METHOD AND APPARATUS FOR A PRODUCT SETTLER
A method and apparatus for settling a product in a package made on a form, fill and seal machine. In one aspect the invention comprises the steps: providing a package material on a product conduit of a form, fill and seal machine; forming a first end seal on the package material to form a partially formed package; filling the partially formed package with product; and settling the product in the partially formed package while continuously conveying the package material along the product conduit. In a second aspect, the invention comprises a product settler comprising a first object positioned to cause an impact against a package material. The impact agitates the package material and settles a product from an unsettled height to a settled height while the package material is continuously conveyed.
The present application is a continuation-in-part of and claims priority to U.S. Nonprovisional patent application Ser. No. 14/581,013, entitled “Method and Apparatus for a Product Settler,” filed Dec. 23, 2014, and published as US 2016/0176548 A1 on Jun. 23, 2016, and U.S. Nonprovisional patent application Ser. No. 14/581,110, entitled “Method and Apparatus for a Product Settler,” filed Dec. 23, 2014, and published as US 2016/0176549 A1 on Jun. 23, 2016, all of which are hereby incorporated by reference in their entirety as examples.
BACKGROUND OF THE INVENTION Technical FieldThe present invention relates to an apparatus and method for settling products in a package.
BackgroundMany foodstuffs, such as potato chips, are packaged in pillow pouch packages that are made using a form, fill and seal (“FFS”) machine. Typically, a form, fill and seal machine forms the film into a tube, seals the bottom of the tube, fills the partially sealed tube with product, and then seals the top of the tube to form a packaged product. Often, a form, fill and seal machine is oriented so that film travels in a direction that is generally vertical as the film is formed into a tube, filled with product and sealed. Such a machine is an example of a vertical form, fill and seal (“VFFS”) machine.
When the product being packaged is an irregularly shaped product such as potato chips, there can be large void spaces between each piece. The void space takes up volume in the package and requires the package to be larger than required for the product alone. This requires more resources, which is less environmentally friendly. It is also more expensive for producers and ultimately consumers.
To avoid these and other problems posed by void space, some form, fill and seal machines are fitted with product settlers. These settlers typically shake the product to make it settle into a more compact configuration and thereby reduce void space.
In addition to reducing void space in a product, it is desirable to package product more quickly. One way to increase the speed with which product is packaged is to increase the speed with which film is fed to the form, fill and seal machines. Other things being equal, continuously feeding film to a machine is faster than intermittently feeding film.
To take advantage of this principle, some machines, called continuous motion machines, are capable of running in a continuous mode in which film is continuously being advanced, as opposed to being paused intermittently. However, running a machine in continuous mode is incompatible with conventional settlers that grab or pinch the film. This is because grabbing or pinching will damage the film unless the film is paused.
Examples of conventional settlers that require a film to be paused include settlers with beater bars that grab and shake the film. Another conventional settler that requires film to be paused uses two swinging panels. The two panels are positioned below the product conduit and can rotate together like doors. When the panels come together, they pinch and seal off the film below the product conduit. After product falls on the closed panels, seal jaws come together to form an end seal on the film. This forms the bottom of a partially formed package. Then, the panels rotate open, which releases the film and allows the product to fall to the bottom of the partially formed package. This process of repeatedly dropping and catching the product causes the product to be settled. However, it can also damage the product by causing breakage, for example, of chips.
As these examples illustrate, when using conventional settlers, form, fill and seal machines must run in an intermittent mode in which the film is stopped when the settlers grab the film, and the film advances when the settlers release the film. As a result, many continuous motion machines do not even come with a settler. Other machines come with a settler that can be installed by a user, but the machine must then be run in an intermittent mode. Running machines in intermittent mode is inefficient and results in additional wear and tear on the machines and film. Thus, using a conventional settler with a continuous motion form, fill and seal machine can be undesirable.
Accordingly, it would be advantageous to have a settler that is compatible with a form, fill and seal machine running in continuous mode. For example, it is desirable to have a settler that does not grab film and can be used with a machine that continuously conveys the film. Such a settler would not require the film to be paused during production of packages. This could, in turn, avoid wear and tear on the machine and film caused by large transient forces that occur when starting and stopping the machine.
It would also be advantageous if an inventive settler could be used to produce product-filled packages more quickly than conventional settlers that require packaging film to be paused intermittently.
In addition, it would be desirable if the inventive settler reduced the volume that product occupies in a package. For example, it would be desirable if the settler reduced the volume occupied by a product at least as much as a conventional settler.
Furthermore, it would be desirable if an inventive settler could increase the head space in a package of a given size. For example, increased head space can help prevent product inside the package from being too close to, or caught in, the end seal of the package. This helps to ensure that the package is properly sealed. Increased head space can also help prevent other manufacturing defects, for example, unintended pleats and unintended tucks. It would be even more desirable if the inventive settler could increase head space and/or reduce manufacturing defects when compared to conventional settlers.
Likewise, it would be beneficial if the inventive settler did not break a substantial amount of product by impacting the product. For example, it would be beneficial if the settler were positioned so that it did not impact a substantial amount of the product through the packaging film. It would also be advantageous if the inventive settler could optionally be mounted somewhere besides the seal jaw carriage of a form, fill and seal machine. As another example, it would be beneficial if the inventive settler could operate intermittently or continuously. For example, it would be beneficial if the inventive settler could stop settling while the product is in a position to be damaged by the settler. However, after the product is no longer in such a position, the inventive settler would begin settling again.
Similarly, it would be desirable if the inventive settler decreased the amount of film required to package a given amount of product. This could help reduce waste, increase the environmental friendliness of a process, reduce manufacturing costs, and further increase the speed of a manufacturing process. For example, using a settler that can be used with a continuous motion form, fill and seal machine can increase the speed of a manufacturing process. Also, if the inventive settler could decrease the amount of film necessary to package a product, less film would need to be conveyed for a unit of product. This could further reduce the amount of time required to produce each unit.
In addition, it would be advantageous if the inventive settler did not interfere with the continuous motion of a package film when the inventive settler stopped. For example, it would be advantageous if the inventive settler had a low torque motor so that if the settler stopped running or even failed while the settler was in contact with a package film, the film could push the settler out of the path of the film, and the film could continue to be advanced. It would also be advantageous if the inventive settler could be stopped in a position where it does not impede the continuous conveyance of packaging film.
It would be another benefit if the inventive settler were simple compared to conventional settlers. For example, it would be beneficial if the inventive settler had fewer moving parts than conventional settlers, had a less complicated operating mechanism, and were easier to maintain, repair and/or replace. It would also be beneficial if the inventive settler required minimal training of or input from maintenance personnel.
Furthermore, it would be useful if the inventive settler were small compared to conventional settlers. For example, conventional settlers can have components that take up a large amount of space and it would be advantageous to avoid these components.
Additionally, it would be desirable if the inventive settler could be easily installed on existing form, fill and seal machines. For example, it would be desirable if the inventive settler were modular and could be easily added to existing continuous motion vertical form, fill and seal machines. It would also be useful if a modular form of the inventive settler were easier to maintain, repair, and/or replace than conventional settlers. For example, it would be desirable if an inventive settler needing maintenance could be easily removed from a continuous motion form, fill and seal machine and replaced with a recently serviced settler. It would also be desirable if the inventive settler were designed so that the form, fill and seal machine could run without needing to be substantially reconfigured if the inventive settler were removed and were not replaced. For example, the machine could be instructed to create bigger packages due to a lack of settling, but the machine would not require other reconfiguration. This could increase the versatility of a product manufacturing line and increase its resilience in the face of maintenance issues.
Similarly, it would be advantageous if a form, fill and seal machine were easier to maintain and repair when the inventive settler is used with the machine instead of a conventional settler. It would also be advantageous if the small size and location of the inventive settler made it easier to access and service the machine compared to conventional settlers. For example, the size and location of conventional settlers can block or substantially impede access to the seal jaw carriage of a form, fill and seal machine. In contrast, it would be advantageous if the inventive settler could be installed on one side of a machine making it easy to access the seal jaw carriage even when the inventive settler is installed. It would also be advantageous if the inventive settler could easily be removed in comparison to a conventional settler, for example, if the inventive settler were modular, as this would also increase the ease of servicing of form, fill and seal machine.
SUMMARY OF THE INVENTIONThe present invention is a method and apparatus for settling products. For example, the inventors have developed a new type of settler that can be used in conjunction with a form, fill and seal machine even when the machine is running in continuous mode.
In a first aspect, the invention provides a method for settling a product in a package made on a form, fill and seal machine. The method comprises the steps: providing a package material on a product conduit of a form, fill and seal machine; forming a first end seal on the package material to form a partially formed package; filling the partially formed package with product; and settling the product in the partially formed package while continuously conveying the package material along the product conduit.
In a second aspect, the invention provides an apparatus comprising an improved continuous motion form, fill and seal machine. The machine comprises a product conduit, a conveyor, and seal jaws. The conveyor is positioned to convey a package material that is wrapped around the product conduit, and the conveyor moves the package material along the product conduit. The seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package. The product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit, and the product conduit is positioned above the seal jaws. The improvement comprises a product settler comprising a first object positioned to cause an impact against the package material. The impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit.
In a third aspect, the invention provides a method for settling a product in a partially formed package. The method comprises the steps: providing a partially formed package; filling the partially formed package with a product; and settling the product in the partially formed package. The settling step comprises rotating a paddle wheel comprising at least one paddle against the partially formed package.
In a fourth aspect, the invention provides an apparatus comprising an improved product settler for settling product in a partially formed package. The improved product settler comprises a paddle wheel. The paddle wheel comprises at least one paddle that is positioned to cause an impact against the partially formed package. The impact agitates the partially formed package and thereby settles the product.
The invention described herein provides many advantages in its various embodiments. In one aspect, the invention provides a settler that is compatible with a form, fill and seal machine running in continuous mode. For example, it provides a settler that does not grab film and can be used with a machine that continuously conveys the film. Such a settler does not require the film to be paused during the production of packages. This, in turn, avoids large transient forces that occur when starting and stopping the machine and avoids associated wear and tear on the machine. In one embodiment, the inventive settler comprises a rotating paddle wheel with a paddle that impacts the film in substantially the same direction that the film is conveyed. Accordingly, in one embodiment, the inventive settler comprises paddles that intermittently contact the film and scrub the film in the film's direction of conveyance.
The inventive settler also can be used to produce product-filled packages more quickly than conventional settlers, which require packaging film to be paused intermittently.
In addition, the inventive settler can reduce the volume that product occupies in a package. For example, the settler reduces the volume occupied by a product at least as much as a conventional settler.
Furthermore, the inventive settler increases the head space in a package of a given size. For example, increased head space can help prevent product inside the package from being too close to, or caught in, the end seal of the package. This helps to ensure that the package is properly sealed. Increased head space can also help prevent other manufacturing defects, for example, unintended pleats and unintended tucks. Additionally, the inventive settler can increase head space and/or reduce manufacturing defects when compared to conventional settlers.
As another advantage, the inventive settler does not break a substantial amount of product by impacting the product. In one embodiment, the inventive settler causes little or no breakage of product. For example, the settler can be positioned so that the settler does not impact a substantial amount of the product through the packaging film when the settler is in operation. In one embodiment, the inventive settler can be mounted somewhere besides the seal jaw carriage of a form, fill and seal machine. For example, the settler can be positioned just below the product conduit of a form, fill and seal machine so that the settler does not impact a substantial amount of product as the product falls from the product conduit and into the packaging film. The inventive settler can also operate intermittently or continuously. For example, the inventive settler can stop settling while the product is in a position to be damaged by the settler. However, after the product is no longer in such a position, the inventive settler can begin settling again.
The inventive settler can also decrease the amount of film required to package a given amount of product. This helps reduce waste, increase the environmental friendliness of the process, reduce manufacturing costs, and further increase the speed of a manufacturing process. For example, the inventive settler can be used with a continuous motion form, fill and seal machine which increases the speed of a manufacturing process relative to using an intermittent machine. Also, although conventional settlers cannot be used with continuous motion machines, the inventive settler can. Accordingly, the inventive settler can decrease the amount of film necessary to package a product on a continuous motion machine. Since less film needs to be conveyed for a unit of product, this further reduces the amount of time required to produce each unit.
In addition, the inventive settler does not interfere with the continuous motion of a package film when the inventive settler stops. For example, the inventive settler has a low torque motor so that if the settler stops running or even fails while the settler is in contact with a package film, the film can push the settler out of the path of the film, and the film can continue to be advanced. As another example, the inventive settler can be stopped in a position where it does not impede the continuous conveyance of packaging film.
The inventive settler is also simple compared to conventional settlers. For example, compared to conventional settlers, the inventive settler has fewer moving parts, has a less complicated operating mechanism, is easier to maintain, is easier to repair and/or is easier to replace. The inventive settler also requires minimal training of and input from maintenance personnel.
Furthermore, the inventive settler is small compared to conventional settlers. For example, conventional settlers can have components that take up a large amount of space and the inventive settler advantageously avoids this.
Additionally, the inventive settler can be easily installed on existing form, fill and seal machines. For example, in one embodiment, the inventive settler is modular and can be easily added to existing continuous motion vertical form, fill and seal machines. Also, the inventive settler is easier to maintain, repair, and/or replace than conventional settlers. For example, a modular form of the inventive settler can be installed, uninstalled, and serviced with ease. As another example, the inventive settler can be easily removed from a continuous motion form, fill and seal machine and replaced with another inventive settler. Also, the inventive settler is designed so that the form, fill and seal machine can run without needing to be substantially reconfigured if the inventive settler is removed and is not replaced. For example, the machine can be instructed to create bigger packages due to a lack of settling, but the machine does not require other reconfiguration to continue producing product. Accordingly, the inventive settler increases the versatility of a product manufacturing line and increases its resilience in the face of maintenance issues.
Similarly, a form, fill and seal machine is easier to maintain and repair when the inventive settler is used with the machine instead of a conventional settler. In one embodiment, the small size and location of the inventive settler during operation make the machine easier to access and service when compared to machines using conventional settlers. For example, the size and location of conventional settlers can block or substantially impede access to the seal jaw carriage of a form, fill and seal machine. In contrast, the inventive settler can be installed on one side of a machine, rather than, for example, having components that are adjacent to opposite sides of the machine. For example, the inventive settler can comprise a paddle wheel that is positioned adjacent to one side of a product conduit of a form, fill and seal machine. Accordingly, when the inventive settler, as opposed to a conventional settler, is installed on a machine, it is easier to access the components (e.g., seal jaw carriage) of the machine. Furthermore, the inventive settler can easily be removed in comparison to a conventional settler. When the inventive settler is modular, this further increases the ease of servicing a form, fill and seal machine when compared to servicing a machine using a conventional settler.
Another benefit of the inventive settler is that it can be used to settle many different kinds of products. For example, the inventive settler is especially useful for settling larger or irregularly shaped products such as tortilla chips or potato chips. The settler is also useful for settling smaller or regularly shaped products such as Cheetos® cheese puffs. Although, when compared to larger or irregularly shaped products, smaller or regularly shaped products may experience less settling.
Other aspects, embodiments and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. The accompanying figures are schematic and are not intended to be drawn to scale. In the figures, each identical or substantially similar component that is illustrated in various figures is represented by a single numeral or notation. For purposes of clarity, not every component is labeled in every figure. Nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention.
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
Several embodiments of Applicant's invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures.
One embodiment of the invention will now be described with respect to
Second, in a longitudinal sealing step 104, the film 202 is sealed to form a longitudinal seal 402 (e.g. back seal) on a package 404.
Third, in a first end-sealing step 106, a first end seal 212a is formed on the film 202 to form a partially formed package (e.g., partially formed second package 404b in
Fourth, in a filling step 108, the partially formed package (e.g., partially formed package 404b) is filled with a product 302. An example of how a package 404b can be filled with product is illustrated in
Fifth, in a settling step 110, the product 302 in the package (see, e.g., partially formed second package 404b in
In some embodiments, the settled package film length 318 required for settled product is about 0.5 to about 1.0 inches shorter than the unsettled package film length 316 required for unsettled product. Accordingly, in some embodiment, the settler can reduce overall package lengths for a product by about 0.5 to about 1.0 inches.
In some embodiments, the settler 308 settles product 302 while the product is falling. In other embodiments, the settler 308 settles product 302 after the product has fallen. In some embodiments, the settler 308 settles product 302 while the product is falling and after the product has fallen. In some embodiments, the settler 308 comprises a paddle (e.g., one of a plurality of paddles 320a,b) that rotates in a rotational direction 322 so that when the paddle contacts the film 202, the paddle pushes the film generally in the direction of conveyance 306 of the film.
Sixth, in a second end-sealing step 112, a second end seal 212b is formed on the partially formed package 404b to form a package 404a. The second end seal 212b is located on a second face of the package (e.g., second end 416 of the first package 404a). This can be seen, for example, in
In the illustration shown in
In one embodiment, the settling step 110 comprises the step of intermittently contacting the package (e.g., the partially formed second package 404b in
In one embodiment, the settling step further comprises the step of intermittently applying a force to the film (e.g., by impacting or contacting the film) that does not pause the conveyance of the film. For example, the component of the force that is opposed to the conveyance of the film is not sufficient to pause the conveyance of the film.
In one embodiment, the settling step 110 further comprises the steps of continuously or intermittently rotating a paddle wheel 326 that comprises a paddle (e.g., paddle 320a or paddle 320b). The paddle is rotated into contact with the package (e.g., second package 404b in
In one embodiment, gas is directed into the partially formed package 404b. For example, some form, fill and seal machines 206 use pressurized gas to maintain positive pressure inside the package 404b. Such a machine can also be used in conjunction with the inventive settler. For example, when pressured gas is used, it can be directed in the fall direction 304 shown in
In one embodiment, gas is directed (e.g., in the fill direction 304) into the package (e.g., partially filled second package 404b in
In one embodiment, the paddle wheel 326 rotates continuously. In another embodiment, the paddle wheel 326 rotates intermittently. When the paddle wheel 326 rotates intermittently, the paddle (e.g. paddle 320a or paddle 320b) also rotates intermittently. In one embodiment, a paddle rotates intermittently in the sense that an actuator (e.g., motor 616 in
One embodiment of the invention will now be described with reference to
As seen in
As shown in the embodiment of
Generally speaking, because the inventive settler does not pause a package film, the number of packages per minute that a machine produces with the inventive settler is greater than the number of packages per minute that a machine produces when using a conventional settler. For example, the speed at which packages of product are produced can depend on the speed at which a film is conveyed for forming a package, the speed at which the package is filled with product, and any pause in conveying the film that is required to settle a product. If a package can be filled with product faster than the film can be conveyed into position to form a package, the limiting factor for producing a package of product is the speed at which the film is conveyed. Furthermore, if film speed is the limiting factor for the rate at which packages of a product can be manufactured, pausing the film during the activation of a conventional settler will further reduce the number packages per minute produced. Thus, when film speed is the limiting factor for a machine's rate of package production and settling is desired, settling with the inventive settler will result in an increased rate of package production when compared to settling with a conventional settler.
Accordingly, the product settler 308 is especially useful in conjunction with continuous, form, fill and seal machines because the product settler does not require the package film 202 to stop in order to settle product 302 in the package film. Although the product settler 308 has been described with reference to a continuous form, fill and seal machine, the product settler can also be used with machines that intermittently advance the package film 202. An example is any form, fill and seal machine that that stops or pauses the film 202 of a package 404a while the package 404a is being formed. Although a partially formed package has been described with reference to a package that has been made on a form, fill and seal machine, this is only an illustrative example.
As another example, the product settler can be used to settle product in a package that is open. For example, a partially formed package can be an open package and the formed package can be the closed package. Although using a product settler on a package that is open, but otherwise formed, may not result in savings related to package materials (e.g., film or paper), it can still provide other benefits. For example, it can decrease the size of the package and reduce costs associated with shipping, including secondary packaging costs for items such as shipping crates.
With reference to
An example of an object directly impacting the film is shown in
In some embodiments, a first object (e.g., paddle 320a) is positioned to intermittently and directly contact the package film 202 and the first object thereby agitates the product 302. In other embodiments, the first object (e.g., paddle 320a) is positioned to intermittently and directly contact a second object (e.g., the product conduit 204), and the second object contacts the product film 202 and thereby agitates the product 302.
As shown in
In one embodiment, the package film 202 comprises an impact face (e.g., back side 406 in
In one embodiment, the settler 308 is used with a form, fill and seal machine that further comprises a source of pressurized gas (e.g., compressor 224). In one embodiment, the source of pressurized gas 224 comprises a nozzle 226 to direct the pressurized gas into the package film 202. In one embodiment, the source of pressurized gas 224 is selected from the group consisting of a fan, a blower, or a centrifugal compressor.
In one embodiment, pressurized gas is used to provide pressure on the inside of the package film 202. This can be useful when a package film is not resilient enough on its own to move out of a deformed position (e.g., the deformed position illustrated in
As another example, in one embodiment, the package film 202 comprises an impact face 406 that is adjacent to the product settler 308. When the package film 202 is filled with the pressurized gas and hangs under the force of gravity, the impact face 406 defines a second position of the impact face. This position can be substantially similar to the first position of the impact face 406 described with reference to
For example, in one embodiment, the distance from the first tip 328 of a paddle 320a to the axle 602 of a paddle wheel 326 is about 2.5 inches and the axle of the paddle wheel is positioned about 0.5 inches from the impact face 406 of a package 202. Accordingly, when the paddle 320a rotates, the first tip 328 reaches past the original position of the impact face 406 by about 2.0 inches and the third distance is about 2.0 inches.
In one embodiment of an apparatus according to the invention, a package film 202 is wrapped around the product conduit 204. The apparatus can comprise a plurality of conveyors 214a,b positioned to convey the package film 202 along the product conduit 204 at substantially a single speed along a perimeter 218 of the packaging film. The product conduit 204 is selected, for example, from the group consisting of a tube, a chute, a duct, and a pipe.
In one embodiment illustrated in
The positional sensor 614 can be, for example, a camera or electromagnetic device. The positional sensor 614 can also be a proximity switch. For example, in one embodiment, the positional sensor 614 senses the presence or absence of a sensor target 622 (e.g., a magnet) within a given range of the positional sensor. In another embodiment, the positional sensor 614 senses a distance from the positional sensor 614 to the sensor target 622. For example, the sensor target 622 can move (e.g. rotate) with the paddle wheel 326 so that the position of the sensor target indicates the position of the paddle wheel. In another example, the position of a portion 624 (e.g., a magnet or discontinuity) of the sensor target indicates the position of the paddle wheel 326.
In one embodiment, the positional sensor 614 is used to position the paddle wheel 326 or a paddle (e.g., paddle 320a). For example, when the paddle wheel 326 is stopped, the paddle wheel can be stopped outside the path of a package film 202. This can be desirable because if the paddle wheel 326 is stopped in the path of the package film 202, the paddle wheel 326 will increase the resistance that must be overcome to convey the package film.
One embodiment of the invention will now be described with reference to
As shown, for example, in
With reference to
Turning back to
As can be seen in
As shown in
For example, in one embodiment, the adjustable mounts 604, 608, 512 can be used to move adjust the position of the product settler 308 in one, two, or three directions. For example, the first adjustable mount 604, second adjustable mount 608, and third adjustable mount 512 can be used to move or adjust the position of the product settler 308 in a first direction 606, second direction 610, or third direction 620, respectively. In one embodiment, the adjustable mounts 604, 608, 512 can be used to move or adjust the position of the product settler 308 in a plurality of mutually perpendicular directions (e.g., two or three). In other embodiments, the frame 618 does not comprise the adjustable mounts 604, 608, 512 and the frame is positioned in a desired location when it is installed on a form, fill and seal machine 206.
As shown in
One embodiment of the invention will now be described with reference to
In one embodiment shown in
The product settler 308, shown in
In the embodiment shown in
As can be seen in
Additionally, the product settler can be easily installed or uninstalled. For example, with reference to the embodiment shown in
Although the inventive product settler has been described by reference to use of a package made from film. The package material can be made from a film or some other form of material. For example, the inventive settler can be used with packages made from package materials of varying thicknesses. Furthermore, the package material can be, for example, paper, metal, metal oxides, polymer, or some combination thereof.
EXAMPLESIllustrative examples of the inventive settler and experiments involving the inventive settler will now be described.
Example 1An experiment was conducted to measure certain benefits of using the inventive product settler 308 described herein. A continuous motion vertical form, fill and seal machine 206 was fitted with the inventive settler 308. Then, the machine 206 was used to produce 13.0 oz packages 202 containing TOSTITOS® Restaurant Style Tortilla Chips. The machine 206 ran at a speed of about 26 packages per minute. The packages 202 were produced on a product conduit 204 (e.g., former) with a circular cross-section. The cross-section of the product conduit 204 had a diameter of about 10.5 inches, and accordingly the packages 202 had a diameter of about 10.5 inches while wrapped around the product conduit. The packages 202 had a length of about 15.75″ from the tip of a first end seal 212a to the opposite tip of a second end seal 212b. Each end seal 212a,b was approximately ⅜ inches long providing a total usable package length of about 15 inches. In other words, the length of the package 202 that could be filled with product was approximately 15 inches.
A first set of five packages 202 were produced on a machine 206 without using the inventive settler 308. The average package head space was about 1.3 inches and the average unsettled height 314 of the product was about 13.7 inches. A second set of five packages 202 were produced on the machine 206 with the inventive settler 308 activated. Using this set up, the average package head space was about 2.9 inches and the average settled height 312 of the product was about 12.1 inches. As can be seen, the inventive settler resulted in an average settling of about 1.6 inches, which is a settling fraction of at least about 0.116 relative to the unsettled height 314 of the product.
Additionally, the inventive settler reduced the average length of film required to package each unit of product by about 1.6 inches. For example, rather than increasing the head space in a package, the product settler could also have been used to maintain a given head space while decreasing the length of film required for the package. In this example, the length of film required to package each unsettled unit of product was 15.75 inches. Since the product settler resulted in settling of about 1.6 inches, the product settler could have reduced the length of film required by 1.6 inches. This is a film reduction fraction of at least 0.101 relative to the length of film required if no settler is used.
Breakage of product occurring with and without the inventive settler activated was substantially the same. The use of the inventive settler did not result in any statistically significant increase in the ratio of broken product to non-broken product in a package. In other words, any increase in breakage was within the margin of error for the experiment.
Table 1
Table 1 provides speeds in packages per minute at which an illustrative form, fill and seal machine can produce packages with a clamp on. All information in the table corresponds to a seal time of 70 milliseconds. In other words, the seal jaws press against the film for approximately 70 milliseconds to form package end seals. The table shows how package production speeds vary with bag length. As can be seen, increased package lengths result in lower package production speeds. This is because, given a fixed speed for conveying packages, longer packages require more time to be convey.
A method for settling a product 302 in a package 404 made on a form, fill and seal machine 206 will now be described with reference, for example, to
Turning to
-
- a. providing a package material (e.g., package film 202) on a product conduit 204 of a form, fill and seal machine 206;
- c. forming a first end seal 212a on the package material 202 to form a partially formed package (e.g., second package 404b in
FIG. 2 ); - d. filling the partially formed package 404b with the product 302; and
- e. settling the product 302 in the partially formed package 404b while continuously conveying the package material 202 along the product conduit 204.
It is contemplated that filling the partially formed package 404b with the product 302 can comprise filling the partially formed package 404b with a desired amount of product 302 or with an amount of product that provides the package 404 with a desired amount of headspace. Additionally, it is contemplated that the first end seal 212a can be formed approximately perpendicularly to a longitudinal seal 402 or the first end seal 212a can be formed within 30, 25, 20, 15, 10, or 5 degrees of perpendicular to the longitudinal seal 402.
In some embodiments, the method comprises at least one step selected from the group consisting of:
-
- b. sealing the package material 202 to form a longitudinal seal 402;
- f. forming a second end seal 212b on the partially formed package 404b to form a package 404 from the partially formed package 404b; and
- a combination thereof.
In some embodiments, the settling step comprises the steps:
-
- (i) pressurizing an interior of the partially formed package 404b to provide resistance; and
- (ii) intermittently contacting the partially formed package 404b to move the partially formed package 404b, thereby moving the product 302.
In some embodiments, the settling step comprises the steps:
-
- (i) rotating a paddle wheel 326 comprising a paddle 320a (or plurality of paddles 320a,b); and
- (ii) intermittently rotating the paddle 320a into contact with the partially formed package 404b, thereby moving the product 302 while the product 302 is inside the partially formed package 404b.
In some embodiments, an actuator 616 oscillates or rotates the paddle 320a and stops the paddle 320a in a desired position. This can be useful, for example, to avoid the paddle stopping in contact with a package material 202 or in the path of a package material, which could among other things, damage the packaging material or damage the actuator 616 if the film pushes the paddle, depending on the type of actuator used.
In some embodiments, the actuator 616 is characterized by a feature selected from the following group of features:
-
- (i) the actuator 616 is a motor 616;
- (ii) the actuator 616 is a stepper motor 616;
- (iii) the actuator 616 is programmable to change (e.g., increase or decrease) an oscillatory or rotational speed of the paddle 320a at a desired rate;
- (iv) the actuator 616 is programmable to control acceleration (e.g., increasing or decreasing rotational speed) of the paddle wheel 326;
- (v) the actuator 616 is programmable to select the position of the paddle 320a when the paddle 320a stops; and
- (vi) a combination thereof.
In some embodiments, the method comprises a step selected from the group consisting of:
-
- (i) using the actuator 616 to change (e.g., increase or decrease) an oscillatory or rotational speed of the paddle 320a at a first desired rate by changing an oscillatory or rotational speed of a component of the actuator 616 (e.g., rotor 516, drive shaft, piston, etc.), wherein the component of the actuator is linked to the paddle, and optionally using the actuator 616 to change the oscillatory or rotational speed of the paddle 320a at a second desired rate by changing the oscillatory or rotational speed of the component of the actuator 616;
- (ii) using the actuator 616 to control acceleration (e.g., increasing or decreasing rotational or oscillatory speed) of the paddle 320a, the plurality of paddles 320a,b, the paddle wheel 326, or a combination thereof;
- (iii) using the actuator 616 to stop the paddle 320a (or each of the plurality of paddles 320a,b) in a desired position (e.g., out of a path of the package material 202 or out of contact with the package material 202); and
- (iv) a combination thereof.
Several illustrative features of a product settler 308 will now be described with reference to
Next, as time progresses, the product settler 308 has moved into contact with the impact face 406 to displace the package material 202 by a first distance 330 in the horizontal direction. Accordingly, the impact face 406 of the package material 202 is in a second position 806.
Then, as time progresses, the product settler 308 has moved out of contact with the package material 202. However, a flow 812 of air created by the movement of the product settler 308 results in a force on the package material 202 that keeps the impact face 406 from returning to the first position 804. Rather, the impact face 406 of the package material 202 has moved to a third position 808. As can be seen, a horizontal displacement of the impact face 406 from the second position 806 to the third position 808 provides an amplitude 802 of vibration for the impact face 406 of the package material 202. As a result of the flow 812 of air created by the movement of the product settler 308, the amplitude 802 of vibration is less than it could be if the impact face 406 returned to the first position 804.
As time continues to progress, the product settler 308 has moved again into contact with the impact face 406 of the package material 202. Accordingly, the impact face 406 of the package material 202 is in a fourth position 810, which is similar to the second position 806, although it could be different if the paddles 320a,b of the product settler 308 were to have different lengths. Also, while not illustrated, the cycling of the impact face 406 between a position similar to the third position 808 and a position similar to the fourth position 810 can continue until the settling movement of the product settler 308 is stopped.
As explained with respect to the third position 808, as a result of the flow 812 of air created by the movement of the product settler 308, the amplitude 802 of vibration can be less than an amplitude 802 of vibration that would occur if the impact face 406 returned to the first position 804, or at least a position closer to the first position 804. Accordingly, in some embodiments, it is desirable to configure the product settler 308 so that it produces no more than a limited, specified flow 812 of air. This can be accomplished, for example, by including at least one aperture 536 in the product settler 308. In some embodiments, the at least one aperture is positioned in a rotating paddle 320a or plurality of paddles 320a,b that make up a paddle wheel 326. As a skilled person would understand after reading this disclosure, by reducing the flow 812 of air created by the movement of the product settler 308, the impact face 406 of the package material 202 can cycle between a position similar to the first position 806 and a position similar to the second position 806 rather than a position similar to the third position 808 and the fourth position 810. Advantageously, this results in a relatively larger amplitude 802 of vibration of the impact face 406 and can help to better settle product 302.
With reference again to
In some embodiments, a method described herein is characterized by one or more of the following features. First, with reference, for example, to
Second, with reference to
Third, with reference to
Fourth, with reference again to
Several illustrative features of a product settler 308 will now be described with reference to
An improved continuous motion form, fill and seal machine 206, will now be described with reference, for example, to
As illustrated in
With reference again to
The product conduit 204 of the machine 206 is positioned so that a product 302 passing through the product conduit 204 will enter the partially formed package 404b after exiting the product conduit 204. Additionally, the product conduit 204 is positioned above the seal jaws 216a-d.
With reference to
With further reference to
With reference to
With reference to
With reference to
With reference to
With reference to
For purposes of illustration, several features of a product settler 308 will now be described with reference to
With reference again to
As a skilled person would understand after reading this disclosure, some embodiments described herein include one or more of the following features. First, with reference to
Second, in some embodiments, no force transfer components (e.g., gears, belt, etc.) apart from the rotor 516 are used between the motor 616 and the paddle wheel 326.
Third, in some embodiments, the product settler 308 occupies less space than a reference product settler 308 that comprises the force transfer components.
Fourth, with reference to
Fifth, with reference to
Sixth, in some embodiments, the motor, the rotor 516, the paddle wheel 326 or a combination thereof fit within a volume equal to no more than and/or at least 2, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.9, 0.8, 0.7, 0.6, 0.6, 0.4, 0.3, 0.2, 0.1, 0.5, 0.1, 0.05, 0.04 cubic feet.
In some embodiments described herein, the motor 616 is characterized by a feature selected from the following group of features:
-
- (i) the motor 616 is a stepper motor 616;
- (ii) the motor 616 can be programmed to change (e.g., increase or decrease) oscillatory or rotational speed of the first object at a desired rate;
- (iii) the motor 616 can be programmed to provide more control over acceleration (e.g., increasing or decreasing rotational or oscillatory speed) of the at least one object (e.g., paddle 320a) or paddle wheel 326, to enable selecting the position of the at least one object when it stops; and
- (iv) a combination thereof.
For purposes of illustration, some features of a product settler 308 will now be described with reference to
In some embodiments, the plurality of paddles 320a-d are spaced around a paddle wheel 326 to provide a paddle spacing angle 1402a-d between each set of two adjacent paddles in the plurality of paddles 320a-d. Additionally, in some embodiments, the paddle spacing angle 1402a-d differs from a common angle 1404 by no more than a specified tolerance 1406a,b. As used in this context, the common angle is defined to equal 360 degrees divided by the number of paddles in the plurality of paddles 320a-d. With reference again to
In some embodiments, it can be useful for all of the paddle spacing angles to be approximately equal because, for example, this can help to provide a vibration of a package material 202 that is relatively constant in terms of the time between impacts of a paddle 320a (or other object) with the package material 202. Although, by way of comparison, it is also possible to create a vibration of a package material 202 that is less constant in terms of the time between impacts of a paddle 320a (or other object) with the package material, or in terms of the amplitude of the vibration caused by subsequent impacts. For example, this can be accomplished using a paddle wheel 326 with different paddle spacing angles, adjacent paddles with different lengths, or adjacent paddles configured to displace the package material 202 by different distances 330.
With reference, for example, to
With reference again to
Second, the at least one aperture 536 can be configured to avoid creating a flow 812 of air that pushes the package material 202 sufficiently far away from the paddle 320a during a rotation of the paddle 320a that the paddle 320a does not contact the package material 202 during the rotation.
Third, the at least one aperture 536 can be configured to avoid creating a flow 812 of air that pushes the package material 202 by more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1 inches from a hanging reference position (e.g., a first position 804) in which the package material 202 hangs under the force of gravity and any force of internal pressure (e.g., from a source of pressurized gas (e.g., compressor 224)),
Fourth, the at least one aperture 536 can be configured to avoid creating a flow 812 of air that prevents the package material 202 from returning to a hanging reference position (e.g., a first position 804) under the force of gravity and any force of internal pressure (e.g., from a source of pressurized gas (e.g., compressor 224)),
Fifth, the at least one aperture 536 can be configured so that the at least one aperture 536 (e.g., the aperture or the plurality of apertures) has a total aperture surface area equal to at least and/or no more than 30, 40, 50, 60, 70, 80, 85, 90, 95, 96, 97, 98, or 99% of a surface area of a leading surface 912 of the paddle 320a.
In some embodiments, the first object (e.g., paddle 320a) is rigid.
With reference to
In some embodiments, the first object (e.g., paddle 320a,b) is made from a material selected from the group consisting of metal, alloy, steel, polymer, plastic, resin, rubber, and wood.
With reference, for example, to
Although the inventive settler is described herein as being installed on specific embodiments of vertical form, fill, and seal machines, the inventive settler is not limited to being used with these machines. Rather, the inventive settler can be used, for example, with essentially any process where a product can be settled in a package. Although, the inventive settler is especially useful with processes where a film is being continuously advanced to form a package that is filled with product and then sealed. When used with such a process, the inventive settler can settle product within the film while the film is being continuously advanced. This is a substantial improvement over conventional settlers that require a film to pause intermittently for settling.
Additionally, while the product settler has generally be described in the form of a paddle wheel, some embodiments of the product settler for use with a form, fill and seal machine are also possible. For example, the product settler can be in the form of an object such as a rod that is positioned and actuated to intermittently impact a partially formed package and thereby settle product in the package. In some embodiments, the object can provide settling by contacting the partially formed package on one and only one face. In some embodiments, the object impacts the partially formed package more than 300 times per minute. In some embodiments, the object impacts the partially formed package more than 600 times per minute.
Furthermore, while the steps for particular embodiments of the invention have been described herein, a person skilled in the art would understand from the disclosure that the steps can be modified. For example, as appropriate, steps can occur at different times, steps can occur simultaneously or sequentially, the order of steps can be swapped or varied, certain steps can overlap even if they start at different times, and steps can be added or removed.
While this invention is particularly shown and described herein with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the elements described herein, in all possible variations thereof, is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. For example, various advantages of the invention can still be realized if additional elements are added to provide additional advantages or if certain elements are omitted because a particular feature is unnecessary or undesirable for a given application.
ADDITIONAL DISCLOSUREThe following clauses are offered as further description of the disclosed invention.
1. A method for settling a product in a package made on a form, fill and seal machine, the method comprising the steps:
-
- a. providing a package material on a product conduit of a form, fill and seal machine;
- c. forming a first end seal on the package material to form a partially formed package;
- d. filling the partially formed package with the product (e.g., with a desired amount of product or with an amount of product provides the package with a desired amount of headspace); and
- e. settling the product in the partially formed package while continuously conveying the package material along the product conduit.
2. The method of any preceding clause further comprising the step: - f. forming a second end seal on the partially formed package to form a package from the partially formed package.
3. The method of any preceding clause further comprising the step: - b. sealing the package material to form a longitudinal seal.
4. The method of clause 3, wherein the first end seal is approximately perpendicular to the longitudinal seal, or wherein the first end seal is within 30, 25, 20, 15, 10, 5 degrees of perpendicular to the longitudinal seal.
5. The method of any preceding clause, further comprising the step: - directing a gas into the partially formed package.
6. The method of clause 5, wherein the gas is directed into the partially formed package as a first jet of gas.
7. The method of clause 5 or 6, wherein the gas pressurizes an interior of the partially formed package.
8. The method of any preceding clause, wherein the settling step further comprises the steps: - pressurizing an interior of the partially formed package to provide resistance; and
- intermittently contacting the partially formed package to move the partially formed package, thereby moving the product.
9. The method of any preceding clause, wherein the settling step further comprises the steps:
rotating a paddle wheel comprising a paddle; and
intermittently rotating the paddle into contact with the partially formed package, thereby moving the product while the product is inside the partially formed package.
10. The method of clause 9,
-
- wherein the method is characterized by a feature selected from the group consisting of:
- wherein the paddle (or each of a plurality of paddles) comprises at least one aperture (e.g., slot or hole);
- wherein the paddle contacts the package once per rotation of the paddle;
- wherein a flow of air created by the rotation of the paddle (as opposed to contact with the paddle) pushes the package material by no more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1 inches from a hanging reference position (e.g., a first position) wherein the hanging reference position is a position of the package material when the package material hangs under the force of gravity and any force of internal pressure (e.g., from a source of pressurized gas (e.g., compressor)) and when the product settler is inactive and out of contact with the package material;
- wherein after impact by a paddle (or each of a plurality of paddles) the package material returns to a hanging reference position, wherein the hanging reference position is a position of the package material when the package material hangs under the force of gravity and any force of internal pressure (e.g., from a source of pressurized gas (e.g., compressor)) and when the product settler is inactive and out of contact with the package material; and
- a combination thereof.
11. The method of clause 9 or 10, wherein an actuator rotates the paddle and stops the paddle in a desired position.
12. The method of clause 11, wherein the actuator is characterized by a feature selected from the following group of features: - the actuator is a motor;
- the actuator is a stepper motor;
- the actuator is programmable to change (e.g., increase or decrease) oscillatory or rotational speed of the paddle at a desired rate;
- the actuator is programmable to control acceleration (e.g., increasing or decreasing rotational speed) of the paddle wheel;
- the actuator is programmable to select the position of the paddle when the paddle stops; and
- a combination thereof.
13. The method of claim 11 or 12, wherein the method further comprises a step selected from the group consisting of: - using the actuator to change (e.g., increase or decrease) an oscillatory or rotational speed of the paddle at a first desired rate by changing an oscillatory or rotational speed of a component of the actuator (e.g., rotor, drive shaft, piston, etc.), optionally wherein the component of the actuator is linked (e.g., mechanically, electromagnetically, or a combination thereof) with the paddle, and optionally using the actuator to change the oscillatory or rotational speed of the paddle at a second desired rate by changing the oscillatory or rotational speed of the component of the actuator oscillates or rotates;
- using the actuator to control acceleration (e.g., increasing or decreasing rotational or oscillatory speed) of the paddle, the plurality of paddles, the paddle wheel, or a combination thereof;
- using the actuator to stop the paddle (or each of the plurality of paddles) in a desired position (e.g., out of a path of the package material or out of contact with the package material); and
- a combination thereof.
14. The method of any preceding clause, wherein the settling step further comprises: - using the product settler to provide the package material with an amplitude of vibration equal to at least and/or no more than 3, 2.5, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1 inches.
15. The method of any of clauses 9-14, wherein the paddle does not bend by more than a specified bend tolerance during use (e.g., as a result of contact with the package material), wherein the specified bend tolerance is an angle measured in a plane that is perpendicular to the axis of rotation of the paddle wheel, wherein the specified bend tolerance is no more than 30, 20, 15, 10, 5, 4, 3, 2, or 1 degrees, and wherein the specified bend tolerance is measured for a leading surface of the paddle and from a proximal reference line to a distal reference line, wherein the proximal reference line is parallel to a proximal end of the paddle (e.g., end closer to an axis of rotation of the paddle wheel) and the distal reference line is parallel to a distal end of the paddle (e.g., end further from an axis of rotation of the paddle wheel).
16. The method of any preceding clause wherein the package material is a film.
17. An improved continuous motion form, fill and seal machine, said machine comprising a product conduit, a conveyor, and seal jaws; wherein the conveyor is positioned to convey a package material that is wrapped around the product conduit; wherein the conveyor moves the package material along the product conduit; wherein the seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package; wherein the product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit; and wherein the product conduit is positioned above the seal jaws; wherein the improvement comprises: - a product settler comprising a first object positioned to cause an impact against the package material;
- wherein the impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit.
18. The machine of any preceding clause, wherein the machine comprises a source of pressurized gas.
19. The machine of clause 18, wherein the machine comprises a nozzle and/or conduit to direct the pressurized gas into the package material.
20. The machine of any preceding clause, wherein the product settler comprises a controller to set a number of impacts per minute that the first object causes on the package material.
21. The machine of any preceding clause, wherein the product settler comprises a positional sensor to determine a position of the first object.
22. The machine of any preceding clause, wherein the impact occurs on one and only one face of the partially formed package.
23. The machine of any preceding clause, wherein the first object directly contacts the package material to cause the impact.
24. The machine of any preceding clause, wherein the impact against the package material occurs below the product conduit and above the unsettled height.
25. The machine of any preceding clause, wherein the product settler comprises a motor with sufficiently low torque that if the motor is deactivated (e.g., stopped, turned off, disengaged) while the first object is in contact with the package material, as the package material is conveyed, the package material will push the first object out of a path of the package material.
26. The machine of any preceding clause, wherein the product settler is modular.
27. The machine of any preceding clause, wherein the product settler comprises a frame that spatially fixes the product settler in relation to a path of the package material.
28. The machine of any preceding clause, wherein the product settler comprises a first adjustable mount to move the product settler in a first direction.
29. The machine of any preceding clause, wherein the settler is positioned so that, as the first object moves into contact with the package material, the first object will first contact the package material at a first point that is a second distance below the product conduit.
30. The machine of any preceding clause, wherein the product settler is positioned adjacent to the package material so that, as the first object moves into contact with the package material, the first object will contact the package material below the product conduit and above the unsettled height of the product.
31. The machine of any preceding clause: - wherein the seal jaws comprise a first seal jaw and a second seal jaw;
- wherein the first seal jaw rotates around a first axis of rotation;
- wherein the second seal jaw rotates around a second axis of rotation;
- wherein the first seal jaw, the first axis of rotation, the second seal jaw and the second axis of rotation are positioned so that, as the first seal jaw and the second seal jaw rotate, the first seal jaw and the second seal jaw come together to form the first end seal.
32. The machine of any preceding clause: - wherein the seal jaws comprise a third seal jaw and a fourth seal jaw;
- wherein the third seal jaw rotates around a first axis of rotation;
- wherein the fourth seal jaw rotates around a second axis of rotation;
- wherein the third seal jaw, the first axis of rotation, the fourth seal jaw and the second axis of rotation are positioned so that, as the third seal jaw and the fourth seal jaw rotate, the third seal and the fourth seal jaw come together to form a second end seal on the package material thereby forming a package.
33. The machine of any preceding clause, wherein the package material is a film.
34. The machine of any preceding clause, wherein the machine is a vertical form, fill and seal machine.
35. The machine of any preceding clause: - wherein the first object is a rotatable paddle wheel;
- wherein the paddle wheel comprises a paddle; and
- wherein the paddle is positioned so that, as the paddle wheel rotates, the paddle causes agitation of the package material and thereby settles the product.
36. The machine of clause 35, wherein the length of the paddle (as measured radially outward from an axis of rotation of the paddle wheel to a distal end of the paddle wheel) is (i) long enough to enable to the paddle to reach the package material and past the package material by at least and/or no more than 0.1, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5, or 2 inches, or (ii) is at least and/or no more than 0.1, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5, 2, 3 or 4 inches, or (iii) a combination thereof.
37. The machine of clause 35 or 36, wherein the product settler comprises: - a motor comprising a rotor, wherein the motor causes the rotor to rotate, optionally, wherein the rotor is or is not an axle for the paddle wheel, and optionally wherein an axis of rotation for the rotor and an axis of rotation for the paddle wheel are or are not concentric.
38. The machine of clause 37, - optionally, wherein the rotor is straight from the motor and along the portion of the rotor that acts as the axle for the paddle wheel;
- optionally, wherein no force transfer components (e.g., gears, belt, etc.) apart from the rotor are used between the motor and the paddle wheel;
- optionally wherein the product settler occupies less space than a reference product settler that comprises the force transfer components;
- optionally, wherein the motor, the rotor, the paddle wheel or a combination thereof fit (e.g, during operation) within a reference cylinder, wherein the reference cylinder has a reference cylinder radius of no more than and/or at least 8, 7, 6, 5, 4, 3, 2, 1.5, 1 or 0.5 inches, and wherein the reference cylinder has a reference cylinder height of no more than and/or at least 24, 20, 18, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, or 2 inches;
- optionally, wherein an axis of rotation for the rotor of the motor and an axis of rotation for the paddle wheel are concentric, and wherein a reference motor cylinder has a central axis that is concentric with the axis of rotation for the rotor and wherein the radius of the reference motor cylinder is the minimum radius that results in the reference motor cylinder being large enough to fully contain the motor (e.g., with no portion of the motor protruding outside the reference motor cylinder), and wherein a reference paddle wheel cylinder has a central axis that is concentric with the axis of rotation for the rotor and wherein the radius of the reference paddle wheel cylinder is the minimum radius that results in the reference paddle wheel cylinder being large enough to fully contain the paddle wheel (e.g., with no portion of the paddle wheel protruding outside the reference paddle wheel cylinder), and optionally wherein the reference paddle wheel cylinder is at least as large or larger than the reference motor cylinder or alternatively, or optionally wherein the reference motor cylinder is at least as large or larger than the reference paddle wheel cylinder;
- optionally wherein the motor, the rotor, the paddle wheel or a combination thereof fit (e.g., during operation) within a volume equal to no more than and/or at least 2, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.9, 0.8, 0.7, 0.6, 0.6, 0.4, 0.3, 0.2, 0.1, 0.5, 0.1, 0.05, 0.04 cubic feet; or
- a combination thereof.
39. The machine of any of clauses 37-38, wherein the motor is characterized by a feature selected from the following group of features: - the motor is a stepper motor;
- the motor can be programmed to change (e.g., increase or decrease) oscillatory or rotational speed of the first object at a desired rate;
- the motor can be programmed to provide more control over acceleration (e.g., increasing or decreasing rotational or oscillatory speed) of the at least one object (e.g., paddle) or paddle wheel, to enable selecting the position of the at least one object when it stops; and
- a combination thereof.
40. The machine of any one of clauses 35-39, wherein the paddle wheel comprises a plurality of paddles (e.g., no more than and/or at least four, three, or two paddles); - optionally, wherein the plurality of paddles are spaced around a paddle wheel to provide a paddle spacing angle between each set of two adjacent paddles in the plurality of paddles;
- optionally, wherein the paddle spacing angle differs from a common angle by no more than a specified tolerance, wherein the common angle is defined to equal 360 degrees divided by the number of paddles in the plurality of paddles, wherein the specified tolerance has a magnitude of no more than 45, 30, 25, 20, 15, 10, 5, 4, 3, 2 or 1 degrees.
41. The machine of any one of clauses 35-40, wherein the paddle (or each of a plurality of paddles) comprises at least one aperture; - optionally, wherein the at least one aperture is configured:
- to avoid creating a flow of air that pushes the package material away from the paddle,
- to avoid creating a flow of air that pushes the package material sufficiently far away from the paddle during a rotation of the paddle that the paddle does not contact the package material during the rotation,
- to avoid creating a flow of air that pushes the package material by more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1 inches from a hanging reference position in which the package material hangs under the force of gravity and any force of internal pressure (e.g., from a source of pressurized gas),
- to avoid creating a flow of air that prevents the package material from returning to a hanging reference position under the force of gravity and any force of internal pressure (e.g., from a source of pressurized gas),
- so that the at least one aperture (e.g., the aperture or the plurality of apertures) has a total aperture surface area equal to at least 30, 40, 50, 60, 70, 80, 85, 90, 95, 96, 97, 98, or 99% of the surface area of a leading surface of the paddle 320a; or
- a combination thereof.
42. The machine of any one of clauses 35-41:
- wherein the package material comprises an impact face;
- wherein the impact face is adjacent to the product settler;
- wherein, when the impact face of the package material hangs under a force of gravity, the impact face defines a first position;
- wherein the settler is positioned so that as the paddle wheel rotates, a first tip of the paddle will reach past (e.g., horizontally) the first position by a first distance; and
- wherein the first distance reaches a maximum of at least and/or no more than 0.25, 0.5, 1, 1.5, 2, 2.5 or 3 inches while the paddle wheel rotates.
43. The machine of any one of clauses 35-42, wherein the paddle wheel comprises a plurality of paddles.
44. The machine of any preceding clause, wherein the first object is characterized by at least one of the following features: - the first object (e.g., paddle) is rigid;
- the first object does not bend by more than a specified bend tolerance during use (e.g., as a result of contact with the package material), wherein the specified bend tolerance is no more than 30, 20, 15, 10, 5, 4, 3, 2, or 1 degrees, wherein the specified bend tolerance is measured from a proximal reference line to a distal reference line and measured in a plane perpendicular to the axis of rotation of the paddle wheel, wherein the proximal reference line is parallel to a proximal end of the first object (e.g., end closer to an axis of rotation of the paddle wheel), and wherein the distal reference line is parallel to a distal end of the first object (e.g., end further from an axis of rotation of the paddle wheel); and
- a combination thereof.
45. The machine of any preceding clause, wherein the first object comprises at least one aperture (e.g., to enable passage of air through the first object, to avoid a fan-like effect in which the first object causes air to move into contact with the package material and push the package material away from the first object).
46. The machine of any preceding clause, wherein the first object is made from a material selected from the group consisting of metal, alloy, steel, polymer, plastic, resin, rubber and wood.
47. A method for settling a product in a partially formed package, the method comprising the steps: - a. providing a partially formed package;
- b. filling the partially formed package with a product; and
- c. settling the product in the partially formed package;
- wherein the settling step comprises:
- rotating a paddle wheel comprising at least one paddle against the partially formed package.
48. The method of any preceding clause, further comprising the step:
- rotating a paddle wheel comprising at least one paddle against the partially formed package.
- g. closing the partially formed package to form a package.
49. The method of any preceding clause, further comprising the step: - h. directing a pressurized gas into the partially formed package.
50. The method of any preceding clause, wherein the paddle wheel rotates intermittently.
51. The method of any preceding clause, wherein the paddle wheel rotates continuously.
52. The method of any preceding clause, wherein the at least one paddle intermittently contacts the partially formed package.
53. The method of any preceding clause, wherein the partially formed package is provided on a form, fill and seal machine that intermittently conveys a package material along a product conduit.
54. The method of any preceding clause, wherein the partially formed package is provided on a form, fill and seal machine that continuously conveys a package material along a product conduit.
55. The method of any preceding clause, wherein the providing step further comprises the steps: - i. providing a package material on a product conduit of a form, fill and seal machine;
- iii. forming a first end seal on the package material to form the partially formed package.
56. The method of clause 55, wherein the providing step further comprises the step: - ii. sealing the package material to form a longitudinal seal.
57. The method of clause 55 or 56, further comprising the step: - f. forming a second end seal on the partially formed package to form a package from the partially formed package.
58. The method of any preceding clause, further comprising the step: - e. settling the product in the partially formed package while continuously conveying a package material along a product conduit.
59. The method of clause 56, 57 or 58: - wherein the first end seal is approximately perpendicular to the longitudinal seal.
60. An apparatus comprising an improved product settler for settling product in a partially formed package; wherein the improved product settler comprises: - a paddle wheel;
- wherein the paddle wheel comprises at least one paddle that is positioned to cause an impact against the partially formed package;
- wherein the impact agitates the partially formed package and thereby settles the product.
61. The apparatus of any preceding clause, wherein the apparatus further comprises a source of pressurized gas.
62. The apparatus of clause 61, wherein the apparatus comprises a conduit (e.g., nozzle) to direct the pressurized gas into the partially formed package.
63. The apparatus of any preceding clause, wherein the product settler comprises a controller to set a number of impacts per minute that the paddle wheel causes on the partially formed package.
64. The apparatus of any preceding clause, wherein the product settler comprises a positional sensor to determine the position of the paddle wheel.
65. The apparatus of any preceding clause, wherein the apparatus comprises a positional sensor to determine the position of the paddle wheel.
66. The apparatus of any preceding clause, wherein the impact occurs on one and only one face of the partially formed package.
67. The apparatus of any preceding clause, wherein the paddle wheel directly contacts the partially formed package to cause the impact.
68. The apparatus of any preceding clause, wherein the product settler comprises a motor with sufficiently low torque that if the motor turns off while the paddle wheel is in contact with the partially formed package, as the partially formed package is conveyed, the partially formed package will push the paddle wheel out of a path of the partially formed package.
69. The apparatus of any preceding clause, wherein the product settler is modular.
70. The apparatus of any preceding clause, wherein the product settler comprises a frame that spatially fixes the product settler in relation to a path of the partially formed package.
71. The apparatus of any preceding clause, wherein the product settler comprises a first adjustable mount to move the product settler in a first direction.
72. The apparatus of any preceding clause, wherein the paddle wheel comprises a plurality of paddles.
73. The apparatus of any preceding clause, wherein the apparatus comprises a form, fill and seal machine.
74. The apparatus of any preceding clause, wherein the apparatus comprises a form, fill and seal machine that advances film continuously along a product conduit.
75. An apparatus comprising at least one element selected from any of the preceding apparatus clauses, machine clauses, or a combination thereof.
76. A method comprising at least one element selected from any of the preceding method clauses, apparatus clauses, machine clauses or a combination thereof.
77. A method comprising elements selected from any of the preceding method clauses or a combination thereof, optionally, wherein the method comprises the apparatus of any of the preceding clauses, the machine of any of the preceding clauses, or a combination thereof, optionally, wherein the method is a method of using an apparatus or machine.
- wherein the method is characterized by a feature selected from the group consisting of:
Claims
1. A method for settling a product in a package made on a form, fill and seal machine, the method comprising the steps:
- a. providing a package material on a product conduit of a form, fill and seal machine;
- c. forming a first end seal on the package material to form a partially formed package;
- d. filling the partially formed package with the product; and
- e. settling the product in the partially formed package while continuously conveying the package material along the product conduit.
2. The method of claim 1 further comprising a step selected from the group consisting of:
- b. sealing the package material to form a longitudinal seal;
- f. forming a second end seal on the partially formed package to form a package from the partially formed package; and
- a combination thereof.
3. The method of claim 1, wherein the settling step further comprises the steps:
- pressurizing an interior of the partially formed package to provide resistance; and
- intermittently contacting the partially formed package to move the partially formed package, thereby moving the product.
4. The method of claim 1, wherein the settling step further comprises the steps:
- rotating a paddle wheel comprising a paddle;
- intermittently rotating the paddle into contact with the partially formed package, thereby moving the product while the product is inside the partially formed package.
5. The method of claim 4, wherein an actuator rotates the paddle and stops the paddle in a desired position.
6. The method of claim 5, wherein the method further comprises:
- using the actuator to change a rotational speed of the paddle at a first desired rate by changing a rotational speed of a component of the actuator, wherein the component of the actuator is linked to the paddle.
7. The method of claim 1, wherein the settling step further comprises:
- using a product settler to provide the package material with an amplitude of vibration of 0.1 to 3 inches.
8. The method of claim 4, wherein the paddle contacts the package once per rotation of the paddle.
9. The method of claim 4, wherein the paddle does not bend by more than a specified bend tolerance during use, wherein the specified bend tolerance is an angle measured in a plane that is perpendicular to the axis of rotation of the paddle wheel, wherein the specified bend tolerance is no more than 30 degrees, and wherein the specified bend tolerance is measured on a leading surface of the paddle and from a proximal reference line to a distal reference line, wherein the proximal reference line is parallel to a proximal end of the paddle, and wherein the distal reference line is parallel to a distal end of the paddle.
10. An improved continuous motion form, fill and seal machine, said machine comprising a product conduit, a conveyor, and seal jaws; wherein the conveyor is positioned to convey a package material that is wrapped around the product conduit; wherein the conveyor moves the package material along the product conduit; wherein the seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package; wherein the product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit; and wherein the product conduit is positioned above the seal jaws; wherein the improvement comprises:
- a product settler comprising a first object positioned to cause an impact against the package material;
- wherein the impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit.
11. The machine of claim 10, wherein the machine comprises a source of pressurized gas, and a conduit to direct the pressurized gas into the package material.
12. The machine of claim 10, wherein the impact occurs on one and only one face of the partially formed package.
13. The machine of claim 10, wherein the impact against the package material occurs below the product conduit and above the unsettled height.
14. The machine of claim 10, wherein the product settler comprises a motor with sufficiently low torque so that if the motor is deactivated while the first object is in contact with the package material, as the package material is conveyed, the package material will push the first object out of a path of the package material.
15. The machine of claim 10:
- wherein the first object is a rotatable paddle wheel;
- wherein the paddle wheel comprises a paddle; and
- wherein the paddle is positioned so that, as the paddle wheel rotates, the paddle causes agitation of the package material and thereby settles the product.
16. The machine of claim 15:
- wherein the package material comprises an impact face;
- wherein the impact face is adjacent to the product settler;
- wherein, when the impact face of the package material hangs under a force of gravity, the impact face defines a first position;
- wherein the product settler is positioned so that as the paddle wheel rotates, a first tip of the paddle will reach past the first position by a first distance; and
- wherein the first distance reaches a maximum of 0.25 to 3 inches while the paddle wheel rotates.
17. The machine of claim 15, wherein the product settler comprises:
- a motor comprising a rotor;
- wherein the motor causes the rotor to rotate; and
- wherein an axis of rotation for the rotor and an axis of rotation for the paddle wheel are concentric.
18. The machine of claim 17,
- wherein, in use, the motor, the rotor, and the paddle wheel fit within a reference cylinder, wherein the reference cylinder has a reference cylinder radius of no more than 8 inches and a reference cylinder height of no more than 24 inches.
19. The machine of claim 17, wherein the motor is a stepper motor.
20. The machine of claim 15, wherein the paddle wheel comprises a plurality of paddles;
- wherein the plurality of paddles are spaced around a paddle wheel to provide a paddle spacing angle between each set of two adjacent paddles in the plurality of paddles;
- wherein the paddle spacing angle differs from a common angle by no more than a specified tolerance;
- wherein the common angle is defined to equal 360 degrees divided by the number of paddles in the plurality of paddles; and
- wherein the specified tolerance has a magnitude of no more than 45 degrees.
21. The machine of claim 15, wherein the paddle comprises at least one aperture; and
- wherein the at least one aperture is configured so that the at least one aperture has a total aperture surface area equal to at least 30% of the surface area of a leading surface of the paddle.
22. The machine of claim 10, wherein the first object does not bend by more than a specified bend tolerance during use;
- wherein the specified bend tolerance is no more than 30 degrees;
- wherein the specified bend tolerance is measured from a proximal reference line to a distal reference line and measured in a plane perpendicular to the axis of rotation of the paddle wheel;
- wherein the proximal reference line is parallel to a proximal end of the first object; and
- wherein the distal reference line is parallel to a distal end of the first object.
23. The machine of claim 10, wherein the first object is made from a material selected from the group consisting of metal, alloy, steel, polymer, plastic, resin, rubber and wood.
24. The machine of claim 15, wherein the length of the paddle, as measured radially outward from an axis of rotation of the paddle wheel to a distal end of the paddle: (i) is long enough to enable to the paddle to reach the package material and past the package material by at least 0.5 inches, or (ii) is at least 0.5 inches.
Type: Application
Filed: Jun 22, 2017
Publication Date: Oct 5, 2017
Inventors: Eduard EDWARDS (Arlington, TX), Chad Arthur HUEBNER (Bedford, TX)
Application Number: 15/630,580