Packaging station for producing cushioning material

Abstract

A packaging station comprising a deformation device for converting a web of packaging material drawn from a supply of packaging material web, such as a leporello folded stacked web, into a dunnage material and a conveyor structure for receiving the drawn web of packaging material and for feeding the drawn web of packaging material into the deformation device, wherein the conveyor structure comprises a conveyor track extending from a reception of the conveyor structure to the deformation device and being dimensioned such that, after passing the reception, the web of packaging material is able to bear over its entire surface on the conveyor track in the conveying direction for at least the twofold of the width of the web.

Claims

1. A packaging station comprising: a deformation device configured to convert a web of packaging material drawn from a supply of packaging web into a dunnage material, the deformation device being channel-shaped having a concavely planar channel bottom surface; and a conveyor structure configured to: receive the drawn web of packaging material, and feed the drawn web of packaging material into the deformation device, wherein the conveyor structure includes a conveyor track having a surface extending from a reception of the conveyor structure to an entrance of the deformation device in a conveying direction, the conveyor track being configured such that after passing the reception, the web of packaging material travels over the surface in the conveying direction, wherein the deformation device adjoins the conveyor structure such that the surface of the conveyor track and the channel bottom surface of the deformation device collectively form an arc-shaped structure having a uniform radius of curvature from the reception of the conveyor structure to a disposal opening of the deformation device in the conveying direction.

2. The packaging station according to claim 1, wherein the conveyor structure comprises a plane sliding support that is formed by a sheet or a mesh and facing the web of packaging material, wherein the reception of the conveyor track is formed by a rectilinear edge extending essentially perpendicular with respect to the conveying direction.

3. The packaging station according to claim 1, wherein the conveyor structure comprises a plane sliding support having a sliding support length.

4. The packaging station according to claim 1, wherein the conveyor track comprises a bridge arc connecting the supply of packaging material web with the deformation device, wherein an inclination of the bridge arc decreases from the reception to an apex of the conveyor track, and, starting from the apex of the conveyor track, the conveyor track descends towards the deformation device.

5. The packaging station according to claim 4, wherein a tangent direction forms an angle of reception smaller than 20 and larger than 0, relative to a vertical direction at the reception of the sliding support of the bridge arc, wherein a tangent direction forms an angle of disposal smaller than 20 and larger than 0 relative to the vertical direction at the disposal opening of the sliding support of the bridge arc.

6. The packaging station according to claim 1, wherein: the deformation device comprises a channel-shaped deformation device that connects to the conveyor track, wherein the channel-shaped deformation device comprises the concavely planar channel bottom surface, the radius of curvature of which corresponds to the radius of curvature of the conveyor track to provide the uniform radius of curvature of the arc-shaped structure; a width transverse to the conveying direction of a channel cross section, at the channel bottom surface, continuously decreases from the entrance of the deformation device to the disposal opening of the deformation device in the conveying direction; and a height of the channel cross section continuously increases from the entrance of the deformation device to the disposal opening in the conveying direction.

7. The packaging station according to claim 1, wherein the deformation device comprises a tapering channel corridor opening into the disposal opening, wherein within the channel corridor, a deformation of the web of packaging material is realized by walls of the channel.

8. The packaging station according to claim 1, wherein the conveyor track is dimensioned such that, after passing the reception, the web of packaging material can bear its entire surface, along an entire width of the web in the direction transverse to the conveying direction, on the conveyor structure.

9. The packaging station according to claim 1, wherein the deformation device is oriented relative to a vertical direction in a fixed manner with an inclination angle, such that the dunnage material leaving the deformation device is oriented vertically downward at the disposal opening, wherein an apex of the conveyor structure is positioned in a direction of gravity above the disposal opening, the reception of the conveyor structure being arranged essentially on a same height as the disposal opening.

10. The packaging station according to claim 1, wherein the conveyor track comprises a bridge arc connecting the supply of packaging material web with the deformation device.

11. The packaging station according to claim 1, wherein the conveyor track comprises a bridge arc connecting the supply of packaging material web with the deformation device.

12. The packaging station according to claim 1, wherein the channel bottom has a radius of curvature that corresponds to a radius of curvature of the conveyor track to provide the uniform radius of curvature of the arc-shaped structure.

13. A packaging station comprising: a deformation device configured to convert a web of packaging material drawn from a supply of packaging web into a dunnage material, the deformation device being channel-shaped having a concavely planar channel bottom surface; and a conveyor structure configured to: receive the drawn web of packaging material, and feed the drawn web of packaging material into the deformation device, wherein the conveyor structure comprises: a conveyor track comprising a plane sliding support having a surface extending from a reception of the conveyor structure to an entrance of the deformation device in a conveying direction, the conveyor track being configured so that after passing the reception, the web of packaging material travels over the surface in the conveying direction and the conveyor track comprises a bridge arc connecting the supply of packaging material web with the deformation device, wherein: the deformation device adjoins the conveyor track such that the surface of the conveyor track and the channel bottom collectively form an arc-shaped structure having a uniform radius of curvature from the reception of the conveyor structure to a disposal opening of the deformation device in the conveying direction, the arc-shaped structure including the bridge arc of the conveyor track, and an inclination of the bridge arc is configured to decrease from the reception to an apex of the conveyor track, and starting from the apex of the conveyor track, the conveyor track is configured to descend towards the deformation device.

14. The packaging station according to claim 13, wherein the plane sliding support is formed by a sheet or a mesh and facing the web of packaging material, wherein the reception of the conveyor track is formed by a rectilinear edge extending essentially perpendicular with respect to the conveying direction.

15. The packaging station according to claim 13, wherein the plane sliding support of the conveyor track comprises a sliding support length.

16. A packaging station comprising: a deformation device including a deformation channel and being configured to convert a web of packaging material drawn from a supply of packaging web into a dunnage material; and a conveyor structure configured to: receive the drawn web of packaging material, and feed the drawn web of packaging material into the deformation device, wherein the conveyor structure includes a conveyor track configured to descend towards the deformation device, the conveyor track including: a plane sliding support having a surface extending from a reception of the conveyor structure to an entrance of the deformation device, the conveyor track being configured such that after passing the reception, the web of packaging material travels over the surface of the plane sliding support in a conveying direction, the plane sliding support forming a bridge arc connecting the supply of packaging material web with the deformation device, an inclination of the bridge arc being configured to decrease from the reception until an apex of the conveyor track in the conveying direction, wherein a width of a base of the deformation channel transverse to the conveying direction of the deformation channel continuously decreases in the conveying direction from the entrance of the deformation channel to a disposal opening of the deformation channel and a height of the deformation channel between the base of the deformation channel and a channel cover continuously increases in the conveying direction from the entrance of the deformation channel to the disposal opening of the deformation channel.

17. The packaging station according to claim 16, wherein the deformation device and the conveyor track collectively form an arc-shaped structure having a uniform radius of curvature from the reception of the conveyor structure to the disposal opening of the deformation device in the conveying direction.

Description

(1) Further advantages, features and characteristics of the invention are explained by the following description of a preferred embodiment with the aid of the attached drawings, in which there are shown:

(2) FIG. 1 a perspective view of a packaging station in accordance with the invention with a web of packaging material supply consisting of a plurality of leporello folded stacks;

(3) FIG. 2 a perspective view of the packaging station in accordance with the invention according to FIG. 1 without the web of packaging material supply;

(4) FIG. 3 a perspective view onto a conveyor structure of the packaging material station in accordance with FIG. 2; and

(5) FIG. 4 a perspective detail view of the disposal end of the deformation device in accordance with the packaging station according to FIGS. 1 and 2.

(6) In FIGS. 1 and 2 the packaging station according to the invention is provided in general with the reference number 1 and comprises as main components a conveyor structure 3 according to the invention and a manually operated deformation device 5, free of gears or toothed wheels, which, however, can also be replaced by another deformation device, which can for example also be motorized with a pair of gears.

(7) In FIG. 1 in addition a packaging table 11 is illustrated, on which a supporting structure 13 in the form, for example, of a supporting frame is arranged, on which the conveyor structure 3 and the deformation device 5 is firmly or movably attached (the mounting is not illustrated in further detail). Behind/adjacent to the packaging table 11 a packaging material web supply 15 is positioned, in the form of eight leporello folded stacks which, unused, have a minimum height of 50 cm and are able to be transported together on a pallet, which is not illustrated in further detail. Of the eight leporello folded stacks, one is already partially used.

(8) In accordance with the packaging station 1, which is illustrated in operation, a packaging material web 21 of constant web width b is unfolded from the partially used leporello folded stack and arrives at a reception 23 of the conveyor structure 3.

(9) The height of the reception 23 is set with respect to the upper side of the unused stack such that at least two fold sheets of the leporello folded web 21 are completely unfolded and that a paper web extends, more or less uninfluenced from the leporello fold, before it reaches the conveyor structure 3 at the reception 23. The reception 23 is formed by the edge 24, essentially perpendicular in conveying direction, of the sheet-shaped conveyor structure 3 which, for damage-free receiving, is free of a flange or is in another manner rounded free of edges.

(10) The conveyor structure 3 is a conveyor track 25, which is formed in a sheet form or a mesh structure, which is brought into a bent curvature by cold forming. The sheet-shaped conveyor track which is illustrated in the figures comprises a concavely planar sliding support 27. The sliding support 27 can, as is indicated in FIGS. 1 and 2, have a continuous concave curvature, whereby a uniform conveying, stabilizing the packaging material, is achieved. In an alternative configuration of the sliding support, the latter can also be formed by a plurality of plane, curvature-free sheet sections adjoining one another in series, which lie at an obtuse angle with respect to one another, wherein two adjacent sheet sections form an edge/bend extending in the direction transverse to the conveying direction, whereby a polygon-shaped sliding support (27) is realized, to realize the bridge-shaped curvature. Preferably, the polygon-shaped sliding support (27) has more than five or ten such edges, wherein each sheet section is dimensioned essentially identically, for example has the same width (in conveying direction), which extends along the direction transverse to the conveying direction constantly from one lateral edge of the sliding support to the other lateral edge of the sliding support. The edges/bends (not illustrated in further detail) in particular have the advantage that possible suction forces generated by the conveying, which can arise owing to underpressure phenomena between the packaging material and the sliding support, are dissipated, because the polygonal sliding support enforces a direct (linear) contact with the packaging material.

(11) The unfolded conveying web 21 lies with its entire surface on the sliding support 27 of the conveyor track 25 and is pressed onto the sliding support and drawn along it in particular exclusively under the influence of gravity and by withdrawal forces. In the embodiment illustrated in the figures, the withdrawal forces are achieved manually by drawing by an operator (not illustrated in further detail), who is working at the packaging material table 11. It is to be clear that the drawing forces can also be automated by a motor, which can be part of the deformation device, which, however, is not illustrated in further detail in the figures.

(12) The sheet-shaped conveyor track 25 forms a bridge-shaped arc from the packaging material supply 15, bridging the rear edge of the packaging table 11, up to the deformation device, to which the operator has easy access. Preferably, the radius of curvature of the conveyor track is essentially constant, so that a partially cylindrical track is realized from the reception 21 up to the deformation device 5. At the reception 23, which is realized by the transverse edge 24, perpendicular to the conveying direction F, a track raise is provided, which is specified by an angle from a track tangential direction at the reception 23 with respect to the vertical. This angle is to be larger than 0 and preferably smaller than 10. In this way, a packaging material web unfolded approximately vertically upwards is reliably received, which owing to the decreasing inclination of the concavely planar conveyor track 25 nestles in a flat manner against the sliding support 27. At higher conveying speeds, an air layer can form between the conveyor track and the packaging material, whereby on the one hand owing to the concavely planar conveyor track a reliable guidance of the packaging material web 21 up to the deformation device 5 arises, on the other hand the packaging material is conveyed gently along the sliding support 27.

(13) The channel-shaped deformation device 5, which is generally formed by a tapering channel structure, immediately adjoins the sheet-shaped conveyor track 25. The channel-shaped deformation device 5 comprises a concavely planar channel bottom 29, which in the course of the radius of curvature corresponds to the sliding support 27 of the conveyor track 25 lying upwards with respect to conveying direction. Lateral channel walls 31 extend from the channel bottom 31, which continue into a channel cover 33, the course of curvature of which corresponds substantially to that of the channel bottom 29.

(14) As can be seen in FIGS. 1 and 2, the channel cross-sectional area decreases continuously in conveying direction, and the channel width (in the direction transverse to the conveying direction) decreases continuously in the conveying direction, whereas the gap height in conveying direction F increases slightly up to the disposal opening 27, so that the web of packaging material can divert in vertical direction during the lateral squeezing. In this way, the desired dunnage form with a sufficiently high dunnage height is achieved. The channel corridor of the deformation device 5 tapers towards the disposal opening 37. The side walls 31 therefore run towards one another in a funnel-shaped manner, so that the web of packaging material, which is drawn through the deformation device 5, can be pressed together owing to the narrowing passage cross-section, whereby a concertina-shaped dunnage material can be created.

(15) At the entry inlet of the deformation channel of the deformation device 5, the cover region is upwardly flanged or bent around, so that a round transverse edge is formed at the inlet region of the deformation channel. As can be seen in FIG. 4, the channel bottom 29, as also the side walls 31, is also bent outwards at the disposal opening 37, so that corresponding bent-around wings and, in particular, one or two tear-off corners 38 are formed. In so doing, a slightest passage cross-section is formed still before the boundary edges of the disposal opening 37.

(16) The disposal opening 37 is widened on the cover side by a recess extending upstream in the conveying direction, so that a manual access by the operator to the packaging material upstream from the winding side of the curvature channel into the disposal opening is facilitated. The disposal opening 37 is configured to be essentially circular on the cover side in the plane of the channel cover 33.

(17) As can be seen in FIGS. 1 and 2, the conveyor track 25 extends essentially along its entire surface above the disposal opening 37. The disposal opening 37 is shaped, dimensioned and oriented manner such that the dunnage material, on leaving the in particular angularly adjustable (not illustrated) deformation device 5, can be directed vertically downward in an angle span of up to 90 (direction of gravity). It is to be clear that the reception 23 can also reach still nearer to the packaging material web supply 15, however the major portion of the conveyor track 35 is to lie above the disposal opening 37.

(18) On the outer side of the side walls 31, handles 35 are able to be grasped for positioning the arrangement of the conveyor structure 3 and the deformation device 5, in particular the disposal opening, over the packaging table 11, in order to bring the unit of conveyor structure 3 and deformation device 5 to the desired packaging site. It is to be clear that a movable mounting in all three dimensions is to realize an adjustment of the disposal opening position.

(19) The disposal opening is realized by the edges, lying downwards with respect to conveying direction, of the channel bottom 29 and the side walls 31 and the channel cover 33, wherein in conveying direction F the side walls 31 and the channel bottom 29 project the furthest. The channel cover 33 is set back with a recess projecting further in contrary to the conveying direction than in the case of the side walls 31 and the channel bottom 29.

(20) In FIG. 3 the conveyor structure 3 is illustrated in a perspective view from the side of the reception 23, wherein the deformation device 5 is not indicated. FIG. 3 shows a retention device 41 arranged above the sliding support 27, which is intended to prevent that on tearing off of the dunnage material 29 downwards, with respect to the conveying direction, of the disposal opening 37 a falling back of the packaging material web contrary to the conveying direction F towards the packaging material web supply 15 is prevented. For this, the holding device 41 has a spanning bracket 43, on which a pressure arm 45, which is spring-preloaded for example, is arranged, which in fact permits a conveying of the conveyor track in conveying direction F in a more or less uninfluenced manner towards the deformation device 5, however prevents a slipping back of the packaging material web 21. Therefore, the pressure arm is prestressed towards the sliding support 27 and extends from a fastening arm 46 pivotably in conveying direction F.

(21) For loading the packaging station 1, the operator goes to the packaging material web supply 15 and grasps the free end of the packaging material web 21 and directs it towards the conveyor structure 3 along the sliding support into the deformation device 5. Finally, the packaging material web 21 is forced through the disposal opening 37, whereby the packaging material web 21 deforms into the desired dunnage material 39. At the disposal opening 37 a tear-off cutting edge can be arranged, in order to accomplish the simple tearing off of the formed dunnage material 39. The tear-off process is further simplified because on the channel bottom 29 and the channel walls 31 in conveying direction at the height of the disposal opening 37 an essentially triangular notch/depression (38) is realized, delimited by an edge section of the respective side wall 31 and the channel bottom 29. These edge sections (tear-off edges) are, in particular, sharpened. Owing to the inwardly projecting tear-off edges, a risk of injury to the operator is reduced in so far as the notch (38) is relatively small and the edge sections, owing to their rear projection are protected by the protruding sections of the channel bottom 29 and of the side walls 31.

(22) After tearing off, in particular at the triangular tear-off corner 38, the end of the deformed packaging material web remains jammed in the corner region, so that a falling back of the packaging material web towards the packaging material web supply 15 is prevented.

(23) At the start of the next dunnage material production, the operator grasps the tear-off end of the dunnage material 39 which is clamped at the tear-off corner 38, and draws on it to generate further dunnage material 39. The packaging material web 21, owing to the traction force in conveying direction F and the curvature inclination of the conveyor track 25 is pressed gently against the sliding support 27, which introduces the packaging material web in a steadying manner into a predefined conveyor track path into the deformation device 5.

(24) It was found that even at high speeds a reliable feeding and deforming of the packaging material web is successful.

(25) The features disclosed in the above description, the figures and claims can be of significance both individually and also in any desired combination for the realization of the invention, in the various embodiments.

LIST OF REFERENCE NUMBERS

(26) 1 packaging station 3 conveyor structure 5 deformation device 11 packaging table 13 supporting structure 15 supply of packaging material web 17 leporello folded stack 21 web of packaging material 23 reception 24 transverse edge 25 conveyor track 27 sliding support 29 channel bottom 31 channel walls 33 channel cover 35 handles 37 disposal opening 38 tear-off corner 39 dunnage material 41 retention device 43 spanning bracket 45 pressure arm 46 fastening arm b web width F conveying direction