APPARATUS AND METHOD FOR CLOSING AND SEALING BAGS IN BALE ENVELOPING APPARATUS
An apparatus for closing and sealing a preformed polypropylene bag after a bale has been inserted therein as the bale and bag traverse along a longitudinal line of travel. Left and right rotatable side flaps fold the left and right bag closure flaps onto the bale. A bottom rotatable fold plate partially folds the bag bottom closure flap and a top fold bar is extended and folds the top bag closure flap onto the bale. The bottom fold plate then folds the bag bottom closure flap onto the bale. The top and bottom bag closure flaps are sandwiched between the rotatable side flaps and the bottom fold plate and over a slack bar therebetween forming a slack portion. A heating assembly directs heat to the slack portion melting the polypropylene and a press plate is extended to the slack melted portion thereby fusing the bag closure flaps together.
1. Field of the Invention
The present invention relates to the field of enveloping generally rectangular shaped bales of material such as cotton, trash, etc. and, more particularly, relates to the use of a web of closed, preformed end-to-end bags for enveloping bales and an apparatus and method for closing and sealing the bags after a bale has been inserted therein.
2. Background
Bulk materials such as cotton, insulation, trash, cloth, scraps, recyclables, etc. are today typically packaged by compressing binding into large rectangular bales. Oftentimes, it is desirable to envelop such bales with a protective covering material which is typically made of plastic such as polyethylene and polypropylene. Cotton bales, for example, are today enveloped in plastic bags so as to protect the cotton during transport. Bales of trash are also similarly enveloped so that, during transport, trash pieces that may fall off the bale will be contained.
Such bales are today enveloped by essentially manually inserting them into large bags and manually closing and sealing the bags. As can be appreciated, this process can be time-consuming and costly. Accordingly there is a need for an automated method and apparatus for enveloping rectangular bales and, more particularly, for automatically closing and sealing the bags after insertion of the bales within the bag.
SUMMARY OF THE INVENTIONIn one form thereof the invention is used in connection with an apparatus for enveloping bales of material with preformed bags having an open end and a closed end, and is directed to an apparatus for closing a bag after a bale has been inserted into the bag through the open end while a bale and bag traverse along a longitudinal line of travel, said apparatus comprising: left and right side flaps, one on each side of said longitudinal line of travel, each of said side flaps being selectively rotatable generally about a vertical pivot axis whereby left and right bag closure flaps at the bag open end can be folded onto the bale therein; a bottom fold plate below said longitudinal line of travel being selectively rotatable generally about a horizontal pivot axis whereby a bottom closure flap at the bag open end can be folded onto the bale therein; and, a top fold bar above said longitudinal line of travel being selectively extendable into and retractable from said longitudinal line of travel whereby a top closure flap at the bag open end can be folded onto the bale therein.
Preferably the apparatus includes a heat seal manifold selectively moveable into said line of travel and adjacent the bag closure flaps whereby heat is provided to a portion of the closure flaps for joining them to one another.
Preferably the apparatus also includes a selectively retractable and extendable press plate moveable into said line of travel and adjacent the bag closure flaps, said press plate being selectively extendable onto said closure flaps heated portion.
Preferably a slack bar is carried on each of said left and right side flaps and the slack bars are selectively retractable and extendable.
Preferably said bottom fold plate is selectively rotatable in a horizontal transition position whereat a bale and bag may traverse thereover.
In another form thereof the invention is used in connection with a method for enveloping bales of material with preformed bags having an open end and a closed end, and is directed to a method of closing a bag after a bale has been inserted into a bag through the open end, wherein the bag is closed with a bag closing assembly as the bale and bag travel along a longitudinal line of travel; the bag closing assembly including left and right side flaps, one on each side of the longitudinal line of travel and wherein each of said side flaps are selectively rotatable generally about a vertical pivot axis; a bottom fold plate below said longitudinal line of travel being selectively rotatable generally about a horizontal pivot axis; a top fold bar above said longitudinal line of travel being selectively extendable into and retractable from said longitudinal line of travel; the bag open end having, adjacent the inserted bale, a lower closure bag flap, an upper closure bag flap and left and right closure bag flaps between said lower and upper flaps;
the invention more particularly directed to a method of closing the bag comprising the steps of: rotating said left and right fide flaps and folding said left and right closure flaps onto the inserted bale; extending said top fold bar and folding said top closure flap onto the inserted bale; rotating said bottom fold plate and folding said lower closure flap onto the inserted bale; retracting said top fold bar; and, securing at least two of said folded closure flaps to one another.
Preferably, prior to said securing, a portion at least two of said closure flaps are folded over a slack bar thereby creating a slack portion.
Preferably, said step of securing comprises heating said slack portion for thereby joining said closure flaps to one another.
Also preferably, said bag is made of polypropylene and during said step of heating the polypropylene material if fused thereby joining said closure flaps to one another.
The method further preferably comprises, prior to said step of rotating said left and right closure flaps, rotating said bottom fold plate in a horizontal transition position whereat a bale and bag may traverse thereover.
In another form thereof the invention is used in connection with a method for enveloping bales of material with preformed bags having an open end and a closed end, and is directed to a method of closing a bag after a bale has been inserted into the bag through the open end, the bag open end having, adjacent the inserted bale, a lower closure bag flap, an upper closure bag flap and left and right closure bag flaps between said lower and upper flaps, said method comprising the steps of: folding said left and right closure flaps onto the inserted bale; partially folding said lower closure flap toward the inserted bale; folding the said upper closure flap onto the inserted bale; and, further folding said lower closure flap onto the inserted bale and sandwiching a part of said upper closure flap between said lower closure flap and said inserted bale; and, securing at least two of said folded closure flaps to one another.
Preferably said bag is made of polypropylene and said step of securing comprises heating a portion of at least two of said closure flaps and fusing the polypropylene material thereof and thereby joining said closure flaps to one another.
Also preferably, prior to said securing, a portion at least two of said closure flaps are folded over a slack bar thereby creating a slack portion and the method further includes heating said slack portion for thereby joining said closure flaps to one another.
Also preferably, said bag is made of polypropylene and during said step of heating the polypropylene material if fused thereby joining said closure flaps to one another.
The above mentioned and other features of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout several views. Although the exemplification set out herein illustrates embodiments of the invention, in several forms, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSAn apparatus constructed in accordance with the principles of the present invention for enveloping bales 12 is shown in
The closed, preformed end-to-end bags 14 and method of making them are diagrammatically shown and depicted in
Sheet 18 is formed into a helix tube 28, as shown in
Accordingly, each of the closed preformed end-to-end bags 14 are thereby defined between side fold edges 34, 36 and between each spaced pair of seam lines 40. Each of the closed preformed end-to-end bags 14 have an effective length D and an effective perimeter length equivalent to the perimeter of the helix tube 28. The plurality of thus formed end-to-end bags 14 form a continuous elongate web 15 and can be rolled up into a roll 16 for easily transporting and use in apparatus 10.
It is contemplated that, rather than making a helix tube 28, bags 14 can be made by folding over the sheet 18 along a longitudinally extending fold line and securing seams 24 and 26 to one another, thereby creating a seam extending longitudinally in a straight line between the longitudinal ends 20, 22. In such an embodiment, the effective perimeter length of the bag 14 would be limited to and would be substantially equivalent to the width W of the elongate sheet 18. However, as should now be appreciated, by forming a helix tube 28 the effective perimeter length of the bag 14 can be made whatever length may be desired for accommodating and enveloping the bales 12.
The securing of the first and second side edges 24, 26 at seam line 29 and of the first and second bag walls 30, 32 at seam lines 40 can be accomplished by heat sealing and/or with adhesives. Preferably, however, this is accomplished by sewing for thereby providing generally low cost high strength securement seams. In this regard, as diagrammatically shown in
Similarly, as diagrammatically shown in
As shown in
Turning now to
The assembly 52 whereat bags 14 are severed from roll 16, opened and placed over a bale 12, and are closed and heat sealed, as best seen in
The adjustable form tube 66, as also shown in
A pivot arm 88 is pivotally secured at a central pivot joint 90 to the frame 53. Links 92L, 92R are provided and are pivotally secured at one of their ends to each of the terminal ends of the pivot arm 88. At its other end, link 92L is pivotally secured to the left horseshoe frame 80L, whereas link 92R, at its other end, is pivotally secured to the right horseshoe frame 80R. As should now be appreciated, pivot arm 88 and links 92L, 92R function to maintain the horseshoe frames 80L, 80R and form tube sections 78L, 78R evenly spaced from the central pivot joint 90 as the form tube sections 78L, 78R are moved between their retracted and expanded positions.
The form tube sections 78L, 78R each include a front flared surface 78F for helping guide the bales 12 into the form tube 66 as they are pushed therein with the ram 60. Form tube sections 78L, 78R each also include a rear edge 78E and exterior surfaces 78SR, 78SR whereupon opened bags 14 are received as further described hereinbelow. An apron 94 extends into the adjustable form tube 66 over the bottom longitudinal edges 78BL, 78BR. Bales 12 traverse over the apron 94 as they are pushed through the form tube 66. The bottom longitudinal edges 78BL, 78BR thereby slide under the apron 94 as the left and right form tube sections 78L, 78R are moved between their retracted and expanded positions without interfering with or contacting the bales 12.
The bag placer assembly 68, as more fully described hereinbelow, grabs an opened bag 14, places the open bag end over the form tube rear edges 78E and on the form tube exterior surfaces 78SL, 78SR and then collects the bag on the form tube 66 placing it in position ready for inserting a bale 12 therein. For accomplishing its intended operations, bag placer assembly 68 is selectively longitudinally movable between the positions shown in
Bag placer assembly 68 is selectively longitudinally movable by selectively energizing electric motors 98L, 98R which are mounted on the bag placer assembly frame 100. Electric motors 98L, 98R are coupled to respective spur gears 102L 102R through toothed belts 104. Spur gears 102L, 102R R, in turn, are coupled to respective left and right gear racks 106L, 106R which are mounted to the frame 53.
Upper and lower bag roller drive wheels 108U, 108L are mounted on respective upper and lower rotatable shafts 110U, 110L. The upper rotatable shaft 110U is carried on upper pivot arms 112U which are, in turn, carried on and pivotally supported on an upper pivot shaft 114U. The lower rotatable shaft 110L is carried on lower pivot arms 112L which are, in turn, carried on and pivotally supported on a lower pivot shaft 114L. Air cylinders 116 are provided and are pivotally coupled between the upper and lower pivot arms 112U, 112L. As depicted between
Electric motors 120 are also provided and are coupled to each of the upper and lower rotatable shafts 110U, 110L for selectively rotatably driving the roller drive wheels 108U, 108L as indicated by arrows R. As further described hereinbelow, electric motors 120 are energized after a bag 14 is placed on the form tube 66 and the upper and lower roller drive wheels 108U, 108L are placed in contact with the bag 14 for collecting the bag 14 on the form tube 66.
Bag placer assembly 68 is also provided with left upper and lower fingers 122LU, 122LL and right upper and lower fingers 122RU, 122RL for placing the open bag end over the form tube rear edges 78E and on the form tube exterior surfaces 78SL, 78SR. At their terminal ends, each of the fingers 122 are provided with a rubber tip 124 for frictionally engaging the interior surface of an open bag 14. The left upper and lower fingers 122LU, 122LL are secured to and extend from a vertical shaft 126L which is pivotally secured to the bag placer assembly frame 100. Similarly, the right upper and lower fingers 122RU, 122RL are secured to and extend from a vertical shaft 126R which is pivotally secured to the frame 100. Vertical shafts 126L, 126R are coupled to one another, as best seen in
Referring now more particularly to
Lower jaw 134L is provided with a guillotine knife 146 slidingly received within slot 148L. A plurality of air cylinders 150 are secured between the lower jaw 134L and the guillotine knife 146. The slot 148L extends through the flat contact surface 154L of the lower jaw 134L. Accordingly, by selectively extending the air cylinders 150, the guillotine knife 146 traverses upwardly thereby extending the knife cutting edge 152 thereof beyond the fiat surface 154L of lower jaw 134L. The upper jaw 134U is also provided with a flat contact surface 154U and a slot 148U which extends through the flat contact surface 154U. When jaws 134U, 134L are placed in their extended position as shown in
Assembly 70 includes a heat sealing assembly 156 which is secured to and travels with the upper jaw 134U. As best seen in
Heat sealing assembly 156 also includes a pair of press plates 170, each of which are selectively slidable between a retracted position as shown in
Assembly 70 also includes left and right vacuum and grip pin assemblies 174LU, 174RU which are secured to and travel with the upper jaw 134U and left and right vacuum and grip pin assemblies 174LL, 174RL which are secured to and travel with the lower jaw 134L. Each of the vacuum and grip pin assemblies 174 are structurally and operationally the same. Referring more particularly to
As further described hereinbelow, after severing a bag 14 from the roll 16, the vacuum and grip pin assemblies 174 draw up and securely hold the bag walls 30, 32 so that the upper and lower jaws 134U, 134L can be retracted to their position shown in
The bottom fold plate assembly 72: provides a transition surface between the form tube 66 and the output conveyor 64; guides the bag 14 as it is collected onto the form tube 66; pinches and holds the next bag as the prior bag which has been collected onto the form tube 66 is severed therefrom; folds the bottom closure flap onto the bale 12; and, provides guide slots 205 for the slack bars 200. Bottom fold plate assembly 72 includes a plate assembly 202 comprising a plate surface 204. Plate assembly 202 is supported on the frame 53 via a transverse pivot shaft 206 which is pivotally secured to the frame 53 at its terminal ends 208L, 208R. A roller shaft 210 is pivotally secured to the plate assembly 202 adjacent to and parallel with the transverse pivot shaft 206. Air cylinders 212L, 212R are pivotally secured between the frame 53 and the respective terminal ends of the roller shaft 210. Accordingly, by selectively extending and retracting the air cylinders 212L, 212R the plate assembly 202 can selectively be pivoted to a lowered horizontal position as shown in
First and second parallel transverse guide rollers 214, 216 are pivotally carried. on the plate assembly 202 and are adapted to receive the closed, preformed end-to-end bags 14 therebetween. Second guide roller 216 is pivotally secured at its terminal ends in slots 218 and is thereby selectively movable between first position and second positions. In its first position, roller 216 is in contact with the first guide roller 214 as shown in
As mentioned hereinabove, left and right guide slots 205L, 205R are provided on the plate surface 204 whereat the slack bars 200L, 200R which are carried on the side fold assembly 72 can be received. It is noted that, when closing the bag 14, the several bag closure flap layers extend around the slack bars 200L, 200R and into the respective guide slots 205L, 205R thereby creating slack/providing additional polypropylene material within the slots 205L, 205R such that it can be partially melted for fusing and sealing the closure flaps.
Referring now more particularly to
As also mentioned hereinabove, stack bars 200L, 200R are carried on the side fold assembly 72. More particularly, slack bars 200L, 200R are attached to the piston of respective air cylinders 230L, 230R which are themselves secured to the respective side flaps 222L, 222R. Accordingly, by selectively retracting and extending the air cylinders 230L, 230R, the slack bars 200L, 200R can be selectively retracted as shown in
The top fold assembly 76 folds down the bag top closure flap after the side closure flaps have been folded in and prior to heat sealing. Top fold assembly 76, as also shown in
As mentioned hereinabove, apparatus 10 employs a plurality of closed, preformed end-to-end bags 14 provided as a continuous elongate web 15 on a roll 16 for enveloping the bales 12. As shown in
A pair of seam sensor assemblies 244, as best seen in
Although other types of seam sensors can be provided, the seam sensor assemblies 244 are economical and function reliably with the bags 14. The seams 40 include U-shaped sewn projections as shown in
The operation of apparatus 10 and method of enveloping the bales 12 within bags 14 is further shown and described with reference to
As shown in
As shown in
A vacuum is then provided at all four of the vacuum and grip pin assemblies 174 such that the back wall portions 198 of the first bag wall 30 are drawn into the inlet openings 178 of the vacuum and grip pin assemblies 174LU and 174RU on the upper jaw 134U, and the back wall portions 198 of the second bag wall 32 are drawn into the inlet openings 178 of the vacuum and grip pin assemblies 174LL and 174RL, on the lower jaw 134L. The grip pins 194 are then extended or, more preferably, the upper and lower jaws 134U, 134L are partially retracted as shown and, thereafter, the grip pins 194 are extended for thereby securely holding the first bag wall 30 on the upper jaw 134U via the vacuum and grip pin assemblies 174LU and 174RU thereon and securely holding the second bag wall 32 on the lower jaw 134L via the vacuum and grip pin assemblies 174LL and 174RL thereon.
As shown in
The bag placer assembly 68 is then longitudinally traversed toward the form tube 66 thereby causing the form tube rear end to be inserted within the bag opening 258 as shown in
The grip fingers 122 are then again retracted disengaging the finger rubber tips 124 from the interior surface of the bag 14 and the bag placer assembly is further traversed longitudinally toward the form tube inlet end/front flared surface 78F thereby removing the fingers from within the bag 14 as shown in
As shown in
Referring now to
With the apparatus components as depicted in
Bag opening 258 can then be closed manually by folding over the closure bag flaps onto the bale rear end R and manually securing the flaps by stapling, sewing, heat sealing and/or with adhesives. Preferably, however, bag opening 258 is automatically closed with assembly 52 by automatically folding over the closure bag flaps onto the bale rear end R and automatically securing the flaps by heat sealing as described hereinbelow.
After the bale 12 has been inserted into the bag 14 as shown in
Thereafter, as shown in
Preferably, the closure bag flaps 262, 264L, 264R and 266 are heat sealed/fused automatically with the heat sealing assembly 156. In this regard, jaw 134U is extended for placing the heat sealing assembly 156 adjacent the closure bag flaps whereby heat can be applied and the closure bag flaps 262, 264L 264R and 266 sealed/fused to one another. In this regard, it has been found that, when bag 14 is made of thin polypropylene material, the application of heat to the closure bag flaps can create undesirable holes therethrough. So as to avoid this, as mentioned hereinabove selectively extendable slack bars 200L, 200R are provided on the left and right side flaps 222L, 222R. After the left and right side flaps 222L, 222R are pivoted and the left and right side closure bag flaps 264L, 264R are folded onto the bale rear end R as shown in
Accordingly, for heat sealing/fusing the closure bag flaps, jaw 134U is extended for placing the heat sealing assembly 156 adjacent the slack lines 268 and directing hot air from the manifold orifices 168 to the slack lines 268. When a sufficient amount of heat has been delivered, the press plates 170 are extended and pressed against the partially melted slack fines 268 of polypropylene thereby assuring that all of the closure bag flaps 262, 264L, 264R and 266 are heat sealed/fused together.
Finally, it is noted that, as the now closed bag 14 travels away from the assembly 52 on the output conveyor 64, the left and right side flaps 222L, 222R are pivoted toward the conveyor 64 and toward the position shown in
While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.
Claims
1. In an apparatus for enveloping bales of material with preformed bags having an open end and a closed end, an apparatus for closing a bag after a bale has been inserted into the bag through the open end while a bale and bag traverse along a longitudinal line of travel, said apparatus comprising:
- left and right side flaps, one on each side of said longitudinal line of travel, each of said side flaps being selectively rotatable generally about a vertical pivot axis whereby left and right bag closure flaps at the bag open end can be folded onto the bale therein;
- a bottom fold plate below said longitudinal line of travel being selectively rotatable generally about a horizontal pivot axis whereby a bottom closure flap at the bag open end can be folded onto the bale therein; and,
- a top fold bar above said longitudinal line of travel being selectively extendable into and retractable from said longitudinal line of travel whereby a top closure flap at the bag open end can be folded onto the bale therein.
2. The apparatus of claim 1 further comprising a heat seal manifold selectively moveable into said line of travel and adjacent the bag closure flaps whereby heat is provided to a portion of the closure flaps for joining them to one another.
3. The apparatus of claim 2 further comprising a selectively retractable and extendable press plate moveable into said line of travel and adjacent the bag closure flaps, said press plate being selectively extendable onto said closure flaps heated portion.
4. The apparatus of claim 3 further comprising a slack bar carried on each of said left and right side flaps.
5. The apparatus of claim 4 wherein the slack bars are selectively retractable and extendable.
6. The apparatus of claim 1 further comprising a slack bar carried on each of said left and right side flaps.
7. The apparatus of claim 7 wherein the slack bars are selectively retractable and extendable.
8. The apparatus of claim 1 wherein said bottom fold plate is selectively rotatable in a horizontal transition position whereat a bale and bag may traverse thereover.
9. In a method for enveloping bales of material with preformed bags having an open end and a closed end, a method of closing a bag after a bale has been inserted into a bag through the open end, wherein the bag is closed with a bag closing assembly as the bale and bag travel along a longitudinal line of travel;
- the bag closing assembly including left and right side flaps, one on each side of the longitudinal line of travel and wherein each of said side flaps are selectively rotatable generally about a vertical pivot axis; a bottom fold plate below said longitudinal line of travel being selectively rotatable generally about a horizontal pivot axis; a top fold bar above said longitudinal line of travel being selectively extendable into and retractable from said longitudinal line of travel;
- the bag open end having, adjacent the inserted bale, a lower closure bag flap, an upper closure bag flap and left and right closure bag flaps between said lower and upper flaps;
- wherein said method of closing the bag comprises the steps of:
- rotating said left and right fide flaps and folding said left and right closure flaps onto the inserted bale;
- extending said top fold bar and folding said top closure flap onto the inserted bale;
- rotating said bottom fold plate and folding said lower closure flap onto the inserted bale;
- retracting said top fold bar; and,
- securing at least two of said folded closure flaps to one another.
10. The method of claim 9 wherein, prior to said securing, a portion at least two of said closure flaps are folded over a slack bar thereby creating a slack portion.
11. The method of claim 10 wherein said step of securing comprises heating said slack portion for thereby joining said closure flaps to one another.
12. The method of claim 11 wherein said bag is made of polypropylene and during said step of heating the polypropylene material if fused thereby joining said closure flaps to one another.
13. The method of claim 12 wherein said bag is made of polypropylene and said step of securing comprises heating a portion of said closure flaps and fusing the polypropylene material thereof and thereby joining said closure flaps to one another.
14. The method of claim 12 further comprising, prior to said step of rotating said left and right closure flaps, rotating said bottom fold plate in a horizontal transition position whereat a bale and bag may traverse thereover.
15. In a method for enveloping bales of material with preformed bags having an open end and a closed end, a method of closing a bag after a bale has been inserted into the bag through the open end, the bag open end having, adjacent the inserted bale, a lower closure bag flap, an upper closure bag flap and left and right closure bag flaps between said lower and upper flaps, said method comprising the steps of:
- folding said left and right closure flaps onto the inserted bale;
- partially folding said lower closure flap toward the inserted bale;
- folding the said upper closure flap onto the inserted bale; and,
- further folding said lower closure flap onto the inserted bale and sandwiching a part of said upper closure flap between said lower closure flap and said inserted bate; and,
- securing at least two of said folded closure flaps to one another.
16. The method of claim 15 wherein said bag is made of polypropylene and said step of securing comprises heating a portion of at least two of said closure flaps and fusing the polypropylene material thereof and thereby joining said closure flaps to one another.
17. The method of claim 15 wherein, prior to said securing, a portion at least two of said closure flaps are folded over a slack bar thereby creating a slack portion.
18. The method of claim 17 wherein said step of securing comprises heating said slack portion for thereby joining said closure flaps to one another.
19. The method of claim 18 wherein said bag is made of polypropylene and during said step of heating the polypropylene material if fused thereby joining said closure flaps to one another.
Type: Application
Filed: Jun 7, 2013
Publication Date: Dec 11, 2014
Inventor: Chris Allen Honegger (Bluffton, IN)
Application Number: 13/912,414
International Classification: B65B 27/12 (20060101); B65B 51/10 (20060101);