Patent Description:
Foam-in-bag dunnage material is known as a technology where a mixture of a plurality of liquid chemical foam precursor substances is injected into a plastic bag. The liquid chemical foam precursor substances react with each other in the mixture by expanding and building a rather low density foam which, after expansion, hardens. This hardened foam may fill a void volume in a container between the container walls and an article placed inside the container, thus blocking the articles inside the container from moving around and also providing a protecting function against shock movements. <CIT> discloses a machine for producing a foam-in-bag dunnage material. <CIT> relates to a dispensing system with a mixing module of foam precursor substances. <CIT> discloses a process for producing flexible polyurethane foam. <CIT> discloses a system for the simultaneous injection of a filling material into a plurality of separate chambers of a boat.

It is an object of the present invention to provide a machine for producing a foam-in-bag dunnage material being more flexible to use.

According to the invention this object is solved by a machine for producing a foam-in-bag dunnage material with the features of claim <NUM>. Further embodiments of the invention are given in the dependent claims.

A major advantage of the invention is that the inventive machine allows to have two separate mixing chambers, which are supplied with the same foam precursor substances from the same foam precursor supplies, which allows to produce first and second mixtures at first and second locations with one machine and, if desired, at the same time, and/or to produce first and second mixtures having different properties with one machine and, if desired, at the same time, and/or to produce first and second mixtures by way of different operating principles, for example automatically/semi-automatically and manually. The inventive machine therefore can be adapted easily to the specific application needs of a specific packaging environment. With the inventive machine a number of important functional elements can be shared for the production of the first and second mixtures, which reduces the costs compared to two separate machines.

More specifically, the inventive machine for producing a foam-in-bag dunnage material comprises first and second foam precursor inlets for first and second foam precursor substances. These inlets may be formed in an interface device, and they may be formed for example as releasable fluid connectors. The first and second foam precursor substances may be liquid. Examples for such foam precursor substances are Isocyanate and Polyol.

The inventive machine further comprises a first mixing chamber for mixing the first and second foam precursor substances into a first mixture, the first mixing chamber being fluidly connected to the first and second foam precursor inlets. A first dispenser is fluidly connected to the first mixing chamber, and in most cases will be arranged directly adjacent to the first mixing chamber. The reason is that when the first and second foam precursor substances are mixed to the first mixture, the substances immediately start to react with each other such that gas bubbles are created. It is therefore advantageous if the first mixture is dispensed immediately after being created.

The machine comprises a branch-off-device fluidly arranged upstream of the first mixing chamber, preferably between the first and second foam precursor inlets and the first mixing chamber. This branch-off-device serves functionally as a fluid divider allowing the first and second foam precursor substances to flow into at least two different fluid branches. The flow divider may be a manifold without control on how to divide the stream. For this purpose, the branch-off-device comprises first and second foam precursor outlets towards the first mixing chamber and third and fourth foam precursor outlets towards a second mixing chamber, preferably towards an interface device being adapted to fluidly connect to the second mixing chamber. While the first and third foam precursor outputs are in fluid connection with the first foam precursor inlet, the second and fourth foam precursor outputs are in fluid connection with the second foam precursor inlet. Typically, the branch-off-device comprises two Y-connectors.

The interface device which is fluidly connected to the third and fourth foam precursor outputs is adapted to fluidly connect to a second mixing chamber for mixing the first and second foam precursor substances into a second mixture. As has been mentioned above, this second mixing chamber may be arranged at a different location than the first mixing chamber, may be structured differently than the first mixing chamber such that the second mixture is different than the first mixture, or may be used according to an operation principle which is different from the operation principle of the first mixing chamber.

The machine also comprises a controller for at least temporarily controlling at least some aspects of the operation of the machine. This provides for a smart, safe and efficient operation of the machine. The controller may comprise a microprocessor and a data storage for storing program code to be executed by the microprocessor. By way of example, the controller may be or comprise a computer.

The controller is programmed such that the machine can be operated either only with the first mixing chamber or simultaneously with the first and the second mixing chamber, or the controller being programmed such that the machine can be operated either only with the second mixing chamber or simultaneously with the first and the second mixing chamber, or the controller being programmed such that the machine can be operated either only with the first mixing chamber or only with the second mixing chamber or simultaneously with the first and the second mixing chamber. Typically, the controller may control the amount and the relation of quantities of first and second foam precursor substances pumped to the first and second foam precursor inlets. The possibility to either manually or automatically select different modes of operation, the amount of first and second foam precursor substances, and the relation of quantities of the first and second foam precursor substances allows to precisely control the operation according to the specific needs of the packaging situation.

The first dispenser is fixedly connected to a frame of the machine, and the machine comprises a bag supply for supplying a bag to a position close to the first dispenser, the first dispenser being close to the first dispenser, the first dispenser being adapted to automatically dispense the first mixture into the bag, if desired. Such an arrangement is typical for the automatic or semi-automatic and stationary production of bags, which are then removed from the machine manually by a user and moved to a packaging site, where a bag may be placed manually into a container. The first mixture then may further expand and hereby gradually fill the void between an article and an inner wall of the container and finally at least partially conform to the shape of the article to be packaged. Preferably, the machine comprises a sealing means which automatically seals the bag filled with the first mixture prior to being grasped by a user and moved to the packaging site.

The machine comprises a handheld dispensing assembly comprising the second mixing chamber. Such an arrangement is typical for the "manual" production of foam-in-place dunnage material. For example, the empty bag may be arranged in the container, and then the handheld dispensing assembly may be moved manually by user to a fill opening of the bag. Thereafter, a quantity of the second mixture may be filled into the bag corresponding to the individual geometric situation, in particular depending on the size and/or the shape of the void to be filled, as desired by a user. Another typical application of an handheld dispensing assembly is to dispense the foam directly into the container, where the item to be packed has been previously enveloped in a protective film.

In a further embodiment thereto, the handheld dispensing assembly comprises an activating device to be manually operated by a user for dispensing the second mixture. This allows a user to individually and situationally control the amount of the second mixture dispensed by the dispensing device.

In a further embodiment, the machine comprises an input means for inputting commands to the controller by a user. This allows a user for example to easily input the desired mode of operation and/or other data, such as for example the amount of first and/or second mixture to be dispensed by the first dispenser and/or the handheld dispensing assembly. It is to be understood that different input means may be used, such as a keyboard, a touchscreen, a microphone for inputting acoustic information, such as speech, and/or a camera for inputting gestures.

In a further embodiment, the machine comprises an output means for outputting information to a user. This allows a user for example to observe an actual condition of the machine, such as machine settings, mode of operation, quantity of foam precursor substances still available, and so on. The output means preferably comprises a display, but may also comprise other optical indicators, or may comprise an acoustic output means, such as a loudspeaker, for outputting signals and/or speech.

In a further embodiment, the interface device comprises an electrical connecting device for electrically connecting the handheld dispensing assembly to the controller and/or an energy supply. This allows the easy connection of the handheld dispenser assembly to the controller and/or energy supply, especially an electrical power supply. By consequence, the handheld dispenser may be a "smart" and/or "intelligent" dispenser. It is to be understood that the connection to the controller may be made by means of a wire connector, but may also be made by means of wireless data transfer, such as Bluetooth are Wi-Fi or the like.

In a further embodiment, the machine comprises first and second foam precursor supply lines fluidly arranged between the first and second foam precursor inlets and first and second foam precursor supplies, and a heating device for heating the first and second foam precursor substances contained within the first and second foam precursor supply lines. In a further embodiment, the machine comprises third and fourth foam precursor supply lines fluidly arranged between the interface and the second mixing chamber, and a heating device for heating the third and fourth foam precursor substances contained within the third and fourth foam precursor supply lines.

The mentioned heating devices provide for the correct viscosity of the foam precursor substances by heating the foam precursor substances to an appropriate temperature, typically to <NUM>-<NUM>. In order to provide a desired temperature, one or more temperature sensors may be arranged in the foam precursor supply lines and be connected to a temperature controller, which controls the heating device and/or devices. The foam precursor supply lines may be formed for example by flexible hoses, independent from whether they are equipped with the heating devices or not.

In a further embodiment, the interface device is adapted to releasably fluidly connect to the third and fourth supply lines. This allows the machine according to the invention to be operated easily with or without the second mixing chamber, and also allows for example to easily exchange a specific handheld dispenser assembly against a different specific handheld dispenser assembly.

In a further embodiment, the interface device comprises closure means to releasably and fluid tightly close the interface device when the machine is operated without the third and fourth foam precursor supply lines being connected. Such closure means may be, for example, a simple screw cap for closing the fluid connectors, but also may be for example a valve which may be operated automatically by the controller when it is detected that the third and fourth foam precursor supply lines are removed or which may be operated manually by the user prior to removing the third and fourth foam precursor supply lines. The mentioned closure means increases the operational safety of the machine.

In a further embodiment, the branch-off-device and the interface device are comprised in a common housing. This reduces the size of the machine and allows even to retrofit already existing machines with the technology according to the invention.

It is to be noted that in the present context the terms "first, second, third, and fourth" are not to be understood in a limiting way or as a firm sequence, but rather and simply are used in order to distinguish functionally similar but separate elements and/or regions from each other. It is also to be understood that it is within the scope of the present invention that "fifth, sixth, and so on" functionally similar elements and/or regions may be present or that only third and fourth elements may be present.

The features and the advantages of the invention will be evident from the following description, regarding particular embodiments thereof, which is made as a nonlimiting example with reference to the attached drawings, wherein:.

In the following detailed description and the attached figures functionally equivalent elements and regions may be designated with identical reference signs. Furthermore, for the sake of clarity in the figures not always all reference signs are drawn.

In the figures, a machine for producing a foam-in-bag dunnage material is generally designated with reference numeral <NUM>. It comprises a main arrangement <NUM>. The main arrangement <NUM> comprises a first interface <NUM> and a second interface <NUM>.

The machine <NUM> further comprises a foam precursor supply arrangement <NUM>, which is fluidly connected to the first interface <NUM>, as will be described in more detail further below. Moreover, the machine <NUM> comprises a handheld dispensing assembly <NUM>, which is fluidly connected to the second interface <NUM>, as will be described in more detail further below.

The foam precursor supply arrangement <NUM> comprises a first foam precursor supply <NUM> and a second foam precursor supply <NUM>. The first foam precursor supply <NUM> comprises a first foam precursor tank <NUM> and a first foam precursor pump <NUM>. The second foam precursor supply <NUM> comprises a second foam precursor tank <NUM> and a second foam precursor pump <NUM>. The first foam precursor tank <NUM> may be filled with a first foam precursor substance, such as Isocyanate. The second foam precursor tank <NUM> may be filled with a second foam precursor substance, such as Polyol. Both foam precursor tanks <NUM> and <NUM> may be formed for example by respective cylindrical drums.

The machine <NUM> further comprises a first foam precursor supply line <NUM> which connects an outlet of the first foam precursor pump <NUM> to a first foam precursor inlet <NUM> of the first interface <NUM>. Similarly, the machine <NUM> comprises a second foam precursor supply line <NUM> which connects an outlet of the second foam precursor pump <NUM> to a second foam precursor inlet <NUM> of the first interface <NUM>. Heating devices <NUM> are provided in both foam precursor supply lines <NUM> and <NUM> for heating the first and second foam precursor substances contained within the first and second foam precursor supply lines <NUM> and <NUM>. As is shown by dotted lines <NUM> in <FIG>, the foam precursor pumps <NUM> and <NUM> and the heating devices <NUM> are also electrically connected to the first interface <NUM>.

The main arrangement <NUM> of the machine <NUM> comprises a first mixing chamber <NUM> for mixing the first and second foam precursor substances into a first mixture, and a first dispenser <NUM> for dispensing the first mixture into a bag <NUM>. Moreover, the main arrangement <NUM> comprises a branch-off-device <NUM> which is fluidly arranged between the first and second foam precursor inlets <NUM> and <NUM> and the first mixing chamber <NUM>. The branch-off-device <NUM> comprises a first Y-channel-arrangement <NUM> and a second Y-channel-arrangement <NUM>. The first Y-channel-arrangement <NUM> comprises a first fluid inlet <NUM> and first and third foam precursor outlets <NUM> and <NUM>. The second Y-channel-arrangement <NUM> comprises a second fluid inlet <NUM> and second and fourth foam precursor outlets <NUM> and <NUM>.

The first fluid inlet <NUM> is fluidly connected to the first foam precursor inlet <NUM>. The second fluid inlet <NUM> is fluidly connected to the second foam precursor inlet <NUM>. The first and second foam precursor outlets <NUM> and <NUM> are fluidly connected to the first mixing chamber <NUM>. The third and fourth foam precursor outlets <NUM> and <NUM> are fluidly connected to first and second fluid connectors <NUM> and <NUM> of the second interface device <NUM>.

The main arrangement <NUM> of the machine <NUM> further comprises a controller <NUM> for controlling at least some aspects of the operation of the machine <NUM> as well as a combined inputting and outputting means <NUM> for inputting commands and/or data to the controller <NUM> and for outputting information to a user. Typically, the controller <NUM> comprises a microprocessor and a storage means for storing program code which may be executed by the microprocessor. The controller <NUM> may comprise or be a computer. The combined inputting and outputting means <NUM> in the present exemplary embodiment is a touchscreen. However, many other types of inputting and/are outputting means may be used, such as a keyboard, a microphone, a loudspeaker, et cetera.

Furthermore, the main arrangement <NUM> comprises a bag supply <NUM> which may automatically provide a plastic bag <NUM> to a position close to the first dispenser <NUM> when requested by a user such that the first dispenser <NUM> may dispense automatically or on demand by a user the first mixture (arrow <NUM> in <FIG>) into the plastic bag <NUM>.

The handheld dispensing assembly <NUM> comprises a second mixing chamber <NUM> for mixing the first and second foam precursor substances into a second mixture (arrow <NUM> in <FIG>). It further comprises a second dispenser <NUM> for dispensing the second mixture <NUM> into a bag <NUM>. The handheld dispensing assembly <NUM> also comprises an activating device <NUM> to be manually operated by a user for dispensing the second mixture <NUM>. The handheld dispensing assembly <NUM> is fluidly connected to the second interface device <NUM> by means of third and fourth foam precursor supply lines <NUM> and <NUM> which are fluidly arranged between the second interface device <NUM> and the second mixing chamber <NUM>.

A heating device <NUM> is arranged in the third and fourth foam precursor supply lines <NUM> and <NUM> for heating the first and second foam precursor substances contained within the third and fourth foam precursor supply lines <NUM> and <NUM>. The second interface device <NUM> is adapted to releasably fluidly connect to the third and fourth foam precursor supply lines <NUM> and <NUM>. As indicated by dotted lines <NUM> in <FIG>, the handheld dispensing assembly <NUM> is also releasably electrically connected to the second interface device <NUM>. For this purpose, the second interface device <NUM> comprises a connecting device (not shown) for electrically connecting the handheld dispensing assembly <NUM> to the controller <NUM> and/or an electrical energy supply (not shown). In a preferred embodiment, the fluid connection and the electrical connection from the handheld dispensing assembly <NUM> to the second interface device <NUM> may be made simultaneously by means of a combined fluid and electrical connecting device.

The second interface device <NUM> comprises closure means (not shown) to selectively and fluid tightly close the second interface device <NUM> when the machine <NUM> is operated without the third and fourth foam precursor supply lines <NUM> and <NUM> being connected. The closure means may be formed by a screw cap or by a valve which may be operated automatically by the controller <NUM> when the controller <NUM> detects that the handheld dispensing assembly <NUM> is removed, or manually by a user.

As has been mentioned, the controller <NUM> may be programmed in order to control at least temporarily and at least aspects of the operation of the machine <NUM>. For this purpose, the controller <NUM> may be programmed in different ways:
According to a first aspect, the controller <NUM> may be programmed such that the machine <NUM> can be operated either only with the first mixing chamber <NUM> and the first dispenser <NUM> in order to dispense the first mixture <NUM> into a bag <NUM>, or simultaneously with the first mixing chamber <NUM> as described above and additionally with the second mixing chamber <NUM> of the handheld dispensing assembly <NUM>, in order to additionally dispense the second mixture <NUM> by means of the second dispenser <NUM> into a bag <NUM>, which might for example be arranged already within a container.

According to a second aspect, the controller <NUM> may be programmed such that the machine <NUM> can be operated either only with the second mixing chamber <NUM> as described above or simultaneously with the first mixing chamber <NUM> and the second mixing chamber <NUM>, both as described above.

According to a third aspect, the controller <NUM> may be programmed such that the machine <NUM> can be operated either only with the first mixing chamber <NUM> as described above or only with the second mixing chamber <NUM> as described above or simultaneously with the first mixing chamber <NUM> and the second mixing chamber <NUM> as described above.

As can be seen from <FIG>, the machine <NUM> comprises a stand <NUM> which is movable on rollers <NUM>. A frame <NUM> is attached to the stand <NUM>, the frame <NUM> fixedly supporting the main arrangement <NUM>. In the specific embodiment of <FIG> and <FIG>, the branch-off-device <NUM> and the second interface device <NUM> are comprised in a common housing <NUM> which is arranged at a lateral portion of the frame <NUM> and the main arrangement <NUM>.

Preferably, the common housing <NUM> comprises two manifold blocks <NUM> and <NUM>. The first manifold block <NUM> is adapted to connect the first and second foam precursor supply lines <NUM> and <NUM> as well as the electrical connection to the heating devices <NUM>, the foam precursor pumps <NUM> and <NUM>, and so on. Moreover, first manifold block <NUM> comprises the first and second Y-channel-arrangements <NUM> and <NUM> which, in the present exemplary embodiment, may be formed by channels within the first manifold block <NUM>. First manifold block <NUM> is fixedly mechanically connected to the frame <NUM> and is also fixedly fluidly connected to the first mixing chamber <NUM>. Its outer lateral area serves as the second interface device <NUM>, while its rear area (in <FIG> and <FIG>) serves as the first interface <NUM>.

The second manifold block <NUM> is mechanically and fluidly fixedly connected to the third and fourth foam precursor supply lines <NUM> and <NUM> of the handheld dispensing assembly <NUM>, as can been seen from <FIG> which shows solely the handheld dispensing assembly <NUM> and the components belonging thereto. The second manifold block <NUM> may be mechanically, fluidly and electrically attached/connected to the first manifold block <NUM> in case that the machine <NUM> is to be operated together with the handheld dispensing assembly <NUM>.

<FIG> shows the machine <NUM> in a first operating condition with the handheld dispensing assembly <NUM> and its second mixing chamber <NUM> connected to the second interface device <NUM>. <FIG> shows the machine <NUM> in a second operating condition without the handheld dispensing assembly <NUM> being connected.

Now the hydraulic principles of the machine <NUM> will be explained with reference to <FIG> shows the machine <NUM> in the first operating condition together with the handheld dispensing assembly <NUM>.

The first foam precursor supply <NUM> comprises the first foam precursor tank <NUM>, a first filter screen <NUM>, and the first foam precursor pump <NUM>, which may be driven by a first pump motor <NUM>. Similarly, the second foam precursor supply <NUM> comprises the second foam precursor tank <NUM>, a second filter screen <NUM>, and the second foam precursor pump <NUM>, which may be driven by a second pump motor <NUM>.

Within the first manifold block <NUM>, there are provided a first pressure sensor <NUM> and a second pressure sensor <NUM> for detecting the liquid pressure of the first and second foam precursor substances. Furthermore, downstream of the first manifold block <NUM> towards the first mixing chamber <NUM>, there are provided a first temperature sensor <NUM> and a second temperature sensor <NUM> for detecting the temperature of the first and second foam precursor substances contained with the first and second foam precursor supply lines <NUM> and <NUM>. The signals of the sensors <NUM>-<NUM> are provided to the controller <NUM> which provides appropriate control signals to the pump motors <NUM> and <NUM> and the heating devices <NUM>.

Downstream of the first manifold block <NUM> are provided first and second manually operated valves <NUM> and <NUM> as well as check valves <NUM> and <NUM>. A first dispenser motor <NUM> is arranged at the first mixing chamber <NUM> and activated either automatically by the controller <NUM> or manually/semi-automatically based on an input of the user at the touchscreen <NUM> in order to dispense the first mixture <NUM> into the bag <NUM> (<FIG>).

Claim 1:
Machine (<NUM>) for producing a foam-in-bag dunnage material, comprising first and second foam precursor inlets (<NUM>, <NUM>) for first and second foam precursor substances, a first mixing chamber (<NUM>) for mixing the first and second foam precursor substances into a first mixture (<NUM>), and a first dispenser (<NUM>) for dispensing the first mixture (<NUM>), wherein the machine (<NUM>) comprises a branch-off-device (<NUM>) fluidly arranged upstream of the first mixing chamber (<NUM>) and having first and second foam precursor outlets (<NUM>, <NUM>) towards the first mixing chamber (<NUM>) and third and fourth foam precursor outlets (<NUM>, <NUM>) towards a second mixing chamber (<NUM>) for mixing the first and second foam precursor substances into a second mixture (<NUM>), characterized in that the machine (<NUM>) comprises a controller (<NUM>) for at least temporarily controlling an operation of the machine (<NUM>), wherein the controller (<NUM>) is programmed such that the machine (<NUM>) can be operated either only with the first mixing chamber (<NUM>) or simultaneously with the first and the second mixing chamber (<NUM>, <NUM>), or the controller (<NUM>) being programmed such that the machine (<NUM>) can be operated either only with the second mixing chamber (<NUM>) or simultaneously with the first and the second mixing chamber (<NUM>, <NUM>), or the controller (<NUM>) being programmed such that the machine (<NUM>) can be operated either only with the first mixing chamber (<NUM>) or only with the second mixing chamber (<NUM>) or simultaneously with the first and the second mixing chamber (<NUM>, <NUM>), wherein the first dispenser (<NUM>) is fixedly connected to a frame (<NUM>) of the machine (<NUM>), and wherein the machine (<NUM>) comprises a bag supply (<NUM>) for supplying a bag (<NUM>) to a position close to the first dispenser (<NUM>), the first dispenser (<NUM>) being adapted to dispense the first mixture (<NUM>) into the bag (<NUM>), and wherein it comprises a handheld dispensing assembly (<NUM>) comprising the second mixing chamber (<NUM>).