Packaging machine with independently controllable movers

Abstract

A packaging machine is provided for producing single and multiple compartment film wrapped pouches. Multiple linear motors allow aspects of the forming, filling, cutting and discharging to run at different speeds. The pouches are formed, filled and discharged from platens that are secured to movers that proceed through the packaging process by following magnetic fields created by independently controlled linear motors. Overall, cycle time is decreased as a result of speeding up parts of the process, including the platen return process, possible because there is no mechanical connection and not a single conveyor moving the platens while the other parts of the process may be simultaneously slowed down or even temporarily stopped. Changeover of platens, to accommodate different products, such as single compartment pouch to multiple compartment pouches, is also simplified because platens are simply connected to the movers and are thus easily removed and replaced.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]The applications claims the benefit of U.S. Provisional Patent Application 62 / 232,570 filed Sep. 25, 2015, which is hereby incorporated by reference.FIELD OF THE INVENTION[0002]The present invention relates to a packaging machine wherein a pouch is processed through multiple stages along a closed loop system using independently controllable movers.BACKGROUND OF THE INVENTION[0003]A vast array of chemical products are manufactured, packaged and distributed as pouches wrapped in film that can be broken down when desired to release the contents therein. The pouches are commonly referred to as sachets, packets, water soluble pouches, etc. In general, the film wraps an accurate quantity of the product and prevents it from reacting with chemicals found in the environment until the film is broken down. In this way, greater control is achieved over when a reaction occurs in addition to improving the accuracy of dosing realized because there is no ...

AI Technical Summary

Benefits of technology

The packaging machine described in this patent text is designed to improve flexibility and efficiency in the manufacturing process of pouches. It has multiple stages and movers that can move the pouch through the process faster or slower depending on the needs. The movers are independent, meaning they can operate without interfering with each other. The machine also has a replaceable mold for easy customization of the pouch design. Additionally, the machine allows for easy removal and replacement of the fill station for transferring fluid products into the pouch, without modifying other stages of the process. Overall, this machine aims to enhance production efficiency and flexibility while maintaining consistent quality.

Problems solved by technology

There are a number of disadvantages with prior art drum technology for pouch creation.

First and foremost, the drum necessarily always rotates at the same speed, and that speed is limited by the slowest stage of the process, the forming, filling, sealing, cutting and expulsion of the pouches.

The speed of the entire process, and the number of pouches it can produce, is limited by the speed limitation of the slowest stage (usually filling) and, in drum technology, the rest of the machine must run at the same speed.

There is a very limited amount of time in each step to perform the necessary processing function.

The flexibility of the rotary drum is very limited because the entire process is built around and defined by the diameter of the drum.

The capability to run different products with a single drum is very limited because the size of the drum is fixed, the speed of rotation is limited by the slowest stage, and changeover requires the complete replacement of the drum.

In addition to limited flexibility in changeover, the stage of filling pouches using drum technology has the serious limitation with respect to using multiple fills, as it is very difficult to fill more than a single product because of the limited period of time for the “filling” stage between 11:30 and 12:30 of the drum's rotation.

The speed of the drum is limited as well, because any spillage of the fill chemical results in poorly formed or sealed pouches that will fail.

In fact, spillage is a disaster for the pouch forming machine, because not only is the quality of the product compromised, but the machine has to be shut down and cleaned of the spillage.

Flatbed technology has a significant disadvantage of moving platens through the forming, feeling, sealing, cutting, discharge and return stations all at a single speed, limited by the speed of the slowest station, wherever that is.

Nonetheless, while flatbed technology does provide some improvement over the prior art, it still has disadvantages as a result of the continuous, endless conveyor that drives the molds and platens through the machine.

Thus, even current flatbed technology, while an improvement upon drum technology, still has a number of disadvantages and drawbacks.

The inclusion of a continuous, mechanically linked conveyor as the mover that carries the platens and molds through the pouch manufacturing process, has a number of limitations.

While the platens may be able to be changed, the changing of every link in a continuous mechanical conveyor is time consuming and complicated.

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