Perforation tool for a device for the production by machine of a filling material product and a device for the production by machine of a filling material product

Abstract

Perforation tool for a device for the manufacturing by machine of a dunnage material which is to be formed of a single layer or multi-layer paper web whereby the perforation tool is configured for introducing a perforation into the dunnage material and comprises: at least one perforation nose, at least one perforation reception wherein the at least one perforation nose and the at least one perforation reception are associated with each other such that, for perforating, the at least one perforation nose can retract and extend with respect to the at least one perforation reception, and at least one stripper which is associated with the at least one perforation nose and/or the at least one perforation reception such that, when disengaging, perforated dunnage material is removed from the at least one perforation nose and/or from the at least one perforation reception.

Claims

1. A device for the production by machine of a three-dimensional dunnage material which is to be formed of a single layer or multi-layer paper web, the device comprising: a pre-shaping station which reshapes the paper web into a three-dimensional dunnage material with at least one hollow crumple space extending in a direction of travel of the paper web; a cutter following the pre-shaping station in the direction of travel of the paper web, the cutter configured to cut off a paper web portion to a desired length of the three-dimensional dunnage material; and a perforation tool configured for introducing a perforation into the dunnage material, the perforation tool comprising: at least one perforation nose, at least one perforation reception wherein the at least one perforation nose and the at least one perforation reception are associated with each other such that, for perforating, the at least one perforation nose can retract and extend with respect to the at least one perforation reception, and at least one stripper which is associated with at least one of the at least one perforation nose or the at least one perforation reception such that perforated dunnage material is removed from at least one of the at least one perforation nose or the at least one perforation reception as the at least one perforation nose extends with respect to the at least one perforation reception; wherein the at least one perforation nose and the at least one perforation reception are each attached to a shaft, further wherein a carrier for a stamp pad is arranged at the shaft of the at least one perforation nose, which comprises at least two holding plates radially extending from the shaft of the at least one perforation reception, wherein the at least two holding plates limit a seat for the stamp pad and each of the at least two holding plates comprises an axially extending end edge which comprises a recess for forming the at least one perforation reception, which is configured for a pushing engagement with the at least one perforation nose.

2. The device according to claim 1, wherein the at least one stripper is an additional, movably arranged component with respect to at least one of the at least one perforation reception or the at least one perforation nose.

3. The device according to claim 1, wherein the at least one stripper comprises an elastic mass in which at least one of the at least one perforation nose or the at least one perforation reception is at least partially embedded.

4. The device according to claim 3, wherein in a passive state of the at least one stripper an engagement portion of at least one of the at least one perforation nose or the at least one perforation reception is at least partially surrounded by the elastic mass, wherein the at least one stripper is brought into an active state when retracting, as the engagement portion is exposed from the elastic mass by compression of the elastic mass, wherein when the at least one stripper extends in the event of a transition from the active state into the passive state, the at least one stripper is configured to push material of the paper web from the at least one perforation nose as the compressed mass elastically relaxes.

5. The device according to claim 1, wherein the at least one perforation nose and the at least one perforation reception are each rotationally mounted with respect to each other such that the at least one perforation nose can gearwheel-like turn in and turn off the at least one perforation reception.

6. The device according to claim 1, wherein the shaft of the at least one perforation nose carries a cutter, the cutter including a blade that extends across a direction of travel (F) of the paper web, wherein the at least one perforation nose is arranged in one of leading or trailing in a rotational direction (R) of the shaft with respect to the blade.

7. The device according to claim 6, wherein the blade is embedded into an elastic mass of the at least one stripper and associated with the stamp pad arranged at the shaft of the at least one perforation reception, such that when cutting off the dunnage material, the stamp pad forces back the elastic mass during an elastic compression of the stamp pad to expose the blade such that when extending, the stamp pad releases the compressed elastic mass, such that the elastic mass pushes material of the paper web from the blade due to an elastic restoring force wherein the elastic mass is softer than the stamp pad which is softer than the blade.

8. The device according to claim 7, wherein the cutter comprises two clamper plates attached to a shaft of the at least one perforation nose for limiting a reception slot in which the cutter is fixed and at which the cutter radially protrudes with the blade, wherein a plurality of perforation noses arranged in a row is provided at an axially extending end edge of the clamper plates wherein the plurality of perforation noses extend substantially to a same radial height as the blade, wherein two lateral gripper pads are attached to the clamper plates and limit a reception space, in which the at least one stripper is fixedly received and which is open for an access of at least one of the at least one perforation reception or the stamp pad, wherein the gripper pads comprise radially and axially extending arm portions which prevent a spreading when the at least one stripper elastically deforms, wherein the at least one perforation nose is coupled with both a first clamping plate of the two clamper plates and a first gripper pad of the two lateral gripper pads.

9. The device according to claim 1, wherein the pre-shaping station of the device is realized by an embossing wheel pair.

10. A device for the production by machine of a three-dimensional dunnage material which is to be formed of a single layer or multi-layer paper web, the device comprising: a pre-shaping station which reshapes the paper web into a three-dimensional dunnage material with at least one hollow crumple space extending in a direction of travel of the paper web; a cutter following the pre-shaping station in the direction of travel of the paper web, the cutter configured to cut off a paper web portion to a desired length of the three-dimensional dunnage material; and a perforation tool with at least one pad cavity extending in the longitudinal direction, to be formed of a single layer or multi-layer paper web, wherein the perforation tool is configured for introducing a perforation into the dunnage material, the perforation tool comprising: at least one perforation nose; at least one perforation reception wherein the at least one perforation nose and the at least one perforation reception are associated with each other such that, for perforating, the at least one perforation nose can retract and extend with respect to the at least one perforation reception; and at least one stripper which is associated with at least one of the at least one perforation nose and the at least one perforation reception such that perforated dunnage material is removed from at least one of the at least one perforation nose and the at least one perforation reception as the at least one perforation nose extends with respect to the at least one perforation reception; wherein the at least one perforation nose and the at least one perforation reception are each attached to a shaft, further wherein a carrier for a stamp pad is arranged at the shaft of the at least one perforation nose, which comprises at least two holding plates radially extending from the shaft of the at least one perforation reception, wherein the at least two holding plates limit a seat for the stamp pad and each of the at least two holding plates comprises an axially extending end edge which comprises a recess for forming the at least one perforation reception, which is configured for a pushing engagement with the at least one perforation nose.

11. The device according to claim 10, wherein the at least one stripper is an additional, movably arranged component with respect to at least one of the at least one perforation reception or the at least one perforation nose.

12. The device according to claim 10, wherein the at least one stripper comprises an elastic mass in which at least one of the at least one perforation nose or the at least one perforation reception is at least partially embedded.

13. The device according to claim 12, wherein in a passive state of the at least one stripper an engagement portion of at least one of the at least one perforation nose or the at least one perforation reception is at least partially surrounded by the elastic mass, wherein the at least one stripper is brought into an active state when retracting, as the engagement portion is exposed from the elastic mass by compression of the elastic mass, wherein when the at least one stripper extends in the event of a transition from the active state into the passive state, the at least one stripper is configured to push material of the paper web from the at least one perforation nose as the compressed mass elastically relaxes.

14. The device according to claim 10, wherein the at least one perforation nose and the at least one perforation reception are each rotationally mounted with respect to each other such that the at least one perforation nose can gearwheel-like turn in and turn off the at least one perforation reception.

15. The device according to claim 10, wherein the shaft of the at least one perforation nose carries a cutter, the cutter including a blade that extends across a direction of travel (F) of the paper web, wherein the at least one perforation nose is arranged in one of leading or trailing in a rotational direction (R) of the shaft with respect to the blade.

16. The device according to claim 15, wherein the blade is embedded into an elastic mass of the at least one stripper and associated with the stamp pad arranged at the shaft of the at least one perforation reception, such that when cutting off the dunnage material, the stamp pad forces back the elastic mass during an elastic compression of the stamp pad to expose the blade such that when extending, the stamp pad releases the compressed elastic mass, such that the elastic mass pushes material of the paper web from the blade due to an elastic restoring force wherein the elastic mass is softer than the stamp pad which is softer than the blade.

17. The device according to claim 16, wherein the cutter comprises two clamper plates attached to a shaft of the at least one perforation nose for limiting a reception slot in which the cutter is fixed and at which the cutter radially protrudes with the blade, wherein a plurality of perforation noses arranged in a row is provided at an axially extending end edge of the clamper plates wherein the plurality of perforation noses extend substantially to a same radial height as the blade, wherein two lateral gripper pads are attached to the clamper plates and limit a reception space, in which the at least one stripper is fixedly received and which is open for an access of at least one of the at least one perforation reception or the stamp pad, wherein the gripper pads comprise radially and axially extending arm portions which prevent a spreading when the at least one stripper elastically deforms, wherein the at least one perforation nose is coupled with both a first clamping plate of the two clamper plates and a first gripper pad of the two lateral gripper pads.

18. The device according to claim 10, wherein the dunnage material comprises two cushion-like hollow crumple spaces extending in the direction of the web which are connected over an embossed middle area.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 a perspective view of a part of the manufacturing device according to one embodiment;

(2) FIG. 2 a perspective view of one of the two main parts of a perforation tool according to one embodiment, namely the nose tool part of the manufacturing device;

(3) FIG. 3 a perspective view of a basic structure of the nose tool part according to FIG. 2;

(4) FIG. 4a a perspective view of a first embodiment of the other part of the perforation tool, namely the receiving tool part;

(5) FIG. 4b a perspective view of a second embodiment of the other part of the perforation tool, namely the receiving tool part;

(6) FIG. 5a a perspective view of a first embodiment of a basic structure of the receiving tool part according to FIG. 4a;

(7) FIG. 5b a perspective view of a second embodiment of a basic structure of the receiving tool part according to FIG. 4b;

(8) FIGS. 6a-6c cross-sectional views of the perforation tool according to one embodiment with the receiving tool part according to FIG. 4a in three different operational states during and after the perforation process; and

(9) FIGS. 7a-7c cross-sectional views of the perforation tool according to one embodiment with the receiving tool part according to FIG. 4b in three different operational states during and after the perforation process.

DETAILED DESCRIPTION

(10) In FIG. 1 the manufacturing device according to one embodiment in general has the reference sign 1 wherein pre-shaping station of the manufacturing device 1 is realized by an embossing wheel pair 5 wherein a transfer station is not shown, arranged in a leading manner with respect to the direction of travel F, at which longitudinal strips of the paper web being unwound from the paper web roll (not shown) can be transferred or wound up across a middle area extending in a longitudinal direction of the paper web. In this way, the paper web layers to be forwarded which are lying above each other double within the manufacturing device 1. In this embodiment, the longitudinal strips of the paper web are lying free in its middle area. The pre-shaping station implemented as an embossing wheel pair 5 deforms the paper web in the middle area, where the longitudinal edges lie, whereby they are hold in the middle area of the paper web and cushion cavities laterally extending in a direction of travel F are formed.

(11) An example for such a pre-shaping station is known from DE 10 2012 018 941 A1 which content shall be included into the description of the figures.

(12) Following the embossing wheel pair 5 in the direction of travel F, an additional tool station 7 is provided which contains the perforation tool 11 according to one embodiment. The paper web is forwarded through a shaft-like housing part 13 of the manufacturing device 1 which contains recesses for bearings. The housing part 13 defines an access and disposal opening 15.

(13) The perforation tool 11 according to one embodiment consists of two main parts, namely a nose tool 21 and a receiving tool 23, which is nearly completely hidden by the housing part 13 in FIG. 1. The nose tool 21 and the receiving tool 23 engage which each other gearwheel-like in order to realize the perforation in the continuously forwarded paper web material and to create the desired dunnage material.

(14) The nose tool 21 is shown in detail in FIGS. 2 and 3 wherein FIG. 3 merely shows its stiff basic structure 25. The stiff basic structure 25 of the nose tool 21 comprises a nose shaft 27 at which two clamper plates 31a, 31b are axially pushed and attached. The clamper plates 31a, 31b limit a reception slot 33, turned to itself, of one or a few millimeters, in which a cutting knife 35 with a blade 37 is fixedly and fittingly arranged. It is shown in FIG. 2 that an essential part of the cutting knife 35 radially protrudes a reinforced axially, straight extending end edge portion 41 of the clamper plates 31a, 31b.

(15) The clamper plates 31a, 31b are held by four hub ring frames 43 which lead integrally into a pair of perforation noses 45a, 45b at its end edges wherein a perforation nose 45a engages the clamper plate 31a hook-like while the other perforation nose 35b engages the clamper plate 31b.

(16) As shown in FIGS. 2 and 3 the end edge portion 41 of the clamper plates 31a, 31b is reinforced and respectively forms an undercut whereby the hook engagement of the perforation noses 45a, 45b is adjusted thereto. Each perforation nose 45a, 45b comprises two punching wheels 47 which are partially exposed at the radial end of the perforation nose 45a, 45b.

(17) Additionally the nose tool 21 includes two gripper pads 51a, 51b each comprising radially extending limiting arms which limit a cavity 55 into which the end edge portion 41 of the clamper plates 31a, 31b, the cutting knife 35 as well as the perforation noses 45a, 45b extend. A stripper 57 is form-fittingly introduced, particularly molded, into the cavity 55 for the perforation noses 45a, 45b in the form of a two-part PU-foam body 61 wherein the one part of the PU-foam body is separated from the other part by means of a reception slot extension which is a radial extension of the reception slot 33 of the clamper plates 31a, 31b. The elastic PU-foam body 61 of the stripper 57, formed as an elastic mass, surrounds approximately completely the cutter knife 35 (at least the part which radially protrudes from the clamper plates 31a, 31b) and partially the perforation noses 45a, 45b. The perforation noses 45a, 45b as well as the cutter knife 35 are contactingly surrounded in such a way by the elastic mass of the PU-foam body that they are partially embedded.

(18) The gripper pads 51a, 51b comprise through holes 59 which allow a screwing of the gripper pads 51a, 51b. Additionally the gripper pads 51a, 51b comprise clearing slits facing the perforation nose shaft 27 in which the respective hub ring frames 43 which carry the perforation noses 45a, 45b protrude and which extend to the axial end edge portion 41 of the clamper plates 31a, 31b.

(19) The hub ring frames 43 and the respectively associated perforation noses 45a, 45b are manufactured from one piece, wherein the shaft-hub-connection can be realized by shrinking.

(20) A locally limited deformation of the areas of the PU-foam body 61 adjacent the respective perforation nose 45a, 45b or of the blade 37 causes an exposure of the perforation nose, in particular of its punching wheels 47, respectively the blade 37, whereby the cutting function of the perforation nose 45a, 45b and the cutting function of the blade 37 is completely activated.

(21) The reception tool 23 is responsible for the local elastic deformation of the PU-foam body 61 which is illustrated with regard to a first exemplary embodiment by means of FIGS. 4a and 5a. As the nose tool 21, the reception tool 23 of the perforation tool 11 comprises a basic structure 63 which also comprises a shaft, namely the perforation reception shaft 65. Two holding plates 67a, 67b extend from the perforation reception shaft 65, which parallel radially extend from the perforation reception shaft 65. The distance between the inner sides of the holding plates 67a, 67b is substantially equal to the diameter of the perforation reception shaft 65 wherein the holding plates 67a, 67b facing each other include a seat 71 for a stamp pad 73.

(22) In order to attach the holding plate 67a, 67b to the perforation reception shaft 65 a plurality of, particularly five, hub ring frames 74 are provided which are substantially equal to the components 43 of the nose tool 21 wherein no perforation noses are provided. It is to be noted that the perforation reception shaft 65 can carry the perforation noses 45a, 45b as well as that the perforation nose shaft 27 can form the perforation receptions, which embodiment is not shown in the drawings.

(23) The function of the reception of the perforation noses is realized at the reception tool 23 at the axial end edge portion 75 of the holding plates 67a, 67b in which a number of slit recesses 77a, 77b, which is equal to the number of perforation noses 45a, 45b, is introduced. The slit recesses 77a, 77b form the perforation receptions in the shown embodiment according to the figures. The slit recesses 77a, 77b are dimensioned in a way that, according to a loose fit, the perforation noses 45a, 45b can contactlessly retract and extend in a circumferential rotational direction, if the tool parts 21, 23 are in a contactless perforation engagement, when turning in and off according to a gearwheel as shown in FIGS. 6a to 6c. In the area of the slit recesses 77a, 77b, the axial end edge portion 75 is locally reinforced such that at the free end of the reinforced area, two pairs of curved punching edges 79 which also interact perforatingly with the respective punching edge of the perforation nose 45a, 45b.

(24) The stamp pad 73 comprises a cutting pad 83 which is centrically arranged and laterally framed by two more elastic deformation bars 83a, 83b. The elastic deformation bars 83a, 83b form the stripper for the perforation reception 77a, 77b. The perforation noses 45a, 45b deform the elastic deformation bars when retracting and displace them sectionwise radially inwardly (adjacent the slit recesses). When extending, the deformation bars 83a, 83b return back to its original unloaded form and potentially thereby displace adhered paper web material. The elastic deformation bars are also formed from PU-foam as the PU-foam body 61 of the stripper 57 for the perforation noses 45a, 45b.

(25) FIGS. 4b and 5b show a receiving tool in a second embodiment where identical or similar components have identical reference signs as in the embodiment of FIGS. 4a and 5a, which are increased by 100.

(26) The receiving tool 123 differs from the embodiment according to FIGS. 4a and 5a in that no deformation bars 83a, 83b are provided and the radial ends of the holding plates 167a, 167b run towards the radial front side of the cutting pad 183. The holding plates 167a, 167b form at its radial stamping front side wedge-shaped strips which form a T-shaped undercut in the seat 171. This variant is, due to the low number of components, assembly-friendly and allows anchoring the cutting pad 183 secure and fix into the receiving tool 123. Apart from the before-mentioned differences, the receiving tool 123 functions like the first embodiment according to FIGS. 4a and 4b with the difference that the perforation noses 145a, 145b do not protrude through the slit recesses into the deformation bars but extend into the slit recesses 177a, 177b which extend to the cutting pad 163.

(27) In FIGS. 6a to 6c, the perforation tool 11 in the manufacturing device 1 is provided to create preassembled dunnage materials wherein the two shafts 27, 65 are mounted at the housing part 11 of the manufacturing device 1.

(28) As can be seen in FIGS. 6a to 6c, both tool parts 21, 23 are arranged with respect to each other that, in case of a rotational passage (6 o'clock respectively 12 o'clock position), the radially extending plates, the clamper plates 31a, 31b as well as the holding plates 67a, 67b, are parallel to each other. The cutting knife 35 comprises the same orientation, wherein both axis of rotation of the shafts 65, 27 lie in the plane of the cutting knife 35.

(29) In FIGS. 6a and 6b, when the nose tool 21 and the receiving tool 23 are in a gearwheel-like passing engagement, it is indicated how the PU-foam body 61 as well as the deformation bars 83a, 83b are radially inwardly elastically compressed, due to the engagement of the reinforced end edge portion 75 adjacent the slit recesses 77a, 77b as well as adjacent the perforation noses 45a, 45b whereby the respective wiping function of both the PU-foam body 61 and the deformation bars 83a, 83b is activated. In this way, the respective perforation noses 45a, 45b and the blade 37 as well as the slit recesses 77a, 77b are completely exposed for the cutting function. In FIG. 6a, the perforation nose 45b and the respective slit recess 77b as well as the blade 37 are activatingly exposed such that they perforate/cut the paper web material as desired, which is not shown in greater detail. The cut, leading dunnage material comprises a row of perforations arranged in a transverse direction, which prevent the preassembled dunnage materials from unfolding, adjacent the cutting edge which extends perpendicular to the direction of travel F.

(30) When the tools 21, 23 rotate further in a rotational direction R, the leading perforation nose 45b disengages the respective slit recess 77b whereby at the same time, due to the elasticity of the PU-foam, the wiping function of both the PU-foam body 67 and the deformation bars 83 is performed to potentially push adhered paper web material from the respective punching edges 45, 79 as well as from the blade 37 whereby a deflection of the preassembled dunnage material from the conveying path is prevented and therefore, the risk of a paper jam is reduced.

(31) Afterwards, the trailing perforation nose 45a engages the respective slit recess 77a (see FIG. 6b). In this way, also the leading cutting edge of the dunnage material, close to the cutting edge already introduced, is provided with a row of transversely consecutively arranged perforations. The reinforced wall at the slit recess 77a displaces the PU-foam body 61 adjacent the perforation nose 45a whereby it is exposed, and vice versa, with respect to the deformation bar 83b. At this stage the blade 37 has already disengaged the cutting pad 83 such that at least the cutting process is completed.

(32) As can be seen in FIGS. 6a to 6c, the packaging material product is cut at the transversely extending straight blade 37 with one stroke, because the cylindrical circumferential rotational casing of the blade 37 tangentially cuts the conveying path of the pre-shaped paper web.

(33) When further disengaging the tools 21, 23 and the elastic restoring forces, all of the paper web material which is potentially adhered to the perforation nose 45a, 45b, the slit recesses 77a, 77b, or the blade 37 is wiped away whereby a paper web material jam can be avoided as far as possible. It is clear that the wiping function is performed by the elastic PU-foam body 61 when using an alternative receiving tool 123. As can be seen in FIGS. 7a to 7c, the perforation tool 11 functions with the alternative receiving tool part 123, which is explained with reference to FIGS. 6a to 6c.

(34) It is also clear that the wiping function can be realized by other components instead of the elastic PU-foam body 61. The wiping components are movably attached to the nose tool part 21 and independently perform a wiping movement relative to the perforation nose 45a, 45b, the perforation reception and/or the cutting knife 37. The movable wiping component can for example be arranged in the area of the cavity 55 limited by the gripper pads 51a, 51b wherein the wiping function can be, for example, similar to a perforation nose and/or a spring-loadable pushing element close to a perforation reception.

(35) The features disclosed in the preceding description, figures and claims can be relevant for the realization of the embodiments individually as well as in any combination of the different embodiments.

LIST OF REFERENCE NUMERALS

(36) 1 manufacturing device 5 embossing wheel pair 7 tool station 11 perforation tool 13 housing part 15 disposal opening 21 nose tool part 23, 123 reception tool part 25 basic structure 27 nose shaft 31a, b clamper plates 33 reception slot 35 cutting knife 37 blade 41 end edge portion 43 hub ring frame 45a, b perforation noses 47 punching edges 51a, b gripper pads 55 cavity 57 stripper 59 through holes 61 PU-foam body 63, 163 basic structure 65, 165 perforation reception shaft 67a, b, 167a, b holding plates 71, 171 seat 73, 173 stamp pad 74, 174 hub ring frame 75, 175 end edge area 77a, b, 177a, b slit recesses 79, 179 punching edge 83, 183 cutting pad 83a, b deformation bars F direction of travel R direction of rotation