Field of the invention
[0001] The present invention relates to the field of machines for making packaging material,
in particular comprising cushions inflated with air or other gas, and precisely it
relates to a machine for making this packaging material.
[0002] Furthermore, the invention relates to a method for making such packaging material.
Description of the prior art
[0003] As well known, among the shock resistant packaging material, "cushions" are used
of plastic film inflated with air, or other gas.
[0004] Such cushions, made usually of high density polyethylene owing to its mechanical
resistance, which is remarkably higher than other plastic materials, can be made as
a continuous strip of cushions placed adjacent to one another, used both for wrapping
the product to package and for avoiding the movement of the product in a container
in which it is housed for being transported.
[0005] A first kind of machines for making these cushions provides overlapping two films
of high density polyethylene, unwound from respective coils and conveyed towards heating
elements capable of melting locally the plastic material forming on it welding lines.
[0006] More in detail, the film of plastic material are, firstly, welded along longitudinal
regularly distant lines, obtaining welding lines parallel to the conveying direction
with formation of tubular chambers. During the advancement, the tubular chambers are
inflated with air and then are closed hermetically by making transversal welding lines
that define the air cushions in combination with the longitudinal lines.
[0007] However, this type of machines provides stopping the web for making each transversal
welding, with subsequent low production rate, which is cost-effective only for webs
of enough width and for multiple transversal rows of cushions.
[0008] Machines also exist to make, without stopping the web, a single chain of air cushions.
These machines start from a web comprising two overlapped films of thermoplastic material
with transversal welding lines and a first longitudinal welding line already made
in a previous process, in order to define respective chambers open at a side. The
machine provides to inflate air between the two films, in order to inflate the chambers
defined by the transversal lines and by the first longitudinal line, and to provide
at the same time, by means of heating elements, the second longitudinal welding line
that was missing and that blocks the air in the chambers, obtaining the air cushions.
This way, the machine can operate continuously, i.e. without stopping the web.
[0009] In particular, the web provides the transversal welding lines that are shorter than
the width of the web and a third longitudinal welding line external opposite to the
first longitudinal welding line, leaving, thus an open passageway for inflating the
air. This is carried out introducing longitudinally an inflation tube, and making
in the meantime the second longitudinal line by means of longitudinal heating elements
after that each cushion is inflated. The welding is made at the inner edge of the
passageway, leaving out the inflation tube by cutting the third longitudinal line.
The machine also comprises a device for longitudinal movement of the web comprising
a plurality of conveying rollers arranged at an edge of the heating elements. Furthermore,
from the inflation tube a longitudinal guide protrudes upstream, on which the web
is put for engaging the passageway by the inflation tube. When the welding line on
the inner edge of the passageway is made, the passageway same is cut at the outer
edge by a blade, thus cutting the third longitudinal line, to let the guide and the
tube exit from the passageway and to release the web with the formed cushions.
[0010] However, such machines have some drawbacks.
[0011] Firstly, the web is conveyed through the machine by means of belts arranged longitudinally
to the web and mounted to a plurality of rollers. The presence of belts requires a
frequent change of the same, forcing the operators to maintenance stops and to bear
maintenance costs.
[0012] Furthermore, heating the thermoplastic material of the web for making the longitudinal
welding line is effected by two heating elements that transmit the heat necessary
for softening the thermoplastic material through respective non-stick tapes, made
normally of Teflon, that are arranged for transmitting the heat. The non-stick tapes
for transmitting the heat have to be moved longitudinally to the web of thermoplastic
material at the same speed, in order to avoid the production of folds. However, the
presence of these non-stick tapes increases the maintenance costs because it requires
a frequent replacement.
[0013] Furthermore, the existing solutions have some limits for achieving high production
rates.
[0014] In
US2006/0218880 an apparatus is described to provide inflated articles obtained starting from a web
consisting of two overlapped films. The apparatus provides a sealing roller that operates
in combination with a counter-roller for actuating the web along the machine and for
sealing the same. In particular, the external roller sealing surface can be equipped
with a groove in which a heating element is housed. A means for conveying the heat
can engage the outer surface of the roller.
[0015] This solution does not allow, however, to provide a precise sealing and can damage
the web owing to the rotation of the sealing element during the sealing step. Furthermore,
it is necessary to work at a low production rate for reducing the above described
drawbacks.
[0017] In 74980449, supports of ceramic material are provided having apertures through which
heating elements irradiate the heat to melt the web. Even this solution does not provide
a precise melting of the web owing to the distance of the heating elements from the
web and to the distance between the different heating elements that cause a non-uniform
heating of the web.
Summary of the invention.
[0018] It is a feature of the invention to provide such a machine to overcome the difficulties
of the machines of the prior art.
[0019] It is another feature of the present invention to provide a machine for making packaging
material in the form of air cushions or other gas that achieves a high production
rate.
[0020] It is also a feature of the invention to provide such a machine for ensuring a correct
arrangement of the web in all the sections of the machine, in particular at the heating
elements.
[0021] These and other features are accomplished with one exemplary machine, according to
the invention, for making packaging material, in particular cushions filled with air,
or other gas comprising:
- a feeding means for feeding a web of thermoplastic material, said web comprising a
first and a second sheet overlapped to each other;
- an inflating means that is arranged to inflate a gas between said sheets, said inflating
means, in use, having an inflating portion arranged between said first and second
sheets;
- a heating means for heating said web, arranged to cause a local melting of said thermoplastic
material along a longitudinal line, in order to provide a longitudinal welding line;
- a moving means for moving the web of thermoplastic material along a feeding direction,
said moving means arranged to cause the movement of the web of thermoplastic material
while said heating means causes said local heating;
whose main feature is that said heating means comprises:
- at least one heating rod arranged to contact said web for causing a local softening
of said thermoplastic material, said heating rod comprising an electric resistance
for heating up to a predetermined temperature;
- an outer layer that coats said heating rod, said outer layer arranged in use between
said heating rod and said thermoplastic material and being made of a material having
a thermal transmission coefficient less than about 0,5 W/mK, in order to cause said
local softening of said thermoplastic material and to provide said longitudinal welding
line, but avoiding in the meantime the adhesion of said heating rod to said thermoplastic
material.
[0022] In particular, the, or each, heating rod is fixed. This provides a uniform heating
of the web melting it to obtain a welding line with high precision. Advantageously,
said coating material has a thermal conductivity coefficient less than about 0, 3
W/mK.
[0023] In particular, the coating outer of the heating rod can be made in polytetrafluoroethylene
(PTFE), or Teflon.
[0024] Advantageously, the means for moving said web of thermoplastic material comprises
at least a first and a second counter rotating rollers arranged downstream of said
heating means and at opposite sides with respect to said web of thermoplastic material,
said first and second counter rotating rollers having respective gripping surfaces
configured to be put adjacent to said first and to said second film of said web, respectively,
in order to apply a pulling action on said web and to drag it along said feeding direction.
[0025] In particular, the counter rotating rollers have a high friction surface.
[0026] Advantageously, the counter rotating rollers are made of a high friction material
selected from the group consisting of:
- synthetic rubber;
- natural rubber;
- an elastomeric rubber, in particular Vulcolan®.
[0027] Advantageously, the counter rotating rollers have a irregular surface, for example
rough, or knurled, in order to increase the gripping force on said web of thermoplastic
material.
[0028] In particular, at least one of the counter rotating rollers comprises a first portion
which is made of a high friction material, such as rubber, or an elastomeric material,
and a second portion of a metal material.
[0029] Advantageously, the portion of a metal material has said irregular surface, for example
rough, or knurled. In particular, it is the metal surface that, in use, produces the
gripping action on the web.
[0030] Advantageously, at least one of the gripping surfaces of said first and of said second
counter rotating rollers has a circumferential groove, at said circumferential groove
aligned, in use, said longitudinal welding line made by said heating means. This way,
it is avoided that the still hot thermoplastic material can stick to the gripping
surface of said first and/or of said second roller.
[0031] Advantageously between said moving means and said heating means a level means is
provided for levelling said softened thermoplastic material, in order to finish said
longitudinal welding line.
[0032] In particular, the level means can comprise a pushing element arranged on one side
of said web and an abutment surface located opposite to the pushing element with respect
to the web of thermoplastic material, said pushing element arranged to compress said
thermoplastic material locally softened against said abutment surface, in order to
finish the welding line.
[0033] Advantageously, the abutment surface is made on a disc movable along a direction
substantially orthogonal to said longitudinal direction of said web biased by resilient
means, for example a spring.
[0034] In particular, the pushing element can comprise a disc having a flat surface that
is arranged, in use, next to said locally softened web to provide said welding line.
[0035] Advantageously, the heating rod comprises a main body and a heating portion protruding
from said main body, said heating portion arranged, in use, to provide a longitudinal
strip of softened material on said web.
[0036] In particular, upstream of said heating means a stretching means can be provided
for stretching the web of thermoplastic material before it reaches said heating means.
This way, it is ensured that the heating means make correctly the welding line on
the thermoplastic material.
[0037] Advantageously, the stretching means comprises a first stretching roller and a second
stretching roller arranged at opposite sides with respect to the web.
[0038] In particular, the first and second stretching rollers squeeze the web avoiding also
that the gas jet, for example air, emitted by the blowing means reaches the heating
means jeopardizing the correct operation.
[0039] Advantageously, furthermore, a longitudinal guide is provided on which said web is
put, for example manually by an operator, before starting the machine.
[0040] In particular, the longitudinal guide is adapted, in use, to cross a longitudinal
passageway made in said web of thermoplastic material. More in detail, the longitudinal
passageway is defined through a plurality of transversal welding lines that separate
a plurality of tubular bodies defined between said first and second sheets.
[0041] In particular, the transversal welding lines define a plurality of tubular bodies.
More precisely, the transversal lines have a length less than the transversal width
of the web of thermoplastic material, in order to form said passageway in which in
use said guide is put. Once inflated by the gas between the two films of thermoplastic
material the passageway is closed by making said longitudinal welding line and then
closing the above described tubular bodies. This way, it is eventually obtained the
formation of chambers in which a certain amount is present of gas closed hermetically
by the transversal welding lines and by said longitudinal welding line. The first
and the second sheet of the web can be defined through a folding line made on a single
sheet of thermoplastic material and therefore the only edge that was longitudinally
open is that in which the longitudinal welding line is made by the heating means.
In an exemplary embodiment, the web of thermoplastic material, opposite to the welding
line, has a longitudinal welding line made in a preliminary step.
[0042] In particular, a means can be provided for cutting said web of thermoplastic material
arranged to provide a longitudinal cut to open longitudinally said passageway, to
make it possible an arrangement of the inflating portion between said sheets and to
make it possible a movement of the web with chambers inflate and sealed.
[0043] In particular, the cutting means longitudinally cuts the tubular web of thermoplastic
material at the portion of the web without the transversal welding lines.
[0044] Advantageously, a sealing means is provided arranged to avoid the outlet of air,
or other gas, through the longitudinal cut made by the means for cutting, during the
inflation by the gas.
[0045] Advantageously, the cutting means is arranged upstream of the heating means.
[0046] In particular, between two consecutive chambers of the web of thermoplastic material
tear lines can be provided that assist the separation between two air cushions.
Brief description of the drawings
[0047] The invention will be now shown with the following description of an exemplary embodiment
thereof, exemplifying but not limitative, with reference to the attached drawings
in which:
- Fig. 1 diagrammatically shows an elevational side view of the improved machine, according
to the invention, for making packaging material in the form of air cushions, or other
gas;
- Fig. 2 diagrammatically shows a top plan view of the machine of Fig. 1 for highlighting
the layout of the main parts and, in particular, their position with respect to the
processed web;
- Fig. 3 diagrammatically shows a perspective front view of the machine of Fig. 1 in
operating conditions;
- Fig. 4 diagrammatically shows a perspective view of the main construction elements
of the machine of Fig. 1;
- Fig. 5 shows a cross sectional view of the heating rod of the machine of Fig. 1 highlighting
some structural features;
- Fig. 6 shows the machine of Fig. 4 in operating conditions;
- Fig. 7 shows a perspective elevational side view of the machine of Fig. 1.
Description of the preferred exemplary embodiment
[0048] With reference to Fig. 1, a machine 1 for making packaging material in the form of
cushions 100 of gas, according to the invention, for example air cushions, comprises
feeding rollers 21 and 22 arranged to bring a web 10 of thermoplastic material along
a longitudinal conveying direction 101. Web 10 comprises, as well known, two films
10a and 10b overlapped and can be unwound starting from a roll 20.
[0049] As also shown in Fig. 2, web 10 can comprise two longitudinal welding lines 13a and
13b and a plurality of transversal welding lines 11, in order to define a plurality
of transversal tubular bodies 16 arranged to be insulated pneumatically from one another.
Alternatively, the tubular bodies 16 can be obtained folding a single sheet of thermoplastic
material and obtaining a single longitudinal welding line at the edges to connect.
[0050] Between two consecutive tubular bodies 16 transversal tear lines 12 can be provided
between two consecutive transversal welding lines 11. More precisely, transversal
tear lines 12 extend for all the width of web 10 and assist the separation of a cushion
100 from the next one when they are used. The transversal welding lines 11 have in
particular length less than the transversal width L of web 10, in order to define
between welding line 13b and their beginning point a open passageway 18.
[0051] More in detail, when starting machine 1, web 10 is put at passageway 18 on a longitudinal
guide 30 arranged downstream of feeding rollers 21 in the conveying direction of web
10. In one exemplary embodiment of the figures, guide 30 is arranged next to inflating
means 35 having a hole 35a through which a predetermined amount of gas, for example
air, can be put into the passageway 18, so that air inflates the chamber of each tubular
body 16. Hole 35 is in pneumatic connection with a source of a gas flow, for example
a fan not shown in the figures.
[0052] At guide 30 a cutting blade 80 is present that can make a longitudinal cut 14 on
web 10. This allows the movement of transversal portion 35b of the inflating means
35 during the movement of web 10 through machine 1.
[0053] Downstream of cutting blade 80 a heating means is provided 50 for heating web 10,
arranged to cause a local melting of the thermoplastic material along a longitudinal
line 15. More in detail, the heating means 50 comprise at least one heating rod 51,
and/or rod 52, can be in particular a elongated rod, that, in use, stops and is arranged
in contact of web 10 for causing it to a local softening.
[0054] In particular, two heating rods 51 and 52 can be provided arranged at opposite sides
with respect to web 10. Furthermore, a means can be provided for approaching, or withdrawing,
two heating rods 51 and 52. More precisely, the means for approaching, or withdrawing
are adapted to withdraw the two heating rods 51 and 52 to allow web 10 to be arranged
easily between thereof. Then, the means for approaching, or withdrawing are adapted
to approach the two heating rods 51 and 52, in order to be put adjacent, or near to,
the respective surfaces of web 10.
[0055] According to the invention, and as shown in detail in Fig. 5, the, or each, heating
rod 51, and/or 52, comprises an electric resistance 53 coated with an outer layer
54 of a material having a low thermal transmission coefficient, for example less than
about 0,5 W/mK such as polytetrafluoroethylene (PTFE), or Teflon. This way, the heating
rod 51, or 52, causes the softening of the thermoplastic material of web 10 to provide
the longitudinal welding line 15 avoiding at the same time that it can adhere to the
heating rod 51, or 52.
[0056] This particular technical solution avoids the use of the welding tapes used in the
apparatus of the prior art for conveying the heat by a heater to the thermoplastic
material of the web, simplifying remarkably the machine and reducing therefore both
the maintenance time that the costs of the same.
[0057] Downstream of the heating means 50, furthermore, a feeding means is provided 70 comprising
a first and a second counter rotating rollers 71 and 72 arranged at opposite sides
with respect to web 10. More in detail, the counter rotating rollers 71 and 72 apply
directly on web 10 a tension which causes it to be fed through machine 1. This is
possible since rollers 71 and 72 have a high friction surface. Rollers 71 and 72 can
be made of a high friction material such as rubber, or in an elastomeric material,
such as Vulcolan ®. This technical solution allows also to avoid that the thermoplastic
material of web 10, still hot near the longitudinal welding line 15, can adhere to
the surface of rollers 71 and 72. For increasing further the grip on the web, rollers
71 and 72 have a irregular surface, for example rough, or knurled. At least one of
counter rotating rollers 71, or 72, for example the roller next to the lower face
of web 10 in movement along machine 1, may comprise a portion 75 made of a metal material
and equipped with a knurled surface. Such particular exemplary embodiment avoids the
use of conveyor belts commonly used for causing the movement of the web in the machines
of the prior art. In an exemplary embodiment at least one among the first and the
second counter rotating rollers 71, 72, comprises a first portion 73 made of a high
friction material selected from the group consisting of: a synthetic rubber, a natural
rubber or an elastomeric material, and a second portion 75 of a metal material. This,
in particular, can be equipped with a knurled surface.
[0058] Furthermore, at least one of rollers 71 and 72 has a circumferential groove 74 to
which, in use, the longitudinal welding line 15 made by the heating means 50 on web
10 can align. This way, it is avoided that welding line 15, which has the shape of
a bead and is still at a softening temperature, enters directly into contact with
the surface of rollers 71 and 72. This way, it is avoided that the thermoplastic material
still hot can damage the rubber surface, or elastomeric surface, of counter rotating
rollers 71 and/or 72.
[0059] Between counter rotating rollers 71 and 72 and the heating means 50 a level means
can be provided 60 for levelling the softened thermoplastic material, in order to
complete the longitudinal welding line 15. More in detail, the heating means 50 have
a heating portion 55 of the thermoplastic material protruding from a main body 56
towards web 10. In particular, the heating portion 55 has a short small width, for
example set between 1 mm and 2 mm, that is arranged to form a longitudinal strip of
softened material 17 on web 10 of width substantially corresponding to about 1-2 mm.
The strip of softened material 17 is brought, then, to the level means 60 that cause
it to be squeezed and therefore an increase of the width up to 2-4 mm obtaining welding
line 15.
[0060] As shown in detail in Figs. 5 and 6, the means 60 for levelling can comprise a pushing
element 61 arranged on one side of web 10, and an abutment surface 62 located opposite
to the pushing element 61 with respect to the web of thermoplastic material 10. More
in detail, the pushing element 61, for example at a flat surface 66, compresses the
thermoplastic material, softened by the heating means 50, against the abutment surface
62, in order to level the softened material of welding line 15. The abutment surface
62 can be made, for example, on a disc 65 movable along a direction 160 substantially
orthogonal to the longitudinal direction of web 10, biased by resilient means, for
example a spring 63. The abutment surface 62 is, in particular made of a heat-resistant
material for example in Polyphenylene sulfide, for example Techtron ®.
[0061] Upstream of the heating means 50 a stretching means can be provided 40 arranged to
stretch web 10 of thermoplastic material before it is subjected to local heating.
The stretching means 40 can comprise a first stretching roller 41 and a second stretching
roller 42 arranged at opposite sides with respect to web 10. The first and second
stretching rollers 41 and 42 squeeze against each other web 10 avoiding also that
the gas jet, for example air, emitted by the blowing means 35 arranged upstream of
the stretching means 40 can arrive at the heating means 50 jeopardizing the correct
operation.
[0062] The foregoing description of specific exemplary embodiments will so fully reveal
the invention according to the conceptual point of view, so that others, by applying
current knowledge, will be able to modify and/or adapt in various applications the
specific exemplary embodiments without further research and without parting from the
invention, and, then, it is meant that such adaptation and modifications will have
to be considered as equivalent to the specific embodiment. The means and the materials
to realise the different functions described herein could have a different nature
without, for this reason, departing from the field of the invention. It is to be understood
that the phraseology or terminology that is employed herein is for the purpose of
description and not of limitation.
1. Machine (1) for making packaging material, in particular cushions (100) of air, or
other gas, comprising:
- a means (21, 22) for feeding a web (10) of thermoplastic material, said web (10)
comprising a first and a second overlapped sheet (10a, 10b);
- an inflating means (35) arranged to inflate a gas between said sheets (10a, 10b),
said inflating means (35), in use, having an inflating portion arranged between said
first and second sheets (10a, 10b);
- a heating means (50) for said web (10), arranged to cause a local melting of said
thermoplastic material along a longitudinal line, in order to provide a longitudinal
welding line (15);
- a moving means (70) arranged to cause the movement of said web (10) of thermoplastic
material along a conveying direction (101), said moving means (70) arranged to cause
the movement of said web (10) of thermoplastic material while said heating means (50)
causes said local heating;
characterised in that said heating means (50) comprises:
- at least one fixed heating rod (51, 52) arranged to contact said web (10) for causing
a local softening of said thermoplastic material, said heating rod (51, 52) comprising
an electric resistance for heating up to a predetermined temperature;
- an outer layer (54) that coats said heating rod, said outer layer arranged in use
between said heating rod and said thermoplastic material and being made of a material
having a thermal transmission coefficient less than about 0,5 W/mK, in order to cause
said local softening of said thermoplastic material and to provide said longitudinal
welding line (15), but avoiding in the meantime the adhesion of said heating rod (51,
52) to said thermoplastic material.
2. Machine, according to claim 1, wherein said outer layer (54) of said heating rod (51,
52) is made of a material having a thermal conductivity coefficient less than about
0, 3 W/mK.
3. Machine, according to claim 1, wherein said moving means (70) of said web (10) of
thermoplastic material comprises at least a first and a second counter rotating rollers
(71, 72) arranged downstream of said heating means (50) and at opposite sides with
respect to said web (10) of thermoplastic material, said first and second counter
rotating rollers (71, 72) having respective gripping surfaces arranged to engage with
said first and said second film (10a, 10b) of said web (10), respectively, in order
to apply a pulling action on said web (10) and to convey it along said conveying direction
(101)
4. Machine, according to claim 3, wherein at least one among said first and said second
counter rotating rollers (71, 72) has a high friction surface.
5. Machine, according to claim 3, wherein at least one among said first and said second
counter rotating rollers (71, 72) is made of a high friction material selected from
the group consisting of:
- synthetic rubber;
- natural rubber;
- an elastomeric material, in particular Vulcolan®.
6. Machine, according to claim 3, wherein at least one among said first and said second
counter rotating rollers (71, 72) comprises:
- a first portion (73) made of a high friction material selected from the group consisting
of: a synthetic rubber, a natural rubber and an elastomeric material;
- a second portion (75) of a metal material, said second portion (75) being equipped
with a knurled surface.
7. Machine, according to claim 3, wherein at least one of said gripping surfaces of said
first and of said second counter rotating rollers (71, 72) has a circumferential groove
(74), with said circumferential groove (74) aligning, in use, said longitudinal welding
line (15), or bead, made by said heating means (50), to avoid that the still hot thermoplastic
material can stick the gripping surface of said first, or of said second, roller (71,
72).
8. Machine, according to claim 1, wherein between said heating means (50) and said moving
means (70) a level means is provided (60) for levelling said softened thermoplastic
material, in order to finish said longitudinal welding line (15).
9. Machine, according to claim 8, wherein said level means (60) comprises a pushing element
(61) arranged at one side of said web (10), and an abutment surface (62) located opposite
to said pushing element (61) with respect to said web (10), said pushing element (61)
arranged to compress said thermoplastic material, locally softened, on said abutment
surface (62), in order to finish said longitudinal welding line (15).
10. Machine, according to claim 9, wherein said abutment surface (62) is made on a mobile
disc, biased by resilient means (65), along a direction (160) that is substantially
orthogonal to said longitudinal direction (101) of said web (10).
11. Machine, according to claim 1, wherein upstream of said heating means (50) a stretching
means is provided (40) for stretching arranged said web (10) of thermoplastic material
before it reaches said heating means (50), in order not to affect the formation of
said longitudinal welding line (15) on said web (10) by said heating means (50).
12. Machine, according to claim 11, wherein said stretching means comprises a first stretching
roller (41) and a second stretching roller (42) arranged at opposite sides with respect
to said web (10).
13. Machine, according to claim 1, wherein said heating rod (51, 52) comprises a main
body (56) and a heating portion (55) protruding from said main body (56), said heating
portion (55) arranged, in use, to provide a longitudinal strip of softened material
(17) on said web.
14. Machine, according to claim 1, comprising, furthermore, a longitudinal guide that
is adapted, in use, to enter a longitudinal passageway made in said web of thermoplastic
material, said longitudinal passageway defined through a plurality of transversal
welding lines that separate a plurality of tubular bodies defined between said first
and second sheets.
15. Machine, according to claim 14, comprising, furthermore, a cutting means for cutting
said web of thermoplastic material to provide a longitudinal cut to open longitudinally
said passageway, and to make it possible an introduction of the inflating portion
between said sheets and to make it possible a movement of the web after that the chambers
have been inflated and sealed.