to <FIG>, the linear actuator <NUM> supports the frame <NUM>. The frame <NUM> supports the base <NUM>. Thus, the base <NUM> is cantilevered relative to the linear actuator <NUM>. In the illustrated example, the frame <NUM> is a triangular brace. The upper multi-functional assembly <NUM> moves toward and away from the base <NUM> via the linear actuator <NUM>. The frame <NUM>, the base <NUM>, and the upper multi-functional assembly <NUM> extend generally perpendicularly outwardly from the linear actuator <NUM> relative to the supporting rail <NUM>. Thus, the base <NUM> and the upper multi-functional assembly <NUM> are generally parallel to one another. Additionally, the base <NUM> defines an outwardly extending inlay <NUM>. In some examples, the inlay <NUM> is lined with an elastomer <NUM>.

More specifically, the linear actuator <NUM> includes a motor (not shown) in a motor housing <NUM>, a guide rail <NUM>, and a sled <NUM>. The second transceiver <NUM> and the battery <NUM> are supported by the motor housing <NUM>. The guide rail <NUM> is engaged to the motor housing <NUM> and to the supporting bracket <NUM>, as shown in <FIG> and <FIG>. The guide rail <NUM> extends upwardly relative to the motor housing <NUM>. The sled <NUM> is moveably engaged with the guide rail <NUM>, e.g., slidably, via bearings, etc. The frame <NUM> is engaged with the motor housing <NUM> and the guide rail <NUM>. The upper multi-functional assembly <NUM> is engaged with the sled <NUM>.

In some embodiments, the linear actuator <NUM> is in electrical communication with the bus <NUM>, e.g., via electrical brushes. In some embodiments, the linear actuator <NUM> is in electrical communication with the battery <NUM>. Thus, the motor of the linear actuator <NUM> is powered by the bus power source 108a and/or the battery <NUM>. In some embodiments, the linear actuator <NUM> is controlled by the main controller 110a via the bus <NUM>. In different embodiments, the linear actuator <NUM> is in electrical communication with the second transceiver <NUM> and is controlled by the main controller 110a via the first and second transceivers <NUM>, <NUM>. In other words, the motor receives instructions from the main controller 110a and drives the sled <NUM> to translate the upper multi-functional assembly <NUM> along the guide rail <NUM>. Thus, movement of the upper multi-functional assembly <NUM> along the guide rail <NUM> is controlled via the main controller 110a.

With reference now to <FIG>, the upper multi-functional assembly <NUM> includes a support arm <NUM>, a first upper biasing member 172a, a second upper biasing member 172b, a first lower biasing member 174a, a second lower biasing member 174b, a hot wire assembly <NUM>, and a clamping assembly <NUM>.

The hot wire assembly <NUM> includes a carrier plate <NUM>, a cutting mechanism <NUM>, a first support wire 184a, and a second support wire 184b. The first support wire 184a and the second support wire 184b are engaged with opposing ends of the cutting mechanism <NUM>. Alternatively, the first and second support wires 184a, b may constitute other connector structures and may be positioned elsewhere along the length of the cutting mechanism <NUM>. Turning again to the present embodiment, the first support wire 184a and the second support wire 184b are engaged with the carrier plate <NUM>. Thus, the cutting mechanism <NUM> is suspended from the carrier plate <NUM>.

The cutting mechanism <NUM> is depicted as generally straight to make straight cuts and seals through the film <NUM>. It is additionally contemplated that the cutting mechanism <NUM> may have a curvilinear form. Thus, the cutting mechanism <NUM> may make corresponding curvilinear decorative and/or functional cuts and seals through the film <NUM>, e.g., scalloped, interlocking, zigzagged, meandering, wave scrolled, undulating, etc. Further, while the cutting mechanism <NUM> is depicted as a wire, it is contemplated that the cutting mechanism <NUM> may be any type of cutting mechanism such as, for example, a knife, a blade, a punch, a saw, etc..

In some embodiments, the hot wire assembly <NUM> is in electrical communication with the bus <NUM>. In other embodiments, the hot wire assembly <NUM> is in electrical communication with the battery <NUM>. Thus, the hot wire assembly <NUM> is powered by the bus power source 108a and/or the battery <NUM>. In some embodiments, the hot wire assembly <NUM> is controlled by the main controller 110a via the bus <NUM>. In different embodiments, the hot wire assembly <NUM> is in electrical communication with the second transceiver <NUM> and is controlled by the main controller 110a via the first and second transceivers <NUM>, <NUM>. In other words, the hot wire assembly <NUM> receives instructions from the main controller 110a to energize and de-energize.

In some embodiments, the hot wire assembly <NUM> is continuously energized by the main controller 110a. When the hot wire assembly <NUM> is energized, the cutting mechanism <NUM> becomes hot to cut and seal the film <NUM>, as will be explained in greater detail below. In other words, when an electric current is applied to the cutting mechanism <NUM>, the cutting mechanism <NUM> heats to a temperature greater than or equal to the melting temperature of the film <NUM>. Thus, the cutting mechanism <NUM> is heatable. Additionally, in some embodiments, the cutting mechanism <NUM> is arranged to be compatible with commercially available heaters that are controlled with controllers mounted on the forming assembly <NUM> (not shown).

It is contemplated that the film <NUM> may comprise any number of materials, including, for example, a thermoplastic material, metallic foil, layered composites, fabric, paper, etc. Illustrative thermoplastic materials that could be used include, for example, polypropylene (PP), polyethylene (PE), metallocene-polyethylene (mPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), ultra-low density polyethylene (ULDPE), biaxially-oriented polyethylene terephthalate (BPET), high density polyethylene (HDPE), and polyethylene terephthalate (PET), among other polyolefin plastomers and combinations and blends thereof. Still other materials that may be used include styrenic block copolymers, polyolefin blends, elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, polymers and copolymers of polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), saran polymers, ethylene/vinyl acetate copolymers, cellulose acetates, polyethylene terephthalate (PET), ionomer, polystyrene, polycarbonates, styrene acryloacrylonitrile, aromatic polyesters, linear polyesters, non-woven materials such as Tyvek®, and thermoplastic polyvinyl alcohols. Those skilled in the art will recognize that a wide variety of other materials may also be used to form the film <NUM>. Illustrative sustainable films materials that could be used include, for example, bio-based polyethylenes such as LDPE, LLPDE, etc., renewable resins and/or bio-based feedstocks, post-consumer recycled plastics, compostable resins such as PHA, PBAT, PCL, PLA, etc..

With reference to <FIG> and <FIG>, the clamping assembly <NUM> includes a first post 186a, a second post 186b, and a clamping plate <NUM>, which defines a cutting opening <NUM>. The cutting opening <NUM> is sized to allow the cutting mechanism <NUM> to pass through the cutting opening <NUM>. The first and second posts 186a, b are slidably engaged with the support arm <NUM>. The clamping plate <NUM> is engaged with the first and second posts 186a, b. The first upper biasing member 172a and the first lower biasing member 174a are disposed about the first post 186a between the clamping plate <NUM> and the support arm <NUM>. The second upper biasing member 172b and the second lower biasing member 174b are disposed about the second post 186b between the clamping plate <NUM> and the support arm <NUM>. Thus, the clamping plate <NUM> is suspended from and moveable relative to the support arm <NUM>. The first and second upper biasing members 172a, b and the first and second lower biasing members 174a, b bias the clamping plate <NUM> away from the support arm <NUM>.

Referring still to <FIG> and <FIG>, the carrier plate <NUM> is slidably engaged with the first and second posts 186a, b. The carrier plate <NUM> is disposed between the first upper biasing member 172a and the first lower biasing member 174a. The carrier plate is disposed between the second upper biasing member 172b and the second lower biasing member 174b. Thus, the carrier plate <NUM> is sandwiched between the first and second upper biasing members 172a, b and the first and second lower biasing members 174a, b. In other words, the carrier plate <NUM> is slidably captured on the first and second posts 186a, b. The first and second upper biasing members 172a, b bias the carrier plate <NUM> away from the support arm <NUM>. The first and second lower biasing members 174a, b bias the carrier plate <NUM> away from the clamping plate <NUM>. Thus, the hot wire assembly <NUM> is suspended from and moveable relative to the support arm <NUM> and the clamping assembly <NUM>.

In the illustrated example of <FIG> and <FIG>, the first and second upper biasing members 172a, b and the first and second lower biasing members 174a, b are coil springs. In some embodiments, the first and second first and second upper biasing members 172a, b have a greater spring force constant than the first and second lower biasing members 174a, b. In a preferred embodiment, the first and second lower biasing members 174a, b provide between approximately <NUM> and <NUM> pounds (<NUM> and <NUM> Newtons) of clamping force. Thus, the first and second upper biasing members 172a, b push the first and second lower biasing members 174a, b during a cut cycle, as will be explained in greater detail below.

In embodiments including the air controller <NUM>, the clamping assembly <NUM> further includes one or more airflow lines <NUM> (see, for example, <FIG>). In such embodiments, the clamping plate <NUM> further defines one or more airflow openings <NUM>. The airflow openings <NUM> are defined in a trailing portion of the clamping plate <NUM> relative to the travel direction of the film processing modules <NUM> along the supporting rail <NUM>. The airflow lines <NUM> attach to the clamping plate <NUM> at the airflow openings <NUM>. In other words, the airflow lines <NUM> correspond to and are in fluid communication with the airflow openings <NUM>. The airflow lines <NUM> are also in fluid communication with the air controller <NUM>. The airflow lines <NUM> are flexible to accommodate movement of the clamping plate <NUM> relative to the support arm <NUM>. In the present embodiment, it is contemplated that plant air is used in combination with a Venturi device to create a vacuum source.

The air controller <NUM> is an airflow directing device. In some embodiments, the air controller <NUM> is an electrically-driven air pump. In other embodiments, the air controller <NUM> is a pneumatically-driven Venturi device associated with an electrically or mechanically-driven valve. In such embodiments, the air controller <NUM> is in fluid communication with the bus <NUM> and the air controller <NUM> is pneumatically powered by the bus air source 108c. In some embodiments, the air controller <NUM> is in electrical communication with the bus <NUM>. In other embodiments, the air controller <NUM> is in electrical communication with the battery <NUM>. Thus, the air controller <NUM> is electrically powered by the bus power source 108a and/or the battery <NUM>. In some embodiments, the air controller <NUM> is controlled by the main controller 110a via the bus <NUM>. In different embodiments, the air controller <NUM> is in electrical communication with the second transceiver <NUM> and is controlled by the main controller 110a via the first and second transceivers <NUM>, <NUM>. In other words, the air controller <NUM> receives instructions from the main controller 110a to draw air through the airflow openings <NUM> and the airflow lines <NUM> to produce a vacuum between the film <NUM> and the clamping plate <NUM>, as will be explained in greater detail below.

With reference to <FIG>, in some embodiments, the hot wire assembly <NUM> further includes an on-board heater controller <NUM>. The heater controller <NUM> is in electrical communication with the cutting mechanism <NUM>. In such embodiments, the cutting mechanism <NUM> includes one or more cartridge heaters.

The support arm <NUM> is engaged with the sled <NUM> to extend outwardly from the guide rail <NUM>. The support arm <NUM> is hollow to reduce weight and to act as a housing for the air controller <NUM>, the airflow lines <NUM>, the heater controller <NUM>, and/or wiring to power the hot wire assembly <NUM>.

With particular reference to <FIG>, in some embodiments, the forming assembly <NUM> further includes one or more module sensors <NUM>. Operation of the module sensor <NUM> will be described in greater detail below.

With reference now to <FIG>, the main controller 110a, the rail controller 110b, the bus <NUM>, the first transceiver <NUM>, the registration sensor 116a, the rail sensors 116b, the carriage assembly <NUM>, the linear actuator <NUM>, the second transceiver <NUM>, the air controller <NUM>, the hot wire assembly <NUM>, and the module sensors <NUM> are collectively referred to as the electronic components <NUM> of the film processing station <NUM>.

In some embodiments, the bus <NUM> communicatively couples the main controller 110a, the linear actuator <NUM>, the air controller <NUM>, the hot wire assembly <NUM>, and the module sensors <NUM>. In some embodiments, the linear actuator <NUM>, the air controller <NUM>, the hot wire assembly <NUM>, and the module sensors <NUM> are communicatively coupled to the second transceiver <NUM>, which is in wireless communication with the first transceiver <NUM>. The bus <NUM> may be implemented in accordance with a controller area network (CAN) bus protocol as defined by International Standards Organization (ISO) <NUM>-<NUM>, a Media Oriented Systems Transport (MOST) bus protocol, a CAN flexible data (CAN-FD) bus protocol (ISO <NUM>-<NUM>), a K-line bus protocol (ISO <NUM> and ISO <NUM>-<NUM>), and/or an Ethernet bus protocol IEEE <NUM> (<NUM> onwards), etc..

The first and second transceivers <NUM>, <NUM> include wired or wireless network interfaces to enable communication with external networks and with one another. The first and second transceivers <NUM>, <NUM> also include hardware, e.g., processors, memory, storage, antennae, etc., and software to control the wired or wireless network interfaces. In some embodiments, the first and second transceivers <NUM>, <NUM> includes a wired or wireless interface, e.g., an auxiliary port, a Universal Serial Bus (USB) port, a Bluetooth® wireless node, etc., to communicatively couple with a mobile device, e.g., a smartphone, a smart watch, etc. In such embodiments, the film processing station <NUM> may communicate with the external network via the mobile device. The external network may be a public network, such as the Internet; a private network, such as an intranet; or combinations thereof, and may utilize a variety of networking protocols now available or later developed including, but no limited to TCP/IP-based networking protocols.

The rail sensors 116b are position sensors, e.g., magnetic eddy-current, ultrasonic, Hall Effect, inductive, etc., to detect locations of the film processing modules <NUM> along the supporting rail <NUM>. The registration sensor 116a and the module sensors <NUM> are featuredetecting sensors, e.g., a camera, optical, ultrasonic, radio frequency, etc., to detect and locate the demarcations <NUM> on the film <NUM> and/or provide discrete inputs to the linear actuator <NUM> to perform specific movements or movement profiles.

The main controller 110a includes a main processor 202a and a main memory 204a. The rail controller 110b includes a rail processor 202b and a rail memory 204b. The processors 202a, b may be any suitable processing device or set of processing devices such as, but not limited to, a microprocessor, a microcontroller-based platform, an integrated circuit, one or more field programmable gate arrays (FPGAs), and/or one or more application-specific integrated circuits (ASICs). The memories 204a, b may be volatile memory (e.g., RAM including non-volatile RAM, magnetic RAM, ferroelectric RAM, etc.), non-volatile memory (e.g., disk memory, FLASH memory, EPROMs, EEPROMs, memristor-based non-volatile solid-state memory, etc.), unalterable memory (e.g., EPROMs), read-only memory, and/or high-capacity storage devices (e.g., hard drives, solid state drives, etc.). In some examples, the memories 204a, b include multiple kinds of memory, particularly volatile memory and non-volatile memory.

The memories 204a, b are computer readable media on which one or more sets of instructions, such as the software for operating the methods of the present disclosure, can be embedded. The instructions may embody one or more of the methods or logic as described herein. For example, the instructions reside completely, or at least partially, within any one or more of the memories 204a, b, the computer readable medium, and/or within the processors 202a, b during execution of the instructions.

The terms "non-transitory computer-readable medium" and "computer-readable medium" include a single medium or multiple media, such as a centralized or distributed database, and/or associated caches and servers that store one or more sets of instructions. Further, the terms "non-transitory computer-readable medium" and "computer-readable medium" include any tangible medium that is capable of storing, encoding or carrying a set of instructions for execution by a processor or that cause a system to perform any one or more of the methods or operations disclosed herein. As used herein, the term "computer readable medium" is expressly defined to include any type of computer readable storage device and/or storage disk and to exclude propagating signals.

The main processor 202a is structured to include a module analyzer <NUM> (see <FIG>). The module analyzer <NUM> includes a module locator <NUM>, a film demarcation detector <NUM>, an offset determiner <NUM>, a module location adjuster <NUM>, a hot wire energizer <NUM>, a vacuum determiner <NUM>, and a clamp adjuster <NUM>.

In operation, the module locator <NUM> receives signals from the rail sensors 116b corresponding to locations of each of the film processing modules <NUM> along the supporting rail <NUM>. The module locator <NUM> monitors the locations of each of the film processing modules <NUM> as the film processing modules <NUM> move about the supporting rail <NUM>. As the module locator <NUM> monitors the locations of the film processing modules <NUM>, the module location adjuster <NUM> adjusts the locations of each of the film processing modules <NUM> along the supporting rail <NUM> and relative to one another via the rail controller 110b, e.g., to move the film processing modules <NUM> through the film working process, to prevent collisions, etc..

Further in operation, the module location adjuster <NUM> of <FIG> successively moves each of the film processing modules <NUM> to a start location <NUM> along the supporting rail <NUM>, as shown in <FIG>. While the film processing modules <NUM> are being moved to the start location <NUM>, the clamp adjuster <NUM> moves their respective upper multi-functional assemblies <NUM> into a ready position <NUM> relative to the base <NUM>, as shown in <FIG> and <FIG>. As shown in <FIG>, the start location <NUM> is distanced away from the film <NUM>. Thus, the film processing module <NUM> will not interfere with the film <NUM> before the upper multi-functional assembly <NUM> is in the ready position <NUM>. When the upper multi-functional assembly <NUM> is in the ready position <NUM>, the film processing module <NUM> is ready to accept the film <NUM> between the upper multi-functional assembly <NUM> and the base <NUM>. In some embodiments, the clamping plate <NUM> is distanced between about <NUM> to about <NUM> inches (<NUM> and <NUM> centimeters) from the base <NUM> when the upper multi-functional assembly <NUM> is in the ready position <NUM>. In a preferred embodiment, the clamping plate <NUM> is distanced approximately <NUM> inches (<NUM> centimeters) from the base <NUM> when the upper multi-functional assembly <NUM> is in the ready position <NUM>. Additionally, when the upper multi-functional assembly <NUM> is in the ready position <NUM>, the hot wire assembly <NUM> is between the support arm <NUM> and the clamping plate <NUM>.

Further in operation, in some embodiments, the hot wire energizer <NUM> energizes the hot wire assembly <NUM> in preparation to cut the film <NUM>. More specifically, the hot wire energizer <NUM> accesses the location of the film processing module <NUM> along the supporting rail <NUM> determined by the module locator <NUM>. The hot wire energizer <NUM> then turns on the hot wire assembly <NUM> such that the cutting mechanism <NUM> will be hot in time to cut the film <NUM> further along the supporting rail <NUM>. Thus, the hot wire energizer <NUM> coordinates and synchronizes energization of the hot wire assembly <NUM> relative to the supporting rail <NUM> using information provided by the rail sensors <NUM>. In other words, the hot wire energizer <NUM> times the heating of the cutting mechanism <NUM> so the cutting mechanism <NUM> is ready to cut the film <NUM> along the first side <NUM>.

In other embodiments, in operation, where the cutting mechanism <NUM> includes cartridge heaters, the hot wire assembly <NUM> is continuously heated via the on-board heater controller <NUM>.

Continuing in operation, the module location adjuster <NUM> of <FIG> successively moves each of the film processing modules <NUM> along the second rounded end <NUM> toward the first side <NUM> to intercept the film <NUM>, as shown in <FIG>. As the film processing modules <NUM> meet the film <NUM>, the upper multi-functional assemblies <NUM> are above the film and the bases <NUM> are below the film <NUM>. When the film processing modules <NUM> reach an aligned location <NUM> along the first side <NUM> of the supporting rail <NUM>, the film processing modules <NUM> are transverse with respect to an axis A along which the film <NUM> travels, shown in <FIG> and <FIG>. Additionally, when the film processing modules <NUM> reach the aligned location <NUM>, their respective upper multi-functional assemblies <NUM> and bases <NUM> extend beyond the film <NUM> with respect to the supporting rail <NUM>, as shown in <FIG>. In other words, once the film processing module <NUM> is in the aligned location <NUM>, the film <NUM> is between and generally perpendicular to the upper multi-functional assembly <NUM> and the base <NUM>. Further, once the film processing modules <NUM> reach the aligned location <NUM>, the film processing modules <NUM> are generally perpendicular to the first side <NUM>. Thus, after reaching the aligned location <NUM>, the film processing modules <NUM> travel along the supporting rail <NUM> parallel to the first side <NUM> and the axis A.

Continuing in operation, in some embodiments, the film demarcation detector <NUM> of <FIG> receives signals from the module sensors <NUM> of <FIG> to detect the demarcations <NUM> on the film <NUM>, as shown in <FIG>. In other words, the film demarcation detector <NUM> looks downwardly on the film <NUM> using the module sensor <NUM> to search for the demarcations <NUM>. It should be understood that as the film <NUM> is provided to the film processing station <NUM> and the film processing modules <NUM> meet the film <NUM> at the aligned location <NUM>, the demarcations <NUM> may not be directly beneath the upper multi-functional assembly <NUM>.

Further in operation, in such embodiments, once the film demarcation detector <NUM> detects one of the demarcations <NUM> on the film <NUM>, the offset determiner <NUM> of <FIG> determines an offset <NUM> for the demarcation <NUM> with respect to the cutting mechanism <NUM>, as shown in <FIG>. More specifically, the offset determiner <NUM> accesses the location of the film processing module <NUM> along the supporting rail <NUM> determined by the module locator <NUM> to determine a distance between the demarcation <NUM> and the cutting mechanism <NUM>. In other words, in such embodiments, the offset determiner <NUM> determines how far the film processing module <NUM> is out of synchronization with the detected demarcation <NUM> along the axis A using information provided by the module sensor <NUM> and the rail sensors <NUM>.

Continuing in operation, in different embodiments, the film demarcation detector <NUM> of <FIG> receives signals from the registration sensor 116a of <FIG> and <FIG> to detect the demarcations <NUM> on the film <NUM>, as shown in <FIG>. In other words, the film demarcation detector <NUM> looks downwardly on the film <NUM> using the registration sensor 116a to search for the demarcations <NUM>.

Further in operation, in such embodiments, once the film demarcation detector <NUM> detects two or more of the demarcations <NUM> on the film <NUM>, the offset determiner <NUM> of <FIG> determines a frequency (a "pitch") of how quickly the demarcations <NUM> pass the registration sensor 116a, as shown in <FIG>. From this frequency, the offset determiner <NUM> determines the offset <NUM> of the demarcations <NUM> with respect to one another, as shown in <FIG>. In other words, in such embodiments, the offset determiner <NUM> determines how far the film processing modules <NUM> are out of synchronization with the detected demarcations <NUM> along the axis A using information provided by the registration sensor 116a and the rail sensors 116b.

Continuing in operation, the module location adjuster <NUM> successively moves the film processing modules <NUM> along the first side <NUM> from the aligned location <NUM> toward a first pressed position <NUM> along the first side <NUM>, as shown in <FIG>. As the film processing modules <NUM> transition from the aligned location <NUM> to the first pressed location <NUM>, the module location adjuster <NUM> adjusts the location of the film processing modules <NUM> to close and/or synchronize with the offset <NUM>. More specifically, in some embodiments, as the film processing modules <NUM> move from the aligned location <NUM> toward the first pressed location <NUM>, the module location adjuster <NUM> adjusts the travel speed of the film processing modules <NUM> along axis A with respect to the film <NUM> to bring the demarcation <NUM> between the inlay <NUM> and the cutting mechanism <NUM>, as shown in <FIG>. In some embodiments, the module location adjuster <NUM> adjusts the travel speed of the film processing modules <NUM> along axis A to bring the demarcation <NUM> in line with a predetermined reference point of the film processing module <NUM>. In other words, the module location adjuster <NUM> coordinates and synchronizes the locations of the film processing modules <NUM> relative to the demarcations <NUM> using information provided by the rail sensors 116b, the registration sensor 116a, and/or the module sensors <NUM>.

Also in operation, as the film processing modules <NUM> transition from the aligned location <NUM> to the first pressed location <NUM>, the clamp adjuster <NUM> moves their respective upper multi-functional assemblies <NUM> toward a clamping position <NUM> relative to the bases <NUM>, as shown in <FIG> and <FIG>.

When the upper multi-functional assembly <NUM> moves downwardly toward the base <NUM>, the clamping plate <NUM> contacts the film <NUM> to compress the first and second lower biasing members 174a, b. When the upper multi-functional assembly <NUM> moves further downwardly toward the base <NUM> into the clamping position <NUM> shown in <FIG> and <FIG>, the first and second lower biasing members 174a, b are compressed and a section of the film <NUM> is clamped between the clamping plate <NUM> and the base <NUM>.

As the film processing modules <NUM> reach the first pressed location <NUM> along the first side <NUM>, their respective upper multi-functional assemblies <NUM> reach the clamping position <NUM> relative to the bases <NUM>. In a preferred embodiment, the cutting mechanism <NUM> is distanced approximately <NUM> inches (<NUM> millimeters) from the base <NUM> when the upper multi-functional assembly <NUM> is in the clamping position <NUM>.

Yet further in operation, the module location adjuster <NUM> successively moves the film processing modules <NUM> along the first side <NUM> from the first pressed location <NUM> toward a second pressed location <NUM>, as shown in <FIG>. Thus, the clamped film <NUM> is carried from the first pressed location <NUM> to the second pressed location <NUM>. In some embodiments, the length of the straight first side <NUM> corresponds to the time required to perform the cutting and sealing operation for a given film material.

Continuing in operation, during the transition of the film processing modules <NUM> from the first pressed location <NUM> to the second pressed location <NUM>, the clamp adjuster <NUM> moves their respective upper multi-functional assemblies <NUM> toward a cutting position <NUM> relative to the bases <NUM>, as shown in <FIG> and <FIG>.

When the upper multi-functional assembly <NUM> moves from the clamping position <NUM> toward the cutting position <NUM> the clamping plate <NUM> remains stationary relative to the base <NUM> and the first and second lower biasing members 174a, b are compressed between the clamping plate <NUM> and the carrier plate <NUM>. Thus, the film <NUM> is tightly clamped between the clamping plate <NUM> and the base <NUM> while the hot wire assembly <NUM> moves closer toward the base <NUM>.

While the film processing module <NUM> continues to transition from the first pressed location <NUM> to the second pressed location <NUM>, the upper multi-functional assembly <NUM> moves yet further toward the cutting position <NUM> relative to the base <NUM> during compression of the first and second lower biasing members 174a, b. The cutting mechanism <NUM> thus passes through the cutting opening <NUM>, compresses the film <NUM> against the inlay <NUM>, cuts and seals the film <NUM>, and contacts the inlay <NUM>. In other words, the cutting mechanism <NUM> cuts and seals the film <NUM> while the film processing module <NUM> is between the first pressed location <NUM> and the second pressed location <NUM>.

More specifically, the clamp adjuster <NUM> accesses the location of the film processing module <NUM> along the supporting rail <NUM> determined by the module locator <NUM>. The clamp adjuster <NUM> then moves the upper multi-functional assembly <NUM> from the clamping position <NUM> toward the cutting position <NUM> such that the location of the cut to the film <NUM> relative to the supporting rail <NUM> is configured for the hot wire assembly <NUM> to stay in the cutting position <NUM> for a predetermined period of time. Thus, the clamp adjuster <NUM> coordinates and synchronizes the cutting of the film <NUM> relative to the supporting rail <NUM> using information provided by the module sensors <NUM> and the rail sensors 116b. In other words, the clamp adjuster <NUM> dynamically times the descent of the upper multi-functional assembly <NUM> from the clamping position <NUM> to the cutting position <NUM> so the cutting mechanism <NUM> remains in contact with the film <NUM> for a period of time after the cut is complete. Thus, the film product <NUM> is robustly sealed when it is deposited on the conveyor <NUM> at a transfer position <NUM>, as will be explained in greater detail below. In some embodiments, the travel time of the hot wire assembly <NUM> from the clamping position <NUM> to the cutting position <NUM> is between about <NUM> to about <NUM> seconds. It should be appreciated that the compression of the film <NUM> between the cutting mechanism <NUM> and the inlay <NUM>, and the dwell period of the hot wire assembly <NUM> in the cutting position <NUM>, act to apply the necessary heat and pressure to a predetermined position on the film <NUM> to cut top and bottom layers <NUM>, <NUM>, respectively, thereof, and to fuse the top and bottom layers <NUM>, <NUM> into a leading seal <NUM> and a trailing seal <NUM>, as shown in <FIG> and <FIG>. Thus, the hot wire assembly <NUM> cuts the film <NUM> into individual sealed film products <NUM>, e.g., individual pouches, with predetermined lengths, as shown in <FIG> and <FIG>. It should also be appreciated that the inlay <NUM> acts as a hard stop for the cutting mechanism <NUM> at the cutting position <NUM> and thus also the upper multi-functional assembly <NUM>, as shown in <FIG> and <FIG>.

Even further in operation, the module location adjuster <NUM> successively moves the film processing modules <NUM> along the first side <NUM> from the second pressed location <NUM> to the transfer location <NUM> along the first side <NUM>, as shown in <FIG>. As the film processing modules <NUM> transition from the second pressed location <NUM> to the transfer location <NUM>, the clamp adjuster <NUM> moves their respective upper multi-functional assemblies <NUM> into an open position <NUM> relative to the bases <NUM>, as shown in <FIG>. In some embodiments, the clamping plate <NUM> is distanced between about <NUM> to about <NUM> inches (<NUM> and <NUM> centimeters) from the base <NUM> when the upper multi-functional assembly <NUM> is in the open position <NUM>. In a preferred embodiment, the clamping plate <NUM> is distanced about <NUM> inches (<NUM> centimeters) from the base <NUM> when the upper multi-functional assembly <NUM> is in the open position <NUM>. Thus, the multi-functional assemblies <NUM> and the carried film products <NUM> are placed over the conveyor <NUM>. Additionally, the base <NUM> is under the conveyor <NUM> at the transfer location <NUM>. When each film processing module <NUM> reaches the transfer location <NUM>, the sealed film product <NUM> is deposited onto the conveyor <NUM>. Thus, a continuous series of individual sealed film products <NUM> is placed along the conveyor <NUM>, as shown in <FIG> and <FIG>.

In some embodiments, the sealed film products <NUM> are temporarily retained against the clamping plate <NUM> adhesively and/or via electrostatic forces.

In embodiments including the air controller <NUM>, in operation, the vacuum determiner <NUM> energizes the air controller <NUM> as the upper multi-functional assembly <NUM> rises from the cutting position <NUM> to the open position <NUM> to draw air out of the airflow lines <NUM> and the airflow openings <NUM>. Thus, the air controller <NUM> forms a vacuum between the cut film <NUM> and the clamping plate <NUM> and the cut film <NUM> is retained against the clamping plate <NUM> by atmospheric air pressure. In such embodiments, the vacuum determiner <NUM> de-energizes the air controller <NUM> at the transfer location <NUM> to release the cut film <NUM> from the clamping plate <NUM> onto the conveyor <NUM>. Alternatively, in such embodiments, the vacuum determiner <NUM> reverses the air controller <NUM> at the transfer location <NUM> to blow the cut film <NUM> from the clamping plate <NUM> onto the conveyor <NUM>. In such embodiments, the vacuum determiner <NUM> de-energizes the air controller <NUM> once the film product <NUM> is blown onto the conveyor <NUM>.

While the above description discusses how the upper multi-functional assembly <NUM> moves toward and away from the base <NUM>, it is contemplated that, in some embodiments, the film processing module <NUM> may be arranged for the upper multi-functional assembly <NUM> to be stationary with respect to the linear actuator <NUM> and the base <NUM> to be engaged with the linear actuator <NUM> to be moveable toward and away from the upper multi-functional assembly <NUM>. It is further contemplated that, in some embodiments, the film processing module <NUM> may be arranged for the upper multi-functional assembly <NUM> and the base <NUM> to be moveably engaged with the linear actuator <NUM> and thus moveable with respect to one another. In other words, all arrangements where the base <NUM> and the upper multi-functional assembly <NUM> move relative to one another via the linear actuator <NUM> are contemplated.

Continuing in operation, in some embodiments, the hot wire energizer <NUM> de-energizes the hot wire assembly <NUM> once the film products <NUM> are deposited on the conveyor <NUM>. More specifically, the hot wire energizer <NUM> accesses the location of the film processing module <NUM> along the supporting rail <NUM> determined by the module locator <NUM>. The hot wire energizer <NUM> then turns off the hot wire assembly <NUM> when the film processing module <NUM> moves past the transfer location <NUM>. Thus, the hot wire energizer <NUM> coordinates and synchronizes deenergization of the hot wire assembly <NUM> relative to the supporting rail <NUM> using information provided by the rail sensors <NUM>. In other words, the hot wire energizer <NUM> times the deenergization of the cutting mechanism <NUM> to save electrical energy when the cutting mechanism <NUM> is not in use.

Continuing in operation, the module location adjuster <NUM> successively moves the film processing modules <NUM> along the first rounded end <NUM> and the second side <NUM>, e.g., a "back stretch," of the supporting rail <NUM> to the start location <NUM>. Meanwhile, the clamp adjuster <NUM> moves the upper multi-functional assembly <NUM> to the ready position <NUM> relative to the base <NUM>, as shown in <FIG> and <FIG>. Thus, the controller <NUM> prepares the film processing modules <NUM> to meet successive new sections of film <NUM> at the aligned location <NUM>.

It is contemplated that in addition or alternatively to the operations of the film processing modules <NUM> coordinated by the main controller 110a using the module analyzer <NUM>, the main controller 110a may also dynamically coordinate functions performed by alternative film processing modules mounted to the supporting rail <NUM>. Thus, the main controller 110a may coordinate and synchronize the clamping and cutting functions performed by the film processing modules <NUM> with additional functions performed by other types of modules. For example, the main controller 110a may coordinate the clamping and cutting of the film by the film processing modules <NUM> with an embossing module that shapes decorative patterns and/or production information into the film <NUM>, a printing module that prints decorative patterns and/or production information onto the film <NUM>, a perforating module that perforates the film <NUM>, etc..

<FIG> is a flowchart representative of an example method <NUM> that may be performed to process plastic film into pouches. The flowchart of <FIG> is representative of machine readable instructions that are stored in memory (such as the memory 204a of <FIG>) and include one or more programs which, when executed by a processor (such as the processor 202a of FIG. 1a), cause the main controller 110a to operate the film processing modules <NUM> of <FIG> on the supporting rail <NUM> of <FIG> and <FIG>. While the example program is described with reference to the flowchart illustrated in <FIG>, many other methods of operating the film processing modules <NUM> on the supporting rail <NUM> may alternatively be used. For example, the order of execution of the blocks may be rearranged, changed, eliminated, and/or combined to perform the method <NUM>. Further, because the method <NUM> is disclosed in connection with the components of <FIG>, some functions of those components will not be described in detail below.

Initially, at block <NUM>, the main controller 110a moves the film processing module <NUM> to the start location <NUM>. Thus, the main controller 110a positions the film processing module <NUM> along the supporting rail <NUM> at a starting location away from the film <NUM>.

At block <NUM>, the main controller 110a moves the upper multi-functional assembly <NUM> to the ready position <NUM>. When the upper multi-functional assembly <NUM> is in the ready position <NUM>, the film processing module <NUM> is ready to accept the film <NUM> between the upper multi-functional assembly <NUM> and base <NUM>. Additionally, the first and second upper biasing members 172a, b and the first and second lower biasing members 174a, b are uncompressed when the upper multi-functional assembly <NUM> is in the ready position <NUM>, as shown in <FIG>.

At block <NUM>, the main controller 110a moves the film processing module <NUM> to the aligned location <NUM>. As the film processing module <NUM> moves to the aligned location <NUM>, the film <NUM> is placed between the upper multi-functional assembly <NUM> and the base <NUM>.

At block <NUM>, the main controller 110a adjusts the location of the film processing module <NUM> along the supporting rail <NUM> to synchronize with one or more of the demarcations <NUM> on the film <NUM>. The film processing module <NUM> is aligned with the demarcation <NUM> to produce regularly-sized film products <NUM>.

At block <NUM>, the main controller 110a moves the upper multi-functional assembly <NUM> to the clamping position <NUM>. When the upper multi-functional assembly <NUM> moves to the clamping position <NUM>, the lower biasing members 174a, b are compressed and the clamping plate <NUM> compresses the film <NUM> against the base <NUM>. Additionally, the first and second upper biasing members 172a, b are uncompressed when the upper multi-functional assembly <NUM> is in the clamping position <NUM>, as shown in <FIG>.

At block <NUM>, the main controller 110a moves the film processing module <NUM> to the first pressed location <NUM>. Thus, the film processing module <NUM> carries the clamped film <NUM> as the film processing module <NUM> reaches the first pressed location <NUM>.

In some embodiments, at block <NUM>, the main controller 110a energizes the hot wire assembly <NUM>. Thus, the cutting mechanism <NUM> of the hot wire assembly <NUM> heats up in preparation to cut and seal the film <NUM>. It should be understood that, in some embodiments, the hot wire assembly <NUM> is continuously heated via the on-board heater controller <NUM>.

At block <NUM>, the main controller 110a moves the upper multi-functional assembly <NUM> to the cutting position <NUM>. When the upper multi-functional assembly <NUM> descends to the cutting position <NUM>, the first and second lower biasing members 174a, b are compressed further, the cutting mechanism <NUM> passes through the cutting opening <NUM>, the cutting mechanism <NUM> cuts and seals the film <NUM>, and the cutting mechanism <NUM> comes to a hard stop against the inlay <NUM>.

At block <NUM>, the main controller 110a moves the film processing module <NUM> to the second pressed location <NUM>. Thus, the film processing module <NUM> carries the clamped film <NUM> as the film processing module <NUM> moves toward the second pressed location <NUM>. It should be understood that the travel time period between the first and second pressed locations <NUM>, <NUM> allows the cutting mechanism <NUM> to form the leading and trailing seals <NUM>, <NUM>.

In embodiments including the air controller <NUM>, the main controller 110a pulls a vacuum at block <NUM>. More specifically, the main controller 110a energizes the air controller <NUM> to draw air through the airflow lines <NUM> and airflow openings <NUM> to retain the film <NUM> against the clamping plate <NUM>.

At block <NUM>, the main controller 110a moves the upper multi-functional assembly <NUM> to the open position <NUM>. Thus, the main controller 110a raises the multi-functional assembly <NUM> along with the film <NUM> away from the base <NUM>. When the multi-functional assembly <NUM> moves to the open position <NUM>, the cutting mechanism <NUM> retracts away from the film <NUM> back through the cutting opening <NUM>.

At block <NUM>, the main controller 110a de-energizes the hot wire assembly <NUM>. The cutting mechanism <NUM> is thus turned off. It should be understood that turning off the cutting mechanism <NUM> after cutting and sealing the film <NUM> may save electrical energy during production of the film products <NUM>.

At block <NUM>, the main controller 110a moves the film processing module <NUM> to the transfer location <NUM>. Thus, the upper multi-functional assembly <NUM> and the carried film product <NUM> are placed over the conveyor <NUM>.

In embodiments including the air controller <NUM>, the main controller 110a releases the vacuum at block <NUM>. In some embodiments, the main controller 110a de-energizes the air controller <NUM> and the film product <NUM> passively falls onto the conveyor <NUM>. In some embodiments, the main controller 110a reverses the air controller <NUM> to actively blow the film product <NUM> onto the conveyor <NUM> and then de-energizes the air controller <NUM>. It should be understood that turning off the air controller <NUM> after depositing the film product <NUM> on the conveyor <NUM> may save electrical energy during production of the film products <NUM>. The method <NUM> then returns to block <NUM>.

From the foregoing, it will be appreciated that the above disclosed system and method disclose a film processing station <NUM> that reduces the number of machines and associated footprint size of machines used to produce film products and may thus aid in reducing associated manufacturing costs and energy consumption. Further, because the film processing modules <NUM> are interchangeable, individual film processing modules <NUM> may be easily removed from the film processing station <NUM>, e.g., for maintenance, thus reducing unproductive down time of the film processing station <NUM> and associated costs. Additionally, because the cutting mechanism <NUM> dwells on the film <NUM> and then retracts away above the clamping plate <NUM>, the film processing modules <NUM> produce film products <NUM> with robust seals while reducing manufacturing defects, associated film waste, and associated disposal costs.

Moreover, because the above disclosed film processing station <NUM> dynamically aligns the film processing modules <NUM> with the web of film <NUM>, asynchronous processing and cutting, sometimes referred to as "creep," in images on pre-printed film rolls may be avoided. The present film processing station <NUM> system and associated methods advantageously allow for real-time adjustment of the film processing modules <NUM> relative to the web of film <NUM> supplied to the film processing station <NUM>. Thus, the present film processing station <NUM> system and associated methods compensate for differences between supplied webs of film <NUM> without the stopping of the process. Such advantages are also applicable to any process that contemplates uniform cutting between sheet and/or film products from the same or different sources.

Claim 1:
A system (<NUM>), comprising:
a film processing module (<NUM>); and
a processor (202a) and memory (204a) in communication with the film processing module (<NUM>) to:
dynamically coordinate movement of the film processing module (<NUM>) relative to a moving web of film (<NUM>),
instruct the film processing module to perform a function on the web of film (<NUM>) with the film processing module (<NUM>) to form a film product (<NUM>), and
instruct the film processing module to deposit the film product (<NUM>) on a conveyor (<NUM>) at a transfer position (<NUM>).