SYSTEMS AND METHODS FOR AIR PILLOW CONVEYANCE AND SEPARATION

Abstract

An inflatable packaging system includes an inflatable cushioning supply and a conveyance module. The conveyance module includes a sliding conveyor, a fixed conveyor, a belt-drive, and an encoder. The sliding conveyor is adjustable, relative to the fixed conveyor, such that a space between the sliding conveyor and the fixed conveyor is adjustable. The belt-drive displaces the inflatable cushioning supply through the space between the sliding conveyor and the fixed conveyor. The encoder is coupled to the belt-drive.

Claims

1. An inflatable packaging system, comprising: an inflatable cushioning supply; and a conveyance module, including a sliding conveyor, a fixed conveyor, a belt-drive, and an encoder; wherein the sliding conveyor is adjustable, relative to the fixed conveyor, such that a space between the sliding conveyor and the fixed conveyor is adjustable, wherein the belt-drive displaces the inflatable cushioning supply through the space between the sliding conveyor and the fixed conveyor, and wherein the encoder is coupled to the belt-drive.

2. The inflatable packaging system of claim 1, wherein the system calculates a total length of inflatable cushioning supply that is displaced through the conveyance module.

3. The inflatable packing system of claim 1, wherein the system calculates a total quantity of inflatable cushioning supply that is displaced through the conveyance module.

4. The inflatable packaging system of claim 1, wherein the inflatable cushioning supply is a strand of air pillows.

5. The inflatable packaging system of claim 1, wherein the conveyance module further includes a separator assembly.

6. The inflatable packaging system of claim 4, wherein the separator assembly is configured to tear the inflatable cushioning supply at a perforation zone.

7. The inflatable packaging system of claim 6, wherein the separator assembly tears the inflatable cushioning supply at the perforation zone by reversing the belt-drive.

8. The inflatable packaging system of claim 6, wherein the separator assembly tears the inflatable cushioning supply at the perforation zone by over-driving the belt-drive.

9. The inflatable packaging system of claim 6, wherein the separator assembly tears the inflatable cushioning supply at the perforation zone by over-driving and reversing the belt-drive.

10. The inflatable packaging system of claim 6, wherein the separator assembly partially tears the inflatable cushioning supply at the perforation zone, such that the inflatable cushioning supply is configured for manual tearing via an operator.

11. The inflatable packaging system of claim 6, wherein the separator assembly includes a plurality of hinged doors.

12. The inflatable packaging system of claim 6, further comprising a proximity sensor.

13. The inflatable packaging system of claim 1, further comprising a spring, wherein the spring is configured for biasing the sliding conveyor and the fixed conveyor towards one another.

14. An inflatable packaging system, comprising: a strand of air pillows; a conveyance module, including a sliding conveyor, a fixed conveyor, a belt-drive, and an encoder; and a separator assembly configured to tear the strand of air pillows at a perforation zone.

15. The inflatable packaging system of claim 14, wherein the sliding conveyor is adjustable, relative to the fixed conveyor, such that a space between the sliding conveyor and the fixed conveyor is adjustable.

16. The inflatable packaging system of claim 15, wherein the belt-drive displaces the strand of air pillows through the space between the sliding conveyor and the fixed conveyor, and wherein the encoder is coupled to the belt-drive.

17. The inflatable packaging system of claim 14, wherein the system calculates a total length or quantity of the strand of air pillows that is displaced through the conveyance module.

18. The inflatable packaging system of claim 14, wherein the separator assembly tears the inflatable cushioning supply at the perforation zone by reversing the belt-drive.

19. The inflatable packaging system of claim 14, further comprising a proximity sensor.

20. The inflatable packaging system of claim 14, further comprising a spring, wherein the spring is configured for biasing the sliding conveyor and the fixed conveyor towards one another.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0028] Understanding that figures depict only typical embodiments of the invention and are not to be considered to be limiting the scope of the present disclosure, the present disclosure is described and explained with additional specificity and detail through the use of the accompanying figures. The figures are listed below.

[0029] FIGS. 1A to 1B illustrate side views of an inflatable packaging system, according to an example embodiment of the present disclosure.

[0030] FIGS. 2A to 2B illustrate side views of an inflatable packaging system, with additional detail regarding a conveyor, according to an example embodiment of the present disclosure.

[0031] FIGS. 3A to 3C illustrate side views of a conveyor, according to an example embodiment of the present disclosure.

[0032] FIGS. 4A to 4B illustrate perspective and side views of a separator, according to an example embodiment of the present disclosure.

[0033] FIG. 5 illustrates a side view of a separator, according to an example embodiment of the present disclosure.

[0034] FIGS. 6A to 6B illustrate a side views of an alternative separator, according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION

[0035] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0036] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0037] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms comprises, comprising, including, and having, are inclusive and therefore specific the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or additional of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0038] When an element or layer is referred to as being on, engaged to, connected to, or coupled to another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to, or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0039] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0040] Spatially relative terms, such as inner, outer, beneath, below, lower, above, upper, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the example term below can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0041] With reference to the Figures, FIGS. 1A and 1B illustrate side views of an inflatable packaging system 100, which includes an inflation module 102 and a conveyance module 104. Generally the inflation module 102 is configured to inflate rolled film 106 (e.g., from an integrated roller at the inflation module 102), and subsequently seal the rolled film 106 after inflation, such that the rolled film 106 is transformed into inflatable packaging (discussed in greater detail herein). For example, an individual portion of the rolled film is inflated and sealed to form an air pillow. A plurality of these individual portions are coupled to one another, prior to inflation, such that inflation module 102 is configured to inflate strands or rows of air pillows. In an embodiment, the strands of air pillows include perforations, between each of the inflated air pillows, such that the total length of an air pillow is adjustable by an operator (e.g., via tearing at the perforation).

[0042] Once inflated, the strands of air pillows are disposed into an integrated hopper 108, which is typically located below the inflation module 102. In an embodiment, the integrated hopper 108 includes an accumulation sensor, for example, to identify when the integrated hopper 108 is full or near-full of a strand of air pillows. It should be appreciated that the integrated hopper 108 is an optional accessory.

[0043] The inflatable packaging system 100 further includes the conveyance module 104. For example, conveyance module 104 may include an entry chute 110 and a dispenser head 112. The strand of air pillows (post-inflation) is received by the entry chute 110, and passes through the dispenser head 112. The dispenser head 112 is configured to dispense the strand of air pillows for an operator (e.g., into a partially filled crate, into an empty crate for filling, into the operator's hands for manual filling, or into integrated hopper 108). As disclosed in greater detail herein, dispenser head 112 includes a number of additional features, including sensors (e.g., for calculating the length of the strand of air pillows) and control features (e.g., for automated separation of the strand of air pillows at a specific perforation).

[0044] As illustrated in FIGS. 1A and 1, each of the inflation module 102 and the conveyance module 104 are disposed on an adjustable height stand 114. In an embodiment, height-adjustment accommodates a variety of air pillow sizes, integrated hopper sizes, and crate sizes for final filling. Inflatable packaging system 100 may further include a bracket or base, with or without wheels for improved portability.

[0045] FIGS. 2A to 2B illustrate side views of the inflatable packaging system 100, with additional detail regarding conveyance module 104. Namely, conveyance module 104 may include one or more switches, such as a feed switch, to power conveyance module 104. The dispenser head 112 of conveyance module 104 includes an opposing pair of driven conveyors.

[0046] Specifically, as illustrated by FIG. 2B, dispenser head 112 includes fixed conveyor 118 and sliding conveyor 120. A strand of inflated air pillows 122 is disposed between fixed conveyor 118 and sliding conveyor 120. In an embodiment, each of fixed conveyor 118 and sliding conveyor 120 are belt-driven, such that each driven conveyor 118, 120 includes an input roller at a top side of dispenser head 112, an output roller at a bottom side of dispenser head 112, and a conveyor belt disposed around an exterior of the input roller and the output roller. Specifically, for example, fixed conveyor 118 includes input roller 124 and output roller 126; a belt is disposed around these respective rollers 124, 126 and is driven by said rollers. Similarly, for example, sliding conveyor 120 includes input roller 128 and output roller 130; a belt is disposed around these respective rollers 128, 130 and is driven by said rollers.

[0047] In an alternate embodiment, the driven conveyors 118, 120 are roller driven conveyors, such that each driven conveyor in the pair includes an input roller and an output roller and a number of additional rollers, but no conveyor belt.

[0048] Generally, one or more of the rollers are powered by an electric motor. In an embodiment, each of the input rollers 124, 128 is powered by an individual electric motor. For example, fixed conveyor 118 includes a first electric motor powering input roller 124. Similarly, sliding conveyor 120 includes a second electric motor for powering input roller 128.

[0049] The strand of air pillows 122 is configured to be conveyed, through the conveyance module 104, via the pair of driven conveyors. For example, the input rollers 124, 128 are driven, which drive belts contacting either side of the strand of air pillows 122, such that the strand of air pillows 122 is conveyed through the dispenser head 112 from the input roller side to the output roller side.

[0050] At the output roller side of the dispenser head 112, the conveyance module 104 further includes a separator assembly 132. In an embodiment, separator assembly 132 is configured for controlled separation of the strand of air pillows 122 at a perforation zone. Separator assembly 132 is described in greater detail herein with respect to FIGS. 4A to 4B and FIG. 5.

[0051] As shown by FIG. 2B, the pair of driven conveyors includes a fixed conveyor 118 and a sliding conveyor 120. Namely, by incorporating a sliding conveyor 120, dispenser head 112 is customizable, to accommodate a variety of sizes and widths of air pillows. In an embodiment, width-adjustment (as described in greater detail herein) is automatically adjusted via a controller. For example, the pair of driven conveyors 118, 120 may be adjusted to convey varying widths of air pillows and, additionally, adjusted to convey flat or deflated material without interruption or operator input.

[0052] With reference to FIG. 2B and FIG. 3C, dispenser head 112 includes a linear bearing 134 (e.g., plain or circular) and a linear shaft 136 or guide, such that sliding conveyor 120 is configured to translate towards and away from fixed conveyor 118, to adjust the width between fixed conveyor 118 and sliding conveyor 120. Linear shafting and related bearings ensure that the two conveyors are maintained in a parallel orientation to one another while simultaneously minimizing the force required to open and close the opposing conveyors relative to one another.

[0053] In an embodiment, dispenser head 112 further includes one or more springs 138 coupled to each of fixed conveyor 118 and sliding conveyor 120; the springs ensure that these components are generally biased in a closed or narrow configuration. In an embodiment, linear actuators may be used to apply biasing force in place of, or in addition to, springs.

[0054] In an embodiment, dispenser head 112 is tilted on an angle, such that gravity biases the sliding conveyor 120 toward the fixed conveyor 118, ensuring that these components are generally biased in a closed or narrow configuration (not illustrated); in this particular embodiment, biasing force can be mechanically adjusted by modifying the weight of sliding conveyor 120 and/or the angle of tilt of the conveyors 118, 120.

[0055] In an alternate embodiment, fixed conveyor 1118 and sliding conveyor 120 are arranged horizontally (e.g., 90-degrees relative to the orientation illustrated in FIG. 2B), and further include compression springs to limit any compressive load due to gravity.

[0056] As noted previously, dispenser head 112 includes a number of additional features, including sensors (e.g., for calculating the length of the strand of air pillows). FIGS. 3A to 3C illustrate side views of the conveyance module 104, depicting some of these features.

[0057] In an embodiment, dispenser head 112 includes a conveyor proximity sensor 140. For example, as discussed above, dispenser head 112 is customizable, to accommodate a variety of sizes and widths of air pillows. Conveyor proximity sensor 140 may be configured to measure the distance between sliding conveyor 120 and fixed conveyor 118, and subsequently communicate this distance to a controller and/or display for the operator. Alternatively, conveyor proximity sensor 140 may be configured to measure whether any distance exists between sliding conveyor 120 and fixed conveyor 118 (e.g., open or closed configuration), and subsequently communicate this information to a controller and/or display for the operator.

[0058] In an embodiment, dispenser head 112 includes an optical sensor 142 (e.g., an optical encoder) configured to measure the total length of the strand of air pillows 122 that is conveyed through the dispenser head 112. In a related embodiment, dispenser head 112 uses the width of an individual air pillow and the total length of the air pillow strand to determine the total number of air pillows in an individual strand. Optical sensor 142 may communicate with a controller and/or display. In an embodiment, the operator enters a desired length of a strand of air pillows, such that the dispenser head 112 conveys air pillows until the controller determines that the dispenser head 112 has dispensed the desired length, via the optical sensor 142. Alternatively, the operator enters a desired number of air pillows air pillows, such that the dispenser head 112 conveys air pillows until the controller determines that the dispenser head 112 has dispensed the desired number of air pillows via the optical sensor 142.

[0059] In an embodiment, dispenser head 112 includes an encoder assembly 144 directly or indirectly coupled to a drive belt. As previously noted, the input rollers 124, 128 are driven, which drive belts contacting either side of the strand of air pillows 122, such that the strand of air pillows 122 is conveyed through the dispenser head 112 from the input roller side to the output roller side via the drive belts. The encoder assembly 144 is thus configured to measure the rotation of the drive belt, and associate that belt-rotation with an overall output length of a strand of air pillows that is conveyed through the dispenser head 112. Encoder assembly 144 may communicate with a controller and/or display. In an embodiment, the operator enters a desired length of a strand of air pillows, such that the dispenser head 112 conveys air pillows until it determines it has reached the desired length via the encoder assembly 144.

[0060] In any of the embodiments described above, it should be appreciated that, at some point, the dispenser head 112 achieves the desired length of a strand of air pillows. When this occurs, the strand of air pillows must be separated or torn at the intended perforation location to conclude the particular strand of air pillows. As noted previously, dispenser head 112 may include control features (e.g., for automated separation of the strand of air pillows at a specific perforation).

[0061] Specifically, FIGS. 4A to 4B and FIG. 5 illustrate perspective and side views of the separator assembly 132. Separator assembly 132 includes a pair of followers 146, which are opposed rotating surfaces that are pivotably configured between an open position (e.g., to permit the strand of air pillows to be dispensed) and a closed positon (e.g., to restrict the strand of air pillows from being dispensed). The pair of followers 146 are mounted on pins and are disposed in an outwardly-angled configuration, to readily permit a strand of air pillows to pass through the pair of followers (e.g., during dispensing) without damaging the strand of air pillows.

[0062] In an embodiment, the pair of followers 146 trace the contour of the strand of air pillows. For example, the pair of followers may be configured to detect mechanical deflection (e.g., deflection outward as a pillow passes and deflection inward between two pillows), such that the pair of followers 146 identifies specifically when a perforation zone is disposed between the pair of followers.

[0063] At the instance where the inflatable packaging system 100 determines that it has dispensed the desired length of the strand of air pillows 122, the dispenser head 112 stops conveyance (e.g., when the perforation zone is disposed between the pair of followers 146), and the dispenser head 112 subsequently reverses conveyance over a short distance. Specifically, while the pair of followers 146 are disposed to readily permit the strand of air pillows 122 to pass through the pair of followers 146 outwardly (e.g., during dispensing), the pair of followers 146 are angled such that air pillows are not capable of being withdrawn back into the dispenser head 112. Therefore, when the dispenser head 112 reverses conveyance, the strand of air pillows 122 is pulled against the pair of followers 146, and torn at the perforation zone via the pair of followers 146. The strand of air pillows then drops into an empty crate or into the operator's hands.

[0064] While separation is described herein with respect to reversing (e.g., reversing the belt drive to tear the inflatable cushioning supply at the perforation zone via the separator assembly 132), it should be appreciated that other types of belt drive control may, likewise, cause separation to occur. For example, in a different example embodiment, over-driving the belt drive (e.g., an increased forward speed) causes perforation to occur. Similarly, in another different example embodiment, separation may be caused by simultaneously over-driving and reversing the belt drive (e.g., increased forward speed on one belt while simultaneous reversing of another belt).

[0065] In an embodiment, each of the pair of followers 146 includes a generally triangular surface area, such that a separation zone 148 is formed at the vertex of the generally triangular surface area. The pair of followers 146 are specifically shaped such that there is a large surface area in contact with the air pillow during forward/dispensing motion, and minimal contact with the air pillow during the reverse/separation motion. This specific geometric configuration lowers the overall stress on the air pillow material during a rapid feed and maximizes the stress on a short, centered portion of the perforation during the separation process.

[0066] Via the separation process explained above, a generally triangular surface area ensures that the perforation zone tearing of a particular air pillow begins in the middle of a perforation line. This advantageously ensures that the total reverse distance to achieve complete tearing is reduced (e.g., approximately half the width of a strand of air pillows) by tearing the perforation in both directions from the center. Separating from the center of the perforation, rather than the edge, thus reduces the force required and also reduces the distance required to ensure complete separation, allowing for a compact conveyor design and requiring less overhead space.

[0067] In an embodiment, each of the generally triangular surface areas includes a beveled or rounded vertex, to ensure tearing while reducing the risk of puncturing an individual air pillow.

[0068] In an embodiment, the pair of followers 146 are mechanically controlled between the open position (e.g., to permit the strand of air pillows to be dispensed) and the closed positon (e.g., to restrict the strand of air pillows from being dispensed). For example, as illustrated by FIG. 5, separator assembly 132 may include a mechanical linkage 150, coupled to a solenoid actuator 152. The solenoid actuator 152 may be used to displace and/or lock the mechanical linkage 150 in the closed position, preventing the inflated article from forcing the pair of followers 146 open when running the dispenser head 112 in the reverse direction. In this example, it is not necessary for the pair of followers 146 to touch when disposed in the closed position. Rather, a small gap is permissible so long as the gap will not permit the inflated article to pass thru the pair of followers 146 during reversing. In an embodiment, a grip, such as silicone, or other mechanical feature may be added to the pair of followers 146 (e.g., at the vertex of the generally triangular surface area) to hold the material and improve tearing during perforation.

[0069] In an alternative embodiment, illustrated by FIGS. 6A to 6B, the pair of followers 146 are mechanically controlled between the open position (e.g., to permit the strand of air pillows to be dispensed) and the closed positon (e.g., to restrict the strand of air pillows from being dispensed) via a rotatable cam 154 and associated mechanical linkage 156. When the cam 154 rotates (driven by a motor 158), the mechanical linkage 156 may be locked in the closed or open position (as generally discussed above).

[0070] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.