Note: Descriptions are shown in the official language in which they were submitted.
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PACKING MATERIAL PRODUCTION AND BAGGING APPARATUS AND
METHODS FOR USING SAME
RELATED APPLICATIONS
This application is a continuation-in-part of pending U.S. Patent Application
No. 11/625,156 filed January 19, 2007, the contents of which are incorporated
herein
by reference.
This application is also related to U.S. Provisional Patent Applications Nos.
60/736,801, filed November 15, 2005, 60/754,101 filed Deceinber 27, 2005 and
lo 60/746,177 filed May 2, 2006, the disclosures of whiclz are herein
incorporated by
reference.
FIELD OF THE INVENTION
The present invention relates to the packaging industry, for example by
providing, in an exemplary embodiment of the invention, an adaptable apparatus
for
filling bags with packing material for use in paclcaging.
BACKGROUND OF THE INVENTION
The packaging material industry has long been confronted with the problem of
creating protective packaging for articles wliich come in various shapes and
sizes and
which should be packaged in as little time as is practicable. One common
method of
manufacturing packing material to counter such problems is reacting component
chemicals on the spot to create a foam type cushioning material which is then
packed
with the article being protected. Often, the foam type cushioning material is
first
placed in a receptacle (e.g. bag) prior to packing the article.
U.S. Pat. No. 6,550,229, the disclosure of which is incorporated herein by
reference, describes a device for sealing two plies of plastic film together
generally
includes an electrically conductive heating element and a rotatable support
cylinder
having an outer, circumferential surface, the cylinder being positioned in
abutting
relationship with the heating element and capable of rotating against the
heating
element, which is in fixed position, along a predetermined contact arc such
that less
than a complete circumference of the outer surface of the cylinder is in
contact with
the heating element.
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U.S. Pat. No. 6,311,740, the disclosure of which is incorporated herein by
reference, describes a mixing chamber assembly which has a reciprocating rod
received within a mixing chamber of a mixing chamber member. The reciprocating
rod is in a non-interference position with the mixing chamber over its entire
length
within the mixing chamber. The non-interference fit provides for continuous
solvent
flow about the exterior of the rod and interior of the wall defining the
mixing chamber
such that solvent drips out the discharge end of the mixing chamber and the
rod is free
to float or ride on a film of solvent. The ability for the rod to ride on a
film of solveiit
over the entire portion received within the mixing chamber, allows for a much
reduced
reciprocating motive force requirement and a corresponding freedom to
iricrease the
mixing chamber volume. The mixing chamber member is preferably received within
a
dispenser housing such that it is free to shift behind a dispensing and a non-
dispensing
mode with a shuttle valve arranged between the housing and mixing chamber to
seal
off chemical precursors for forming polyurethane foam or the like from
entering the
mixing chamber when the mixing chamber member is in a non-dispensing mode.
U.S. Pat. No. 6,131,375, the disclosure of which is incorporated herein by
reference, describes a protective foam cushion-making apparatus which
dispenses
reactive foam components into an interior space between two panels of plastic
film to
form protective foam cushions. The apparatus includes a supply of plastic film
and a
film a driving assembly, such as two pliable rollers. A foam component
dispensing
assembly is interposed between the film panels and injects reactive foam
components
into the interior space where they are mixed together to form a mass of
expandable
foam. The plastic film forms a flexible mixing chamber in the area between the
two
pliable rollers in which the reactive foam components are mixed togetlier
after they
are dispensed from the foam dispensing assembly.
U.S. Pat. No. 5,679,208, the disclosure of which is incorporated lierein by
reference, describes a sealing and severing apparatus for sealing plastic bags
forined in
succession from stock plastic film material and then severing the sealed bags
from one
another. The bags are filled with a foamable coinposition while they are being
formed
so that wlien the formed and filled bags are placed in a container, the
foamable
composition fills the bag with foam to thereby produce a customized foam
cushion for
any objects in the container.
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U.S. Pat. No. 5,139,151 and U.S. Pat. No. 5,027,583, the disclosures of which
are incorporated herein by reference, describe methods of forming large-volume
foam
cushions for packaging purposes wherein each cushion comprises a closed bag
formed
from respective first and second superposed sheets of plastic material and
filled with
foam. Exemplary methods comprise folding at least one of the first and second
sheets
of plastic material along one side edge portion of the sheets inwardly to form
a first
longitudinally extending gusset therein; folding at least one of the first and
second
sheets of plastic material along the opposite side edge portion of the sheets
inwardly to
form a second longitudinally extending gusset therein; longitudinally sealing
the outer
side edges of the first and second sheets together to form a gusseted tube
thereof;
transversely sealing the first and second sheet together along a line
generally
perpendicular to the longitudinal side edge seals to thereby form a closed end
of the
gusseted tube; injecting a predetermined amount of a foamable composition into
the
closed eiid of the gusseted tube; and transversely sealing the gusseted tube
along a line
longitudinally spaced from the first transverse seal to thereby form a sealed
bag
containing the foainable composition, wherein as the foainable composition
foams the
gussets expand to produce a cushion of greater volume.
SUMMARY OF THE INVENTION
An aspect of some exemplary embodiments of the invention relates to
providing a software programmed controller for coiitrolling and/or modifying
and/or
adapting the operation of a packing material production and bagging apparatus
based
on sensed and/or operator input inforination. In some exemplary embodiments of
the
invention, delay times and/or receptacle packing information is modified by an
operator of the apparatus during operation by using the controller.
Optionally,
receptacle packing information includes delay times between filling each
receptacle.
Optionally, receptacle packing information includes a receptacle queue.
Optionally,
receptacle packing information includes standard receptacle type, size and/or
filling
data (such as fill percentage). In some exemplary embodiments of the
invention,
controller is operationally connected to a plurality of input devices.
Optionally, an
input device is an environmental sensor, such as at least one of a
temperature,
humidity or atmospheric pressure sensor. In some einbodiments of the
invention,
sensed information from a sensor is used by the controller to adapt operation
of the
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apparatus to the sensed information. In an exemplary embodiment of the
invention, an
operator activated control is an input device which is used for operating the
packing
material production and bagging apparatus. Optionally, the operator activated
control
is a delay button for delaying the filling of the next receptacle in the
queue. In some
exemplary embodiments of the invention, controller outputs receptacle packing
information to a display.
An aspect of some embodiments of the invention relates to detection,
notification and resolution of faults in a packing material production and
bagging
apparatus. In some exemplary embodiments of the invention, sensing devices
operationally connected to a software programmed controller sense faulty
operation of
apparatus. In some embodiments of the invention, the controller notifies an
operator of
the apparatus of a fault. Optionally, exterior panels of the apparatus are
opened by the
controller upon the detection of a receptacle becoming stuck in the apparatus
or other
malfunction. Optionally, an audible alarm is activated by the controller upon
the
sensing of faulty operation of the apparatus. In some exemplary einbodiments
of the
invention, the controller activates fault counter-measures, such as the use of
a cleaning
solvent when faulty operation of an applicator assembly is detected. In some
embodiments of the invention, sensors for detecting movement of a transport
system
(described below) and/or receptacle alignment are provided. In some exemplary
embodiments of the invention, at least one sensor is provided for determining
the end
of a receptacle material feed.
In some exemplary embodiments of the invention, the packing material
production and bagging apparatus is provided witll a dynamic receptacle
transport
system which decreases the likelihood of faulty operation of rollers within
the system.
In an exemplary embodiment of the invention, receptacle transport system
improves
reliability of roller operation by providing a "floating" motor configuration
which
eliminates the need for a special coupling between the motor and the shafts of
the
rollers transporting the receptacle material through the apparatus. In an
einbodiment of
the invention, a motor in a "floating" configuration is mounted so that it can
move in a
plurality of degrees of freedom in the event that the roller to wliich it is
attached is
slightly misaligned (i.e. does not rotate precisely about its longitudinal
axis). In some
exemplary embodiments of the invention, a cut and seal roller is provided to
the
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dynainic receptacle transport system for causing the forced release of the
receptacle
material after cutting and/or sealing has been performed, thereby reducing the
likelihood of a jam.
In an exemplary embodiment of the invention, a heated system is provided to
5 the packing material production and bagging apparatus for cutting and/or
sealing
receptacles. In an exeinplary embodiment of the invention, a cutting and/or
sealing
element is a heated element which is comprised of a ribbed strip which adapted
for
cutting individual receptacles. In some exemplary embodiments of the
invention, the
heated element is used for sealing individual receptacles. Optionally, cutting
and/or
1o sealing is performed simultaneously on the receptacles using the heated
element.
In an exemplary embodiment of the invention, a material to which the cut
and/or sealed (e.g. melted) receptacle material does not stick is used to
insulate the
heated element from the receptacles being cut and/or sealed thereby preventing
the
receptacles from sticking to the heated element. Optionally, the material is
Teflon .
In some exemplary embodiments of the invention, spring elements are provided
to
mechanically separate a receptacle from the heated element after the heated
element
has performed cutting and/or sealing on the receptacle.
In an exemplary embodiment of the invention, at least one spring is provided
in operative connection to the ribbed, heated eleinent for at least adjusting
the
resistance (for example, by using different k constant springs) exerted by the
heated
element on a cut and seal roller wliich serves to provide counter force to the
heated
element as it operates on the receptacle being cut and/or sealed. In an
embodiment of
the invention, the at least one spring acts as a shock absorber type spring.
In some
embodiments of the invention, at least one spring in operative connection with
the
heated element is used to overcome planar irregularity between the heated
element and
the cut and seal roller preventing an uneven cut and/or seal from being formed
by the
heated element.
In an exeinplary embodiment of the invention, at least one leaf spring is used
for removably mounting a cutting aiid sealing system which includes the
cutting
and/or sealing element on the apparatus. Optionally, the leaf spring is
provided witli a
slot which mates with a protrusion adapted to fit within the slot located on
the cutting
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and sealing system. In an embodiment of the invention, the leaf spring is used
to bias
the cutting and sealing system.
In some embodiments of the invention, the heated element is provided with a
speed control system comprising a combination of at least one cam-follower and
a
motor speed control. In some exemplary embodiments of the invention, the power
imparted to the heated element for heating is relative to the speed of
operation of the
apparatus wherein the faster the speed of operation the hotter the heated
element is
made and/or vice versa.
In some exemplary embodiments of the invention, heating is provided to tubes
used for chemical transport in the apparatus in order to modify
characteristics of the
chemicals. For example, foaming speed and/or viscosity are characteristics
that are
modified by supplying heating to the chemicals.
In some exemplary embodiments of the invention, a software-progrannned
controller is used to control any of the above features as a result of data
received from
at least one sensor, for example controlling the heating of the tubes based on
data
received from an ambient temperature sensor.
An aspect of some exemplary embodiments of the invention relates to
providing a method for producing and bagging packing material using a packing
material production and bagging apparatus wlierein at least one action of the
method
is adapted by a controller in response to data received from at least one
sensor
positioned on the apparatus.
An aspect of some exemplary embodiments of the invention relates to
providing a method of displaying and using a receptacle manufacturing queue in
a
packing material production and bagging apparatus. In an einbodiment of the
invention, a controller is preprogrammed with receptacle information to create
predefined receptacle profiles. Optionally, receptacle information is at least
one of size
and/or packing material fill percentage and/or a packing material property. In
an
embodiment of the invention, receptacle information is displayed graphically
to an
operator by the controller on at least one display. Optionally, receptacle
information is
displayed in the form of a queue wllich shows the fortlicoming receptacles in
the
production series and/or receptacle information regarding the receptacles.
Optionally,
the operator can alter one or more receptacles, by manually modifying
receptacle
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information, in the production series. For example, the operator can input
modification commands via the controller. Optionally the graphically displayed
receptacle representation is in the form of a bar graph, wherein the height of
the bars
indicates receptacle size and the fill of the bars iildicates the percentage
of fill of the
receptacles.
There is thus provided, in accordance with an exemplary embodiment of the
invention, a packing material production and bagging apparatus, comprising: a
packing material production and bagging section, wherein the section makes
receptacles filled with packing material; at least one sensor, configured to
sense data
related to operation of said apparatus; and, a controller in communication
with said at
least one sensor programmed to automatically adapt operation of said apparatus
in
response to data received from said at least one sensor.
In an embodiment of the invention, the apparatus further comprises a display
for displaying information to an operator of the apparatus.
In an embodiment of the invention, the apparatus further coinprises a base on
wllich the production and bagging section is adjustably mounted. In an
embodiment of
the invention, the apparatus further comprises a delay button for temporarily
halting
operation of the apparatus.
Optionally, the controller is programmed to with receptacle packing
information. Optionally, receptacle packing information includes delay times
between
making of the receptacles. Optionally, receptacle packing information includes
at least
one of receptacle type, size and/or filling data. Optionally, the at least one
sensor is an
environmental sensor sensing at least one of temperature, humidity or
atmospheric
pressure. Optionally, the at least one sensor is adapted to sense faulty
operation of the
apparatus and communicate the faulty operation sensing to the controller.
Optionally,
the controller notifies an operator of the apparatus of sensed faulty
operation.
Optionally, the controller automatically activates at least one fault counter-
measure
upon sensed faulty operation. Optionally, at least one fault counter-measure
is an
alarm. Optionally, at least one fault counter-measure is automatically opening
a door
to the packing material production and bagging section to allow access to
apparatus
for service. Optionally, the packing material production and bagging section
includes
a cutting and sealing system adapted for cutting and sealing a material used
for
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manufacturing the receptacles. Optionally, the cutting and sealing system is
comprised
of a cutting and sealing element. Optionally, the cutting and sealing element
is heated.
Optionally, the cutting and sealing element is comprised of a ribbed strip.
Optionally,
the cutting and sealing element is insulated from at least one other component
of the
apparatus by a non-stick material. Optionally, the cutting and sealing system
is
provided with at least one spring to buffer contact between the cutting and
sealing
system and at least one other component of the apparatus. Optionally, the
controller
modifies the operation of the cutting and sealing system based on sensed data
from the
at least one sensor.
In an embodiment of the invention, the apparatus further comprises a spring-
loaded clamp adapted to clamp the material used for manufacturing the
receptacles to
cutting and sealing system.
In an embodiment of the invention, the apparatus further comprises a floating
motor provided to the packing material production and bagging section.
In an embodiment of the invention,'the apparatus further comprises an external
door on which at least one component of the packing material production and
bagging
section is located wherein when the external door is open the at least one
component
does not obstruct access to an interior area of the packing material
production and
bagging section.
There is further provided in accordance with an exemplary embodiment of the
invention, a method of producing and bagging packing material, comprising:
sealing
at least two edges of said receptacle material to define a bottom and at least
one side
of said receptacle; manufacturing packing material for injection into said
receptacle;
injecting said packing material into said receptacle; perforining at least one
of cutting
or sealing a top of said receptacle; and, wherein at least one of said
sealing,
manufacturing, injecting, or cutting is adapted by a controller in response to
data
received from at least one sensor positioned on said apparatus. Optionally, at
least one
of sealing or cutting is adapted by the controller based on sensed speed of
receptacle
tlirough said apparatus. Optionally, at least one of sealing or cutting is
adapted by
modifying the temperature used to perform the sealing or cutting. Optionally,
manufacturing is adapted by the controller based on sensed ambient
enviroiunental
conditions. Optionally, producing and bagging packing material is performed
using
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predefmed receptacle packing information. Optionally, the controller is pre-
programmed with at least one of a delay time, receptacle size or fill
percentage
according to the predefined receptacle packing information.
There is further provided in accordance with an exemplary embodiment of the
invention, a method of displaying a receptacle manufacturing queue in a
packing
material production and bagging apparatus, comprising: pre-programming a
controller
of the packing material production and bagging apparatus with receptacle
packing
information; receiving a command from an operator of the apparatus to produce
receptacles with receptacle packing information; and, communicating from the
controller to a display the receptacles to be produced, wherein the display
presents a
graphical representation of the receptacle queue which shows at least the size
and the
percentage of fill for the receptacles in the queue. Optionally, the graphical
representation includes a hollow outline of each receptacle in the queue,
indicating
size and/or shape of each receptacle, and wherein the amount of the hollow
outline
that is filled in indicates percentage of fill for each receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary non-limiting embodiments of the invention are described in the
following description, read with reference to the figures attaclied liereto.
In the figures,
identical and similar structures, elements or parts thereof that appear in
more than one
figure are generally labeled with the same or similar references in the
figures in which
they appear. Dimensions of components and features shown in the figures are
chosen
primarily for convenience and clarity of presentation and are not necessarily
to scale.
The attached figures are:
Fig. 1 is an external, perspective view of a packing material production and
bagging apparatus, in accordance with an exemplary embodiment of the
invention;
Fig. 2 is an internal, perspective view of a packing material production and
bagging apparatus, in accordance with an exemplaiy embodiment of the
invention;
Fig. 3 is a detailed view of the packing material production and bagging
section of the apparatus, in accordance wltll an exemplary enibodiment of the
invention;
Fig. 4 is an illustration showing a"floating" motor configuration, in
accordance with an exemplary embodiment of the invention;
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Fig. 5 is a perspective view of a cutting and/or sealing element, in
accordance
with an exemplary embodiment of the invention;
Fig. 6 is a detailed view of a gun system and packing material production and
bagging apparatus, in accordance with an exemplary embodiment of the
invention;
5 Fig. 7 is a detailed view of a base, in accordance with an exemplary
embodiment of the invention;
Fig. 8 is a schematic of a controller, in accordance with an exemplary
embodiment of the invention;
Fig. 9 is a flowchart of a general method of use for a packing material
10 production and bagging apparatus, in accordance with an exemplary
embodiment of
the invention; and,
Figs. l0A-D are a flowchart of a method of using a packing material
production and bagging apparatus, in accordance with an exemplary embodiment
of
the invention. -
. DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary Packing Material Production and Bagging Apparatus
Referring to Fig. 1, an external, perspective view of a packing material
production and bagging apparatus 100 is depicted, in accordance with an
exemplary
embodiment of the invention. In an exemplary einbodiment of the invention,
apparatus 100 is comprised of a production and bagging section 102 and a base
104.
Production and bagging section 102 is described in more detail with respect to
Figs. 3
through 6 and base 104 is described in more detail witli respect to Fig. 7,
below. In an
exemplary embodiment of the invention, apparatus 100 is used to manufacture
packing material. Optionally, the packing material is created by mixing and/or
reacting togetller at least two component chemicals. In some exemplary
embodiments
of the invention, the manufactured packing material is placed by apparatus 100
into
receptacles, such as bags, for providing packaging for items to be
transported.
Receptacles are optionally made from receptacle material 106 located in
proximity to
production and bagging section 102, as described below with respect to Fig. 3.
Optionally, receptacle material 106 is any heat sealable, water. non-permeable
material. Optionally, receptacle material 106 is high density polyethylene. In
some
embodiments of the invention, apparatus 100 is provided with at least one
wheel 108
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for mobility. Optionally, base 104 is provided with at least one operator
graspable
handle 110 for mobility. In some exemplary embodiments of the invention, a
display
112 is provided to apparatus 100 to convey information to an operator or user
of
apparatus 100.
It should be understood that although apparatus 100 is often described in the
context of production of paclcing material and bagging simultaneously, or
nearly
simultaneously, in some exemplary embodiments of the invention, bagging is not
performed. In some exemplary embodiments of the invention, apparatus 100 is
not
used for producing the packing material but for bagging only.
Fig. 2 shows an internal, perspective view of a packing material production
and bagging apparatus 100, in accordance with an exemplary embodiment of the
invention. Production and bagging section 102 is provided with an external
door 202,
in an exemplary embodiment of the invention, which provides access to the
inside of
production and bagging section 10-2, assisting an apparatus 100 operator with
the use
and maintenance of apparatus 100. Base 104 is depicted in more detail in Fig.
7, in
accordance with an exemplary embodiment of the invention. Optionally, base 104
is
provided with at least one access door 204 (shown open in Figs. 2 and 7) for
providing
operator access to internal components of base 104. In some embodiments of the
invention, a reservoir 206 is provided inside and/or outside base 104 for
providing
solvent and/or component chemicals to apparatus 100.
Referring to Fig. 3, a detailed, perspective view of production and bagging
section 102 is shown in accordance with an exemplary embodiment of the
invention.
External door 202 is shown in an open condition revealing exemplary internal
components and an exemplary internal configuration of production and bagging
section 102. It should be understood that components are optionally added
and/or
removed depending on the application of use and/or needs of the operator.
Briefly, in
an exemplaiy mode of operation, receptacle material 106 is fed into production
and
bagging section 102 where components act upon receptacle material 106 to form
receptacles, such as bags, for packing material. In an exemplary embodiment of
the
invention, the packing material is produced in production and bagging section
102,
and optionally, within the receptacle itself. Upon completion of the
production of an
appropriate receptacle filled with the produced packing material, the
receptacle is
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expelled from apparatus 100 by production and bagging section 102 and/or by
gravity.
Exemplary methods of use of apparatus 100 are described in more detail with
respect
to Figs. 9, 10A and lOB below.
In an exemplary embodiment of the invention, at least one feeding roller 302
is
provided to apparatus 100 for initially aligning receptacle material 106
and/or
introducing receptacle material 106 into production and bagging section 102
for use
by apparatus 100. In an exemplary embodiment of the invention, receptacle
material
106 fed into section 102 by feeding roller 302, and is transported past and
around a
gun assembly 304, described in more detail with respect to Fig. 6, to at least
one
pulling roller 306. Pulling roller 306 pulls receptacle material 106 througli
machine to
a cutting and sealing system 312, described below. In soine embodiments of the
invention, receptacle material 106 is stored and fed into apparatus 100 in a
folded
configuration, wherein the receptacle material has been folded in half around
its
longitudinal axis creating material which is closed on one end, where the fold
is, and
is open on the top, bottom and other longitudinal side. In an embodiment of
the
invention, receptacles are created by sealing the bottom, side and top as
described
herein.
In an exemplary embodiment of the invention, section 102 is provided with at
least one sensor for determining when receptacle material 106 is running low
and/or is
depleted. For example for sensing a running low condition, at least one leaf
spring
connected to a switch can be provided between two feeding rollers 302 which
cradle a
roll of receptacle material 106. In an embodiment of the invention, as the
roll of
receptacle material 106 is exhausted it gradually decreases in overall
diameter. This
causes the roll to slowly sink into a gap between the feeding rollers 302 due
to its
decreased diameter. When receptacle material 106 runs "low", the reduced
diameter
roll of receptacle material 106 exerts a load on the leaf spring, triggering
the switch
and signaling to a controller 800 (described in more detail below) that
receptacle
material 106 is running low. In some embodiments of the invention, the at
least one
leaf spring is positionable and/or is replaced to select the minimum ainount
of load
exerted on it necessary to establish a connection between the spring and the
electrical
contact.
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In an embodiment of the invention, a sensor for sensing receptacle material
106 depletion is comprised of at least one spring loaded contact mounted
opposite an
opposing contact. In an embodiment of the invention, receptacle material 106
passes
between the spring loaded contact and the opposing contact during operation,
preventing an electrical contact between the two contacts from being made.
Upon
receptacle material 106 depletion, spring loaded contact is urged against
opposing
contact, creating an electrical connection, optionally signaling to controller
800 that
receptacle material has been depleted. In some embodiments of the invention,
the at
least one spring loaded contact is mounted on external door 202 and the
opposing
contact is mounted opposite the spring loaded contact in the interior of
section 102 or
could be, for example one of the rollers 302, 306 (the roller being
conductive). In an
embodiment of the invention, the sensor is comprised of two spring loaded
contacts.
Both contacts are inounted on external door 202 and the supporting roller that
the film
passes over is conductive. One contact is mounted out of the film's path and
always
contacts the roller. The other is mounted in the film path and contacts the
roller when
the film is exhausted, thereby triggering the sensor.
In an exemplary embodiinent of the invention, pulling roller 306 operates to
pull enough receptacle material 106 to create a receptacle of the size
dictated by
controller 800, depicted in Fig. 8. Optionally, pulling roller 306 is manually
controlled
by an operator. In an exeinplary embodiment of the invention, lengths of
receptacle
material 106 passing through production and bagging section 102 are determined
by
using at least one encoder which counts revolutions of one or both of the
rollers 302,
306. Using a count of the revolutions of a roller, it can be determined the
total lengtli
of receptacle material 106 pulled through that roller. Optionally, the at
least one
encoder is positioned on a roller around which the receptacle material 106 is
wrapped
prior to use. Rollers 302, 306 are optionally constructed of a material which
is at least
slightly flexible and exhibits a high enough coefficient of friction on its
surface to
provide motion to receptacle material 106 without significant slippage. In
some
embodiments of the invention, only roller 306 is used to provide motion to
receptacle
material 106.
In some exemplary einbodiments of the invention, a motor 400 for controlling
at least one of rollers 302, 306 is dynamically located on a shaft 402
extending
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through a longitudinal axis of at least one of the rollers, as shown in Fig.
4. Typically,
a coupling is used between shaft 400 and motor 400 to account for shaft
rotational
irregularities (not rotating precisely around the shaft's longitudinal axis),
however, in
an embodiment of the invention, motor 400 is provided with space aroui-id it
for
freedom of movement such that as shaft 402 rotates, any irregular rotation is
translated
to motor 400. It is believed that such a configuration reduces alignment
problems
between roller 306 and motor 400 in embodiments of the invention wherein
roller 306
does not rotate precisely around its longitudinal axis, decreasing the
likelihood of
shaft 402 locking up and failing to rotate. Optionally, the motor 400 is an AC
motor.
Optionally, the motor 400 is a DC motor, for highly responsive motor control.
In some
embodiments of the invention, the motor is controlled by controller 800, for
example
for better speed control. Optionally, at least one of motor 400 and/or other
motors
described herein is a brushless motor.
In order to enhance control over receptacle material 106 passing through
production and bagging section 102, a pulling support roller 310 is provided
opposite
pulling roller 306. In an exemplary embodiment of the invention, receptacle
material
106 is passed by feeding roller 302 and subsequently between pulling roller
306 and
pulling support roller 310. Optionally, a feeding support roller is provided
opposite the
feeding roller 302 to provide improved contact between the receptacle material
106
and the roller 302 pulling the material 106 into apparatus 100. In an
embodiment of
the invention, the feeding support roller and pulling support roller 310 are
located on
the inside of external door 202.
In an exemplary embodiment of the invention, various devices are provided to
apparatus 100 for facilitating nominal operation of apparatus 100, for example
to
prevent inadvertent touching and/or sticking of receptacle material 106 to
cutting and
sealing system 312. A spring-loaded clamp is optionally used to clamp
receptacle
material 106 to cutting and sealing system 312 during the cutting and/or
sealing of
receptacles as they pass through section 102. It is believed that using a
clamp to secure
receptacle material 106 during the cutting and/or sealing process provides
more
effective cutting and/or sealing and also reduces the lilcelilZood of
receptacle material
106 sticking to the at least one cutting and/or sealing element after
receptacle material
106 and the cutting and/or sealing element come into contact.
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In some exemplary embodiments of the invention, devices are provided which
reduce the likelihood or prevent receptacle material 106 from catching on
parts of
production and/or bagging section 102. For example, plate coverings 316 are
used to
provide a smooth protective surface over apparatus 100 components reducing the
5 likelihood of receptacle material 106 becoming caught. In some embodiments
of the
invention, separators are positioned between components of apparatus 100 and
receptacle material 106 as it transits through apparatus 100 to prevent
electrostatic
sticking of receptacle material 106 to components. Optionally, the separator
elements
are bent wire type spring elements and/or formed sheet metal strips.
10 As described above, receptacle material 106 width is approximately twice
the
length of feeding roller 302 and is loaded into apparatus 100 at feeding
roller 302 in a
folded-in-half condition, such that the width of receptacle material 106 is
substantially
the length of feeding roller 302 when folded. Using the view of Fig. 3 for
reference,
receptacle material is folded such that the right, vertical edge of receptacle
material
15 106 is closed due to the fold and the left, vertical edge of receptacle
material .106 is
open. Prior to the commencement of any operations by apparatus 100 on
receptacle
material 106, the bottom edge is also open since no cutting and/or sealing has
been
performed on it by cutting and sealing system 312. Receptacle inaterial 106 is
fed into
section 102 by feeding roller 302 and as it moves down through section 102,
the
folded material 106 is split so that one side of the folded material 106, a
distal side,
passes on a distal side of gun assembly 304 and a second side of the folded
material
106, a proximal side, passes on a proximal side of gun assembly 304. In an
exemplary
embodiment of the invention, the splitting of receptacle material 106 is
enabled by the
left, vertical edge which is still open at this stage.
The cutting and sealing system 312 is provided to section 102 for assisting
with the creation of receptacles, in some exemplary embodiments of the
invention. In
the configuration depicted in Fig. 3, cutting and sealing system 312 is
located near a
lower portion of production and bagging section 102. In an exemplary
embodiment of
the invention, cutting and sealing system 312 is comprised of a cutting and/or
sealing
element 318, described in more detail in Fig. 5. For example, the cutting
and/or
sealing element is conzprised of a ribbed strip of metal, wherein the ribbing
extends
along the center of the strip along the longitudinal axis thereof. Optionally,
there are
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16
more cutting and/or sealing elements depending on the requirements of use.
Optionally, these cutting and/or sealing elements are heated. In some
exemplary
embodiments of the invention, at least one of the cutting and/or sealing
elements is
wire-like, thin and elongated. Optionally, the cutting and/or sealing elements
are
comprised of aluminum or other heat conductive material.
In an exemplary embodiment of the invention, cutting and/or sealing element
318 is used to cut (performing a cross-cutting function) and seal receptacle
material
106, defining a bottom and/or a top of a receptacle. In an embodiment of the
invention, an additional cutting and/or sealing element is optionally used to
form an
additional seal proximal to the bottom and/or or top of a receptacle. In an
exemplary
mode of operation, cutting and/or sealing element 318 cuts and seals the top
of a
receptacle while at the same time creates a sealed bottom of a new receptacle.
Cutting
and/or sealing element 318 is optionally used before, during and/or after the
cutting
and/or sealing process to provide an additional seal at or near the top and/or
bottom of
the receptacle.
In an exemplary embodiment of the invention, cutting and/or sealing element
318 is moveable into a cutting and/or sealivig position when cutting and/or
sealing is
performed and into a standby position when cutting and/or sealing is not
performed. In
an exeinplary embodiment of the invention, cutting and/or sealing element 318
is
positioned on cutting and sealing system 312 and is provided with movement
which
causes cutting and/or sealing element 318 to transition between the standby
position to
the cutting and/or sealing position.
In an exemplary embodiment of the invention, a cut and seal roller 314 is
provided to apparatus 100 opposite cutting and sealing system 312 to piovide
counter
force to the at least one cutting and/or sealing element as it operates on
receptacle
material 106, which would be pressed between them at least temporarily.
Optionally,
cut and seal roller 314 is positioned on external door 202 such that
receptacle material
106 passes between cut and seal roller 314 and cutting and sealing system 312
allowing easy loading of receptacle material 106 into apparatus 100 (by
trapping
material 106 between the interior surface of external door 202 and the
components
located in section 102). In an exemplary embodiment of the invention, cut and
seal
roller 314 rotates as receptacle material 106 passes through apparatus 100 so
that
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consecutive cut and sealing operations are performed against a different part
of the
rotating surface area of cut and seal roller 314, thereby preserving life of
the roller
314. Furthermore, rotation of cut and seal roller 314 causes a forced release
of
receptacle material 106 from roller 314 in some exemplary embodiments of the
invention, reducing the likelihood of receptacle material 106 sticking to
roller 314
after the cut and/or sealing process. In some embodiments of the invention,
cut and
seal roller 314 is motorized to rotate roller both for preserving life of
roller 314 and
for causing the forced release of receptacle material 106 after cutting and/or
sealing
has been performed.
lo In an exemplary embodiment of the invention, the forward movement of
cutting and sealing system 312 against cut and seal roller 314 is buffered by
providing
at least one spring between cutting and sealing system 312 and the moving
parts of
apparatus 100 that provide movement to the cutting and sealing system 312. In
some
embodiments of the invention, the at least one spring is used to overcome
planar
irregularity between the cutting and/or sealing element 318 and the cut and
seal roller
314 preventing an uneven cut and/or seal from being formed by the cutting
and/or
sealing element 318. For example, if one side of the cutting and/or sealing
element
318 is closer to the cut and seal roller 314, when the cutting and/or sealing
element
318 is advanced the closer side naturally comes into contact with the roller
314 first.
Without the spring, forward movement of cutting and/or sealing elemeilt 318
towards
the cut and seal roller 314 would halt, perhaps not yet cutting and/or sealing
the part of
the receptacle located near the farther side of the cutting and/or sealing
element 318.
Using the spring, however, even after the closer side contacts the cut and
seal roller
314, forward movement can continue at least until the farther side of the
cutting
and/or sealing element 318 has had a chance to perform a cut and/or seal on
the
receptacle material 106. Optionally, the resistance exerted by the at least
one spring is
altered by using springs with different k constants.
As described above, cutting and sealing system 312 is used in some
embodiments of the invention to cut and/or seal the tops and/or bottoms of
receptacles. In an exemplary embodiment of the invention, a side sealing
system is
used to seal the left, vertical open side of receptacles as they are being
made. Side
sealing system includes a heated side sealing element 320, in accordance with
an
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18
embodiment of the invention. Optionally, side sealing element 320 is a
protrusion
which is heat conductive. Again, using the view of Fig. 3 for reference, the
side
sealing element 320 is located on the left side of section 102 below gun
assembly 304.
In some exemplary embodiments of the invention, the. open vertical edge and
the
location of the side sealing system are switched from left to right.
Optionally,
receptacle material 106 is not folded and exhibits an open edge on both the
left and
right and is sealed on both sides by side sealing system. In an exemplary
embodiment
of the invention, the side sealing eleinent 320 is stationary and seals
receptacle
material 106 with heat as it moves by the side sealing element 320. In some
embodiments of the invention, the side sealing element moves into a sealing
position
when receptacle material 106 is iui motion through section 102 and moves into
a
standby position when material 106 is not moving. Optionally, side sealing
element
320 is positioned on an arm 322 which is biased towards the external door 202,
for
example by a spring. Optionally, a side seal roller (not sliown) is provided
to external
door 202 to provide counter pressure to side sealing element during the side
sealing
process.
As will be described in more detail below with respect to Fig. 8, a controller
800 is optionally in operative communication with at least one of cutting and
sealing
system 312, side sealing system, roller 314, and/or side seal roller. In an
exemplary
embodiment of the invention, lieated cutting and/or sealing elements (e.g.
cutting
and/or sealing element 318 and/or side seal element 320 and/or a ventilation
element
321) are heated to a temperature which is sufficient for cutting and/or
sealing factoring
in the speed at which receptacle material 106 is passing through section 102.
Optionally, the temperature to which the cutting and/or sealing element 318
and side
seal element 320 and/or ventilation element 321 are heated is determined by
controller
800 depending on the type of material being used for receptacle material 106.
In some
embodiments of the invention, the speed at which cutting and/or sealing
element 318
and side seal element 320 deploy into cutting and/or sealing position is
determined by
controller 800 factoring in the speed at wliich receptacle material 106 is
passing
through section 102. Optionally, the speed at which the cutting and/or sealing
element
318 and side seal element 320 operate are determined by controller 800
depending on
the type of material being used for receptacle material 106.
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In some embodiments of the invention, ventilation element 321 is provided
near side seal element 320, to create ventilation openings in the top of
receptacles.
Optionally, ventilation openings are created on only one side, proximal or
distal, of
the receptacle. In an exemplary embodiment of the invention, the ventilation
element
321 uses anything capable of penetrating receptacle material 106 for creation
of the
ventilation openings. For example, a mechanical cutting element, such as a
sharp
blade, could be used. Optionally, a heated element is used to create the
ventilation
openings.
Referring to Fig. 5, a perspective view of cutting and/or sealing element 318
is
shown, in accordance with an exemplary embodiment of the invention. In some
einbodiments of the invention, the cutting and sealing are performed by a
single
element. Optionally, cutting and/or sealing element 318 is heated to
facilitate the
cutting and/or sealing. Cutting and/or sealing element 318 is comprised
generally of a
strip which is comprised of a "flat" portion 504 on either side of a central
rib 502,
which extends the longitudinal lengtli of cutting and/or sealing element 318.
In an
embodiment of the invention, central rib 502 is urged against receptacle
material 106,
which is trapped between central rib 502 and cut and seal roller 314, in order
to
provide cutting. The flat portions 504 of cutting and/or sealing element 318
use heat to
melt the receptacle material 106 and form a seal on either side of the cut
location. As
described herein, the seal formed by the lower flat portion seals the top of
the
receptacle just manufactured, and the upper flat portion seals the bottom of
the
receptacle about to be inanufactured. In some embodiments of the invention,
connections 506 both mechanical and electrical are provided to cutting and/or
sealing
element 318 to provide heating energy and mechanical attachinent to cutting
and
sealing system 312. It should be understood that in some embodiments of the
invention rib 502 does not have to talce the squarish shape shown, for example
rib 302
could be other raised shapes like a semi-circle or a triangle.
An apparatus heiglit adjustment mechanism is optionally provided to enable
the adjustment of the height of section 102 off the floor. The apparatus
height
adjustment mechanism is described in more detail with respect to Fig. 7 below.
In
some embodiments of the invention, various power and control elements (e.g.
printed
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circuit boards, controller 800) are located in section 102 and/or on the
exterior of
section 102.
Referring to Fig. 6, gun assembly 304 is more clearly shown in relation to
section 102 of apparatus 100, in accordance with an exemplary embodiment of
the
5 invention. It should be understood that gun assembly 304 is optionally
substantially
comprised of any of the substance injecting apparatuses described in U.S. App.
Serial
No. 60/754,101, the disclosure of which is incorporated herein by reference.
For
example, gun cartridge 602 is optionally similar to or the saine as the
cartridge
designated with reference numeral "102" described in that application. In an
10 exemplary embodiment of the invention, gun cartridge 602 is used to inject
reacted
chemicals, which will create a packing material, into a receptacle that has
been formed
for receiving the reacted chemicals. In some embodiments of the invention,
apparatus
100 is provided with more than one gun assembly. For example, a handheld gun
assembly is optionally used in conjunction with the section 102 mounted gun
15 assembly 304, which can be used by an operator to fill receptacles which
are too large
to be produced in apparatus 100 and/or to manually add additional packing
material to
receptacles. In an exemplary embodiment of the invention, gun assembly 304 is
provided with a casing which is configured to reduce the likelihood of
receptacle
material 106 wrinkling as it passes by gun assembly 304. For example, the
surfaces of
20 gun assembly 304 that come into contact witli receptacle material 106 are
designed to
be flat and/or smooth. In some embodiments of the invention, the component
chemicals of the packing material are reacted in the receptacle in addition
to, or
alternatively to, reacting them in gun cartridge 602. Chemical inlet ports 604
are
provided to gun assembly 304 for introducing component chemicals into gun
cartridge
602. In an exemplary embodiment of the invention, chemical inlet ports 604 are
supplied with component chemicals from chemical reservoirs, described in more
detail below with respect to Fig. 7.
Gun assembly 304 is optionally positioned on a moveable arm 606 that allows
gun assembly 304 to pivot around a vertical axis (e.g. towards and/or away
from
external door 202) to allow easier operator access to other internal
components of
section 102. Optionally, moveable arm 606 can be locked in a closed position
(typically assumed for apparatus 100 operation) and/or in an open position
(typically
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21
assumed for maintenance). In some embodiments of the invention, apparatus 100
is
operated with moveable arm 606 locked in the open position, and gun assembly
304 is
used to fill pre-made bags which do not pass through apparatus 100. In some
exemplary embodiments of the invention, cartridge 602 is easily removable and
replaceable in the event of operational malfunction. In some embodiments of
the
invention, external door 202 is forward opening, allowing an operator of
apparatus
100 easy access to the internal components of section 102 for maintenance
and/or
service. In some embodiments of the invention, some components of section 102
are
located on external door 202 so that when external door 202 is opened, these
components do not block access to the components located within section 102.
For
example, pulling support roller 310 and/or cut and seal roller 314 are located
on
external door 202 so that when door 202 is opened for service, loading and/or
maintenance of apparatus, these rollers do not obstruct an operator's access
to the
interior of section 102. In embodiment of the invention, components mounted on
door
202 are components which during operation are located on an opposite side of
receptacle material 106 from the components which are not mounted on external
door
202. This can be useful, for example, to assist with loading apparatus 100
with
receptacle material 106 for use.Page: 21
Fig. 7 depicts base 104 of apparatus 100, in accordance with an exemplary
embodiment of the invention. At least one reservoir is optionally located in
and/or on
base 104 for providing substances to production and bagging section 102, in an
embodiment of the invention. For example, at least one reservoir located in
and/or on
base 104 can contain solvent used for cleaning gun assembly 304 before, during
and/or after operation. Optionally, at least one reservoir is located in
and/or on base
104 which contains a component chemical used for manufacturing packing
material.
An exemplary reservoir 702 is shown located on a shelf on the exterior of base
104. In
some exemplary embodiments of the invention, reservoirs for solvent and/or
component chemicals are not located in and/or on base 104, for example if
their size is
prohibitive for such location. In an exemplary embodiment of the invention, at
least
one puinp is located in and/or on base 104. The pump is used for transporting
component chemicals from the at least one reservoir to section 102 for
injection by
gun assembly 304 into receptacles. The pump is optionally similar to, or the
same as,
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22
the type described in U.S. Apps. Serial No. 60/736,801 and 60/754,101. In some
exemplary embodiments of the invention, transportation of substances is
conducted
through heated tubing, which is intended to improve the flow characteristics
of the
substances.
In some exemplary embodiments of the invention, the apparatus height
adjustment mechanism is in operative communication with controller 800, wliich
automatically adjusts the height of section 102 off the floor, for example if
an
exceptionally large and/or long receptacle is produced which requires more
space
below section 102 than is typically available. Optionally, the height of
section 102 is
adjusted to accommodate a conveyor belt and/or an assembly line type
apparatus, with
packages located thereon, passing beneath section 102. In an exemplary
embodiment
of the invention, height adjustment arms 704 operatively connect section 102
to at
least one motor located in base 104 which moves height adjustment arms 704.
Optionally, the apparatus height adjustment mechanism includes at least one
motor
which is controlled by 'controller 800. Optionally, spring pistons are used to
help
provide movement to arms 704, reducing the force that the motor has to exert.
In an
embodiment of the inveiition, the apparatus height adjustment mechanism is
manually
operated and controlled. In an exemplary embodiment of the invention, the
heated
tubing which feeds substances from the reservoirs to section 102 is secured to
at least
one heiglit adjustment arm 704 to reduce clutter around apparatus 100.
Base 104 is optionally provided with a tooling point near the pump for
brealcing loose the pump, which may become stuck to base 104 by leaked and
reacted
component chemicals. Optionally, base 104 is provided with at least one
grasping
handle 110 and at least one wheel 108 for provided mobility to apparatus 100.
Exemplary Controller Confi urg ation
Referring to Fig. 8, a schematic of controller 800 is shown in accordance with
an exemplary embodiment of the invention. Controller 800 is optionally in
operative
communication with at least one of the various components of apparatus 100:
display
112, cutting and sealing system 312, side sealing system, feeding roller 302,
pulling
roller 306, pulling support roller 310, cut and seal roller 314, side seal
roller, at least
one pump, at least one sensor, at least one reservoir, at least one heating
element, gun
assembly 304, the height adjustment mechanism, at least one motor, at least
one
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23
operator operated control, and/or at least one fault indicator. The preceding
list is not
intended to be exhaustive, but to give examples only. In an exemplary
embodiment of
the invention, controller 800 is comprised of at least one of a processor 802,
a
database 804 and/or a communication interface 806, for communication between
controller 800 and the various components of apparatus 100, examples of which
are
listed above.
In an exemplary embodiinent of the invention, controller 800 communicates
information regarding the operational status of apparatus 100 to an operator
via
display 112. For example, display 112 can provide information to the operator
pertaining to receptacle sizes and/or the amount of packing material which
will be
used to fill the receptacles being produced. In some embodiments of the
invention,
receptacle packing information is pre-programmed into controller 800 prior to
operation of apparatus 100. In some embodiments of the invention, receptacle
packing
information is stored as a receptacle profile such that commands to produce
receptacles of like size, like fill percentage, material properties of the
packing material
(e.g. solid, liquid, something in between), etc. can be input into controller
800 by an
operator using the predefined profile. Other examples of information could
include
not only information regarding the current receptacle being produced but at
least one
other receptacle which is to be produced subsequently. Optionally, icons (e.g.
a
hollow outline of the receptacle, a hollow outline of a bar graph) are used
which show
the size and/or shape and the percentage of fill (e.g. how much of the hollow
is filled
in) for the receptacles being produced by apparatus 100, for example in a
receptacle
queue.
In some exemplary embodiments of the invention, information regarding the
operational status of apparatus 100 can also include speed of receptacle
production,
speed of receptacle filling, stage of the packing material production and
bagging cycle
(described in more detail with respect to Figs. 9, 10A and lOB) and/or
information
related to various components of apparatus 100, such as the cutting and
sealing systein
312. Iiiforination is optionally stored in database 804. In some embodiments
of the
invention, operator operated controls are located on display 112, such as a
touch
screen display, which enable the operator to modify the operation of apparatus
100.
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For example, the operator can select a size of the receptacle to be produced
and/or the
amount of packing material used to fill the receptacle using display 112.
In an exemplary embodiment of the invention, controller 800 is programmed
to adapt the operation of apparatus 100 based on at least one of a variety of
factors,
examples of factors including: data sensed by sensors, operational status of
components, operator input, and/or a pre-programmed operation schedule. The
following is list of examples of how controller 800 optionally adapts
operation of
apparatus 100 for these exemplary factors:
Data Sensed by Sensors
A. Ambient Environmental Conditions- At least one sensor is optionally
provided to apparatus 100 which senses ambient environmental conditions
in the area surrounding apparatus 100, in accordance with an exemplary
embodiment of the invention. Conditions optionally include temperature,
atmospheric pressure, and/or humidity. Based on these sensed conditions,
.15 which can alter the reaction between the coinponent chemicals, controller
800 optionally adapts operation by altering the temperature at which the
heated tubing operates, changes the amount of component chemicals
pumped, changes the speed at which the component chemicals are pumped
and/or changes the atnount of solvent used in order to produce desired
reaction characteristics.
B. Gun Assembly Status- At least one sensor is provided to gun
assembly 304 which can detect abnormal operation in an exemplary
embodiment of the invention. For example, if the speed of cartridge 602
slows down below a certain nominal threshold during operation, controller
800 is optionally programmed to signal for a release of solvent or
additional solvent for cleansing the cartridge 602 and/or gun assembly.
C. Receptacle Material Status- In an exemplary embodiment of the
invention, at least one sensor is provided to section 102 which can detect
if receptacle material 106 has been expended and needs refilling. In some
exemplary embodiments of the invention, at least one sensor is provided
to section 102 which can detect if receptacle material 106 becomes stuck
and/or becomes unusable for its purpose as it passes through section 102.
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Controller 800 receives data from such sensors and signals to operator that
more receptacle material is needed, automatically loads more receptacle
material into apparatus 100 and/or slows or halts operation of apparatus
100 until more receptacle material has been provided to apparatus 100 or
5 the faulty receptacle material condition has been corrected.
Operational Status of Components
The following items are related to data sensing above in some embodiments of
the invention since sensors may be used to detect receptacle material speed
and/or
cutting and/or sealing element temperatures, among others. In addition, the
10 following items are optionally interrelated with one item being used by
controller
800 to deterinine, in at least some part, the operation of another item. It
should be
noted that where an item is described as primary and other items variable
based on
that primary item, for example in the case of receptacle material speed below,
any
of the other items could be the primaiy instead.
15 A. Receptacle Material Speed- As described above, in some exemplary
embodiments of the invention, receptacle material 106 is fed into
apparatus 100 at feeding roller 302; receptacle material is then transported
tlirough apparatus by pulling roller 306. Depending on the sensed
rotational speed of pulling roller 306, which essentially determines the
20 speed of receptacle material 106 through section 102, controller 800
optionally adapts the speed of operation of cutting and sealing system 312
(by cutting/sealing faster or slower), side sealing system (by sealing faster
or slower), gun assembly 304 (by injecting more or less reacted chemical
into receptacle), and/or at least one pump (by transporting more or less
25 component chemicals to be reacted) to provide for nominal operation of
apparatus 100.
B. Cutting and/or Sealing Element Temperatures- In addition to the
above modifications, controller 800 adapts the operating temperature of at
least one of cutting and sealing system 312 and/or side sealing system, in
accordance with an embodiment of the invention. For example, controller
800 could be programmed to raise the temperature of these components as
the speed of receptacle material 106 through section 102 increases since
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cutting and/or sealing would need to be performed faster to match the
faster speed.
Operator Input
A. Delay Control- In an exemplary embodiment of the invention,
apparatus 100 is provided with a delay control button which when
triggered by an operator causes controller 800 to delay apparatus 100
operations for a period of time. Optionally, the delay period of time is
preset. Optionally, the delay period of time persists as long as the operator
holds the delay coiitrol button. In some embodiments of the invention, the
delay control button is located on display 112. Optionally, delay control
button is not located on the display, for example the delay control button is
located in a foot pedal and is controlled by the foot of the operator.
B. Operator Input Delay- In some embodiments of the invention, an
operator of apparatus 100 can inanually input a delay time for at least the
next receptacle. Controller 800 modifies the speed of various components
of apparatus, for example pulling roller 306, to provide the requisite delay.
Optionally, the delay time is input using display 112.
C. Individual Operator Profiles- Controller 800 is used to store individual
operator profiles in some exemplary embodiments of the invention.
Operator profiles are optionally stored in database 804. Depending on the
selected operator profile, or even if no profile is selected (a default
profile
will be used by controller 800), controller 800 adapts apparatus 100
parameters such as height of section 102 (using height adjustment system),
rate of receptacle production and filling and/or other parameters which
may vary depending on an operator's individual preferences.
Pre-programined Schedule
A. Pre-prograinmed Production Schedule- In some embodiments of the
invention, controller 800 stores at least one production schedule.
Optionally, the production schedule includes receptacle size, pacleiiig
material amount to be manufactured, amount of coinponent chemicals to
be pumped, speed of receptacle material tlirough section 102, delay
between receptacles, speed of cutting and sealing system 312, speed of side
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27
sealing system and/or other parameters related to producing receptacles
and packing material for filling them. In some exemplary embodiments of
the invention, these parameters are optionally changed by controller 800
from one receptacle to the next, depending on the pre-programmed
schedule. Optionally, at least one production schedule is stored in database
804.
It should be understood that the preceding list is neither exhaustive of the
factors that can be considered by controller 800 nor is it exhaustive of the
ways
controller 800 can adapt the operation of apparatus 100 using these factors.
In some embodiments of the invention, controller 800 is programmed so that it
can make automatic adjustments to operational parameters of apparatus 100,
such as
those described herein, to maintain a desired level of operation. In some
exemplary
embodiments of the invention, controller 800 regulates apparatus 100 in
embodiments
where there is more than one gun assembly (for example, an additional handheld
gun)
allowing for operation of a specific one or both of the gun assemblies. For
example,
when operating two gun assemblies from one pump, controller 800 may alternate
which gun is fed by pump as activation of each gun assembly is detected by
controller
800. In some exemplary embodiments of the invention, controller 800 modifies
the
volume of chemicals in an initial injection to counteract a "cold shot"
effect, wherein
more chemicals are needed to manufacture a set volume of packing material when
using cold chemicals rather than heated chemicals (as is often the case when
apparatus
100 is used for the first time before the tubing and/or chemicals heat up).
At least one fault sensor is provided to apparatus 100 in some embodiments of
the invention. This at least one fault sensor is operatively connected to
controller 800
which alerts an operator of apparatus 100 via an alarm. The alai7n can be
audible,
visual or both. For example, a fault warning is depicted on display 112 in an
exemplary embodiment of the invention. As described above, controller 800 also
modifies operation of apparatus 100 depending on the fault detected For
example, if
controller 800 is notified with an alarin that receptacle material 106 is
stuclc in section
102, it migllt stop pulling roller 306 so that no more receptacle material is
drawn into
apparatus 100. In an exemplary embodiment of the invention, detected stuck
receptacle material 106 causes controller 800 to open external door 202 so
that an
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28
operator can attend to the problem. In some embodiments of the invention,
apparatus
operational logs are kept by controller 800 for fault analysis or other
analytical
purposes. Optionally, the logs are stored in database 804.
Exemplary Method of Use of Packing Material Production and Bagging Apparatus
Referring to Fig. 9, a flowchart 900 showing a generalized method of use for
apparatus 100 is sliown, in accordance with an exemplary embodiment of the
invention. Use of apparatus 100 is commeiiced by loading (902) with receptacle
material 106 by placing it on or near section 102, in an embodiment of the
invention.
Loading (902), in an embodiment of the invention, includes advancing
receptacle
material 106 through section 102 into a position where it is in a position
where a
receptacle could be made. For example, extenial door 202 is opened and
receptacle
material is pulled down past feeding roller 302, gun assembly 304 (folded
receptacle
material 106 is split at gun assembly 304 so that a fold goes on each side of
gun
assembly 304) and pulling roller 306 by the operator of apparatus 100.
External door
202 is then closed trapping receptacle material 106 between the interior
surface of
external door 202 and the components of section 102. After the initial cycle,
the length
of receptacle material 106 that is pulled by pulling roller 306 is determined
by the size
of receptacle desired. Optionally, the operator does not open external door
202 for
loading and instead feeds receptacle material 106 into apparatus 100, past
feeding
roller 302 and gun assembly 304 (folded receptacle material 106 is split by
gun
assembly 304 so that a fold goes on each side of gun assembly 304) until the
material
106 is engaged by pulling roller 306 which pulls as much receptacle material
106 as is
necessary to create the receptacle size desired. Receptacle material 106 is
then cut and
sealed (904) by cutting and sealing system 312 and/or side sealing system
which, in
some embodiments of the invention, defines at least one side and/or the top
and/or the
bottom of a receptacle.
In an exemplary embodiment of the invention, packing material is made by
reacting component chemicals togetlzer in a mixing chamber (found inside
cartridge
602 in some embodiments of the invention) and then is iiijected (906) by gun
assembly 304 into the receptacle. It should be understood at least one of the
operational parameters of apparatus 100 are susceptible to adaptation by
coiitroller
800 depending on at least one of a number of factors, such as those described
above
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29
with respect to Fig. 8. While controller-adapted operation of apparatus 100 is
not
described here, in an exemplary embodiment of the invention, any of the
actions
performed in the method portrayed in Figs. 9, l0A and lOB are adapted by
controller
800. In an embodiment of the invention, the receptacle is ventilated (908) by
ventilation element 321. Optionally, the receptacle is ventilated near the
top. Once a
desired amount of packing material has been produced and injected into the
receptacle, the receptacle is cut and sealed (910) on top by cutting and
sealing system
312. Optionally, solvent used for cleaning gun assembly 304 is also enclosed
within
the receptacle, providing clean operation of apparatus 100. The final action
in the
packing material production and bagging cycle is ejecting (912) the receptacle
from
apparatus 100. Optionally, "ejecting" (912) occurs when the receptacle falls
out of
section 102 as a result of gravitational forces.
Referring to Fig. 10A, and continued on Figs. 10B-D, a flowchart 1000 for a
detailed method of use of apparatus 100 is shown, in accordance with an
exemplary
embodiment of the invention. It should be understood that the sequence of
actions
depicted in flowchart 1000 is by way of example only, is not completely
inclusive, and
that some actions can be perforined before or after they appear in Figs. 10A
and lOB,
or not at all, as long as the method of use stays in accordance with the
general
objective of producing packing material and/or filling receptacles with it.
Figs. l0A
and lOB are constructed along two axes, the horizontal axis being divided into
different operational categories including: chemicals, mechanical parts of gun
assembly 304, motors/pumps, sensors/counters and operator inputs. The vertical
axis
is time starting at the top of the page moving towards the bottom of the page
representing elapsed time. A"t" axis is shown on the left side of each Figure.
In an exemplary embodiment of the invention, an operator of apparatus 100
initiates (1002) a production and bagging cycle by, for example, pressing a
start
button. Optionally, the start button is located on display 112. In some
einbodiments of
the invention, the operator manually selects (1004) a receptacle size.
Optionally, the
receptacle size is selected (1004) automatically by controller 800 as a result
of a pre-
progranimed production schedule. At this stage, the operator and/or controller
800
have the opportunity to define paraineters regarding the production cycle, for
example
overall speed of production, whether ventilation holes will be added to
receptacle,
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delay period between receptacle production, and the like. In some embodiments
of the
invention, receptacle material 106 is fed into production and bagging section
102 of
apparatus 100 at least until receptacle material 106 is engaged by pulling
roller 306.
As receptacle material 106 is pulled, side sealing system is activated (1006)
to define
5 at least a side of the selected (1004) receptacle (if this is the first
receptacle of the roll
a blank receptacle can be run using the described receptacle production
method, minus
the packing material manufacturing and filling, to create a bottom seal for
the first bag
of the actual run). Pulling roller 306 is activated (1008) to pull enough
receptacle
material 106 as is necessary to create a receptacle of the size selected
(1004) by the
10 operator or controller 800. As described above, at least one sensor is
optionally used
in combination with controller 800 to calculate (1010) the length of
receptacle
material 106 pulled into apparatus 100 by pulling roller 306. Optionally, the
sensor
counts revolutions of pulling roller 306.
The pump is started (1012) to transfer component chemicals from the
15 reservoirs to gun assembly 304, in an embodiment of the invention. Because
it is
lcnown that it will take some time for the component chemicals to transport
from the
reservoirs to gun assembly 304, operation of gun assembly 304 is delayed
(1014) by a
gun delay counter, where the delay is timed to coincide with the anticipated
time of
transit of the component chemicals. Once this aiiticipated time has passed,
the gun
20 delay counter releases (1016) the hold on gun assembly 304 operation and
gun
assembly 304 commences (1018) operation.
Gun assembly 304 is comprised of a number of moving parts, which are used
to not only mix the component chemicals but also to inject them out of gun
assembly
304 and keep gun assembly 304 in worlcing order. While any suitable gun
assembly
25 could be used as gun assembly 304, the gun assembly as described in U.S.
App. Serial
No. 60/754,101 is used in an exemplary embodiment of the invention. This gun
assembly is comprised of at least a purge rod and a mixing chamber located
within
cartridge 602, in an exemplary embodiment of the invention. The purge rod is
configured to travel coaxially within the mixing chamber, the mixing chamber
3o defining a substantially cylindrical area in wliich component chemicals
react to form
the packing material. In an exemplary einbodiinent of the invention, gun
assembly
operation commences (1018) with the activation of a gun assembly motor and the
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31
subsequent movement (1020) of the purge rod by the motor towards an "open"
position, where in the "open" position the component chemicals are allowed to
enter
the mixing chamber. In an exemplary embodiment of the invention, movement
(1020)
of the purge rod towards an open position causes mixing chamber to also
transition
(1022) to the open position. Once the mixing chamber has attained (1024) the
open
position, and at least one sensor detects (1026) this position has been
achieved and
communicates it to controller 800, the chemicals start to flow (1028) into the
mixing
chamber. In some embodiments, controller 800 signals for the start of at least
one
chemical pump counter (1030) which will help controller 800 control the
ainount of
coinponent chemicals that are delivered from the reservoirs to the mixing
chamber of
gun assembly 304. The gun motor is stopped (1032) while the chemicals flow
into
mixing chamber and react to form the packing material, in accordance with an
embodiment of the invention.
Referring now to Fig. 10C, once the at least one cliemical puinp counter has
reached (1034) the threshold establislzed by controller 800 signaling that the
desired
amount of component chemical has been transported to the mixing chamber, the
chemical pump is stopped (1036) by controller 800, in some embodiments of the
invention. The gun motor is reversed (1038) causing the purge rod to reverse
direction
and travel downwards (1040). As the purge rod travels downwards (1040) or just
prior
to when the purge rod commences travel, in some embodiments of the invention,
a
purge rod advance sensor is activated (1042) which starts (1050) the solvent
pump.
Although the pump starts (1050) operation while the solvent can't actually
flow, this
primes the pressure in the solvent line so that the solvent flow can start at
the instant
the chemical flow stops. Once the mixing chamber starts movement downwards
(1044), in an exemplary embodiment of the invention, the chemical flow stops
(1046)
as a result of the mixing chamber occluding the chemical inlets into the
mixing
chamber. Using the built up pressure, the solvent flows (1052) into gun
assembly 304,
commencing a process wliich substantially cleanses gun assembly 304 of reacted
and
component chemicals. In some exemplaiy embodiments of the invention, a solvent
counter monitors (1054) the amount of solvent used for cleansing. The solvent
puinp
runs for a period determined by a solvent pump timer which starts (1048) once
the
solvent puinp starts (1050).
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In an exemplary embodiment of the invention, the mix chamber continues its
movement downwards until is reaches its ultimate down position (1056),
followed by
the purge rod reaching its ultimate down position (1058). In some embodiments
of the
invention, the purge rod travels past the tip of the mixing chamber in order
to reduce
the amount of reacted chemical that remains on the mixing chamber after the
chemical
reaction. At least one sensor detects (1060) the "closed" position has been
achieved by
gun assembly 304 and communicates this to controller 800 which in turn signals
for
the gun motor to stop (1062). The solvent pump is stopped (1064) after
controller 800
stops the gun motor (1062), causing the solvent flow to stop (1066) in
accordance
with an exemplary embodiment of the invention. Controller 800 halts solvent
counter
(1068) when solvent pump is stopped (1064).
In an embodiment of the inventioii, a ventilation element 321 is activated
(1070) to provide for at least one ventilation perforation in the receptacle
before it is
removed from apparatus 100. Optionally, this ventilation element 321
activation
(1070) is a cycle, wllerein element 321 switches on and then off again
according to a
pre-prograinmed plan. In an embodiment of the invention, a material
counter/vent
position sensor (1076) is used to sense the amount of receptacle material 106
that has
passed by in the making of an individual receptacle so that ventilation
element 321
can be activated (1070) at the right time to create ventilation in the
receptacle at the
desired location, for example near the top of the receptacle. Once a desired
size of
receptacle has been "pulled" tlirough section 102, as tracked by the pulling
roller
counter, the pulling roller motor is stopped (1078), along with the pulling
roller
counter (1080). Optionally, material counter/vent position sensor is the same
as the
pulling roller counter. In an exeinplary embodiment of the invention, the
cutting and
sealing system 312 motor is reactivated (1072) to cut and seal a top of the
receptacle.
This cutting and sealing defines the bottom of the next receptacle in some
embodiments of the invention. The cycle is ended (1074) upon the ejection of
the
receptacle from apparatus 100. Optionally, the operator removes the receptacle
manually from apparatus 100. In some embodiments of the invention, the
receptacle
falls out of apparatus 100 as a result of gravitational forces.
The present invention has been described using non-limiting detailed
descriptions of embodiments thereof that are provided by way of example and
are not
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33
intended to limit the scope of the invention. It should be understood that
features
and/or steps described with respect to one embodiment may be used with other
embodiments and that not all embodiments of the invention have all of the
features
and/or steps shown in a particular figure or described with respect to one of
the
embodiments. Variations of embodiments described will occur to persons of the
art.
Furtliermore, the terms "comprise," "include," "have" and their conjugates,
shall mean,
when used in the disclosure and/or claims, "including but not necessarily
limited to."
It is noted that some of the above described einbodiments may describe the
best mode contemplated by the inventors and therefore may include structure,
acts or
details of structures and acts that may not be essential to the invention and
which are
described as examples. Structure and acts described herein are replaceable by
equivalents, which perform the same function, even if the structure or acts
are
different, as known in the art. Therefore, the scope of the invention is
limited only by
the elements and limitations as used in the claims.
