US3017795A - Method and apparatus for forming individual wrapped pads from otherwise continuous batt strips - Google Patents

Description

Jan. 23, 1962 c. G. JOA 3,017,795

METHOD AND APPARATUS FOR FORMING INDIVIDUAL WRAPPED PADS FROM OTHERWISE CONTINUOUS BATT STRIPS Filed June 6, 1957 3 Sheets-Sheet l INVENTOR. (oer 6. JOF? kmjrmvarm A Tree/veal;

Jan. 23, 1962 c. 3,017,795

G. 'JOA METHODAND APPARATUS FOR FORMING INDIVIDUAL WRAPPED PADS FROM OTHERWISE CONTINUOUS BATT STRIPS 5 Sheets-Sheet 2 Filed June 6, 95?

INVENTOR. Cuzr 6-. Jan

A T TOENE Y! A 3,017,795 ING INDIVIDUAL WRAPPED PADS FROM OTHERWISE CONTINUOUS BATT STRIPS Jan. 23,1962 c. G. JO

METHOD AND APPARATUS FOR FORM Filed June 6, 1957 3 Sheets-Sheet 3 N N h JNVENTOR. 60,27- 6-. J06

BY I Am, 44% D m QM A United States 3,017,795 METHOD AND APPARATUS FOR FORMING- INDI- VIDUAL WRAPPED PADS FRUM OTHERWIE CONTINUOUS BATT STRIPS Curt G. Jon, Town of Ocean Ridge, Fla., assignor to Falls Paper & Power Company, Chester, Pa., a corporation of Wisconsin Filed June 6, 1957, Ser. No. 664,063 2 Claims; (Cl. 83-129) This invention relates to a method and apparatus for forming individual wrapped pads from otherwise continuous batt strips.

Cross reference is made to my co-pending applications, Serial No. 550,653, filed December 2, 1955, now abandoned, and Serial No. 646,696, filed March 18, 1957, which disclose devices for forming continuous batt strips as a procedure preliminary to procedures of the present invention.

Of course, it is immaterial to the present invention how the batt strip is initially formed, the cross referenced patent applications being cited merely as illustrative of batt forming devices andexemplifying devices which I have actually commercially used for this purpose.

In the method and apparatus of the present invention, one or more elongated strips of batt material discharged from the forming machine is divided at longitudinally spaced points into discrete portions spaced longitudinally by dividing gaps, such portions being then ensleeved in wrapping paper which is continuous across the" discrete portions of batt material, as Well as across the spacing gaps intervening therebetween. In the continued advance of the ensleeved strip, the opposed plies of wrapping paper in the area of thegaps are pressed to,- gether and sealed.

Knife means subsequently severs, preferably with a tearing stroke, the wrapping paper across the seals aforesaid to-subdivide the wrapped strip into discrete wrapped pads consisting ofbattv material confined in sealed wrapping paper. While the pads made according tothe present invention may be used for any pad purposes, they are specifically intended for use ascushion pads in packaging furniture. The pads must be sturdy to withstand shipping and handling stresses and yet provide a soft cushion to protect the furniture. Moreover, the pads may not have any abrasive or rough surfaces which might otherwise scratch the furniture finish.

A unique feature of the method and apparatus of the present invention is my procedure for severing the elongated strip of batt material intodiscrete portions with subdividing gaps intervening therebetween. I do this by removing entirely batt material segments of substantial width from the strip. These segments are removed by a convection. current induced by establishing a. pressure differentialv across. the batt segment to be removed.

The resultantconvention current of air or like fluid picks up the batt segment, removes it from the strip and returns it to the batt forming machine for redeposit. I havefound that. such. pressure differential can most conveniently be established by subjecting the batt segment to vacuum. In some instances, the pressure differential is advantageously increased by impinging a stream of air or like fluid against the side of the segment opposite that subject to the vacuum- The foregoing procedure presents a problem in that the strip. of batt material is ordinarily in motion on a conveyor belt. The method andapparatus of the present invention accommodates for such. motion.

According: to the present invention, a vacuum. box is disposed in. fixed relation to the strip conveyor. It may be continuously at subatmospheric. pressure, or at such pressure only periodically as the strip passes the vacuum 3,017,795 Patented Jan. 23, 1962 2 box inlet. The convection current which flows into the vacuum box is localized or channelled to confine it to effect only the batt segment to be removed by at least partially enclosing the segment with an air confining hood. I may optionally bl'ow air, etc. into the end of the hood opposite the vacuum box inlet;

The air blower, and if desired the vacuum pump as well, is desirably actuated only for that period of time during which the batt segment is opposite the vacuum box inlet. At all other times the air blower is disabled to permit the strip to pass without change of form.

Continuous strips'of pro-glued wrapping paper are then applied to the longitudinally separated batt portions and the wrapping paper strips ensleeved thereabout. Thereafter, the paper is sealed' in the area of the spacing gaps and severed as aforestated.

To avoid formation of abrasive material on theouter surface of the pad, such as might be formed byextrusion of conventional glue from between the plies of wrapping paper as they are squeezed together, I use a special form of adhesive which is very pliable even after it has set. Accordingly, such glue as is extruded will be very pliable, even after setting, and will not scratch finished furniture surfaces. Moreover, the wrapping paper is desirably severed by tearing it to-fray out the fibers of the paper and entrapped glue. This avoids a sharp or clean cut edge which might otherwise abrade or scratch furniture finish.

Other objects and advantages of the invention will be more apparent from an examination of the following disclosure in which:

FIGURE 1 is a diagrammatic perspective view showing a simplified form of apparatus for practicing the present invention.

FIGURE 2 is a side elevation, partly in cross section, showing in more detail the apparatus diagrammatically illustrated in FIGURE 1.

FIGURE 3 is a cross sectional view taken along the line 3-3 of FIGURE 4 and is a vertical cross section taken through. the. vacuum box and associated apparatus.

FIGURE 4 is an end view, partly in cross section and partly in elevation, of the device shown in FIGURE 3.

FIGURE 5 is an' enlarged fragmentary perspective view showing the vacuum box and associated apparatus.

FIGURE 6 is a greatly enlarged fragmentary view, partly in cross section, of the cut-off apparatus for severing the ensleevedstrip into individual wrapped pads.

FIGURE 7 is a: fragmentary view similar to FIGURE 6, but showing the position of the parts during severing co-action of the knife blades.

FIGURE 8 is a fragmentary side view of the-stationary knife blade and its push-oft blade.

FIGURE 9 is a perspective view' on a reduced scale showing a cushioning'pad as produced by the method and apparatus of the present invention.

FIGURE 10 is an enlarged cross section takenthrough the completed pad of FIGURE 9.

FIGURE 1'1 is: an enlarged fragmentary plan view of the severed margin of a pad.

The batt formingapparatusmore fully described in my prior applications aforesaid is illustrateddiagrammatically at 14 at the right in FIGURE. 2 and includes: a screen. 15 on Whichfibrousmaterial 16 is: deposited in-the form of: a batt 1-7" which is discharged from the screen in the form of a batt. strip 18. As in the devices of my c'o-pending applications aforesaid, a levelingdevice 19 functions to provide for substantially uniform thickness anddensity of the batt material.

The end product of the method. and apparatus of. the present invention is illustrated in FIGURE 9 as acushion pad 22 which may be usedfor packing. A particular use. forpad 22 is as a filler pad in furniture shipping cartons. The loosely compactedsection 33 of batt material is not self-sustaining and is ensleeved in a wrapping paper cover consisting of abase strip 23 having its side margins formed in channels to receive therein thebatt 33 and to marginally overlap acover wrapping strip 24.

To keep thebatt section 33 secure against dislocating movement within the wrapping paper, the inner surfaces of the wrapping strips 23, 24 are coated withglue layers 25, 26. Accordingly, thebatt section 33 will be anchored against shifting movement within its wrapper.

FIGURE 1 diagrammatically illustrates my novel method and apparatus for forming thepads 22. The

continuous strip 18 of batt material discharged from the forming machine 14 is received onbelt conveyor 27 on which it is conveyed past appropriate means for creating a convection current of air. As illustrated in FIGURE 1, the inlet or nozzle 28 of a vacuum pump or blower 31 may be disposed at one side of thebelt 27 and a source 29 of air under pressure may be disposed at the other side of theconveyor 27.

Accordingly, a stream of air can be blown across theconveyor 27 to remove by convection a segment of batt material intervening between the nozzles 28, 29.

To localize and channel the convection current, I find it desirable to temporarily position on the strip 18 anair hood 32 which desirably presses down on spaced portions of the batt strip 18 to define the batt segment removed by the convection current. This procedure subdivides the strip 18 intodiscrete batt portions 33 longitudinally spaced bygaps 47.

It is broadly immaterial if all of theapparatus 28, 29, 32 moves as a unit with theconveyor 27 in the course of removing the batt segment by convection. In the preferred form herein illustrated the vacuum tube 28 and air nozzle 29 are relatively stationary and intermittently operated in time with the advance ofconveyor 27 to remove batt segments at points appropriately spaced in the strip.

In any event, the strip 18 is sub-divided into discrete spacedbatt sections 33 which are discharged fromconveyor 27 onto thestrip 23 of wrapping paper which is drawn over theroll 34 and ontoapron 42. Thestrip 23 is unwound from asupply roll 35 and passes through gluing apparatus 36 including a glue tank 37 and transfer roll 38 which coats the surface of thestrip 23 which is uppermost onapron 42.

Theupper strip 24 of wrapping paper is applied to the upper surface of the batt after having been unwound from a supply roll 43 and having received a coating of glue from glue tank 44 and transfer roller 45.Strip 24 is substantially the same width as the batt strip 18 butstrip 23 is somewhat wider. Accordingly, the edge margins ofstrip 23 may be folded by conventional folding plows 46 to form the channels aforesaid and overlap thewrapping strip 24. As illustrated in FIGURE 2, the plows 46 may gradually taper toward their outlet ends to press the wrapping paper against theensleeved batt sections 33 while the adhesive at least partially sets.

In the foregoing operation, the wrapping paper ensleeves the spaceddiscrete batt sections 33 and thegaps 47 therebetween.

As the ensleeved longitudinally spacedbatt sections 33 are discharged fromconveyor 39, the sealing dies 48, timed to co-act only when thegaps 47 are therebetween. press together portions of the wrapping strips 23, 24 which are at opposite sides of thegaps 47 between thebatt sections 33. Accordingly, the glue coated on the facing surfaces of the strips seal the strips together under pressure of the dies 48 to constituteconnective links 49 between therespective pads 22.

After sealing, thepads 22 are further compressed between theco-acting belt conveyors 52, 53 during continued advance thereof. Meanwhile theglue coatings 25, 26 have time to set and the spaced discreteuncut pads 22 are in due course discharged from theconveyors 52, 53 onto a spring biasedapron 54 preceding the pad severing apparatus shown diagrammatically in FIGURE 2 and in greater detail in FIGURES 6-8.

The apparatus for severing the wrapped bat-t strip through the flattened and sealedconnective links 49 intervening between thepads 22 consists ofco-acting knife blades 55, 56 respectively havingteeth serrations 57, 58 which intermesh in the co-action of the blades.Stationary knife 55 is mounted on a fixedsupport 59.Movable knife 56 is mounted on a rotary shaft 62 having an axis of rotation offset rearwardly fromknife 55.

Accordingly,knife 56 sweeps pastknife 55 in a downward direction.

Apron 54 is normally biased byspring 63 to its position shown in FIGURE 6 in which the discharge end of theapron 54 is above the level of theteeth 57 ofknife 55. Accordingly, except during the time of knife coaction, theconveyors 52, 53 will simply feed the linkedpads 22 through the gap between theknives 55, 56 and onto the take-awayconveyor belt 64. However, whenrotary knife 56 reaches its position shown in FIGURE 7 in which itsteeth 58 cooperate with theteeth 57 of theknife 55, the downward component of thrust ofknife 56 will compressspring 63 and depressapron 54 to lower theconnective links 49 ontoteeth 57 ofblades 55. After severance of thelinks 49,spring 63 will bias the apron '54 to its elevated portion shown in FIGURE 6 in which thepad 22 will clear thestationary knife 55 in its continued advance through the machine.

To insure disengagement of theteeth 57 ofstationary knife 55 from the severed edges of theconnective links 49,knife blade 55 is provided with a push-off plate or bar 65 mounted for reciprocation on theknife 55 by reason of the engagement of its pins 66 withslots 67 formed in theblade 55. The push-off bar orplate 65 is provided with a bracket 61 connecting it to rod 68 of thepiston 69 of a fluid operatedmotor 72. Conventional means (not shown) is provided for co-ordinating themotor 72 with the rotation of shaft 62 for actuating the fluid opera-ted motor 72 immediately after thelink 49 is severed. Accordingly, push-off plate 65 assists thespring 63 in clearing the fibers 71 of thelink 49 from entanglement with theteeth 57 of theblade 55.

The serratedco-acting teeth 57, 58 are regarded as of considerable significance in the present invention in that a sharp or clean cut severed edge in thelink 49 is avoided. By reason of the meshingteeth 57, 58 theconnective link 49 is torn in the course of knife co-action therewith. Accordingly, the fibers 71 of thelink 49 are frayed out as illustrated in FIGURE 11. The fraying or tearing action aforesaid is attributed to the difference in peripheral speed of radially offset portions of the serrated knife teeth.

The frayed out fibers 71 are softer and more pliant and less damaging to furniture finish than would be a clean-cut edge, particularly if such edge contains hardened glue. The tearing action aforesaid not only frays out the fibers of the paper but frays out such glue as is extruded from between the plies of wrapping paper.

To further reduce the possibility of abrading furniture finish, I use for an adhesive a product which desirably sets in pliable form. Asphalt has been used successfully as well as a rubber base adhesive sold by the 3-M Company under its mark E1025.

The detailed construction of the preferred apparatus for dividing the batt strip 18 into discrete spaced portions is shown in FIGURES 3, 4, and 5. In practice, there may be more than one strip 18 discharged from the batt forming machine 14. In FIGURES 3 through 5, three such strips are illustrated. These may first be compacted slightly againstconveyor belt 27 and itsunderlying apron 73 by the compacting roll 30. Theapron 73 is provided withports 75 intervening between the laterally spaced bel-t runs 27 and communicating with avacuum duct 74 suspended from theapron 73. Accordingly, theports 75 are laterally offset from the path of travel of the respective batt strips 18.

As shown in FIGURES 3 and 4, the edge margins of theapron 73 support side plates 76 which are provided with bearings for the fourcross shafts 77 to whichend sprockets 78 are applied. Thesprockets 78 mesh with interconnectingchains 79. Oneshaft 77 has an additional sprocket 82 meshing with the driving chain 83. Chain 83 meshes with drive sprocket 81 mounted onshaft 84.Shaft 84 desirably receives through conventional mechanism (not shown) power from the same source as drives theconveyor belts 27. Accordingly, thechains 79 move in timed co-ordination with the belts Laterally aligned spacedair hoods 32 are mounted on thechains 79 as best shown in FIGURE 5. At spaced intervals along thechain 79, are provided pairedcrossbars 85 on which thehoods 32 are screwed or otherwise secured. In the specific apparatus illustrated,chains 79 are provided with two sets of pairedbars 85 andhoods 32. The longitudinal spacing between the sets of hoods determines the spacing between thegaps 47 formed in the batt strips 18. Thelowermost shafts 77 forchains 79 are relatively widely separated so that a set ofhoods 32 will be positioned against the advancing batt strips 18 before the portions of the batt covered by the hoods reaches thevacuum duct 74. Even if the duct '74 is continuously at sub-atmospheric pressure, batt material will not be removed from the strip until thehoods 32 are laterally aligned with theinlets 75, thus to direct the stream of air entering theinlets 75 through the hoods and against the batt segments. Of course, I may optionally provide conventional apparatus to evacuateduct 74 only periodically, when thehoods 32 in their position substantially as shown in FIGURE 4.

At a timing of the parts shown in FIGURE 4, a timing cam 86 mounted onshaft 84 engages theactuator 90 ofvalve 87 in the compressedair supply pipe 88.

Pipe 88 supplies air under pressure to thenozzles 89. Note that thenozzles 89 are directed laterally into thehoods 32 which have theirrespective end walls 92 at an appropriate angle to direct the convection current of air induced by thevacuum duct 74 and pressure ofnozzles 89 into theports 75 which are then directly below the inclined ends 92 of thehoods 32. The stream of air picks up by convection the loosely compacted fibers of the segments of batt material localized beneath thehoods 32 and carries such fibers through thevacuum duct 74 to a point of deposit which may conveniently be the mass of batt material in the batt forming machine 14.

In some cases, vacuum alone is suflicient to remove the segment of batt material from beneath thehoods 32. In other cases, the addition of pressurized air from thenozzle 89 is beneficial. In any event,gaps 47 intervening between spacedbatt portions 33 are formed by removing by convection segments of batt material beneath thehoods 32. To prevent loss of vacuum, the bars may be provided withsealing pads 93 of rubber or the like which bridge across theconveyor belts 27 between the laterally spaced batt strips 18.

The removal of batt material segments occurs concurrently with continued forward movement of theconveyor belts 27. Substantially immediately after the batt material segment has been removed from beneath thehoods 32, cam 86 will have rotated to the point where actuator forvalve 87 is released to shut off the supply of air tonozzles 89 and de-energize blower 31. Accordingly, the batt strips 18 between the spaced sets ofhoods 32 are not displaced by any convection current until the next set ofhoods 32 is positioned upon the batt strips and reach FIGURE 4 position when cam 86 again actuatesvalve 87 and blower 31.

I claim:

1. In a device of the character described a pad severing knife comprising co-acting serrated knife blades, one of said blades having a clearing bar mounted for reciprocation thereon.

2. The device of claim 1 in which one of said blades is provided with means mounting it for rotation, the other said blade being stationary, a motor for said clearing bar and means for energizing said motor to clear said blade after co-action of said blades.

References Qited in the file of this patent UNITED STATES PATENTS 1,623,983 Speer Apr. 12, 1927 1,651,096 Molins Nov. 29, 1927 1,676,048 Philbrick July 3, 1928 1,738,076 Molins Dec. 3, 1929 2,051,242 Birr Aug. 18, 1936 2,286,960 Hall June 16, 1942 2,338,132 Sandberg Jan. 4, 1944 2,372,020 Sandberg Mar. 20, 1945 2,617,528 Moore Nov. 11, 1952 2,649,035 Cloud Aug. 18, 1953 2,751,981 Hawkins June 26, 1956 2,803,304 Kessler Aug. 20, 1957 2,827,742 Bursak Mar. 25, 1958 2,913,862 Sabee Nov. 24, 1959 FOREIGN PATENTS 659,184 Great Britain Oct. 17, 1951

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