Dunnage conversion machine and method with auxiliary tear device

Abstract

A dunnage conversion machine includes a forming assembly configured to form a sheet of material into a dunnage strip and a feed assembly downstream of the forming assembly and configured to pull the sheet of material through the forming assembly. The machine also includes a tear assist assembly downstream of the feed assembly, the tear assist assembly including a clamp arm on one side of the path and a stop on an opposite side of the path opposite the clamp arm. The clamp arm is movable between a rest position, in which the clamp arm is positioned on one side of the path, and a clamp position, in which the clamp arm is positioned in the path to capture the dunnage strip between the clamp arm and the stop. The feed assembly is reversed when the clamp arm is in the clamp position to cause the dunnage strip to tear.

Description

Technical Field

[0001] This invention relates primarily to the field of padding conversion systems, and more specifically, to a padding conversion machine and method having a means for separating molded padding products. Technical Background

[0002] Protective packaging materials (cushioning products) are typically placed inside packaging containers along with the goods before they are transported from one location to another. Culling products are used to fill any gaps or cushion the goods during transport. Paper packaging materials are recyclable, biodegradable, and eco-friendly packaging materials composed of renewable resources. While sheet paper can be used as a protective packaging material, it is best to convert sheet paper into lower-density cushioning products.

[0003] Once converted in the padding conversion machine, discrete padding products are typically separated from the conversion machinery via a manual pulling process or a semi-automatic or automatic blade cutting mechanism within the machine. Manual tearing becomes difficult when the resulting padding product comprises multiple layers of sheets joined together. Furthermore, manual tearing is challenging when no perforations are provided in the areas requiring separation. The semi-automatic and automatic blade cutting mechanisms incorporated into the padding conversion machine are typically large, heavy, and expensive. Summary of the Invention

[0004] This application provides a padding conversion machine and method that uses a tearing aid assembly to improve upon previous manual tearing processes and semi-automatic or automatic blade cutting devices used for separating discrete padding products from the padding conversion machine. The padding conversion machine of the present invention includes: a forming assembly for forming sheet material into a padding strip; a feeding assembly for pulling the sheet material from a supply source and passing it through the forming assembly; and a tearing aid assembly cooperating with the feeding assembly to create a tear in at least a portion of the padding strip. Therefore, the tearing aid assembly facilitates the separation of discrete padding products from the padding strip for removal from the padding conversion machine without the need for a cutting blade.

[0005] Specifically, an exemplary padding converter includes a forming assembly configured to form sheet material into a padding strip with a lower density than the sheet material. The converter also includes a feed assembly downstream of the forming assembly, configured to pull the sheet material from a supply source, through the forming assembly, and advance the padding strip downstream along a path. The converter further includes a tearing aid assembly downstream of the feed assembly. The tearing aid assembly includes a clamping arm on one side of the path and a stop on the opposite side of the path. The clamping arm is movable between a rest position and a clamped position, wherein in the rest position the clamping arm is located on one side of the path and away from the path, and in the clamped position the clamping arm is located in the path to capture the padding strip between the clamping arm and the stop. The converter also includes a controller configured to control the operation of the converter.

[0006] The controller can be configured to operate the feed assembly in the feed direction to advance a desired length of padding strip in the downstream direction, and to stop the operation of the feed assembly in the feed direction after advancing the desired length of padding strip. The controller can also be configured to activate a tearing assist assembly to move the clamping arm from a rest position to a clamping position to capture the padding strip between the clamping arm and the stop at a capture point on the padding strip. The controller can then be configured to operate the feed assembly in the reverse direction opposite to the feed direction to reverse the upstream region of the padding strip upstream of the capture point in the upstream direction, thereby creating a tear in the padding strip. The controller can then be configured to stop the operation of the feed assembly in the reverse direction and deactivate the tearing assist assembly to move the clamping arm from the clamping position to a rest position, thereby releasing the padding strip between the clamping arm and the stop.

[0007] The feed assembly may include a pair of rotating members that cooperate to advance and reverse the padding strip along the path.

[0008] The controller can be configured to operate the feed assembly in the feed direction to cause a pair of rotating members to reach a first predetermined number of revolutions in order to advance a padding strip of desired length. Therefore, the controller can also be configured to stop the operation of the feed assembly in the feed direction after the pair of rotating members have rotated the first predetermined number of revolutions.

[0009] The controller can be configured to operate the feed assembly in the reverse direction, causing the pair of rotating members to rotate a second predetermined number of revolutions to reverse the upstream region of the padding strip upstream of the capture point in the upstream direction, thereby creating a tear in the padding strip. Therefore, the controller can also be configured to stop the operation of the feed assembly in the reverse direction after the pair of rotating members have rotated the second predetermined number of revolutions.

[0010] The controller can be configured to operate the feed assembly in the feed direction during a first predetermined time period to advance a padding strip of desired length. Therefore, the controller can also be configured to stop the operation of the feed assembly in the feed direction after the first predetermined time period has elapsed.

[0011] The controller can be configured to operate the feed assembly in the reverse direction during a second predetermined time period to reverse the upstream region of the padding strip in the upstream direction and create a tear in the padding strip. Therefore, the controller can also be configured to stop the operation of the feed assembly in the reverse direction after the second predetermined time period has elapsed.

[0012] The bedding conversion machine may also include a bedding production sensor configured to detect the length of the bedding strip that has been advanced in the downstream direction.

[0013] The tearing aid assembly may include a power device operatively coupled to the clamping arm and configured to move the clamping arm between a rest position and a clamping position.

[0014] The controller can be configured to activate the tearing assist assembly to move the clamping arm from the rest position to the clamping position by sending a capture signal to the power unit after the stop feed assembly has operated in the feed direction. The controller can also be configured to deactivate the tearing assist assembly to move the clamping arm from the clamping position to the rest position by sending a release signal to the power unit after the stop feed assembly has operated in the reverse direction.

[0015] Power equipment may include electric motors.

[0016] The feed assembly can be configured to connect two or more layers of the padding strip that are being advanced therebetween to form a connecting portion of the padding strip.

[0017] The tear-aid component can be configured to at least capture the joint portion of the padding strip, such that a tear is generated at least in the joint portion of the padding strip.

[0018] An exemplary method for manufacturing discrete padding products in a padding converter may include: forming a sheet material into a padding strip with a density lower than that of the sheet material, and advancing the padding strip of a desired length in a downstream direction along a path of the padding converter. The method may include capturing the padding strip at a capture point. The method may then include reversing an upstream region of the padding strip in an upstream direction opposite to the downstream direction to create a tear in the upstream region of the padding strip, thereby at least partially separating the discrete padding product from the padding strip. The upstream region is located upstream of the capture point. The method then includes releasing the padding strip at the capture point. The padding converter includes a tearing aid assembly comprising a clamping arm on one side of the path and a stop on the path opposite to the clamping arm. Therefore, the capture and release steps include moving the clamping arm between a rest position and a clamped position, wherein in the rest position the clamping arm is located on one side of the path and in the clamped position the clamping arm is located in the path.

[0019] The advancing step may include rotating a pair of rotating members in the feed direction for a first predetermined number of revolutions. The pair of rotating members rotating in the feed direction cooperate with each other to advance the pad belt in the downstream direction.

[0020] The reversing step may include rotating a pair of rotating members in the opposite direction for a second predetermined number of revolutions. The pair of rotating members rotating in the opposite direction cooperate with each other to reverse the padding strip in the upstream direction.

[0021] The implementation steps can occur within the first predetermined time period.

[0022] The reverse step can occur within a second predetermined time period.

[0023] The capture step may include activating the tear assist component to move the clamping arm from a rest position to a clamping position, thereby capturing the padding strip between the clamping arm and the stop at the capture point.

[0024] The release step may include deactivating the tear assist component to move the clamping arm from the clamping position to the rest position. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the bedding material conversion system;

[0026] Figure 2 This is a perspective view of a padding converter with a tearing aid assembly, wherein the clamping arm of the tearing aid assembly is in a stationary position;

[0027] Figure 3 yes Figure 2 A perspective view of a padding conversion machine, in which the clamping arm of the tearing aid assembly is in the clamping position;

[0028] Figure 4-7 yes Figure 1 A schematic diagram showing the operation sequence of the padding conversion machine, especially the tearing auxiliary component;

[0029] Figure 8 yes Figure 4-7 A schematic diagram illustrating an implementation of the tearing aid component. Detailed Implementation

[0030] The following describes in detail the padding material conversion machine and method of the present invention, which uses a tearing aid assembly to improve upon previous manual tearing processes and semi-automatic or automatic blade cutting devices used for separating discrete padding material products. The tearing aid assembly cooperates with the feed assembly in the padding material conversion machine to create a tear in at least a portion of the padding material strip formed in the padding material conversion machine without using a blade cutting device. Therefore, the tearing aid assembly of this application allows for convenient manual separation and removal of discrete padding material products from the padding material conversion machine.

[0031] Figure 1 A schematic padding converter 10 is shown, having a forming assembly 12 and a feeding assembly 14. The forming assembly 12 cooperates with the feeding assembly 14 to pull sheet material 22 from a supply source 20 and to convert the sheet material 22 into padding strip 24 as it travels downstream 30 through the padding converter 10. The padding converter 10 also includes a tearing aid assembly 16 located downstream of the feeding assembly 14, configured to assist in separating discrete padding products 28 from the substantially continuous padding strip 24 formed by the padding converter 10 without the need for cutting blades. The padding converter 10 includes a controller 32 for controlling the operation of the padding converter 10.

[0032] The supply source 20 of the sheet material 22 may include one or more layers of sheet material 22 supplied, for example, in the form of rolls or fan-fold stacks. Multiple rolls or stacks may be used to provide multiple layers of sheet material 22 for conversion. Paper is an environmentally friendly option for sheet material 22 because paper is generally recyclable, reusable, and composed of renewable resources. Therefore, exemplary sheet material 22 used in the padding converter 10 includes single or multiple layers of kraft paper supplied in rolls or as a series of connected rectangular sheets arranged in a fan-fold stack. Subsequent rolls or stacks may be spliced ​​to the end of previous rolls or stacks to provide sheet material 22 of continuous length to the padding converter 10.

[0033] A forming assembly 12, which pulls the sheet material 22 downstream in the direction 30, is configured to transform the planar sheet material 22 into a padding strip 24 having a three-dimensional shape with a smaller width dimension, a larger thickness dimension, and a lower density than the sheet material 22. For example, the forming assembly 12 may be configured to form and randomly wrinkle at least a portion of the sheet material 22. The forming assembly 12 may include a converging forming chute and a forming member, such as a forming frame, extending into the converging forming chute for forming the planar sheet material 22 into the padding strip 24. Specifically, the planar sheet material 22 may be fed into the forming member, located between the converging forming chute and the forming member, such that the side edges of the sheet material 22 rotate inward toward each other about the forming frame. When rotated inward, the sheet material 22 may randomly wrinkle, and the side edges of the sheet material 22 may gather together such that multiple layers overlap each other. However, the forming assembly is not limited to the forming assembly 12 described herein, but may be any other type suitable for forming a pad strip 24 having a three-dimensional shape with a lower density than the sheet material 22.

[0034] The feed assembly 14 is located downstream of the forming assembly 12 in the padding converter 10 and is configured to perform at least one function during the operation of the padding converter 10, typically two functions. One function is the feeding function. To perform the feeding function, the feed assembly 14 is configured to pull sheet material 22 from the supply source 20 and pass it through the forming assembly 12, thereby pulling padding strip 24 from the forming assembly 12. In doing so, the feed assembly 14 is also configured to feed a continuous stream of sheet material 22 from the supply source 20 through the forming assembly 12 in a downstream direction 30.

[0035] Another function of the feed assembly 14 can be a joining function. To perform the joining function, the feed assembly 14 can be configured to join at least a portion, such as overlapping side edges, of two or more overlapping layers in the padding strip 24 pulled from the forming assembly 12 to form a joined padding strip 24 downstream of the feed assembly 14. The portion of the two or more layers or overlapping layers in the padding strip 24 that are joined is referred to herein as the joining portion of the joined padding strip 24.

[0036] Feed assembly 14 is configured to advance padding strip 24 along path 46 of padding converter 10 to tearing aid assembly 16 located downstream of feed assembly 14. Tearing aid assembly 16 is configured to cooperate with feed assembly 14 to at least partially tear or otherwise separate at least a portion of padding strip 24 to assist in separating discrete padding products 28 of desired length from substantially continuous padding strip 24. Specifically, tearing aid assembly 16 is configured to capture padding strip 24 at a capture point on padding strip 24. Once padding strip 24 is captured, feed assembly 14 reverses its operation to at least partially tear or otherwise separate at least a portion of padding strip 24 upstream of the capture point. The capture point may be at least in the connecting portion of connected padding strip 24, such that a tear is created at least in the connecting portion of connected padding strip 24.

[0037] Controller 32 is configured to control the operation of the padding converter 10 and each of its components. Controller 32 may include a processor, memory, and a program stored in the memory. Controller 32 may also include one or more input devices, such as for determining the desired length of the padding strip 24, and one or more outputs, including outputs for controlling the elements of the padding converter 10. Input devices may be connected to or include one or more of a keyboard, mouse, touchscreen display, scanner or sensor, barcode reader, radio frequency identification (RFID) sensor, microphone, camera, etc. Controller 32 may be programmed to recognize appropriate inputs representing the desired length of the padding strip 24, or to identify locations where one or more lengths are needed to locate a particular packaging container.

[0038] Reference Figure 2 and Figure 3The exemplary feed assembly 14 and the exemplary tearing aid assembly 16 will now be described in more detail. Regardless of whether the feed assembly 14 has one or both feeding and connecting functions, the exemplary feed assembly 14 includes a pair of rotating members 40. The pair of rotating members 40 includes a first rotating member 42 and a second rotating member 44, which are spaced apart across a path 46 of the padding changer 10 through which the padding strip 24 travels. The pair of rotating members 40 cooperate with each other to advance the padding strip 24 downstream in a direction 30 along the path 46. In order to perform the feeding function, the pair of rotating members 40 progressively engage the padding strip 24 on opposite lateral sides of the padding strip 24 to pull the padding strip 24 through the forming assembly 12, thereby pulling the sheet material 22 from the supply source of the sheet material 20 and into the forming assembly 12. The first rotating member 42 and the second rotating member 44 each have a surface that provides sufficient friction to grip the padding strip 24, and may be knurled or have a rubber or other high-friction surface, for example, to provide the desired grip on the sheet material 22. The first rotating member 42 and the second rotating member 44 are preferably, but not necessarily, offset from each other to maintain grip on the padding strip 24 passing between them.

[0039] To perform the joining function, the pair of rotating members 40 can be configured to deform the padding strip 24 on its opposite sides to form a connecting portion of the joined padding strip 24. Specifically, the first rotating member 42 and the second rotating member 44 may alternatively be formed by a pair of meshing gears that wrinkle layers of sheet material 22 passing between them, or may cut the sheet material 22 to form one or more flaps that are displaced from the plane of adjacent portions of the sheet material 22, thereby maintaining the joined padding strip in its three-dimensional shape. For example, each of the first rotating member 42 and the second rotating member 44 may have interlaced teeth for deforming the padding strip 24 passing between them. By deforming the padding strip 24, the interlaced teeth mechanically interlock the multiple or overlapping layers of sheet material 22 in the padding strip 24 along the joining line, so that they are held together within the joined padding strip 24. This mechanical connection is different from chemical or adhesive bonding between multiple or overlapping layers. The first rotating member 42 and the second rotating member 44 can be configured to flatten, wrinkle, emboss, cut, stamp, or otherwise deform the sheet material 22 as it passes between them.

[0040] The tear assist assembly 16 includes a clamping arm 48 on one side of path 46 and a stop 50 on the opposite side of path 46. The stop 50 is opposite to the clamping arm 48 and provides a surface against which the clamping arm 48 can capture the padding strip 24. The stop 50 may include a plate or another clamping arm positioned on the side of path 46 opposite to the clamping arm 48. The stop 50 may be formed as part of a chute defining path 46 from an inlet adjacent to the feed assembly to an outlet downstream of the tear assist assembly.

[0041] Clamping arm 48 can be in a stationary position ( Figure 2 ) and clamping position ( Figure 3 Move between ( ). In a stationary position ( Figure 2 The clamping arm 48 is located on one side of the path 46, opposite and away from the stop 50, and outside the path 46, so as not to obstruct the passage of the padding strip through the path 46. Therefore, in the rest position of the clamping arm 48 ( Figure 2 As the padding belt 24 is advanced downstream 30 along path 46 via the feed assembly 14, the padding belt 24 is able to pass freely between the clamping arm and the stop 50. In the clamping position ( Figure 3 The clamping arm 48 is located in path 46 to capture the padding strip 24 passing between the clamping arm 48 and the stop 50. Therefore, in the clamping position ( Figure 3 The padding strip 24 can no longer pass freely between the clamping arm 48 and the stop 50 because the padding strip is captured at the capture point and held between them.

[0042] If the padding strip 24 includes connecting lines on which multiple layers of sheet material 22 are connected, then the clamping arms 48 and stops 50 are preferably positioned to engage the padding strip 24 at the connecting lines. If the strip padding 24 includes multiple connecting lines, the tear aid assembly 16 may include multiple pairs of clamping arms 48 and stops 50, which are positioned to engage the respective connecting lines.

[0043] The clamping arm 48 may be pivotally or rotatably mounted in the padding changer 10, such that the clamping arm 48 pivots or rotates between a rest position and a clamping position. Alternatively, the clamping arm 48 may be mounted in the padding changer 10 such that the clamping arm 48 moves linearly between a rest position and a clamping position. The movement of the clamping arm 48 is powered by a power device in at least one direction of movement. The clamping arm 48 may be spring-biased to a rest position and may be actively moved to the clamping position by a power device 58, the operation of which will be referred to below. Figure 8 A more comprehensive description.

[0044] Now refer to Figures 4 to 7The feeding assembly 14 and the tearing aid assembly 16 are described as cooperating to at least partially tear or otherwise separate at least a portion of the padding strip 24. Figure 4 As shown, controller 32 is typically configured to operate feed assembly 14 in feed direction 52 to advance a pad strip 24 of desired length along path 46 in downstream direction 30. Pad changer 10 may include pad production sensor 34 for detecting the length of the pad strip 24 that has been advanced. Pad production sensor 34 is connected to controller 32 and may be separate from or integrated into controller 32. Once the desired length of pad strip 24 has been advanced, controller 32 is configured to stop operation of feed assembly 14 in feed direction 52.

[0045] The controller 32 can be configured to operate the feed assembly 14 in the feed direction 52 for a first predetermined time period. In this embodiment, the padding changer 10 includes a timer 38 for determining the elapsed time period. The timer 38 is coupled to the controller 32 and can be separate or integrated into the controller 32. For example, the first predetermined time period can be selected as sufficient to advance the padding strip 24 to a desired length. After the first predetermined time period has elapsed, the controller 32 is configured to stop the operation of the feed assembly 14 in the feed direction 52.

[0046] Alternatively, controller 32 may be configured to operate feed assembly 14 in feed direction 52 to bring a pair of rotating members 40 to a first predetermined number of revolutions. In this embodiment, padding changer 10 may include rotation counter 31 for determining the number of revolutions the pair of rotating members 40 has made. Rotation counter 31 is coupled to controller 32 and may be separate or integrated into controller 32. For example, the first predetermined number of revolutions may be selected as sufficient to advance padding strip 24 to a desired length. After the pair of rotating members 40 has made the first predetermined number of revolutions, controller 32 is configured to stop operation of feed assembly 14 in feed direction 52.

[0047] like Figure 5 As shown, after the padding strip 24 has been advanced to the desired length, the controller 32 is configured to stop the operation of the feed assembly 14 in the feed direction 52, as previously described. Then, the converter 32 is configured to activate the tear assist assembly 16 to move the clamping arm 48 from the rest position ( Figure 2 and 4 Move to the clamping position. Figure 3 and 5 This allows the padding strip 24 between the clamping arm 48 and the stop 50 to be captured at the capture point 54.

[0048] Continue to refer to Figure 6Once the tearing assist assembly 16 is activated to capture the padding strip 24 between the clamping arm 48 and the stop 50, the controller 32 is configured to operate the feed assembly 14 in a reverse direction 53, opposite to the feed direction 52. The padding changer 10 may include a clamping arm activation sensor 51 for detecting that the clamping arm 48 is in the clamping position. When the clamping arm activation sensor 51 detects that the clamping arm 48 is in the clamping position, the controller 32 instructs the feed assembly 14 to operate in the reverse direction 53. In this way, the controller 32 is configured to operate the feed assembly 14 in the reverse direction 53 only when the clamping arm 48 is in the clamping position.

[0049] The controller 32 is configured to operate the feed assembly 14 in a reverse direction 53 to at least partially tear or otherwise separate at least a portion of the padding strip 24. For example, when the padding strip 24 is caught at the capture point 54 between the clamping arm 48 and the stop 50, operating the feed assembly 14 in the reverse direction 53 pulls the upstream portion of the padding strip 24 (i.e., the portion of the padding strip 24 upstream of the capture point 54) in an upstream direction 31 opposite to the downstream direction 30. This causes a tear 56 to be created in the padding strip 24 in the upstream portion. In embodiments where the padding strip 24 includes a connecting portion, the capture point 54 is preferably at least in the connecting portion, such that the tear 56 is created at least in the connecting portion, where manually separating the padding product from the padding strip 24 may be more difficult. The tear 56 is at least a partial tear.

[0050] The controller 32 can be configured to operate the feed assembly 14 in the reverse direction 53 using a timer 38 for a second predetermined time period. The second predetermined time period can be selected to be sufficient to reverse the padding strip 24 to a point sufficient to create a tear 56 in the padding strip 24. After the second predetermined time period has elapsed, the controller 32 is configured to stop the operation of the feed assembly 14 in the reverse direction 53.

[0051] Alternatively, controller 32 can be configured to operate feed assembly 14 in the reverse direction 53 to bring the pair of rotating members 40 to a second predetermined number of revolutions. For example, the second predetermined number of revolutions can be selected to be sufficient to reverse the padding strip 24 to a point sufficient to create a tear 56 in the padding strip 24. After the pair of rotating members have rotated the second predetermined number of revolutions, controller 32 is configured to stop the operation of feed assembly 14 in the reverse direction 53.

[0052] like Figure 7 As shown, after tear 56 is generated, controller 32 is configured to stop the operation of feed assembly 14 in the reverse direction 53, as previously described. Then, converter 32 is configured to deactivate tear assist assembly 16 to move clamping arm 48 from the clamping position ( Figure 3 , 5 and 6) Move to a stationary position ( Figure 2 , 4 (and 7), thereby releasing the padding strip 24 between the clamping arm 48 and the stop 50.

[0053] Reference Figure 8 Clamping arm 48 is in the stationary position ( Figure 2 , 4 and 7) and clamping position ( Figure 3 , 5 At least one direction of movement between (6) and (7) is driven by a power device 58. The power device 58 may include a low-torque, high-speed electric motor, pneumatic motor, hydraulic motor, solenoid, or any other device capable of moving the clamping arm 48 relative to the stop 50. The power device 58 can move the clamping arm 48 in both directions, or it may use a spring or other biasing device to move the clamping arm 48 in one direction. The power device 58 is operatively coupled to the controller 32 and the clamping arm 48, and is configured to cause the clamping arm 48 to be in a rest position ( Figure 2 , 4 and 7) and clamping position ( Figure 3 , 5 The controller 32 is configured to activate the tearing assist assembly 16 to move the clamping arm 48 from the rest position (6) after the operation of the stop feed assembly 14 in the feed direction 52. Figure 2 , 4 7) Move to the clamping position ( Figure 3 , 5 And 6). Controller 32 is configured to deactivate tear assist assembly 16 to move clamping arm 48 from the clamping position after operation of stop feed assembly 14 in the reverse direction 53. Figure 3 , 5 and 6) Move to a stationary position ( Figure 2 , 4 and 7).

[0054] This application will now describe a method for manufacturing discrete padding products in a padding conversion machine, such as using padding conversion machine 10 and its various components, as previously described herein. The method includes the step of forming a padding strip with a lower density than the padding material. The method includes the step of advancing the padding strip of a desired length downstream along the path of the padding conversion machine. This advancing step may be stopped after the padding strip of the desired length has been advanced.

[0055] The method may also include a step of detecting that the padding strip has been advanced to the desired length. This advancement step may stop after the step of detecting that the padding strip has been advanced to the desired length has been completed.

[0056] The advancement step can occur within a first predetermined time period. Therefore, the method may also include a step of detecting that the first predetermined time period has elapsed. After detecting that the first predetermined time period has elapsed, the advancement step can be stopped.

[0057] The propulsion step may include causing a pair of rotating members, such as those previously referenced. Figure 2 and Figure 3 The described rotating members rotate a first predetermined number of revolutions in the feed direction. These rotating members, rotating in the feed direction, cooperate with each other to advance the padding strip in the downstream direction. Therefore, the method may further include a step of detecting that the pair of rotating members has rotated the first predetermined number of revolutions in the feed direction. Then, after detecting that the pair of rotating members has rotated the first predetermined number of revolutions in the feed direction, the advancing step can be stopped. The advancing step may also include connecting multiple layers, particularly by the rotating members connecting multiple layers in the connecting portion of the padding strip.

[0058] The method also includes the step of capturing a pad strip of the desired length at the capture point. As previously described, the pad conversion machine 10 includes a tearing aid assembly 16. Figure 3 The tear-assist assembly includes a clamping arm on one side of the path and a stop on the opposite side of the path. Therefore, the capture step may include activating the tear-assist assembly to move the clamping arm from a rest position to a clamped position. As previously described, in the rest position, the clamping arm is located on one side of the path, while in the clamped position, the clamping arm is located in the path to capture a desired length of padding strip between the clamping arm and the stop at the capture point. In one embodiment, the capture step includes engaging a connecting portion, and may only engage the connecting portion to create a tear in the connecting portion.

[0059] The method then includes, after the capture step, a step of reversing the upstream region of the padding strip of the desired length in an upstream direction opposite to the downstream direction. The upstream region of the padding strip of the desired length is upstream of the capture point. The reversal step creates a tear in the padding strip to at least partially separate the discrete padding product from the padding strip of the desired length.

[0060] The reversal step can occur within a second predetermined time period. Therefore, the method includes stopping the reversal step after the second predetermined time period has elapsed.

[0061] Alternatively, the reversing step may include rotating the pair of rotating members a second predetermined number of revolutions in the opposite direction. The pair of rotating members, rotating in the opposite direction, cooperate to reverse the direction of the padding strip in the upstream direction. Therefore, the method may also include a step of detecting that the pair of rotating members have rotated the second predetermined number of revolutions in the opposite direction. Then, after detecting the second predetermined number of revolutions in the opposite direction, the reversing step may be stopped.

[0062] The method also includes a step of releasing the padding strip of the desired length at the capture point after the reversal step. The release step may include deactivating the tear assist assembly to move the clamping arm from the clamped position to a rest position. The method may also include a step of separating the discrete padding product from the padding strip of the desired length. This advancing step may be a first advancing step, and the method may further include a second advancing step following this step, or releasing the padding strip of the desired length after the reversal step. If the reversal step does not completely separate the discrete padding product from the padding strip, the user may manually separate the discrete padding product from the padding strip after the reversal step.

[0063] Therefore, the padding conversion machine and the method of operating the padding conversion machine include a tearing aid assembly for creating a tear in at least a portion of the padding strip passing through it without using a cutting blade. The tearing aid assembly improves upon the manual tearing process and blade cutting equipment previously used in conventional padding conversion machines for separating discrete padding products. Using a padding conversion machine including the tearing aid assembly, the padding strip can be formed from sheet-like raw material, and discrete padding products can be separated from the padding strip without the need for additional cutting blades. If the padding strip is only partially torn, preferably at least in the connecting line if present, the discrete padding products can be easily separated manually from the padding strip.

[0064] In summary, the exemplary padding converter 10 includes a forming assembly 12 configured to form sheet material 22 into a padding strip 24 with a lower density than the sheet material 22. The padding converter 10 also includes a feed assembly 14 downstream of the forming assembly 12, configured to pull the sheet material 22 from the supply source 20 through the forming assembly 12 and advance the padding strip 24 downstream in a downstream direction 30 along a path 46. The padding converter 10 also includes a tearing aid assembly 16 downstream of the feed assembly 14. The tearing aid assembly 16 includes a clamping arm 48 on one side of the path 46 and a stop 50 on the side of the path 46 opposite to the clamping arm 48. The clamping arm 48 is movable between a rest position and a clamped position, wherein in the rest position, the clamping arm 48 is located on one side of the path 46 and away from the path 46, and in the clamped position, the clamping arm is located in the path 46 to capture the padding strip 24 between the clamping arm 48 and the stop 50. The padding converter 10 also includes a controller 32 configured to control the operation of the padding converter 10. When the clamping arm 48 is in the clamped position, the reverse feed assembly 14 causes the strip padding 24 to tear.

[0065] Although the invention as defined by the appended claims has been shown and described with respect to specific embodiments, equivalent substitutions and modifications will be made by those skilled in the art upon reading and understanding this specification and the accompanying drawings. In particular, with respect to the various functions performed by the foregoing entities (components, assemblies, devices, compositions, etc.), unless otherwise stated, the terminology used to describe these entities (including references to “device”) is intended to correspond to any entity performing the specified function of said entity (i.e., functionally equivalent), even if structurally not equivalent to the disclosed structures performing the functions of the exemplary embodiments of the invention shown herein. Furthermore, although a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, this feature can be combined with one or more other features of other embodiments, which is desirable and advantageous for any given or particular application.

Claims

1. A pad material conversion machine, characterized in that, include: A forming assembly configured to form a sheet material into a pad strip with a lower density than the sheet material; A feeding assembly located downstream of the forming assembly is configured to pull the sheet material through the forming assembly and advance the padding strip along a path in a downstream direction. A tearing aid assembly located downstream of the feed assembly includes a clamping arm on one side of the path and a stop on the opposite side of the path, opposite to the clamping arm. The clamping arm is movable between a rest position and a clamped position, wherein in the rest position the clamping arm is located on one side of the path, and in the clamped position the clamping arm is located in the path to capture the padding strip between the clamping arm and the stop. as well as A controller configured to control the operation of the padding converter; The feeding assembly is configured to connect two or more layers of the padding strip being advanced therebetween to form a connecting portion of the padding strip; and the tearing aid assembly is configured to capture at least the connecting portion of the padding strip such that a tear is generated at least in the connecting portion of the padding strip.

2. The pad material conversion machine according to claim 1, characterized in that, The controller is configured to: The feed assembly is operated in the feed direction to advance the pad strip of the desired length in the downstream direction; After the padding strip has been advanced to the desired length, the operation of the feeding assembly in the feeding direction is stopped; Activate the tearing aid assembly to move the clamping arm from the rest position to the clamping position to capture the padding strip between the clamping arm and the stop at the capture point on the padding strip; The feed assembly is operated in the opposite direction to the feed direction to reverse the upstream region of the padding strip upstream of the capture point in the upstream direction, thereby creating the tear in the padding strip; After the tear has been formed, the operation of the feed assembly in the reverse direction is stopped; as well as Deactivate the tearing aid assembly to move the clamping arm from the clamping position to the rest position to release the padding strip between the clamping arm and the stop.

3. The pad material conversion machine according to claim 2, characterized in that: The feeding assembly includes a pair of rotating members that cooperate with each other to advance and reverse the padding strip along the path.

4. The pad material conversion machine according to claim 3, characterized in that: The controller is configured to operate the feed assembly in the feed direction to cause the pair of rotating members to reach a first predetermined number of revolutions to advance a padding strip of desired length, and to stop the operation of the feed assembly in the feed direction after the pair of rotating members have rotated the first predetermined number of revolutions.

5. The pad material conversion machine according to claim 3, characterized in that: The controller is configured to operate the feed assembly in the reverse direction, causing the pair of rotating members to reach a second predetermined number of revolutions, thereby reversing the upstream region of the padding strip upstream of the capture point in the upstream direction, thus creating the tear in the padding strip, and stopping the operation of the feed assembly in the reverse direction after the pair of rotating members have rotated the second predetermined number of revolutions.

6. The pad material conversion machine according to claim 2, characterized in that: The controller is configured to operate the feed assembly in the feed direction during a first predetermined time period to advance a padding strip of desired length in the downstream direction, and to stop the operation of the feed assembly in the feed direction after the first predetermined time period has elapsed.

7. The pad material conversion machine according to claim 2, characterized in that: The controller is configured to operate the feed assembly in the reverse direction during a second predetermined time period to reverse the upstream region of the padding strip in the upstream direction and create a tear in the padding strip, and to stop the operation of the feed assembly in the reverse direction after the second predetermined time period has elapsed.

8. The pad material conversion machine according to any one of claims 1-7, characterized in that: It also includes a pad production sensor, which is configured to detect the length of the pad strip that has been advanced in the downstream direction.

9. The pad material conversion machine according to any one of claims 1-7, characterized in that: The tearing aid assembly includes a power unit operatively connected to the clamping arm and configured to move the clamping arm between the rest position and the clamping position.

10. The pad material conversion machine according to claim 9, characterized in that: The controller is configured to, after stopping the operation of the feed assembly in the feed direction, activate the tearing assist assembly by sending a capture signal to the power device to move the clamping arm from the rest position to the clamping position, and the controller is configured to, after stopping the operation of the feed assembly in the reverse direction, deactivate the tearing assist assembly by sending a release signal to the power device to move the clamping arm from the clamping position to the rest position.

11. A method for manufacturing discrete pad products in a pad conversion machine, characterized in that, The method includes the following steps: Forming sheet materials into padding strips with a lower density than sheet materials; The pad strip of the desired length is advanced downstream along the path of the pad conversion machine; Capture the padding strip at the capture point; and Reverse the upstream region of the padding strip located upstream of the capture point in an upstream direction opposite to the downstream direction to create a tear in the upstream region of the padding strip, thereby at least partially separating the discrete padding product from the padding strip; and Release the padding strip at the capture point; The padding material conversion machine includes a tearing aid assembly, which comprises a clamping arm on one side of the path and a stop on the side of the path opposite to the clamping arm; and The capture and release steps include moving the clamping arm between a rest position and a clamping position, wherein the clamping arm is located on one side of the path in the rest position and in the clamping position the clamping arm is located in the path; The advancing step includes rotating a pair of rotating members along the feed direction a first predetermined number of revolutions to pull the padding strip therebetween, wherein the pair of rotating members rotating along the feed direction cooperate with each other to advance the padding strip along the downstream direction to connect two or more layers of the padding strip advancing between the pair of rotating members, thereby forming a connecting portion of the padding strip; and the capturing step includes capturing at least the connecting portion of the padding strip such that a tear is generated at least in the connecting portion of the padding strip during the reversing step.

12. The method according to claim 11, characterized in that: The advancing step includes rotating a pair of rotating members along the feed direction a first predetermined number of revolutions, wherein the pair of rotating members rotating along the feed direction cooperate with each other to advance the padding strip along the downstream direction.

13. The method according to claim 11 or 12, characterized in that: The reversing step includes rotating a pair of rotating members in the opposite direction a second predetermined number of revolutions, wherein the pair of rotating members rotating in the opposite direction cooperate with each other to reverse the direction of the padding strip in the upstream direction.

14. The method according to claim 11, characterized in that: The advancement step occurs within a first predetermined time period.

15. The method according to claim 11 or 14, characterized in that: The reversal step occurs within a second predetermined time period.

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