TECHNICAL FIELDThe present invention relates generally to thermoplastic bag production machinery, and more particularly, to an apparatus and method for splicing thermoplastic bag closer tape in an automated fashion.[0001]
BACKGROUND ARTThe process of producing storage bags includes the steps of folding a web of thermoplastic to obtain an elongate folded web of material and laminating a thermoplastic closer or zipper tape to free ends of the elongate folded web of material. Sliding closure members are then placed on the closer tape at spaced locations thereon and end stops are formed in the closer tape between the sliding closure members. The elongate folded web is then severed at the end stops using an automated hot knife to create individual bags.[0002]
The thermoplastic closer tape is stored on a rotatable spool and is unwound therefrom during production and fed to a production line. In a known production process the production line must be shut down when the spool has been emptied so that a full spool of closer tape can be substituted for the empty spool. This, in turn, results in significant downtime, and increases the cost of producing bags.[0003]
WO 99/12725 discloses a splicing unit and method of splicing of a reclosable zipper strip. The trailing end of one strip and the leading end of a next strip are brought together in abutting relationship within the splicing unit and sealing material is overlaid on the trailing and leading ends. Heat and pressure are applied to the sealing material and the trailing and leading ends to seal the trailing and leading ends together. Flanges of the zipper strips are held apart by separator plates during the sealing operation.[0004]
SUMMARY OF THE INVENTIONIn accordance with one aspect of the present invention, an apparatus for splicing closer tape includes a first clamping assembly adapted to hold a first section of closer tape and a second clamping assembly adapted to hold a second section of closer tape. A moving assembly is adapted to move the first and second clamping assemblies relative to one another so as to permit alignment of the first and second sections of closer tape. A joining assembly is adapted to join the first and second sections of closer tape together.[0005]
According to a further aspect of the present invention, an apparatus for splicing closer tape includes first means for clamping a first section of closer tape and second means for clamping a second section of closer tape. Means are provided for moving the first clamping means relative to the second clamping means so as to permit alignment of the first and second sections of closer tape. Means are also provided for joining the first and second sections of closer tape together.[0006]
According to yet another aspect of the present invention, a method of splicing closer tape includes the steps of clamping a first section of closer tape, clamping a second section of closer tape and moving the first clamping means relative to the second clamping means so as to permit alignment of the first and second sections of closer tape. The method further includes the step of joining the first and second sections of closer tape together.[0007]
Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description.[0008]
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is an isometric view of an apparatus for automated splicing of closer tape according to the present invention wherein a front cover plate is removed therefrom to reveal components therein;[0009]
FIG. 2 is an exploded isometric view of the rear of the apparatus of FIG. 1;[0010]
FIG. 3 is a fragmentary isometric view of a clamp box subassembly together with a base plate of a heater block subassembly of the apparatus of FIGS. 1 and 2;[0011]
FIG. 4 is a front elevational view of the subassembly of FIG. 3;[0012]
FIG. 5 is a fragmentary isometric view of the heater block subassembly of the apparatus of FIGS. 1 and 2;[0013]
FIG. 6 is a side elevational view of the subassembly of FIG. 5;[0014]
FIG. 7 is a sectional view taken generally along the lines[0015]7-7 of FIG. 6;
FIG. 8 is a fragmentary side elevational view of the subassembly of FIG. 5 with a side plate removed to reveal components therein;[0016]
FIG. 9 is an exploded isometric view of the components of FIG. 1 except that front and back cover plates are not shown;[0017]
FIG. 10 is an isometric-fragmentary view of a rear clamping assembly utilized in the apparatus of FIG. 1;[0018]
FIG. 11 is a front elevational view of the rear clamping assembly of FIG. 10;[0019]
FIG. 12 is an isometric view of a cutting assembly utilized in the apparatus of FIG. 1;[0020]
FIGS. 13 and 14 are side and front elevational views, respectively, of the cutting assembly of FIG. 12;[0021]
FIG. 15 is an elevational view of a section of closer tape prepared for splicing with another section of closer tape by the apparatus of FIG. 1;[0022]
FIG. 16 is an isometric view of a tool for preparing the section of closer tape of FIG. 15 for splicing;[0023]
FIG. 16A is a trimetric, enlarged, fragmentary view of the tool of FIG. 16;[0024]
FIGS.[0025]17-20 are fragmentary isometric views of portions of the apparatus of FIG. 1 during various stages of a splicing operation;
FIG. 21 is a sectional view similar to FIG. 7 illustrating the apparatus of FIG. 1 during a joining stage of operation; and[0026]
FIG. 22 is a block diagram of a control circuit for controlling the apparatus of FIG. 1.[0027]
DESCRIPTION OF THE PREFERRED EMBODIMENTSReferring first to FIGS.[0028]1-4 and9, anapparatus30 according to the present invention is operable to splice zipper or closer tape when a spool of the closer tape runs out and is to be replaced by a fresh spool of closer tape. This splicing is preferably undertaken automatically and results in little or no downtime of an associated thermoplastic bag production line. Theapparatus30 includes first andsecond clamping assemblies32,34 that are operable during splicing to hold ends of the closer tape sections from the empty spool and fresh spool and a cutter assembly36 (FIGS. 1, 2,9 and12-14) that severs portions of the closer tape sections. As seen in FIGS.1-4 and9, theapparatus30 further includes a movingassembly38 for moving theclamping assembly32 holding the closer tape section from the fresh spool into alignment with theclamping assembly34 holding the closer tape section from the empty spool. A joining assembly40 (FIGS. 1, 2 and5-8) is movable into engagement with the aligned sections of closer tape to join such sections together. Thereafter, the clamping assemblies32,34 open to release the joined sections.
Specifically, FIG. 1 illustrates the[0029]apparatus30 during production of thermoplastic bags and before a splicing operation is to occur.Closer tape50 stored on aspool52 is fed throughopen clamping assemblies32 and34 by a feeding mechanism (not shown) to a thermoplastic bag production line (also not shown). The diameter of the storedcloser tape50 decreases as thecloser tape50 is unwound from thespool52. Eventually, the diameter of the closer tape stored on thespool52 reduces to a point where a stored closer tape diameter sensor54 (FIG. 22) develops a command signal indicating that a splicing operation is to be undertaken. Alternatively, as seen in FIG. 22, the command signal may be developed on a line56 (shown in dotted lines in FIG. 22) by manually actuating anoptional switch56 commanding initiation of a splicing operation. Preferably, a fresh spool of closer tape is positioned adjacent theapparatus30 just prior to generation of the command signal and a leading end of the closer tape stored on the fresh spool is prepared and inserted into theclamping assemblies32 and34 in a fashion noted in greater detail hereinafter. Thereafter, upon generation of the command signal, theapparatus30 executes a sequence of steps resulting in splicing of the leading end of the closer tape stored on the fresh spool with a trailing end of thecloser tape50 stored on thespool52.
The[0030]apparatus30 includes a clamp box subassembly60 (FIGS.1-4) and a movable heater block subassembly62 (FIGS. 1, 2 and5-8) mounted bybearing assemblies64a,64b(FIGS. 3, 4 and9) in the clamp box subassembly60. The movableheater block subassembly62 is movable up and down as seen in FIGS. 1 and 2 in the bearing assemblies64 under the influence of a piston and cylinder device66 (hereinafter each such device is referred to as a cylinder for simplicity). The joiningassembly40 is disposed within and carried by the movableheater block subassembly62 and is movable therewith. As seen in FIGS. 1, 3,4 and9, a firstclamping jaw portion68 is mounted for sliding movement from side-to-side on abearing assembly72 carried by anupper surface74 of abase plate75aof the clamp box subassembly60. The clamp box subassembly further includes atop plate75bandside plates75cand75dwherein theplates75a-75dare secured together by bolts or other suitable fasteners (not shown). One or more pins may be carried by thebase plate75aand thetop plate75band may extend into corresponding bores in theside plates75cand75dto assist in aligning the various parts during assembly.
A second[0031]clamping jaw portion76 is mounted for sliding movement from side-to-side on abearing assembly77 secured to alower surface78 of abottom plate79aof the movableheater block subassembly62. (As seen in FIGS. 1, 2 and5-8, the heater block subassembly further includes atop plate79bandside plates79cand79dthat are aligned together by alignment pins and secured together by bolts or other suitable fasteners (not shown)). The first and secondclamping jaw portions68,76 are substantially complementarily-shaped in the sense that thejaw portions68,76 include an m-shapedupper surface80 and an inverted w-shapedlower surface82, respectively. Thesurfaces80,82 are opposed and the secondclamping jaw portion76 is movable up and down with theheater block subassembly62 toward and away from the firstclamping jaw portion68. First and second spaced alignment pins84a,84bare carried by the firstclamping jaw portion68 and slide inapertures86a,86b, respectively, (FIG. 9) in the secondclamping jaw portion76 during relative movement of the clampingjaw portions68,76 so that the opposed surfaces80,82 are maintained in precise alignment with one another.
As seen in FIGS. 2 and 9-[0032]11, a thirdclamping jaw portion90 is secured to theupper surface74 of thebase plate75aof theclamp box subassembly60 and a fourthclamping jaw portion92 is secured to thesurface79 of the movableheater block subassembly62. The third and fourthclamping jaw portions90,92 are immovable from side-to-side and the fourthclamping jaw portion92 is movable up and down with the movableheater block subassembly62 toward and away from the thirdclamping jaw portion90, which is stationary in all respects. The thirdclamping jaw portion90 includes an m-shapedupper surface94 and the fourthclamping jaw portion92 includes an inverted v-shapedsurface96 that opposes a first taperedportion94aof the m-shapedupper surface94. A fifth clamping jaw portion98 (best seen in FIGS.9-11) is mounted on a spring-loadedarm assembly100 and is guided byposts95aand95bcarried by the thirdclamping jaw portion90 that extend intobores97aand97bin theportion98. Bushings99a-99dare disposed in thebores97a,97bsurrounding theposts95a,95b. Thejaw portion98 includes an inverted v-shapedsurface102 opposing a second taperedportion94bof the m-shapedupper surface94. The fifthclamping jaw portion98 is urged by aspring104 of thearm assembly100 toward the position shown in FIGS. 10 and 11 such that the inverted v-shapedsurface102 is normally in engagement with the second taperedportion94bof the m-shapedupper surface94. An operator of theapparatus30 may push up on aknob106 mounted on arod108 that extends upwardly through a bushing107 (FIG. 9) of thearm assembly100 to displace the fifthclamping jaw portion98 upwardly such that the inverted v-shapedsurface102 is spaced from the second taperedportion94b.
A zipper stop plate[0033]109 (FIGS.9-11) is secured by any suitable fasteners to a face of the thirdclamping jaw portion90.
When the various parts are in the positions shown in FIGS.[0034]1-4 the first and secondtapered portions94a,94bof the m-shapedupper surface94 are aligned from front to back of theapparatus30 with correspondingtapered portions80a,80bof the m-shapedupper surface80. Similarly, the inverted v-shapedsurface96 and the inverted v-shapedsurface102 are aligned in the same relationship with taperedportions82a,82bof the inverted w-shapedlower surface82. Twocloser tape paths110,112 (FIGS. 1 and 17) extending from front to back through theapparatus30 are thereby established through the first through fifthclamping jaw portions68,76,90,92 and98.
The moving[0035]assembly38 includes a piston and cylinder device120 (hereinafter this device as well as other piston and cylinder devices are simply referred to as “cylinders”) (FIGS.1-4 and9) having a connecting rod122 (FIGS. 4 and 9) that is threaded to the firstclamping jaw portion68. A lock nut (not shown) prevents unthreading of the connectingrod122 from the firstclamping jaw portion68. If desired, thecylinder120 may include an anti-rotation feature that prevents rotation of the connectingrod122 during operation of thecylinder120, in which case the lock nut would not be required. Thecylinder120, when actuated, moves the first and secondclamping jaw portions68,76 from the position shown in FIGS.1-4,17 and19 to the position shown in FIG. 20 wherein the taperedportions80band82bare aligned with the taperedportion94aof the thirdclamping jaw portion90 and the inverted v-shapedsurface96 of the fourthclamping jaw portion92, respectively.
Referring next to FIGS. 9 and 12-[0036]14, thecutter assembly36 includes amovable bracket130 having first and secondblade mounting portions132,134. Theblade mounting portions132,134 are offset relative to another such that cuttingedges136,138 of single-edge razor blades140,142, respectively, are parallel to one another and such that the cutting edges136,138 are spaced apart by a predetermined distance (seen in FIG. 13). Preferably, the predetermined distance is equal to 0.125-0.25 inch, although a different spacing could alternatively be used. Referring specifically to FIGS.12-14, each of theblade mounting portions132,134 includes a clampingmember144,146, respectively, that bears against a base member of therespective razor blade140,142. Referring again to FIGS. 9 and 12-14, acylinder148 is carried by a mountingbracket150 secured to theclamp box subassembly60 and thecylinder148 includes a threaded connectingrod152 that extends though abushing154 and which is threaded into a threaded bore in themovable bracket130 so that the connectingrod152 and thebracket130 move together as a unit. A lock nut (not shown) may be threaded onto the connectingrod152 to prevent unthreading of the connectingrod152 from themovable bracket130. If desired, thecylinder148 may include an anti-rotation feature that prevents rotation of the connectingrod152 during operation of thecylinder148, in which case the lock nut would not be required. Thecylinder148 is actuable to move thebracket130 andblades140,142 upwardly to a cutting position and downwardly to a retracted position.
Referring next to FIGS. 1 and 5-[0037]9, the joiningassembly40 includes a fusing member or bar160 having afirst end162. The joiningassembly40 further includes acylinder164 having acollar166 threaded into a threaded bore168 (FIGS. 7 and 9) formed in theupper plate79bof the movableheater block subassembly62. Thecylinder164 includes acylinder connecting rod172 having anend174 threaded into a first threaded bore176 of abracket178. As was the case with the connectingrods122,152, a set screw (not shown) may be threaded onto the end of the connectingrod172 or thecylinder164 may have an anti-rotation feature to prevent unthreading of the connectingrod172 from thebracket178. Astop member184 extends through abore185 in theupper plate79band includes alower end186 threaded into a second threaded bore188 of the bracket178 (see FIGS. 7 and 9). A threadedstop collar190 is threaded onto a threadedouter surface192 of thestop member184. The outer diameter of thestop member184 is smaller than the diameter of thebore185 so that thestop member184 is freely movable within thebore185. In addition, the position of thestop collar190 on thestop member184 is adjusted to define a downward end-of-travel limit for thebar162. An upward end-of-travel limit for thebar162 is established by contact of anupper surface193 of thestop member184 with asurface194 of the clamp box subassembly60 (FIGS.1-4 and9).
A[0038]second end195 of the fusingbar160 is secured by suitable fasteners together with first and second thermal insulatingmembers196a,196band acover plate197 to the bracket178 (FIGS.7-9). Thefirst end162 of the fusingbar160 is bifurcated whereby first andsecond wings200a,200bare separated by anopening202. Theopening202 includes a taperedportion204 and a notched portion206 (FIGS. 7 and 9). When the fusingbar160 is in the position shown in FIG. 7, thesecond end162 is disposed in aheater assembly208 carried on atop surface209 of thebottom plate79aof the movableheater block subassembly62. The heater assembly includes acover member210 disposed over first and second heater blocks212a,212b, a thermally insulative heater stand-off member214 and aheater spacer plate216. The first and second heater blocks212a,212binclude mating mirror-image recesses therein (one of which,218, is visible in FIG. 7) and resistive or other heater elements therein that are energized during a splicing operation to develop heat that is transferred to the fusingbar160. In the preferred embodiment, theelements210,212,214 and216 are secured to thebase plate75aby bolts or other fasteners. Also preferably, thecover member210 and theheater spacer plate216 are fabricated of ceramic or other heat resistant material.
Industrial ApplicabilityReferring next to FIGS.[0039]16-21, the operation of theapparatus30 will now be described under the assumption that the command signal has not yet been generated and the movableheater block subassembly62 is disposed in the uppermost position so that the firstclamping jaw portion68 and the thirdclamping jaw portion90 are spaced from the secondclamping jaw portion76 and the fourthclamping jaw portion92. It is also assumed that closer tape is being fed off of a spool of closer tape through thecloser tape path110 of theapparatus30 to a production line (not shown). An operator prepares for a splicing operation by cutting or otherwise forming anotch220 and ahole221 in a leadingsection222 of closer tape stored on the fresh spool, as seen in FIG. 15. Preferably, thenotch220 and thehole221 are formed by atool223 shown in FIGS. 16 and 16A. Thenotch220 is substantially rectangular, approximately 0.125-0.25 inch wide (although a different width might alternatively be formed) and extends from anupper edge224 to a point just at or beyond arail226 of thecloser tape section222. Also preferably, thehole221 is located a distance of approximately 2.3125 inches from aleading edge228 of thenotch220. The operator then pushes up on theknob106 to space the fifthclamping jaw portion98 from the second taperedportion94bof the thirdclamping jaw portion90. The closer tape includescloser elements225 that are closed (or occluded) so that the portions of the closer tape are held together. Free ends227a,227bof the leadingsection222 opposite thecloser elements225 are spread apart and the leadingsection222 is thereafter inserted into thecloser tape path112, and specifically into the space between the fifthclamping jaw portion98 and the second taperedportion94b, until the free ends227a,227brest on the surfaces of the taperedportion80band the surfaces of the taperedportion94band such that thehole221 is aligned (from front-to-back) with a front surface of a 0.25 inch cover plate (not shown) secured to the front of theapparatus30. When the closer tape is so positioned, thenotch220 is disposed over thezipper stop plate109 such that theleading edge228 of thenotch220 contacts asurface229 of thezipper stop plate109, as seen in FIG. 18. The operator then releases theknob106, thereby capturing the leadingsection222 of the closer tape between the fifthclamping jaw portion98 and the second taperedportion94b. Thecloser elements225 are captured within aslot230 in the fifth clamping jaw portion98 (FIG. 9). Theapparatus30 is then in the state illustrated in FIG. 17.
Once the leading[0040]section222 is clamped, the sequence of operation may pause until the command signal is generated. At this point, the closer tape feeding mechanism is automatically or manually deactuated so that further feeding ofcloser tape50 from thespool52 is prevented. Thereafter, a controller232 (FIG. 22) develops a signal to actuate thecylinder66, thereby causing the movableheater block subassembly62 to move downwardly until the secondclamping jaw portion76 and the fourthclamping jaw portion92 are moved into clamping contact with the leadingsection222 and the trailing end of thecloser tape50 from thespool52. At this time, thecloser elements225 of both portions of closer tape are positioned inslots234,236 and238 in the secondclamping jaw portion76 and the secondclamping jaw portion92, respectively (FIGS. 9 and 19). Thecontroller232 then actuates the cylinder148 (FIGS. 1 and 9), thereby driving thebracket130 upwardly to the cutting position whereby the leadingsection222 and the trailing end of thecloser tape50 on thespool52 are severed. As should be evident from the above description, the portion of the leadingsection222 held by the firstclamping jaw portion68 and the secondclamping jaw portion76 extends rearwardly in theapparatus30 beyond the portion of the trailing end of thecloser tape50 held by the thirdclamping jaw portion90 and the fourthclamping jaw portion92 by an amount equal to the spacing between the cuttingedges136,138.
Once the severing step is complete, the controller[0041]232 (FIG. 22) deactuates thecylinder148 to retract thebracket130 and actuates thecylinder120 to cause the clampingjaw portions68,76 to move to the position shown in FIG. 20. This movement causes the portion of the leadingsection222 held by the firstclamping jaw portion68 and the secondclamping jaw portion76 to contact and slide over the portion of the trailing end of thecloser tape50 held by the thirdclamping jaw portion90 and the fourthclamping jaw portion92 so that the former is disposed atop and overlaps the latter. During this movement, the material of the leadingsection222 and/or the material of the trailing end of thecloser tape50 deform as necessary to accommodate such movement.
Once the portions of closer tape are aligned as noted above, the[0042]controller232 actuates thecylinder164 to move thebar160 until theend162 moves out of contact with the heater blocks212a,212band into contact with the overlapping portions of closer tape. Thewings200a,200bof thebar160 heat the overlappingportions222 and50 of closer tape and fuse such portions together. Advantageously, thewings200a,200bof thebar160 are not actively heated during fusing of the overlapping portions of closer tape; rather, the heat stored by these portions200 of thebar160 is transferred to the sections of closer tape and thebar160 cools to a temperature below the melting point of the thermoplastic material of the closer tape. Sticking of thebar160 to the portions of closer tape is thereby avoided.
In addition to the foregoing, the[0043]closer elements225 of both portions ofcloser tape222 and50 are positioned in the notchedportion206 of theopening202 so that thecloser elements225 are not fused together.
The[0044]controller232 thereafter deactuates thecylinder164 to raise thebar160. In addition, thecontroller232 deactuates thecylinder66 so that the movableheater block subassembly62 is raised. This, in turn, causes the secondclamping jaw portion76 and the fourthclamping jaw portion92 to be spaced from the firstclamping jaw portion68 and the thirdclamping jaw portion90, thereby releasing the joined sections of closer tape, as well as the severed trailing end of thecloser tape50 from thespool52. The severed end of thecloser tape50 may then be removed from theapparatus30. Thereafter, thecontroller232 deactuates thecylinder120, thereby moving the first and secondclamping jaw portions68,76 back to the positions shown in FIG. 17. During this movement the spliced sections of closer tape slide over the m-shapedupper surface80 and are positioned in thecloser tape path110. The operator may then (or at any other point in the splicing process subsequent to the severing step) push up on theknob106 and remove the severed leading end of the closer tape held by the fifthclamping jaw portion98. The operator may thereafter release theknob106 and production of thermoplastic bags may resume.
The present invention is not limited to the concept of splicing portions of closer tape on a strictly automated basis as noted above. Rather, any or all of the steps described herein may be undertaken as a result of manual steps taken by an operator. Also, one or more of the[0045]cylinders120,148 and164 may be replaced by another moving assembly, such as a linear servo or other motor, if desired.
Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications that come within the scope of the appended claims are reserved.[0046]