Note: Descriptions are shown in the official language in which they were submitted.
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EQUIPMENT FOR FORMING PAPER PACKAGES AND METHODS OF USE
Field
[001] Equipment for forming paper packages and methods of use are described
herein
and, in particular, equipment for folding paper into packages or package
precursors.
Back2round
[002] Flow wrap packages are often formed by progressively folding a web of
packaging
film about one or more products, then forming a seal in a longitudinal
direction and a pair of
transverse seals and singulating the packages in a sequential manner.
Equipment for forming flow
filmic wrap packages can including a folding shoulder positioned adjacent the
entrance to a
forming box. The folding shoulder functions to covert a planar web of film
into a generally
inverted U-shape for further forming in the forming box.
[003] Packaging materials are shifting from film to paper for some products.
However,
the differences between film and paper can limit the package configurations
that can be made with
paper. A particular package configuration made with film may be more difficult
to make with
paper due to the difference in properties between film and paper. For example,
film can readily
be used in typical flow wrap forming equipment, but using paper in the same
flow wrapping
equipment configured for film can result in unwanted creasing, breaking of
fibers or other
undesirable changes to the paper.
Summary
[004] Equipment for folding paper as part of a flow wrap process is described
herein,
where the equipment includes a folding shoulder configured for folding paper
prior to entrance
into a forming box or other downstream equipment. The folding shoulder is
advantageously
configured to reduce stress concentrations in the paper as it flows along the
underside of the
shoulder, thereby reducing creasing and/or breaking of fibers in the paper.
[005] In one aspect, a folding shoulder is provided for folding paper upstream
of a
forming box. The folding shoulder can be configured for use with paper by
reducing contact
between the folding shoulder and the paper by having one or more protrusions,
such as a roller or
rollers, positioned at geometry changes in the folding shoulder positioned to
contact paper
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traveling on the underside of the folding shoulder to reduce stress
concentrations in the paper by
reducing friction between the folding shoulder and the paper.
[006] In another aspect, the folding shoulder can optionally include a roller
positioned to
contact the paper at an upstream end of the folding shoulder.
[007] In another aspect, a roller can be positioned at an intersection of the
folding
shoulder and the forming box, and can optionally extend through an opening in
the folding
shoulder.
[008] In yet another aspect, lateral ends of a roller are contoured and
positioned to contact
the paper as the paper travels along the underside of the forming shoulder.
[009] In another aspect, the forming shoulder includes an entrance portion
angled relative
to a pair of intermediate wing portions and a pair of downstream wing
portions. One or more
rollers can be positioned at the intersection of the entrance portion and
intermediate wing portions.
[0010] In another aspect, a pair of rollers can be positioned on either side
of an entrance of
the forming box, the rollers being tapered.
[0011] In another aspect, rollers are positioned in pairs with adjacent pairs
configured to
form a pre-crease line in the paper. Optionally, each of the pair can include
a circumferentially
extending, radial projection and the other of the pair includes a
corresponding circumferential
groove.
[0012] Any of the folding shoulders described herein can be provided in
combination with
a forming box.
[0013] A method of forming a flow wrap paper package can be performed using
the
forming shoulders described herein. The method can include contacting the
paper at the geometry
change using the one or more protrusions, such as rollers, to reduce stress
concentrations in the
paper by reducing friction between the folding shoulder and the paper.
[0014] In another aspect, an apparatus for forming a package from a continuous
roll of
packaging material can include a forming box having an upper piece and a lower
piece, the upper
piece having a horizontal portion and an upwardly angled portion, the lower
piece having a portion
extending at least partially inside the horizontal portion of the upper piece
and spaced by a gap
therefrom such that the packaging material passes under the upper piece of the
forming box and
through the gap between the upper and lower pieces of the forming box to form
a tube-like or
inverted U-shape package precursor containing a packaging item.
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[0015] In one aspect, the apparatus can include at least one set of
cooperating shaped
rollers which create a machine-direction embossed folding line in the
packaging material.
[0016] In one aspect, the apparatus can include at least one rotating drum,
wheel or roller
which assists movement of the packaging material over the leading edge of
upper piece of the
forming box.
[0017] In another aspect, the apparatus can include two or more tensioning
wheels,
arranged at diverging angles with respect to the direction of the packaging
material movement,
and which act to keep the packaging material flat as it passes from the
upwardly angled and the
horizontal portions of the forming box.
[0018] In another aspect, the upper and lower pieces of the forming box are an
assembly
of at least two components, wherein the two components are adjustable to
accommodate various
package widths.
[0019] In another aspect, the apparatus includes rollers at one or more
locations where the
material undergoes a change of angle or direction, thereby eliminating a
friction point which can
strain the material, creating undesirable creases in the finished package.
[0020] The apparatus and equipment described herein can be used to form a flow
wrap
paper package.
Brief Description of the Drawings
[0021] FIGURE 1 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a web of paper being fed along the underside of a
folding shoulder
upstream of a forming box, where the folding shoulder has rollers positioned
to contact the web of
paper to reduce stress concentrations in the paper;
[0022] FIGURE 2 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a web of paper being fed along the underside of a
folding shoulder
upstream of a forming box, where the folding shoulder has tapered rollers
positioned to contact
the web of paper to reduce stress concentrations in the paper;
[0023] FIGURE 3 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a web of paper being fed along the underside of a
folding shoulder
upstream of a forming box, where the folding shoulder has gradual angle
changes to reduce stress
concentrations in the paper flowing there against;
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[0024] FIGURE 4 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a folding shoulder upstream of a forming box,
where the folding
shoulder has rollers positioned to contact the web of paper to reduce stress
concentrations in the
paper at an upstream end portion of the shoulder and changes in surface angles
adjacent the
forming box entrance;
[0025] FIGURE 5 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a folding shoulder upstream of a forming box,
where the folding
shoulder has rollers with tapered ends positioned to contact the web of paper
to reduce stress
concentrations in the paper;
[0026] FIGURE 6 is a diagrammatic view of a portion of the rollers of FIGURE 5
showing
the tapered end of one of the rollers;
[0027] FIGURE 7 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a folding shoulder upstream of a forming box,
where the folding
shoulder has pairs of associated rollers for pre-forming creases in the paper;
[0028] FIGURE 8 is a diagrammatic view of one of the pairs of associated
rollers of
FIGURE 7;
[0029] FIGURE 9 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing the underside of a folding shoulder upstream of a
forming box,
where the forming shoulder includes a roller at an upstream end portion of the
shoulder;
[0030] FIGURE 10 is a perspective view of packaging equipment for forming a
flow wrap
package using paper, showing a folding shoulder extending into a forming box
to reduce stress
concentrations in the paper;
[0031] FIGURE 11 is a perspective view of packaging equipment for forming a
flow wrap
using paper, showing an adjustable folding shoulder upstream of an adjustable
forming box;
[0032] FIGURE 12 is a top plan view of packaging equipment for forming a flow
wrap
package using paper, showing a folding shoulder upstream of a forming box;.
[0033] FIGURE 13 is a cross-sectional view of the packaging equipment of
FIGURE 12
taken along line XIII-XHI of FIGURE 12; and
[0034] FIGURE 14 is a cross-sectional view of the packaging equipment of
FIGURE 12
taken along line MV-XVI of FIGURE 12 and showing packaging material spaced
between inner
and outer portions of the forming box.
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Detailed Description
[0035] Equipment for folding paper as part of a flow wrap process is described
herein and
shown in FIGURES 1-14, where the equipment includes a folding shoulder
configured for folding
paper prior to entrance into a forming box or other downstream equipment. A
typical flow
wrapped package will include a fin seal and a pair of transverse seals. The
folding shoulder is
advantageously configured to reduce stress concentrations in the paper as it
flows along the
underside of the shoulder, thereby reducing creasing and/or breaking of fibers
in the paper, or even
tearing. As described further herein, stress concentrations are reduced by
reducing friction at
specific locations where the geometry of the folding shoulder changes,
providing for gradual
geometry changes, and/or pre-creasing the paper. As used herein, the term
"paper" includes
paperboard or paper or other similar products made from fibrous materials,
including wood fiber,
as well as laminates of film, foil, or other barriers with those materials,
which will tend to have
dead-fold properties.
[0036] Generally, and with reference to FIGURE 1, the equipment for forming a
flow wrap
package using paper includes an infeed of items 10 to be packaged, such as
food items, an upstream
roller 12 for directing a web of paper 14 unwound from a roll of paper toward
the underside of a
folding shoulder 16. The folding shoulder 16 is positioned upstream of a
forming box 18. The
folding shoulder 16 includes a leading edge 20 and multiple surfaces that
function to fold the paper
14 as it is drawn along the underside thereof before leading into the forming
box 18. The folding
shoulder 16 can be used to form the paper 14 into a generally inverted U-
shape. The forming box
18 can perform additional functions, such as positioning lateral edges of the
web of paper 14 to
form a fin or lap seal with the paper 14 folded about the items 10 to be
packaged. A tube of paper
22 exits the forming box 18 and can be directed to downstream equipment, such
as a sealing station
for forming transverse seals and singulating the sealed packages from the
remainder of the tube of
paper 22. Conventional aspects of the equipment, such as the infeed apparatus,
e.g., conveyor, for
the item 10, have been omitted for clarity.
[0037] The folding shoulder 16 of the embodiment of FIGURE 1 includes a pair
of rollers
24, 26 positioned where there is a change in geometry. More specifically, the
folding shoulder 16
includes a planar entrance portion 28, a middle pair of lateral wing portions
30, and a downstream
pair of lateral wing portions 32. To reduce stress concentrations in the paper
14 caused by the
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intersection between the planar entrance portion 28 and the middle pair of
lateral wing portions
30, each of those intersections has a roller 24/26. Each of the rollers 24, 26
extends through an
opening 34, 36 at the intersection. The reduced friction between the rollers
24, 26 and the paper
14 as compared to if there were no rollers at those intersections (instead
only the folding shoulder
material) advantageously can reduce stress concentrations in the paper 14,
thereby leading to
benefits such as reduced creasing or other deformations in the paper 14. The
rollers 24, 26 can be
mounted in any suitable manner, including on axels supported by bearing mounts
on the top surface
of the folding shoulder 16.
[0038] Like the forming shoulder 16 of FIGURE 1, the forming shoulder 116 of
FIGURE
2 is positioned adjacent the entrance of a folding box 118 configured to wrap
the paper 14 around
the items 10 to be packaged, as described generally above. The forming
shoulder 116 of FIGURE
2 differs in that it does not have an upstream planar entrance portion 28, as
in the forming shoulder
16 of FIGURE 1. Instead, a pair of tapered or conical rollers 124, 126 are
positioned on either
side of the entrance of the forming box 118. However, the rollers 124, 126
could instead be
positioned in respective openings of the folding shoulder 116. Due to the
different diameters along
the axial length of the tapered rollers 124, 126, a given point along the
roller 124/126 more lateral
than another point will be rotating at a different angular velocity. This
angular velocity difference
can be used to speed up or slow down the paper 14 as may be suitable. The pair
of tapered or
conical rollers 124, 126 both reduce the stress concentrations as the paper 14
initially contacts the
folding shoulder 116 and, due to their shape, the stress concentrations as the
paper 14 transitions
toward a pair of intermediate lateral wings 130 which then transition to
downstream lateral wings
132 of the folding shoulder 116 that are disposed on either side of the
forming box 118. The
reduced friction between the rollers 124, 126, due to the fact that they
rotate, and the paper 14 as
compared to if there were no rollers (instead only the folding shoulder
material) advantageously
can reduce stress concentrations in the paper 14, thereby leading to benefits
such as reduced
creasing or other deformations in the paper. The rollers 124, 126 can be
mounted in any suitable
manner, including on axels supported by bearing mounts on the top surface of
the folding shoulder.
[0039] Like the forming shoulders 16, 116 of FIGURES 1 and 2, the forming
shoulder 216
of FIGURE 3 is configured to be positioned adjacent the entrance of a folding
box 218 configured
to wrap the paper 14 around the items 10 to be packaged, as described
generally above. Additional
details of the forming box 218 are shown; specifically, an exit opening of the
box. The forming
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shoulder 216 of FIGURE 3 includes geometry configured to reduce stress
concentrations in paper
14 traveling along its underside. The forming shoulder 216 includes an
upturned, planar entrance
portion 202, followed by a trapezoidal portion 204 extending to the entrance
of the forming box
218. A pair of lateral wings 206 extend along the lateral sides of the
trapezoidal portion 204 and
past the entrance of the forming box 218. Advantageously, the planar entrance
portion 202 can
provide for adjustment of the approach angle of the packaging material so as
to have a reduced
change in angle of the material. This can lead to reduced stress on the
material.
[0040] Like the previously-discussed embodiments of the folding shoulders 16,
116, 216
of FIGURES 1-3, the folding shoulder 316 of FIGURE 4 is positioned configured
to be positioned
adjacent the entrance of a folding box 318 configured to wrap the paper 14
around the items to be
packaged. The geometry is similar to the folding shoulder 216 of FIGURE 3,
including a
trapezoidal portion 304 and a pair of lateral wings 306. However, rollers 302,
326, 328, 330 are
strategically positioned to contact the paper 14 and reduce stress
concentrations in the paper 14 as
it passes along transitions in geometry of the forming shoulder 316. More
specifically, instead of
an upturned planar entrance portion 202, as in the embodiment of FIGURE 3, the
folding shoulder
316 of FIGURE 4 includes a roller 302 at the initial contact of the paper 14
and the folding shoulder
316. Also, a roller 328 is positioned in an opening 334 at the intersection of
the trapezoidal portion
304 and the forming box 318. Rollers 326, 330 are also positioned in openings
332, 336 in the
lateral wings 306 adjacent the roller 328 of the trapezoidal portion 304. The
reduced friction
between the rollers 302, 326, 328, 330 and the paper 14 as compared to if
there were no rollers
(instead only the folding shoulder material) advantageously can reduce stress
concentrations in the
paper 14, thereby leading to benefits such as reduced creasing or other
deformations in the paper
14. The rollers 302, 326, 328, 330 can be mounted in any suitable manner,
including on axels
supported by bearing mounts on the top surface of the folding shoulder 316.
[0041] Turning now to the embodiment of a folding shoulder 416 depicted in the
FIGURES 5 and 6, a roller 428 having multiple segments (which may optionally
be able to rotate
independently) is positioned adjacent the intersection of a trapezoidal
portion 404 of the folding
shoulder 416 and the forming box 418 and extending through an opening 434 to
contact paper 14
traveling along the underside of the folding shoulder 416. As with the
embodiments of FIGURES
3 and 4, the trapezoidal portion 404 is flanked by a pair of lateral wings
406. The roller 428 can
advantageously reduce stress concentrations in the paper 14 moving along the
underside of the
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folding shoulder 416 by reducing friction between the roller 428 and the paper
14, as compared to
between a roller-less shoulder and the paper. In addition to being at the
intersection of the
trapezoidal portion 404 and entrance of the forming box 418, the roller 428
has ends 436 that
extend into a portion of the opening 434 that extends through the lateral
wings 406. The ends 436
of the rollers 434 are tapered or chamfered, as shown in FIGURE 6, although
other shapes, such
as rounded, can be suitable. The ends 436 of the rollers 434 are positioned to
contact the paper 14
as it moves along the underside of the folding shoulder 416. By contacting the
paper 14 with
rollers 434, reduced friction between the forming shoulder 416 and the paper
14 can result.
[0042] The forming shoulder 616 of FIGURES 7 and 8 includes multiple pairs of
rollers
608, 610, 612, 614 position to contact both sides of the paper 14 as it
travels along the underside
of the shoulder 616. The shoulder 616 includes a trapezoidal portion 604 and
lateral wings 606.
The upper of the pair of rollers extends through a respective opening 628,
630, 632, 634. The pairs
of rollers 608, 610, 612, 614 are configured to pre-crease the paper 14. In
particular, one of the
rollers 620 includes a circumferentially extending, radial projection 624 that
mates with a
corresponding grove 626 in the other of the rollers 622, as shown in detail in
Figure 8. The creases
formed by the rollers 620, 622 can reduce stress concentrations in the paper
14 by pre-creasing the
paper 14 in specific areas. As the paper 14 is folded, it will beneficially
have a propensity to fold
along those pre-creased lines, thereby reducing stress concentrations in the
paper 14. A first and
second pair of the rollers 612, 614 are spaced to form creases that will
define the top of the package
between the creases. A third pair of rollers 608 are laterally spaced from the
first pair of rollers
612 so as to form creases that will define a first side of the package.
Similarly, a fourth pair of
rollers 610 are latterly spaced from the second pair of rollers 614 so as to
form creases that will
define a second side of the package.
[0043] A folding shoulder 716 having a roller 712 at its entrance is depicted
in FIGURES
9 and 10. The forming box 718 includes an outer portion 720, shown in FIGURE
9, and an inner
portion 722, shown in FIGURE 10. During use, the inner portion 722 is disposed
within the outer
portion 720. Advantageously, the entrance of the forming box 718 has an
upwardly-inclined
entrance ramp 726, supported by a pair of sidewalls 728, 730 that reduces the
angular transition
experienced by the paper 14 during formation, thereby leading to reduced
stress in the paper 14.
A gap 724 can provide space for conveying equipment to drop below the forming
box 718 aft the
item 10 is at least partially supported by the paper. More specifically, as
the paper 14 contacts the
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exterior of the inner portion 722, the initial contact on the top of the inner
portion 722 is at an angle
that is less than it would be if there were no such upwardly-inclined
entrance. A similar folding
shoulder is shown in FIGURES 12-14, thus the same references are used for like
or similar
components. The roller of the embodiment of FIGURES 9 and 10 is omitted, but
could be added.
As shown in FIGURE 14, the inner portion is disposed within the outer portion
of the forming box.
[0044] Any of the folding shoulders and forming boxes discussed herein can be
adapted to
be adjustable in width and/or height. For example, as shown in FIGURE 11, the
folding shoulder
816 can be split into a first part 820 and second part 822. Fingers of the
first part 820 can interleave
with fingers of the second part 822. Any manner of selectively fixing the
spacing between the first
and second parts 820, 822 can be used. The attached forming box 818 includes a
first part and a
second part with an adjustable gap therebetween. The height of the forming box
818 can also be
adjusted, such as by moving a top part 824 and a bottom part 826 away from
each other. Any
manner of selectively fixing the spacing between the top and bottom parts 824,
826 can be used.
[0045] Although rollers are discussed herein as being useful for reducing
stress
concentrations in the paper, other structures can be used. For example,
protrusions can be used at
the geometry intersections of the folding shoulder and/or forming box. The
protrusions can reduce
the contact points between the paper and the shoulder or box at those
intersections or elsewhere.
Low-friction materials can also be added. Dipples and/or corregations can also
be added to places
of contact with the forming shoulders. Moreover, the features described herein
with respect to the
specific embodiments are interchangeable as may be suitable.
