BAG, METHOD, AND MACHINE FOR PRODUCING A FOAM-IN-BAG DUNNAGE MATERIAL

Abstract

A bag for producing a foam-in-bag dunnage material comprises a closed edge portion and, in a non-sealed state of the bag, an open edge portion, the closed and open edge portions delimiting an inner bag volume. The invention proposes that a bag structure of the bag comprises a mixing chamber which is adapted to receive foam precursor substances, which is arranged within the inner bag volume, which is at least partially and initially delimited against the remainder of the inner bag volume, and which in the non-sealed state of the bag is connected to the open edge portion.

Claims

1. Bag for producing a foam-in-bag dunnage material, comprising a closed edge portion and, in a non-sealed state of the bag, an open edge portion, the closed and open edge portions delimiting an inner bag volume, wherein a bag structure of the bag comprises a mixing chamber which is adapted to receive foam precursor substances, which is arranged within the inner bag volume, which is at least partially and initially delimited against the remainder of the inner bag volume, and which in the non-sealed state of the bag is connected to the open edge portion.

2. Bag according to claim 1 wherein the mixing chamber is at least partially and initially delimited against the remainder of the inner bag volume by means of a weld seal connecting two side walls of the bag to each other.

3. Bag according to claim 2 wherein the weld seal has a first portion and a second portion, wherein a seal strength of the second portion is lower than a seal strength of the first portion, such that the mixing chamber is initially fully separate from the remainder of the inner bag volume, and such that by breaking the second portion of the weld seal, a fluid connection is created between the mixing chamber and the remainder of the inner bag volume.

4. Bag according to claim 1 wherein the mixing chamber has, seen from the side, a conical shape or a funnel shape.

5. Bag according to claim 1 wherein the mixing chamber comprises mixing elements which preferably provide a labyrinth type path for a fluid mixture moving within the mixing chamber.

6. Bag according to claim 5 wherein at least some mixing elements are formed by point shape connecting portions of the side walls of the bag at which the side walls are connected to each other, preferably by welding.

7. Bag according to claim 1 wherein, in a sealed state of the bag, the open edge portion is closed by providing a weld seal such that the inner bag volume and the mixing chamber are sealed against an outside of the bag.

8. Method for producing foam-in-bag dunnage material, comprising the following steps: a. providing a bag according to claim 1 in a non-sealed state; b. providing at least two foam precursor substances into a mixing chamber of the bag through a connection of the mixing chamber to the open edge portion; c. transforming the bag from its non-sealed state into its sealed state wherein the open edge portion is closed such that the inner bag volume and the mixing chamber are sealed against an outside of the bag; d. providing a mixing action to the foam precursor substances enclosed within the mixing chamber in order to create a mixture of the foam precursor substances; and e. allowing the mixture to discharge from the mixing chamber into a remainder of an inner bag volume of the bag.

9. Method according to claim 8 wherein in step c the transformation is carried out by providing a weld seal along the open edge portion.

10. Method according to claim 8 wherein in step e the mixture is allowed to discharge from the mixing chamber through an outlet into the remainder of the inner bag volume.

11. Method according to claim 8 wherein in step e the mixture is allowed to expand from the mixing chamber by breaking a second portion of a weld seal delimiting the mixing chamber against the inner bag volume wherein a seal strength of the second portion is lower than a seal strength of an adjacent first portion of the weld seal.

12. Machine for producing a foam-in-bag dunnage material, comprising a feed device for feeding a bag to an injection device adapted to inject foam precursor substances into the bag and a mixing device which is adapted to provide a mixing action onto an exterior surface of a bag after injection, wherein the injection device can be arranged during injection in an injection section and wherein the mixing device can be arranged in a mixing section during the mixing action, wherein the mixing section is arranged, seen in a feed direction, downstream from the injection section, and wherein the feed device is adapted to move the bag such that a mixing chamber of the bag, after injection, moves from the injection section to the mixing section, wherein the injection device is movable and is arranged to inject the foam precursor substances into the mixing chamber of the bag, the mixing chamber being delimited against the remainder of the bag, wherein the mixing device is separate from the feed device and is adapted to only act on the foam precursor substances comprised within the mixing chamber of the bag.

13. Machine according to claim 12 wherein the mixing device comprises at least one mixing roller having an outer surface area which comprises at least one protrusion, preferably a screw thread, wherein a contact region of the outer surface area of the roller with the outer surface of the bag is essentially parallel to a plane of the bag.

14. Machine according to claim 12 wherein the mixing device comprises at least one rotational stirrer having a rotational axis which is orthogonal to a plane of the bag.

Description

[0025] The features and the advantages of the invention will be evident from the following description, regarding particular embodiments thereof, which is made as a non-limiting example with reference to the attached drawings, wherein:

[0026] FIG. 1 is a schematic side view of a first embodiment of a web type bag material for producing a foam-in-bag dunnage material;

[0027] FIG. 2 is a schematic side view of the web type bag material of FIG. 1 and of essential parts of a first embodiment of a machine for producing a foam-in-bag dunnage material;

[0028] FIG. 3 is a sectional view along the lines III-III of FIG. 2;

[0029] FIGS. 4-8 are schematic side views similar to the one of FIG. 2 during the production of a foam-in-bag dunnage material;

[0030] FIG. 9 is a schematic side view of a second embodiment of a web type bag material for producing a foam-in-bag dunnage material;

[0031] FIG. 10-14 are schematic side views of the web type bag material of FIG. 9 and of essential parts of a second embodiment of a machine for producing a foam-in-bag dunnage material during production of a foam-in-bag dunnage material;

[0032] FIG. 15 is a schematic side view of the second embodiment of a web type bag material and essential parts of a third embodiment of a machine for producing a foam-in-bag dunnage material;

[0033] FIG. 16 is a sectional view along the lines XVI-XVI of FIG. 15; and

[0034] FIG. 17 is a schematic side view of the second embodiment of a web type bag material and essential parts of a fourth embodiment of a machine for producing a foam-in-bag dunnage material.

[0035] In the following detailed description, equivalent elements and regions of different embodiments are designated with identical reference signs.

[0036] A bag for producing a foam-in-bag dunnage material is generally designated with reference numeral 10. It is part of a web type film material 11 rolled to a cylindrical supply roll 12 having a rotational axis 14. In FIG. 1, the bag 10 is shown in an initial condition just after being unrolled from supply roll 12. In this initial condition, the bag 10 has a rectangular flat and thin shape with four straight edges 16a-d and is formed by two parallel, adjacent, and flat side walls (without reference numeral). A perforation 18 is provided between adjacent bags 10 such that a “finished” bag 10 can easily be separated from the remainder of the web type film material 11.

[0037] The bottom edge 16b and the two side edges 16a and 16c form a closed and sealed edge portion, whereas top edge 16d in the non sealed state of the bag 10 of FIG. 1 forms an initially open and unsealed edge portion. The bottom edge 16b is formed by folding upon itself a thin plastic film material. The two side edges 16a and 16c are closed by weld lines 20 which connect and seal the two parallel, adjacent and flat side walls which are arranged in a parallel and adjacent relationship by the above mentioned folding step when the web type supply material 11 is preconfigured prior to being rolled into the cylindrical supply roll 12.

[0038] The two parallel side walls and the edge portions 16a-d delimit an inner bag volume 22. As can be seen from FIG. 1, the bag 10 comprises a bag structure comprising a mixing chamber 24. The mixing chamber 24 is adapted to mix foam precursor substances as will be shown in more detail further below. As can be seen from FIG. 1, the mixing chamber 24 is arranged within the inner bag volume 22. It comprises two lateral side limits 26a and 26b which are formed by weld seal lines. These weld seal lines 26a and 26b connect the two opposing and adjacent side walls of the bag 10 to each other and are provided also during preconfiguration of the web type supply material 11 prior to forming the cylindrical supply roll 12.

[0039] The weld seal lines 26a and 26b partially delimit and seal the mixing chamber 24 against a remainder 28 of the inner bag volume 22. “Partially” means that the mixing chamber 24 has a small orifice 30 formed between adjacent ends of the weld seal lines 26a and 26b which orifice 30 opens into the remainder 28 of the inner bag volume 22. Furthermore, in the non-sealed state of the bag 10 shown in FIG. 1, the mixing chamber 24 is fluidly connected to the open edge portion 16d of the bag 10 by an opening 32 formed between adjacent ends of the weld seal lines 26, these ends being opposite to the ends forming the orifice 30.

[0040] As can be seen from FIG. 1, seen from the side the mixing chamber 24 generally has a funnel shape, the small dimension of the funnel being at the orifice 30 opening into the remainder 28 of the inner bag volume 22. However, other shapes are possible, such as a conical shape, a rectangular shape, or a rectangular shape with a rounded bottom (pocket shape), as will be seen further below.

[0041] As also can be seen from FIG. 1, the mixing chamber 24 may comprise mixing elements 34 which are drawn in FIG. 1 as a plurality of black points. In the embodiment of FIG. 1, by way of example the mixing elements 34 are formed by point shape connecting portions of the side walls of the bag 10 at which the side walls are connected to each other, for example by welding. As will be seen hereinbelow, the mixing elements 34 form an obstacle for the liquid chemical foam precursor substances contained within the mixing chamber 24 in order to further enhance the mixing efficiency. Preferably, the mixing elements 34 are arranged within the mixing chamber 24 such that they provide a labyrinth type path for a fluid mixture and/or the liquid foam precursor substances moving within the mixing chamber 24 during the mixing action, as will be described further below.

[0042] Now, reference is made to FIGS. 2 and 3, which additionally show essential parts of a machine 36 for producing a foam-in-bag dunnage material using a bag 10 as described above in connection with FIG. 1. The machine 36 comprises a feed device 38 in the form of a pair of driven rotating traction rollers 40. As can be seen from FIG. 3 the web type film material 11 is clamped between the driven rotating traction rollers 40 such that it is pulled from the cylindrical supply roll 12 in the direction of arrow 42.

[0043] Furthermore, the machine 36 comprises an injection device 44 comprising two injection nozzles 46a and 46b and a first foam precursor supply 48a for a liquid chemical foam precursor substance A and a second foam precursor supply 48b for a liquid chemical foam precursor substance B. In a preferred embodiment, the foam precursor supplies 48a and 48b may comprise plastic cylindrical cartridges containing the liquid chemical foam precursor substances A and B. The cartridges may act like a syringe and therefore each may comprise a motorized pusher in order to dispense the liquid chemical foam precursor substance A and B, respectively. The cartridges may be unitary with injection nozzles 46a and 46b such that the whole group may be disposed when a cartridge is empty. Alternatively, each foam precursor supply 48a-b may comprise a delivery pump (non-shown) and a foam precursor tank (non-shown). The injection nozzles 46a and 46b may be in a fixed and stationary position. Alternatively, they may be movable from an upper retracted position where they are outside of the travel path of the web type film material 11 to a lower extended position which is shown in FIG. 2 where they are arranged in an injection section 50 of the machine 36.

[0044] Downstream of the injection device 44 is arranged a sealing device 52 presently in the form of a pair of sealing rollers 54 comprising a circumferential heated welding portion 56. As can be seen from FIG. 3 the web type film material 11 is clamped between the sealing rollers 54 such that, when the web type film material 11 is pulled through the sealing device 52 by means of feed device 38, a weld seal 58 is formed which closes the initially open edge portion 16d such that the inner bag volume 22 as well as the mixing chamber 24 are sealed against an outside of the bag 10.

[0045] Downstream of the sealing device 52, that is between the sealing device 52 and the feed device 38, a mixing device 60 is arranged which comprises a pair of mixing rollers 62 each having an outer surface area (without reference sign). In the present exemplary embodiment this outer surface area may comprise a protrusion, which in the present exemplary embodiment may be in the form of a screw thread 64. Alternatively, a cylindrical mixing roller may be used having a flat outer surface area without any protrusion. The main task of these cylindrical mixing rollers 62 is to push the liquid chemical foam precursor substances A and B through the labyrinth formed by the mixing elements 34 in the funnel-shape mixing chamber 24, which provides a mixing action, like in a static mixer. As can be seen from FIG. 3 a contact region of the outer surface area of the mixing rollers 62 with the outer surfaces of the bag 10 is essentially parallel to a plane 76 of the bag 10 and the web type film material 11, respectively.

[0046] The mixing device 60 is arranged in a mixing section 66 of the machine 10, which is downstream from the injection section 50, when seen in the feed direction 42. As can be seen from FIG. 3 the web type film material 11 is clamped between the mixing rollers 62 such that, when the web type film material 11 is pulled through the mixing device 60, a mixing action is exerted onto any foam precursor substance present within the mixing chamber 24 of the bag 10.

[0047] Now, operation of the machine 36 and a method for producing foam-in-bag dunnage material using a bag 10 is explained with respect specifically to FIGS. 4-8. However, it is to be noted that for the sake of clarity not all reference signs are drawn in FIGS. 4-8.

[0048] Initially, as can be seen from FIG. 4, a bag 10 having a mixing chamber 24 and close and open edge portions 16a-d is provided in a non-sealed state where the upper edge 16d is open. In FIG. 4, the bag 10 has been moved by means of the feed device 38 such that the mixing chamber 24 with its opening 32 connected to open edge portion 16d is in the injection section 50 of the machine 36. When the mixing chamber 24 is in the injection section 50, movement of the web type film material 11 by the feed device 38 is stopped, such that the bag 10 becomes stationary for the short period of time. It is to be noted that, until the web type film material 11 is stopped as shown in FIG. 4, the sealing device 52 already has started to create the weld seal 58.

[0049] Then, the injection nozzles 46a-b are lowered into the opening 32 of the mixing chamber 24, and each nozzle 46a and 46b delivers a respective liquid chemical foam precursor substance A and B through the opening 32, which insofar is a connection of the mixing chamber 24 to the open edge 16d, into the mixing chamber 24, namely in that part of the mixing chamber 24 which is adjacent to the opening 32 and which is free from mixing elements 34. The situation after the injection of the foam precursor substances A and B is shown in FIG. 5.

[0050] Thereafter, the feed device 38 is activated again, such that the web type film material 11 is pulled in the direction of arrow 42 in FIG. 3. By consequence, the sealing device 52 with its sealing rollers 54 continues to build the weld seal 58 which now extends over the opening 32 of the mixing chamber 24, as is shown in FIG. 6. By consequence, the mixing chamber 24 now is fully closed against an outside of the bag 10 by means of the weld seal 58, the only remaining opening of the mixing chamber 24 being the orifice 30 opening into the remainder 28 of the inner bag volume 22.

[0051] In the course of the movement of the web type film material 11 and the bag 10 through the machine 36, the mixing chamber 24 is moved from the injection section 50 of the machine 36 in which the injection nozzles 46a-b can be arranged to the mixing section 66 of the machine 36 where the mixing rollers 62 of the mixing device 60 are arranged. In the course of the further movement of the web type film material 11 and of the mixing chamber 24 through the mixing device 60 and, more specifically, through the gap between the two mixing rollers 62, the foam precursor substances A and B are squeezed towards the orifice 30 of the mixing chamber 24 such that the foam precursor substances A and B are urged onto a labyrinth type path between the mixing elements 34.

[0052] Or, in other words: the mixing device 60 provides a mixing action onto the exterior surface of the bag 10 and by consequence to the foam precursor substances A and B enclosed within the mixing chamber 24 such that a mixture 68 of the film precursor substances A and B is created which is discharged from the mixing chamber 24 into the remainder 28 of the inner bag volume 22, as is shown in FIG. 7.

[0053] In the further course of the movement of the web type film material 11 and of the mixing chamber 24 through the mixing device 60, the mixture 68 of the foam precursor substances A and B is fully squeezed out of the mixing chamber 24 through orifice 30 into the remainder 28 of the inner bag volume 22 of the bag 10, as is shown in FIG. 8. Also, in this further course of the movement of the web type film material 11 the initially open edge 16d is fully closed by means of the weld seal 58, which transforms the bag 10 from its initially non-sealed state into a fully sealed state in which the open edge portion 16d is closed such that the entire inner bag volume 22 and the mixing chamber 24 are sealed against an outside of the bag 10.

[0054] As can be seen from a comparison of FIGS. 7 and 8, the mixture 68 provides for chemical reaction between the film precursor substances A and B wherein gas bubbles are created making the volume of the mixture 68 to expand. As also can be seen from FIG. 8, the bag 10 now can be separated by means of the perforation 18 from a remainder of the web type film material 11.

[0055] The separated bag 10 with the expanding and still liquid mixture 68 now can be inserted, for example, into a shipping container (not shown) having one or more articles therein. The expanding mixture 68 will more or less fill out the void volume existing initially between the articles and the inner walls of the container and then harden, whereby the hardened expanded mixture 68 creates a rather low density foam dunnage material which is separated from the outside by means of the plastic material of the bag 10 which thereby functions as an enclosure for the hardened expanded mixture 68.

[0056] An alternative embodiment of a bag 10 and a web type film material 11 is shown in FIG. 9. The bag 10 of FIG. 9 distinguishes over the bag 10 of FIGS. 1-8 in the shape and implementation of the mixing chamber 24.

[0057] As can be seen from FIG. 9, the mixing chamber 24 of the bag 10 has a rectangular shape with a rounded bottom, like a pocket in a trouser. Furthermore, the mixing chamber 24 is initially delimited against the remainder 28 of the inner bag volume 22 by means of a weld seal line 26 having a first portion 70a and a second portion 70b. The first portion 70a delimits the upper part of the mixing chamber 24, whereas the second portion 70b delimits the lower rounded part of the mixing chamber 24. The second portion 70b has a seal strength which is lower than a seal strength of the first portion 70a.

[0058] When the web type film material 11 of FIG. 9 is used for producing a foam-in-bag dunnage material in the same machine 36 of FIGS. 2-8, as is shown in FIGS. 10-14, during the action of the mixing device 60 and the mixing rollers 62 onto the film precursor substances A and B enclosed within mixing chamber 24, the mixture 68 is created without this mixture 68 being able to discharge into the remainder 28 of the inner bag volume 22. By consequence, at the end of the mixing step, as is shown in FIG. 13, the mixture 68 is still within the mixing chamber 24 which is entirely closed to the outside by the weld seal 58 and which still remains entirely closed to the remainder 28 of the inner bag volume 22 by the weld seal lines 26.

[0059] However, as the chemical reaction of the mixture 68 makes the mixture 68 to expand, the expanding mixture 68 breaks the first portion 70a of the weld seal 26 such that the expanding mixture 68 may discharge into the remainder 28 of the inner bag volume 22, as is shown in FIG. 14.

[0060] The web type film material 11 of FIGS. 9-14 is shown in FIGS. 15-16 together with an alternative embodiment of a machine 36. The machine 36 of the FIGS. 15-16 distinguishes over the machine 36 shown in FIGS. 2-14 by the implementation of the mixing device 60. As can be seen specifically from FIG. 15, the mixing device 60 of FIGS. 15-16 comprises a rotational stirrer 72 having a rotational axis 74 (FIG. 16) which is orthogonal to a plane 76 of the bag 10 and the web type film material 11, respectively, in the initial flat configuration, as shown in FIG. 16. The rotational stirrer 72 preferably has a plurality of arms 78 with rollers 80 at the end.

[0061] A further alternative machine 36 is shown in FIG. 17, again together first with the web type film material of FIGS. 9-16. As can be seen from FIG. 17, this machine 36 does not comprise a mixing device and does not comprise a separate feed device. Instead, the sealing device 52 provides also the transport of the web type film material 11. The mixing action of the foam precursor substances A and B inside the mixing chamber 24 in this case must be provided manually, for example by means of the hands of a person.

[0062] While in all above embodiments all connections of the two walls of the bag 10 are realized by welding, it is to be understood that also other connection methods are possible, such as for example gluing.