Apparatus for the production of a cushion product

Abstract

An apparatus for the production of a cushion product from a single or multi-layer continuous paper strip includes a chute-like preforming station for the compression of a paper strip in the transverse direction and a deformation station following the preforming station in the feed direction of the paper strip having two embossing rollers engaging into each other in a deformation area in order to form the paper strip to a cushion product with at least one crumple hollow space extending in the longitudinal direction. The preforming station has a lifting unit and is positioned upstream in the feed direction of the embossing rollers for lifting a central area of the paper strip.

Claims

1. An apparatus for production of a cushion product from a single or multilayer continuous paper strip, comprising: a chute-like preforming station configured to compress the paper strip in a transverse direction that is transverse to a feed direction, the preforming station including a lifting unit having a wedge being formed in the feed direction at least in sections sloping upwards, the wedge including: a cross-sectional area in the transverse direction narrowing upwardly from a lower base of the wedge in a vertical direction to an upper portion, and a sloping ramp surface that increases in height as the sloping ramp surface extends in the feed direction, the sloping ramp surface including a first portion having an increasing transverse width in the feed direction and a second portion having a decreasing transverse width in the feed direction, the second portion being located downstream of the first portion in the feed direction, wherein the wedge is configured to lift a central area of the paper strip without lifting other areas of the paper strip, the central area of the paper strip to be lifted being centrally arranged in a transverse direction of the paper strip, and the narrow upper portion of the wedge being configured to contact the central area of the paper strip to lift the central area of the paper strip; and a deformation station following the preforming station and positioned downstream of the wedge in the feed direction of the paper strip, the deformation station having two embossing rollers engaging into each other in a deformation area in order to form the paper strip to a cushion product with at least one crumple hollow space extending in a longitudinal direction.

2. The apparatus according to claim 1, wherein the preforming station comprises a lower guiding surface from which the lifting unit causes a harmonic or continuous upward sloping lifting of the paper strip by at least 10 mm.

3. The apparatus according to claim 1, wherein the lifting unit is configured to lift the central area of the paper strip at vertical height of the deformation area, wherein the embossing rollers comprise a pitch circle diameter whose contact point defines a deformation plane, wherein the lifting unit lifts the central area of the paper strip up to at least the height of the deformation plane.

4. The apparatus according to claim 1, wherein the wedge further comprises a saddle area of constant height at its rear section in the feed direction.

5. The apparatus according to claim 4, wherein the lower base has a transverse width in the feed direction measuring section-wise at least 10 mm, wherein the lower base has, at least in sections, an increasing transverse width in the feed direction or the base having, at least in sections, a constant transverse width in the feed direction.

6. The apparatus according to claim 1, wherein a distance from a rotation axis of one of the embossing rollers to the lifting unit in the feed direction is at least as great as an embossing roller radius, wherein the distance from the rotation axis of one of the embossing rollers to the lifting unit in the feed direction is different from a distance from the rotation axis of one of the embossing rollers to a rear end of the first guiding member and/or the second guiding member in the feed direction.

7. The apparatus according to claim 1, wherein the deformation station has an inner channel configured for guiding the preformed paper strip, having channel walls with recesses, each being protruded by an embossing roller, wherein a lower guiding surface of the deformation station merges kink-free or with a transition edge in the inner channel.

8. The apparatus according to claim 1, further comprising a guiding unit is positioned upstream of the preforming station in the feed direction and configured to adjust the paper strip for the preforming station.

9. The apparatus according to claim 8, wherein the guiding unit comprises a sliding edge or a deflection roller.

10. The apparatus according to claim 1, wherein the compression comprises a folding or a rolling of the paper strip.

11. The apparatus according to claim 1, wherein the lifting unit is configured to leave free spaces on both sides of the lifting unit for generating hollow crumple spaces of material web.

12. The apparatus according to claim 1, wherein the other areas of the paper strip are areas that are not the central area of the paper strip.

13. The apparatus according to claim 1, wherein the preforming station further comprises: first and second guiding members configured to support a folding or rolling of the paper strip in the preforming station, the first and second guiding members being disposed between first and second lateral chute inner walls of the preforming station, wherein the first and second guiding members respectively extend parallel to the first and second lateral chute inner walls in the feed direction; and a connecting member extending in the transverse direction being configured to connect the first and second guiding members together, the connecting member being connected to upstream ends of the first and second guiding members.

14. The apparatus according to claim 13, wherein the guiding members are aligned in a constant vertical distance to a lower guiding surface of the preforming station, the preforming station further comprising a holding unit that is configured hold down the central area of the paper strip between the holding unit and the lower guiding surface, wherein the holding unit is arranged at the first and second guiding members that are extending in the feed direction and at least in sections transversely between the first and second guiding members.

15. The apparatus according to claim 14, wherein the wedge is configured to lift the central area of the paper strip up to above a lower edge of the first and second guiding members or of the holding unit, wherein the wedge lifts the central area of the paper strip up to below an upper edge of the first and second guiding members.

16. The apparatus according to claim 13, wherein the wedge is disposed between downstream ends of the first and second guiding members in the transverse direction, the downstream ends of the first and second guiding members being downstream of the upstream ends of the first and second guiding members in the feed direction.

17. The apparatus according to claim 13, wherein a downstream end of the first guiding member is closer to the deformation station in the feed direction than a downstream end of the second guiding member, the downstream ends of the first and second guiding members being downstream of the upstream ends of the first and second guiding members in the feed direction.

18. The apparatus according to claim 13, wherein downstream ends of the first and second guiding members are cone-shaped, the downstream ends of the first and second guiding members being downstream of the upstream ends of the first and second guiding members in the feed direction.

19. The apparatus according to claim 13, wherein the first and second guiding members and the connecting member are cylindrically shaped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The system and method may be better understood with reference to the following drawings and description. Non-limiting and non-exhaustive embodiments are described with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the drawings, like referenced numerals designate corresponding parts throughout the different views.

(2) FIG. 1 is a cross-sectional side view of a cushion product production apparatus according to one embodiment;

(3) FIG. 2 is a side view of a cushion product production apparatus according to one embodiment according to FIG. 1;

(4) FIG. 3 is a perspective sectional view of the production apparatus according to one embodiment according to FIG. 2;

(5) FIG. 4 is a view of the cushion product production apparatus according to one embodiment according to FIG. 1 from the rear side;

(6) FIG. 5 is a perspective view of a cushion product production apparatus according to one embodiment according to FIG. 1 from a diagonal back side;

(7) FIG. 6a is a side view of a wedge;

(8) FIG. 6b is a front view of the wedge according to FIG. 6a;

(9) FIG. 6c is a top view of the wedge according to FIG. 6a; and

(10) FIG. 6d is a perspective view of the wedge according to FIGS. 6a to 6c for a cushion product production apparatus according to one embodiment.

DETAILED DESCRIPTION

(11) The apparatus for the production of a cushion product according to one embodiment is generally attributed with the reference numeral 1. The cushion product production apparatus 1 comprises as components a preforming station and a deformation station 13 as well as a lifting unit 4 positioned upstream of the deformation station 13 in the feed direction F. The lifting unit 4 can be realized for example pneumatically, by a stream of air, mechanically, for example by a ramp, a freely turnable wheel, or as shown exemplarily, a wedge 41. The cushion product production apparatus 1 shown in the Figures further comprises a rotation cutter 15 in order to cut separate cushion pillows from the tube-like cushion product 3 having two crumple hollow spaces 7, 9 extending in the longitudinal direction L. Instead of a rotation cutter 15, also a different mechanism, for example a teethed blade at the exit of the cushion product production apparatus 1 for tearing off a long cushion strand, can be provided.

(12) The paper strip 5 is fed through the apparatus 1 along a feed direction F in that feed or embossing rollers 31, 33 draw in the paper strip 5 from a paper strip supply not shown in detail, a Leporello stack or a roll. The embossing rollers 31 and 33 can therefore serve in functional union to feeding the paper strip 5 in the feed direction F as well as to the forming of the paper 5 into a cushion product. At least one feed roller 31, 33 is driven by an electromotor not shown in detail, which can also drive a rotation cutter 15. The rotation cutter 15 can also have an own electro motor.

(13) In the course of the production of the cushion product 3, the paper strip 5 is passing the apparatus 1 as the paper strip 5 is at first drawn in at the guiding unit 17, being realized by two deflection rollers 18, 19 extending in transverse direction Q into the cushion product production apparatus 1. The paper strip 5 arrives at the preforming station 11, which chute-like in the feed direction F being positioned in the feed direction behind the guiding station 17 until it leads to the rear side of the deforming station 13 in the feed direction F. The paper strip 5 is preformed in the preforming station 11 as being compressed at least in the transverse direction Q, for example in that the longitudinal edges of the paper strip 5 are folded by the lateral chute inner walls 23, 25 optionally by means of guiding members 27, 29 and being rolled, if applicable. The preformed paper strip 5 is then further fed into an inner channel 37 of the deforming station in which the embossing wheels 31, 33 are protruding.

(14) The embossing wheels 31, 33 are catching the paper strip with their teeth engaging each other in the deformation area 35 and form the same to a cushion product 3 having two crumple hollow spaces 7, 9 extending in the longitudinal direction L and a wavelike imprint profile 8 being formed between the crumple hollow spaces 7 and 9 by the embossing rollers 31, 33. The cushion product 3 is ejected from the apparatus 1 in the following feed procedure as shown schematically in FIG. 3. Before the ejection from the apparatus 1, the cushion product 3 can be fed along or respectively through a cutting station such as the rotation cutter 15 shown here exemplarily, which can cut off a single pillow from the strand-shaped cushion product 3 with one (rotation) cutting stroke.

(15) The deformation station 13 is shown in the FIGS. 1 and 2 in cross-section. As shown in FIG. 3, the upper feed roller 31 comprises of a embossing teeth wheel 31a having a side disc 31b rotating with the embossing teeth wheel to the left and to the right transverse to the feed direction F. The side discs 31b have just about the same as or a slightly smaller outer diameter than the embossing wheel 31. The lower embossing wheel 33 only comprises of an embossing teeth wheel equally wide in the transverse direction Q as the teeth while 31a of the upper embossing roller 31. The teeth of the embossing rollers 31 and 33 engage into each other in a deformation area 35 for feeding and deforming the paper strip 5. The pitch circle diameter D31 of the upper embossing wheel 31 of the embodiment shown here exemplarily is as large as the pitch circle diameter D33 of the lower embossing wheel 33. The axial distance of the embossing rollers 30, 33 more or less equals the sum of the pitch circle diameters. A deformation plane D is defined by a mutual pitch circle tangent in the contact are of the embossing rollers 31, 33. The deformation D is located in the vertical direction, approximately in the middle of the feed height of the paper strip 5 in the feed direction F.

(16) The deformation station 13 has, as explained above, an inner channel 37 being limited in the vertical direction by a lower channel wall 38 and an upper channel wall 39, each having a recess 32, 34 for the upper or lower embossing roller 31, 33, respectively, coming into touch contact with the paper strip 5 operation-conformingly, always having a velocity component in the horizontal direction H being oriented in the same direction as the feed direction F. An accumulation of the paper strip 5 and the embossing rollers 31, 33 with the possible outcome of a paper jam is thereby prevented. The pitch circle diameter D31 or D33 of the embossing rollers 31, 33, respectively, are preferably between 8 and 12 cm and preferably below 10 cm. The width of the embossing roller 31, 33 in transverse directly is commonly below 30 cm, preferably below 20 cm, particularly less than 10 cm. The transverse width of the embossing roller 31, 33 can for example be about 30 mm to about 70 mm, preferably between 30 and 50 mm.

(17) FIGS. 1 and 2 show the rear part of the preforming station 11 in the feed direction F. FIGS. 4 and 5 show a rear view or a perspective view, respectively, of the exemplarily shown embodiment of the cushion product production apparatus 1 according to one embodiment with view on the preforming station 11, wherein a cover of the preforming station 11 is not shown for being able to see the inner components. It shall be clear that operation-accordingly a cover extends completely in transverse direction Q and horizontal direction H over the preforming station, on the opposite side of the guiding surface 21 of the preforming station 11.

(18) The lower guiding surface 21 of the preforming station 11 shapes the base of the preforming station 11 in the vertical direction V. The lower guiding surface 21 extends in transverse direction between a left side wall 23 and a right side wall 25. The side walls 23 and 25 lead to the inlet of the deforming station 13 chute-like. The longitudinal edges of the paper strip 5 are guided against the chute inner walls 23-25 of the preforming station 11 during the transport of the paper strip 5 through the cushion product production apparatus 1 in order to fold the longitudinal edges of the paper strip 5.

(19) The folding and rolling of the longitudinal ends of the paper strip is supported by guiding members 27 or 29, respectively, each extending parallel to one of the chute inner walls 23 or 25. The left guiding member 27 in the feed direction ends in front of the right guiding member 29 in the feed direction F. The distance of the right guiding member 29 to the deformation station 13 is therefore smaller than the distance of the left guiding member 27 to the deformation station 13. The longitudinal ends 40 of the guiding members are widening cone-like. The guiding members 27 and 29 may be connected together by a connecting member 36. For example, the connecting member 36 may extend in the transverse direction Q and connect to upstream ends of the guiding members 27 and 29 to connect the guiding members 27 and 29 together. In this arrangement, the longitudinal ends 40 of the guiding members 27 and 29 are located downstream of the upstream ends in the feed direction F.

(20) A down-holder plate 28 is attached at the bottom side of both of the guiding members 27 and 29 along the front half of the guiding members 27 and 29 in the feed direction F. The down-holder plate extends completely between the guiding members 27 and 29 being positioned above opposingly to the guiding surface 21.

(21) The paper strip 5 is, after entering into the apparatus 1 between the deflection rollers 18 and 19 of the guiding station 17, guided underneath the down-holder plate 28 and above the guiding surface 21. The down-holder plate 28 has a convexly protruding section in the central are of the preforming station 11 in the feed direction F ending several centimeters before the guiding members 27 and 29, particularly already before their widened end sections. A lifting unit 4 being exemplarily designed as a wedge 41 is arranged between the in the feed direction rear end of the down-holder plate 28 and the deformation station 13. The central area of the paper strip 5 being guided between the guiding surface 21 and the down-holder plate 28 (compare for example FIG. 2) is guided in the feed direction F against the lifting unit 4 during the cushion product production which is then lifting the central area of the paper strip. In order to prevent damage or even ripping and an eventual paper jam, the wedge 41 is continuously directing upwards from the guiding surface 21.

(22) The lower base 43 is in contact with the guiding plate 21. A guiding wedge 41 is shown in detail in FIGS. 6a, 6b, 6c and 6d. As conceivable in the perspective view according to FIG. 6d, the wedge has an adaptable cross-sectional area in the feed direction F, wherein the cross-sectional areas being discussed here extend vertically in one plane in the transverse direction Q and vertical direction V on the guiding surface 21 and/or the deformation plane D.

(23) The wedge has a sloping ramp surface 42 spanning an angle with the flat guiding surface 21 of between 130 and 160, particularly 155. As shown, the ramp surface 42 can be designed as surface between the guiding surface 21 and a upper end of the wedge 41 in the vertical direction V sloping upwards continuously, particularly evenly.

(24) The highest point of the wedge 41 can run as a saddle area 45 with a longitudinal extension in the horizontal direction, that means across, particularly transversely to the vertical direction V as well to the transverse direction Q. The length LS of the saddle area 45 is between 5 mm and 35 mm, preferably about 10 mm. The vertical height hK of the wedge 41 is between 25 mm and 45 mm, preferably about 35 mm. The wedge length LK can be between 80 mm and 120 mm and is preferably about 100 mm.

(25) The preferable largest transverse width bK of the wedge 41 can preferably be between 10 mm and 60 mm, between 25 mm and 45 mm, preferably about 35 mm. The wedge 41 can for example have in its rear section 47 in feed direction F a maximal transverse width bK of about 35 mm. In a front part in the feed direction F, the wedge 47 can widen in transverse direction Q wedge-like. The wedge 41 can have a sweep section 46 with a sweep angle , wherein the sweep angle is 25 at the most, particularly 15 at the most. The sweep angle can approach 0 and in so far be infinitesimal.

(26) The front view of FIG. 6b gives a hint of the cross-sectional area of the wedge 41. The cross-sectional area of the wedge 41 can narrow upwardly, starting from the base 43 in the vertical direction V, for example with a narrowing angle , being 45 at the most, particularly about 35. The narrowing angle can also be realized infinitesimally, practically equaling 0.

(27) The distance a in the feed direction F between the rear end or the rear side A, respectively, of the wedge 41 in the feed direction F and the axis A of the embossing rollers 31, 33 is smaller than 200 mm. The distance a is in the range between 30 mm and 170 mm.

(28) The distance b in the feed direction F between the end of the longer feed member 29 and the rear part of the wedge 41 in the feed direction F is less than 100 mm, particularly about 60 mm or less. The rear wedge end in the feed direction F is located behind the end of the guiding members 27 or 29, respectively. Nevertheless, it is also thinkable that the rear side R of the wedge already ends in the feed direction F in front of the guiding members 27, 29.

(29) The feed members 27, 29 are arranged in a distance f of 25 mm to 45 mm with their respective member axis parallel above the guiding surface 21. The top edge of the wedge 41 is particularly arranged up to 10 mm above or up to 10 mm below the deformation plane D. The top edge of the wedge 41 is located about 10 mm5 mm above the deformation plane D.

(30) The attributes disclosed in the preceding description, the Figures and the claims, can be used in both separately or in arbitrary combination for the realization of the invention in the different embodiments.

(31) The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.

(32) One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term invention merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.

(33) The above disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

LIST OF REFERENCE NUMERALS

(34) 1 cushion product production apparatus 3 cushion product 4 lifting unit 5 paper strip 7, 9 crumple hollow spaces 8 imprint profile 11 preforming station 13 deformation station 15 rotation cutter 17 guiding unit 18, 19 deflection rollers 21 guiding surface 23, 25 chute inner wall 27, 29 guiding member 28 down-holder plate 31, 33 embossing roller 31a embossing teeth wheel 31b side disc 32, 34 recess 35 deformation area 37 inner channel 38, 39 channel wall 41 wedge 42 ramp surface 43 base 45 saddle area 46 sweep section 47 section A axis D deformation plane F feed direction H horizontal direction L longitudinal direction Q transverse direction R rear side V vertical direction