Systems and methods for fan-shaped folding of continuous webs for stacking sheets

Abstract

A system (1) for stacking fan-folded continuous webs (M) of sheets of variable length, such as corrugated cardboard, the system (1) comprising: a feeding device having means for guiding the continuous web (M) in a longitudinal direction (L); a crease device (2) located downstream of the feeding device for forming transverse creases (C) spaced at constant longitudinal spacing (K) on the continuous web (M) to define a series of adjacent partitions (P); a folding device (14) located downstream of the crease device (2) for fan-folding the adjacent partitions (P) gradually and alternately along the creases (C); and a collecting device (39) for collecting the folded web (M) into a stack of adjacent partitions (P); wherein the collecting device (39) includes a vertically extending post (40) for holding the stack of fan-folded adjacent partitions (P). A dynamic cutting unit (52) is mounted on top of the column (40) to dynamically act on the top adjacent partition (P) of the stack without stopping the folding device (14), while tracking the formation of the stack. A method for stacking sheets of variable length, such as fan-folded continuous webs (M) of corrugated cardboard.

Description

Technical Field

[0001] This invention is generally applied to the field of packaging, and particularly relates to a system for stacking fan-shaped folded continuous webs of sheets of varying lengths.

[0002] The present invention also relates to a method for stacking continuous webs of corrugated cardboard of varying lengths in a fan-shaped fold. Background Technology

[0003] Sheets, typically corrugated cardboard, have long been known for use in box packaging production in sheet web form. Sheet webs are folded into fan-shaped folds to reduce volume and facilitate handling.

[0004] In fact, the original sheet was initially provided as a continuous web, just like the continuous form of an old dot matrix printer, which consisted of a continuous sheet of indefinite length. This continuous sheet was composed of a series of adjacent portions or sections of the same size (called partitions), which were defined by fold lines and folded up and down alternately to form a stack of overlapping partitions.

[0005] Stacked pieces of the same or different sizes are loaded into bins of automatic or semi-automatic machines or equipment to manufacture boxes of the desired size.

[0006] In order to obtain stacked parts, the continuous web first undergoes a process of forming fold lines transverse to the longitudinal direction of the continuous web, usually by means of a crease machine having at least two opposing pressing rollers to form creases on both sides of the continuous web separating adjacent partitions, as described, for example, in JPS4931775 or US2012 / 021886.

[0007] Once the fold lines or creases are formed, the web undergoes a fan-folding step, in which adjacent partitions are folded up and down alternately, followed by stacking in the final unloading unit and cutting to the desired or standard height, as described, for example, in WO2013 / 132325 or US7402130.

[0008] Then, the fan-shaped folded stack of the sheet is loaded into one or more storage bins of the cutting and creasing machine, from which it is continuously unfolded and partitions are conveyed to supply the cutting and creasing unit, which will form individual pieces (thick layers) to be assembled into boxes.

[0009] DE102012020943 discloses an apparatus for folding and stacking continuous webs into flat partitions, the apparatus having a supply device and a plurality of support elements, the supply device for supplying sheet strips and the support elements being guided along an annular guide to support the strips at the fold lines.

[0010] In addition, the support element has a separate actuation control device and can move perpendicular to the feeding direction of the continuous web.

[0011] Specifically, the continuous web has a horizontal orientation relative to the feeding device and is stacked horizontally on top of a conveyor belt adapted to temporarily support the stack of fan-shaped folded sheets and move them away from the equipment.

[0012] One drawback of this known system is that fold lines are formed only on one side of the strip, and the support elements always support the strip from the bottom. This can also lead to indentations in the strip due to continuous variations in the supply speed of the support elements.

[0013] In addition, the support element protrudes in a cantilever manner and retracts laterally to slide out of the fold line, which reduces the supply speed and thus seriously affects the operating speed of the entire device.

[0014] Another drawback of this known system is that once the continuous web is folded, the conveyor belt supports the stack only along one side of the stack and along a single series of fold lines, which may cause the stack to deform under its own action and further lead to the formation of indentations.

[0015] EP2409939 discloses a folding device equipped with a guide latch member for moving corrugated cardboard web at the fold. Other latch members are guided independently of the preceding latch member to convey along the corrugated cardboard web at another fold located upstream of the preceding fold.

[0016] Additionally, the collecting device is located downstream of the folding device for stacking corrugated cardboard webs, which are folded along creases to form stacks.

[0017] One drawback of this known folding device is that the latching member operates on the cardboard web only on one side of each pair of fold lines, and cannot prevent the formation of creases near the first latching member.

[0018] Furthermore, the supply speed is limited by the complexity of the mechanism used to move the individual latching component element, which is driven by an annular belt or chain.

[0019] Another drawback is that the feed rate of the continuous web is reduced each time the stack must be cut in the collection device to allow the partitions to be cut higher than the stack.

[0020] Technical issues

[0021] In view of the prior art, the technical problem to be solved by the present invention is to allow continuous webs to be cut to form stacked parts, while avoiding the formation of creases and without slowing down or stopping the folding device. Summary of the Invention

[0022] The object of this invention is to eliminate the above-mentioned disadvantages by providing an efficient and cost-effective system and method for stacking continuous webs of sheet material (such as corrugated cardboard) of variable length.

[0023] The specific object of the present invention is to provide a system as described above that can minimize the formation of creases near the fold line and avoid the need to slow down or stop the folding device.

[0024] Another object of the present invention is to provide a system as described above that enables high-speed stacking of continuous webs without limitation in cutting the uppermost partition in the stack.

[0025] Another object of the present invention is to provide a system as described above that can be easily adapted to continuous webs of different widths.

[0026] Another object of the present invention is to provide a system as described above that can vertically align the two sides of the stacked components.

[0027] These and other objectives, as explained more clearly below, are achieved by a system for stacking continuous webs of sheets of varying lengths, such as corrugated cardboard, as defined above.

[0028] The system includes: a supply device having means for guiding the continuous web in a longitudinal direction; a crease device located downstream of the supply device for forming transverse creases spaced at constant longitudinal intervals on the continuous web to define a series of adjacent partitions; and a folding device located downstream of the crease device for gradually and alternately fanning and folding adjacent partitions along the creases.

[0029] A collection device is also provided to collect the folded web into stacked adjacent partitions, the collection device including vertically extending posts for holding the stack of adjacent fan-shaped folded partitions.

[0030] According to a particular aspect of the invention, a dynamic cutting unit is mounted on top of the column to dynamically act on the top adjacent partition of the stack without stopping the folding device, while tracking the formation of the stack.

[0031] Because of this dynamic cutting operation of the cutting unit, the stacking process can be tracked while the basically horizontal plane on which the continuous web is placed on the stack remains unchanged, thereby avoiding the need to slow down or stop the folding device.

[0032] Advantageously, the column is equipped with a first stacking support, a second stacking support, and a stacking unloading unit mounted to the column on a corresponding lifting bracket designed to move vertically along the column, and the cutting unit is mounted to the lateral end of the first support and is movable along a substantially horizontal lateral guide.

[0033] Furthermore, the cutting unit includes a blade, a pair of blades, and a motorized drive device of the type of belt and pulley, the motorized drive device being adapted to move the cutting blade about its own axis and the lateral movement bracket of the cutting unit simultaneously.

[0034] With this arrangement, the uppermost adjacent partition of the stack can be cut while it moves vertically during stacking, thereby avoiding the formation of creases and the need to slow down or stop the folding device.

[0035] The present invention also relates to a method for stacking sheets (such as fan-folded continuous webs of corrugated cardboard of variable length according to the present invention) as defined above.

[0036] Advantageous embodiments of the invention are as defined above. Attached Figure Description

[0037] Other features and advantages of the invention will become more apparent from the detailed description of a system for stacking continuous webs of sheet material (such as corrugated cardboard) of variable length, which is described as a non-limiting example with the aid of the accompanying drawings, in which:

[0038] Figure 1 , Figure 2 Figures 2 and 3 are respectively the side view, top view, and perspective view of the system of the present invention;

[0039] Figure 4 is a cross-sectional view of the system in Figure 3;

[0040] Figure 5 yes Figure 1 A perspective view of the system's collection device;

[0041] Figure 6 and Figure 7 They are Figure 5 Top and side views of the collection device;

[0042] Figure 8 and Figure 9 They are Figure 5 Perspective and magnified views of the collection device;

[0043] Figures 10 to 2 1 is Figure 5 Perspective and side views of the device at different operating steps. Detailed Implementation

[0044] Referring specifically to the accompanying drawings, a system generally indicated by the numeral 1 is shown for stacking fan-shaped folded continuous webs M of sheets of varying lengths, such as corrugated cardboard.

[0045] As is known by itself, the continuous web M is substantially longitudinal, has a bottom side S1, a top side S2, a longitudinal side edge B, and includes a predetermined maximum width E defined by the distance of the longitudinal side edge B.

[0046] like Figure 1 As shown in Figure 4, system 1 includes a frame defining a vertical center plane π and a supply device (not shown) having means for guiding a continuous web of material M along a longitudinal direction L parallel to the vertical center plane π.

[0047] The crease device 2 is also located downstream of the supply device and is adapted to form transverse creases C spaced at constant longitudinal spacing K on the continuous web M to define a series of adjacent partitions P.

[0048] The crease device 2 may include two crease rollers 6', 6'', which have tools configured to alternately form creases C on the bottom side S1 and top side S2 of the continuous web M to form a "Z" shaped crease.

[0049] Therefore, at the output of the crease device 2, the web M will alternately and continuously include creases C1 formed on the bottom side S1 to fold the web M upward, and creases C2 formed on the top side S2 to fold the web M downward.

[0050] Conveniently, system 1 includes a folding device 14 located downstream of the folding device 2 to gradually and alternately fan-fold adjacent partitions P along the fold C.

[0051] As shown in the figure, downstream of the folding device 14, the system 1 includes a collecting device 39 to collect the folded web M for stacking adjacent partitions P.

[0052] The collecting device 39 includes a vertically extending column 40 to hold the stack of adjacent partitions P that have been fan-folded by the folding device 14.

[0053] The column 40 includes a plurality of columns 41 anchored to the ground G and a plurality of transverse members 42 adapted to reinforce the column 40 and form a compartment 43 for holding stacked components.

[0054] like Figures 5 to 8 As shown, the first stacking component support frame 44, the second stacking component support frame 45, and the stacking component unloading unit 46 are installed on the column 40.

[0055] Specifically, the first support frame 44 and the second support frame 45 include a plurality of arms 47 laterally offset at predetermined intervals, and the unloading unit 46 includes a closed-loop conveyor belt 48 to temporarily support the stack and move it laterally away from the column 40.

[0056] In addition, the first support frame 44 and the second support frame 45 are respectively installed on the first lifting bracket 49 and the second lifting bracket 50. The first lifting bracket 49 and the second lifting bracket 50 can move vertically along the column 40, and the lifting brackets 49 and 50 are installed on the first lateral end 44' of the first support frame 44 and the second lateral end 45' of the second support frame 45.

[0057] Similarly, the unloading unit 46 is mounted to a third lifting bracket 51, which is vertically movable along the vertical column 40 to allow the unloading unit 46 to move downwards during the formation of the stack, wherein the substantially horizontal plane Q on which the continuous web M rests above the stack remains unchanged, as... Figures 10 to 1 As shown in Figure 7.

[0058] Of course, a suitable vertical sliding device (not shown) is installed along the vertical range of the column 40 for the vertical and independent movement of the lifting brackets 49, 50, 51.

[0059] According to a particular aspect of the invention, a dynamic cutting unit 52 is mounted on top of the column 40 to dynamically act on the top adjacent partition P of the stack without stopping the folding device 14, while tracking the formation of the stack.

[0060] Therefore, multiple stacked pieces can be obtained from the continuous web M without slowing down or stopping the crease device 2 and / or the folding device 14, as further described below.

[0061] like Figure 8 and Figure 9 As shown, the dynamic cutting unit 52 is mounted to the second lateral end 44'' of the first support frame 44 facing the stack, and includes a fourth bracket 53 designed to move along a generally horizontal lateral guide 54.

[0062] The cutting unit 52 includes circular cutting blades 55 facing a pair of blades 56 for cutting a continuous web M, the blades 55 being tilted at a predetermined angle to enable the cutting of adjacent top partitions P of the stack.

[0063] In addition, a belt and pulley type motor drive 57 is provided to simultaneously move the cutting blade 55 about its own axis and move the fourth bracket 53 along the lateral guide 54.

[0064] like Figures 10 to 1As shown in Figure 7, in order to facilitate the tracking of the stacked components, the first lifting bracket 49 and the second lifting bracket 50 include corresponding generally longitudinal guide devices 58 for selectively moving the first support bracket 44 and the second support bracket 45 toward the stacked components to temporarily support the stacked components after the adjacent partition P is cut.

[0065] Then, the continuous web M is dynamically cut before the first bracket 44 and the second bracket 45 are moved toward the holding chamber 43 to support the forming stack.

[0066] like Figures 14 to 2 As shown in Figure 1, the stacked pieces that have just been cut are supported by the support frames 44 and 45 by tracking the formation of the stacked pieces. At the same time, the plane Ω where the continuous web M is located remains unchanged during the time required for the unloading unit 46 to unload the previous stacked piece outside the column 40 and climb up the corresponding vertical sliding device to collect the stacked piece.

[0067] Then, the first support frame 44 and the second support frame 45 move away from the holding chamber 43 along the longitudinal guide device 58 to unload the stacked components onto the unloading unit 46.

[0068] In addition, to facilitate alignment of the creases C1 and C2 of each stacked component, the column 40 includes a first substantially vertical adjustment plate 59 and a second substantially vertical adjustment plate 60 for vertically aligning the crease C2 on the top side S2 and the crease C1 on the bottom side S1, respectively.

[0069] Preferably, before the stack is formed on the unloading unit 46, the first support frame 44 is removed from the stack, while the second support frame 45 is pushed toward the first support frame 44, and the stack is kept level by adjusting the plates 59 and 60. Figures 14 to 1 As shown in Figure 7.

[0070] On the other hand, the present invention relates to a method of stacking sheets, such as a fan-shaped folded continuous web M of corrugated cardboard of variable length having a bottom side S1, a top side S2 and a longitudinal side edge B.

[0071] The method includes the following steps:

[0072] - Provide a feeding device for feeding a continuous web of material M in the longitudinal direction L;

[0073] - A crease device 2 is provided downstream of the supply device to form transverse creases C spaced apart at a constant longitudinal spacing K on a continuous web M, and to define adjacent partitions P;

[0074] - A folding device 14 is provided downstream of the folding device 2 to gradually and alternately fan-fold adjacent partitions P along the fold C;

[0075] - A collecting device 39 is provided downstream of the folding device 14 to collect the folded web M and form a stack of adjacent partitions P;

[0076] - A vertically extending column 40 is provided in the collecting device 39 to hold the stack of adjacent fan-shaped folded partitions P;

[0077] - The collection device 39 provides a first stack support frame 44 and a second stack support frame 45, a stack unloading unit 46, and a dynamic cutting unit 52 for cutting at least one adjacent partition P of the stack.

[0078] - Creases C1 and C2 are alternately formed on the bottom side S1 and top side S2 of the continuous web material M by means of crease device 2;

[0079] - Actuation folding device 14;

[0080] - The first support frame 44 and the second support frame 45 are moved horizontally toward the stack and vertically toward the stack unloading unit 46, thereby tracking the formation of the stack without stopping the folding device 14;

[0081] - Dynamically actuate the dynamic cutting unit 52 and make it interact with the uppermost adjacent partition P in the stack, thereby avoiding the need to stop the folding device 14;

[0082] - Store the stacked components in the unloading unit 46.

[0083] As can be understood from the above, the system and method of operation for fan-shaped folding continuous web of stacked sheets according to the present invention achieve the intended purpose, namely, to achieve the formation of stacked parts without producing creases and without slowing down or stopping the folding device.

[0084] Within the disclosed inventive concept, the system and operating method of the present invention are readily subject to various changes and modifications.

[0085] Although the system and operating methods have been described in detail with reference to the accompanying drawings, the figures cited in the disclosure are for the purpose of better understanding the invention only and should not be intended to limit the scope of the claims in any way.

[0086] References to “one embodiment”, “this embodiment”, or “some embodiments” herein indicate that a particular feature, structure, or element being described is included in at least one embodiment of the subject matter of this invention.

[0087] Furthermore, specific features, structures, or elements may be combined in any suitable manner to provide one or more embodiments.

[0088] Industrial applicability

[0089] This invention can be applied in industry because it can be produced on an industrial scale in factories that process sheets into packages.

Claims

1. A system (1) for stacking continuous webs (M) of fan-folded sheets of variable length, said sheets being corrugated cardboard, said system (1) comprising: - A supply device having means for guiding the continuous web (M) in the longitudinal direction (L); - A crease device (2), located downstream of the supply device, is used to form transverse creases (C) spaced apart at a constant longitudinal spacing (K) on the continuous web (M) to define a series of adjacent partitions (P). - Folding device (14), located downstream of the crease device (2), for gradually and alternately fanning and folding adjacent partitions (P) along the crease (C). - Collection device (39) for collecting the continuous web (M) into a stack of adjacent partitions (P); The collecting device (39) includes a vertically extending column (40) for holding the stack of adjacent fan-shaped folded partitions (P); The dynamic cutting unit (52) is installed on the top of the column (40) to dynamically act on the top adjacent partition (P) of the stack without stopping the folding device (14), while tracking the formation of the stack. The feature is that the first support frame (44), the second support frame (45) and the stack unloading unit (46) are installed on the column (40).

2. The system according to claim 1, characterized in that, The first support frame (44) and the second support frame (45) are respectively installed on the first lifting bracket (49) and the second lifting bracket (50). The first lifting bracket (49) and the second lifting bracket (50) can move vertically along the vertically extending column (40). The lifting brackets (49, 50) are installed on the first lateral ends (44', 45') of the first support frame (44) and the second support frame (45).

3. The system according to claim 2, characterized in that, The unloading unit (46) is installed on the third lifting bracket (51), which is capable of moving vertically along the vertically extending column (40).

4. The system according to claim 3, characterized in that, The dynamic cutting unit (52) is mounted to the second transverse end (44'') of the first support frame (44), and the dynamic cutting unit (52) includes a fourth bracket (53) and a circular cutting blade (55), the fourth bracket (53) being adapted to move along a generally horizontal transverse guide (54), and the circular cutting blade (55) facing a pair of blades (56) for cutting the continuous web (M).

5. The system according to claim 4, characterized in that, The system includes a belt and pulley type motor drive (57) adapted to simultaneously move the cutting blade (55) about its own axis and move the fourth bracket (53) along the lateral guide (54).

6. The system according to claim 2, characterized in that, The first lifting bracket (49) and the second lifting bracket (50) include corresponding generally longitudinal guide devices (58) adapted to selectively move the first support frame (44) and the second support frame (45) toward the stack to temporarily support the stack after the adjacent partition (P) is cut, and to track the formation of the stack without stopping the folding device (14).

7. The system according to claim 1, characterized in that, The first support frame (44) and the second support frame (45) include a plurality of arms (47) that are laterally offset at predetermined intervals.

8. The system according to claim 1, characterized in that, The unloading unit (46) includes a closed-loop conveyor belt (48) adapted to temporarily support the stack and move it laterally away from the column (40).

9. The system according to claim 1, characterized in that, The crease device (2) is configured to alternately form creases on the bottom side (S1) and top side (S2) of the continuous web (M), and the column (40) includes a substantially vertical first adjustment plate (59) and a substantially vertical second adjustment plate (60) for vertically aligning the crease (C1) on the bottom side (S1) and the crease (C2) on the top side (S2) respectively.

10. A method for stacking sheets of variable length, said sheets being continuous webs (M) of corrugated cardboard folded in a fan shape, said method comprising the following steps: - A feeding device is provided for feeding the continuous web (M) in the longitudinal direction (L); - A crease device (2) is provided downstream of the supply device to form transverse creases (C) spaced at constant longitudinal spacing (K) on the continuous web (M) and to define adjacent partitions (P). - Provide a folding device (14) located downstream of the crease device (2) to gradually and alternately fan-fold adjacent partitions (P) along the crease (C); - A collecting device (39) is provided downstream of the folding device (14) to collect the continuous web (M) and form a stack of adjacent partitions (P); - A vertically extending column (40) is provided in the collecting device (39) to hold the stack of adjacent partitions (P) in a fan-shaped fold; - The collection device (39) provides a first support frame (44) and a second support frame (45), a stack unloading unit (46) and a dynamic cutting unit (52) for cutting at least one adjacent partition (P) of the stack. - Move the first support frame (44) and the second support frame (45) horizontally toward the stack and vertically toward the unloading unit (46) to track the formation of the stack without stopping the folding device (14); - Dynamically actuate the dynamic cutting unit (52) and make it interact with the uppermost adjacent partition (P) in the stack, thereby avoiding the need to stop the folding device (14). - The stacked components are stored in the unloading unit (46).

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