System for dispensing pillows for product packaging

Abstract

The present invention provides an apparatus for dispensing pillows for use in a package arranged in a web and having a relatively thick portion defined by a relatively thin portion contiguous with each pillow within the web. The system of the present invention may include a transfer unit having a pushing member. The urging member is configured to engage the web of the pillow upon movement of the urging member such that the urging member drags the web into the transfer unit and moves the web through the transfer unit toward an exit of the transfer unit. The device of the present invention may also include a separation unit having a cutting device, and a movable cover at least partially enclosing the cutting device to prevent accidental contact with the cutting device.

Description

Background Art

[0001] An inflatable cushion or air pillow is a pillow-like object that is widely used in product packaging. For example, air pillows are often used as protective packaging in a manner similar to or in place of foam peanuts, crumpled paper, and similar products. As another example, air pillows can be used as protective packaging in place of molded or extruded packaging components. A typical air pillow is formed from a film having two plies joined together by a seal. The seal can be formed simultaneously with the inflation of the pillow to trap air in the pillow, or the seal can be formed prior to inflation to define a film configuration having an inflatable chamber. The inflatable chamber can be inflated with air or another gas and thereafter sealed to inhibit or prevent the release of the air or gas.

[0002] Typically, air pillows are formed as a web of contiguous air pillows, each connected to its neighboring pillows by a web-joint portion, which is the non-inflated portion of the air pillow bordering the inflatable portion. One or more individual air pillows can be separated from the web and placed in a freight container when the container is loaded with items to be protected by the air pillows. The air pillows can be separated from the web-joint portion by cutting, tearing, or otherwise separating the web-joint portion between adjacent air pillows, while leaving the inflated portion of the air pillow intact.

[0003] In some applications, the webs may be dispensed directly from the equipment that produces the webs. In other applications, the webs may be transported to storage bins for temporary storage, and the air pillows may be dispensed from the bins when they are needed. Because inflated air pillows can be punctured or otherwise damaged if not handled properly, using automated equipment to transport the webs can present challenges. For example, the transport equipment can damage the air pillows if the web connection becomes jammed. Additionally, the transport equipment may be unable to move the web if one or more pillows become fully or partially deflated due to leaks, manufacturing defects, or other damage. Furthermore, in applications where automated equipment is used to cut individual pillows or otherwise separate the pillows from the web, it can be difficult to align the web connection with the cutting equipment so that the cut is made on the web connection rather than the inflated pillows. Summary of the Invention

[0004] In one aspect of the disclosed technology, a device for dispensing pillows for product packaging is provided. Each of the cushioning pillows includes a first portion and a second portion, each second portion having a thickness less than that of the first portion. The second portions of adjacent pillows abut one another to form a continuous web of pillows. The web defines peaks coinciding with the locations of the maximum thickness of the first portions and valleys located between the peaks.

[0005] The apparatus includes a transfer unit having at least one pushing member configured to engage a web of the pillow such that the pushing member draws the web of the pillow into the transfer unit and moves the web of the pillow through the transfer unit toward an outlet of the transfer unit, and the pushing member is tilted away from a direction of rotation of the pushing member.

[0006] In another aspect of the disclosed technology, the pushing member includes a blade.

[0007] In yet another aspect of the disclosed technology, the device further includes a plurality of pushing members.

[0008] In still another aspect of the disclosed technology, the transfer unit further includes a hub, the pushing member is mounted on the hub, and the pushing member extends in a direction substantially tangential to an outer surface of the hub.

[0009] In yet another aspect of the disclosed technology, the transfer unit further includes a guide configured to guide the web of pillow along a path.

[0010] In another aspect of the disclosed technology, the front side of the pushing member is configured to contact the pillow and advance the pillow, the front side of the pushing member is inclined at a first angle relative to an adjacent portion of the guide, and the rear side of the pushing member is inclined at a second angle that is a supplementary angle to the first angle relative to the adjacent portion of the guide, and the first angle is smaller than the second angle.

[0011] In yet another aspect of the disclosed technology, the guide includes a curvilinear portion configured to guide the web of the pillow along a curvilinear path and a vertical portion adjacent to the curvilinear portion and configured to guide the web of the pillow to the outlet.

[0012] In yet another aspect of the disclosed technology, the guide interferes with the pushing member when the pushing member moves past the guide.

[0013] In yet another aspect of the disclosed technology, the urging member is configured to flex in response to the interference between the urging member and the guide.

[0014] In yet another aspect of the disclosed technology, the pushing member and the guide are configured such that the second portion of the pillow is entrained between a tip of the pushing member and the guide as the pushing member moves past the guide.

[0015] In yet another aspect of the disclosed technology, a spacing between the tips of adjacent pushing members is substantially equal to a length of the pillow.

[0016] In yet another aspect of the disclosed technology, the guide is a second guide, the dispensing unit further includes a first guide, the first guide and the second guide are configured to guide the web of the pillow toward the pushing member, the first guide and the second guide are spaced apart from each other by a spacing that ensures that the web of the pillow is properly engaged within the transfer unit, and the second guide is configured as a ramp that raises the web of the pillow as the second guide guides the web of the pillow along the path.

[0017] In yet another aspect of the disclosed technology, the pushing member is configured to advance the web of the pillow in a first direction, and the dispensing unit further includes an anti-reverse feature configured to inhibit movement of the web of the pillow in a second direction opposite to the first direction.

[0018] In yet another aspect of the disclosed technology, the anti-reversal feature includes a brush.

[0019] In yet another aspect of the disclosed technology, the dispensing unit further includes a wiper configured to contact the pillow and separate the pillow from the pushing member as the pushing member and the pillow rotate past the wiper.

[0020] In yet another aspect of the disclosed technology, the wiper includes a brush.

[0021] In yet another aspect of the disclosed technology, the apparatus further comprises a holding box.The pushing member is configured to engage the web of the pillow when the pushing member rotates, such that the pushing member pulls the web of the pillow from the holding box into the transfer unit.

[0022] In yet another aspect of the disclosed technology, the transfer unit is configured to be mounted on and removed from the holding box as a modular unit.

[0023] In another aspect of the disclosed technology, a device for dispensing pillows for product packaging is provided. Each of the cushioning pillows includes a first portion and a second portion, each second portion having a thickness less than that of the first portion. The second portions of adjacent pillows abut one another to form a continuous web of pillows. The web defines peaks coinciding with the locations of the maximum thickness of the first portions and valleys located between the peaks.

[0024] The apparatus includes a separating unit configured to receive the web of packaging articles. The separating unit includes an anvil, a cover, and a press, wherein the cover is mounted on the anvil and configured to move relative to the anvil between a first position and a second position of the cover, and the press is movable between the first position and the second position of the press. The apparatus also includes a cutting device mounted on the anvil and configured to sever the second portion of the pillow when in contact with the second portion. When the cover is in the first position of the cover, the cover at least partially encloses the cutting device, when the press moves from the first position of the press to the second position of the press, the press is configured to move the cover from the first position of the cover to the second position of the cover and push the web portion into the cutting device, and when the cover is in the second position of the cover, the press is configured to at least partially enclose the cutting device.

[0025] In another aspect of the disclosed technology, a device for dispensing pillows for product packaging is provided. Each of the cushioning pillows includes a first portion and a second portion, each second portion having a thickness less than that of the first portion. The second portions of adjacent pillows abut one another to form a continuous web of pillows. The web defines peaks coinciding with the locations of the maximum thickness of the first portions and valleys located between the peaks.

[0026] The apparatus includes a holding box defining an interior volume configured to receive a web of the pillow, a duct defining a channel configured to receive the web of the pillow and direct the web of the pillow in a first direction into the interior volume of the holding box, and an air circulation device in fluid communication with the channel and configured to, during operation, direct air into the channel at a pressure and flow rate sufficient to move the web of the packaged article through the channel in the first direction. The apparatus also includes an anti-reverse feature mounted within the channel and configured to inhibit movement of the web of the pillow in a second direction opposite to the first direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The following drawings illustrate specific embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not drawn to scale and are intended to be used in conjunction with the explanations in the following detailed description. Embodiments of the present disclosure will be described hereinafter in conjunction with the accompanying drawings, wherein like reference numerals indicate like elements.

[0028] Figure 1is a side view of a system for dispensing air pillows depicting a chain of air pillows fed to the system from an inflation and sealing machine and depicting individual strings of air pillows being packaged in containers after being dispensed by the system, with the side walls of the system's holding box removed for clarity.

[0029] Figure 2 yes Figure 1 An enlarged view of a portion of Figure 1 The distribution unit of the system shown in .

[0030] Figure 3 yes Figure 2 A top perspective view of the dispensing unit is shown in FIG.

[0031] Figure 4 yes Figure 1 A top view of the holding box of the system shown in FIG, with the top of the holding box removed for clarity.

[0032] Figure 5 yes Figure 1 An enlarged view of another part of the .

[0033] Figure 6 yes Figure 1 , depicting the pressure lever of the cutting device in a retracted position and depicting the cover of the cutting device in a safe position.

[0034] Figure 7 yes Figure 6 A side view of the shut-off device shown in , depicting the pressure lever moving from the retracted position toward the extended position, and depicting the cover in the safety position.

[0035] Figure 8 yes Figure 6 and Figure 7 , depicting the pressure lever moving further from the retracted position toward the extended position, and depicting the cover in the safety position when the pressure lever initially contacts the cover.

[0036] Figure 9 yes Figures 6 to 8 A side view of the cutting device shown in , depicting the pressure lever in the extended position and depicting the cover in its retracted position.

[0037] Figure 10 yes Figure 9 An enlarged view of a portion of the air pillow further depicts the web connection portion of the chain of the air pillow Figures 6 to 9 The cutting line contacts of the separation device shown in FIG.

[0038] Figure 11 yes Figure 10, which depicts the web portion after being severed by the cutting line.

[0039] Figure 12 yes Figures 6 to 11 , depicting the pressure lever in its retracted position, depicting the cover in the safe position, and depicting the locking arm of the cutting device in the locked position.

[0040] Figure 13 yes Figures 6 to 12 , depicting the pressure lever moving from its retracted position toward its extended position, depicting the cover in the safety position, and depicting the locking arm in the locked position.

[0041] Figure 14 yes Figures 6 to 13 , depicting the pressure lever moving further from its retracted position toward the extended position, depicting the cover in the safety position, and depicting the locking arm moving from the locked position to the unlocked position.

[0042] Figure 15 yes Figures 6 to 14 , depicting the pressure lever moving further from its retracted position toward its extended position, depicting the cover in the safety position when the pressure lever initially contacts the cover, and depicting the locking arm in the unlocked position.

[0043] Figure 16 yes Figures 6 to 15 , depicting the pressure lever in an extended position, depicting the cover in its retracted position, and depicting the locking arm in an unlocked position.

[0044] Figure 17 yes Figure 2 An enlarged view of a portion of . DETAILED DESCRIPTION

[0045] The following discussion omits or only briefly describes conventional features of the disclosed technology that would be apparent to one skilled in the art. Reference to various embodiments does not limit the scope of the appended claims. Furthermore, any examples set forth in this specification are intended to be non-limiting and merely illustrate some of the many possible embodiments for the appended claims. In addition, specific features described herein may be used in conjunction with other described features in each of various possible combinations and permutations. One of ordinary skill in the art will understand how to use the present invention in conjunction with routine experimentation to achieve other results not specifically disclosed in the examples or embodiments.

[0046] Unless otherwise expressly defined herein, all terms are to be given their broadest possible interpretation, including the meaning implicit in this specification and the meaning understood by those skilled in the art and / or as defined in dictionaries, papers, etc. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as that commonly understood by those skilled in the art in the disclosed technical field. It must also be noted that, as used in this specification and the appended claims, the singular indefinite articles "a", "an" and "the" include plural referents unless otherwise stated, and the terms "comprise" and / or "comprising" when used in this specification specify the presence of the features, elements and / or parts set forth, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or groups thereof. In addition, methods, equipment and materials similar or equivalent to those described herein may also be used in the practice or testing of the disclosed technology.

[0047] Throughout this disclosure, various examples of the disclosed technology are provided. The use of these examples is illustrative only and in no way limits the scope and meaning of the present invention or any illustrative form. Likewise, the present invention is not limited to any specific preferred embodiment described herein. Indeed, modifications and variations of the present invention will be apparent to those skilled in the art after reading this specification and may be made without departing from its spirit and scope. Therefore, the present invention is limited only by the terms of the claims and the full scope of equivalents to which the claims are entitled.

[0048] The terms "substantially" or "substantially equal" are used herein to describe certain relationships between the features of a suppressor. As used herein, the terms "substantially" and "substantially equal" indicate that the relationship of equality is not a strict relationship and does not exclude variations in their functions. Unless the context or description indicates otherwise, the use of the terms "substantially" or "substantially equal" associated with two or more described dimensions indicates that the equality relationship between the dimensions includes the least significant digit that will not change the dimensions using mathematical and industrial principles generally recognized in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.). As used herein, the term "substantially parallel" indicates that the relationship of parallelism is not a strict relationship and does not exclude variations in their functions. As used herein, the term "substantially orthogonal" indicates that the relationship of orthogonality is not a strict relationship and does not exclude variations in their functions.

[0049] A device 10 for dispensing pillows (eg, air pillows 20) for product packaging is disclosed. Figures 1 to 3, the pillows 20 are provided to the system 10 as a continuous web 22 of interconnected pillows 20. Each pillow 20 includes a relatively thick or inflated portion 23 and a relatively thin portion or web 24 adjacent to opposite sides of the inflated portion 23. The inflated portion 23 is filled with a fluid, such as air, and is sealed by its associated web 24 to prevent fluid leakage. The inflated portion 23 forms the relatively thick portion of the pillow 20, and the web 24 forms the relatively thin portion of the pillow 20. The web 24 acts as a hinge that allows adjacent pillows 20 to rotate relative to each other. The web 24 of adjacent pillows 20 abut each other so that the air pillows 20 form a continuous chain 22. In some applications, the web 24 may include perforations that facilitate separation of adjacent pillows 20 by tearing or other means. The relatively thick inflated portions 23 and the relatively thin web-linked portions 24 define depressions or valleys 25 between the inflated portions 23 of adjacent pillows 20. The longitudinal midpoints of the inflated portions define peaks 27 of the chains 22, or the locations of the greatest thickness of the chains 22. (As used herein, the "longitudinal" direction of the pillows 20 coincides with the longitudinal direction of the web 22 and with the direction in which the web 22 and pillows 20 are fed through the apparatus 10.)

[0050] Each pillow 20 can have a longitudinal dimension of, for example, approximately four inches when deflated and approximately three inches when inflated. Each pillow 20 can have a transverse dimension of, for example, approximately eight inches when deflated and approximately seven inches when inflated. Each pillow 20 can have a maximum thickness of, for example, approximately 1 inch to 5 / 16 inch when inflated. The above dimensions for pillows 20 are presented for illustrative purposes only. Device 10 can be configured for use with pillows 20 having dimensions and dimension ratios that are both smaller and larger than the above dimensions.

[0051] The chains 22 of the pillows 20 may be produced, for example, by a pillow inflation and sealing device 8, such as that disclosed in US Pat. No. 11,577,484, the entire contents of which are incorporated herein by reference. Figure 1 A pillow inflation and sealing device 8 is shown, which feeds a chain of air pillows 20 directly to the device 10. In the alternative, the pillow chain 22 may be produced by other types of devices and systems.

[0052] In an alternative embodiment, the chain 22 may be directed to a storage bin or other temporary storage device before being supplied to the apparatus 10 .

[0053] Alternative embodiments of pillows 20 need not be inflated and need not be formed from inflatable materials. For example, the web of non-inflatable pillows can be formed from one or more plies of paper or other material configured such that the paper defines an internal cavity within each pillow. Each internal cavity can be filled with padding or other material that provides cushioning and / or insulation. In this embodiment, the filled cavities form relatively thick sections of the web, and adjacent unfilled portions of the web connecting adjacent pillows form thinner sections of the web. In other alternative embodiments, the web can comprise a continuous mailing envelope. In some of these embodiments, the web can comprise a continuous loaded envelope, with the loaded portion forming a relatively thick section and the envelope's corresponding top and bottom seals forming relatively thin sections. In other alternative embodiments, the web can include a sheet or pad having relatively thick or relatively thin portions, such as foam padding, thermal insulation padding, or cold chain material having compressed areas, such as fold lines, to form the sheet or pad, for example, to cushion the interior of a box or other packaging container. The relatively thick and relatively thin portions of these alternative embodiments can function in a similar manner to the corresponding inflated portions 23 and web-joined portions 24 of the web 22.

[0054] If you can Figure 1 , the apparatus 10 includes a holding or accumulation box 12, a distribution or transfer unit 14, and a separation unit 16. The accumulation box 12 receives inflated pillows 20 from the inflation and sealing machine 8. The pillows 20 are arranged in a chain 22 upon entering the apparatus 10, wherein adjacent pillows 20 are interconnected by webs 24. The pillows 20 are fed into and accumulated in the box 12.

[0055] like Figure 1 As shown in FIG, the inflation and sealing device 8 is located upstream of the accumulation box 12 relative to the direction of movement of the chain 22. The inflation and sealing device 8 can be positioned at a first height relative to the accumulation box 12, such that the chain 22 exits the inflation and sealing device 8 at a point below the bottom 38 of the accumulation box 12. Positioning the inflation and sealing device 8 at the first height can allow an operator to easily access, for example, the chain 22 or a roll 610 of preformed chain material. This arrangement between the inflation and sealing device 8 and the accumulation box 12 also creates sufficient space for the chain 22 to be fed into the accumulation box 12 without becoming tangled or interfering. Additionally or alternatively, a conveyor 152 can be positioned below the accumulation box 12, and in some embodiments, a conveyor 152 can be positioned below the transfer unit 14 at a second height relative to the accumulation box 12 to facilitate transferring the chain 22 from the accumulation box 12 to the packaging container 150.

[0056] The chain 22 is drawn into the transfer unit 14, which dispenses one or more pillows 20 in response to an operator manually activating the transfer unit 14 using a foot pedal (not shown) or other activation device, where the number of pillows 20 dispensed at a time is determined by how long the operator depresses the foot pedal. Additionally or alternatively, the transfer unit 14 can be configured to automatically dispense a predetermined number of pillows 20 at a time. For example, the transfer unit 14 can be configured to dispense a specific number of pillows 20 in response to input from an external system, such as an automated packaging machine having void sensing capabilities, i.e., the ability to sense and / or quantify voids or empty volumes within a package to be filled with pillows 20.

[0057] Once the pillows 20 have been dispensed, the separation unit 16 separates or cuts the relatively short string of dispensed pillows 20 from the remainder of the chain 22 .

[0058] Reference Figure 1 、 Figure 3 and Figure 4 , the accumulation box 12 includes a first side wall 30 and a second side wall 32. The box 12 also includes a front wall 34 and a rear wall 36, each of which is connected to the first side wall 30 and the second side wall 32 by a frame 37 of the box 12. Figure 4 As can be seen from the figure, the first side wall 30 and the second side wall 32 have substantially the same length. The front wall 34 and the rear wall 36 also have substantially the same length. The length of the front wall 34 and the rear wall 36 is less than the length of the first side wall 30 and the second side wall 32, so that when viewed from above, that is, when viewed from above, the front wall 34 and the rear wall 36 are substantially the same length. Figure 4 This provides the box 12 with a generally rectangular configuration when viewed from an angle.

[0059] The accumulation box 12 also includes a bottom 38 and a top 39. The bottom 38 and the top 39 are each connected to the first and second side walls 30, 32 and to the front and rear walls 34, 36 by a frame 37. The first and second side walls 30, 32, the front and rear walls 34, 36, the bottom 38, and the top 39 define an interior volume 40 of the box 12. The interior volume 40 receives the chain 22 of pillows 20. The first and second side walls 30, 32, the front and rear walls 34, 36, the bottom 38, and the top 39 can be formed of a transparent or translucent material so that the pillows 20 in the interior volume 40 are visible from outside the box 12.

[0060] If you can Figure 4, the first and second side walls 30, 32 are spaced apart by a distance that is substantially equal to the maximum width 19 or transverse dimension of the pillows 20. The chain 22 of pillows 20 is fed into the interior volume 40 in a direction substantially parallel to the first and second side walls 30, 32 such that the respective side or outer edge of each pillow 20 occupies a position directly adjacent to either the first or second side wall 30, 32, as shown. Figure 4 Because the first and second side walls 30, 32 are spaced apart a distance substantially equal to the maximum width 19 of the pillow 20, the first and second side walls 30, 32 constrain lateral or sideways movement of the pillow 20 and constrain twisting of the pillow 20 about the longitudinal axis of the chain 22 as the chain 22 is pulled through the interior volume 40 of the box 12.

[0061] Reference Figure 1 、 Figure 3 and Figure 4 The device 10 also includes a three-sided duct 42 mounted on the outer surface of the front wall 34. The duct 42 includes side panels 44 and two end panels 46, which are adjacent to opposite sides of the side panels 44 and extend perpendicular to the side panels 44. The duct 42 and the lower surface of the front wall 34 define a vertically extending channel 48. Figure 1 and Figure 3 As can be seen in Figure 1 As seen in FIG, the lower end of the channel 48 receives the chain 22 of the pillows 20 coming from the inflation and sealing machine 8. In an alternative embodiment, the duct 42 may be mounted separately from the accumulation box 12.

[0062] The device 10 further comprises an air circulation device 50 in the form of a fan or a blower mounted on the duct 42 near its lower end. Figure 3 4. The air circulation device 50 is in fluid communication with the channel 48 and provides an upward airflow within the channel 48. The upward airflow entrains the pillow 20 within the channel 48 and causes the chain 22 to move upward within the channel 48. Figure 1 The air flow generated by the air circulation device 50 is indicated by arrows 51 .

[0063] The channel 48 may have a cross-sectional profile that substantially matches the height (ie, thickness) of the pillow 20 and the maximum width 19 of the pillow 20. Thus, the pillow 20 is constrained from rotating or twisting while being transported upwardly through the channel 48.

[0064] Reference Figure 1 and Figure 5The duct 42 includes an anti-reverse feature that allows the chain 22 of the pillow 20 to move upward within the channel 48 while preventing the pillow chain 22 from falling downward (i.e., in a direction opposite to the direction in which the chain 22 was fed into the accumulation box 12) due to gravity when the air circulation device 50 is deactivated. For example, the anti-reverse feature can be an upwardly angled plastic tab 52 that is flexible enough to allow the pillow 20 to pass over the tab 52 as the pillow 20 travels upward within the channel 48, while being rigid enough to support the chain 22 of the pillow 20 when the air circulation device 50 is not pushing the chain 22 upward. In alternative embodiments, the anti-reverse feature can be a brush, a reed, or other type of device having the above characteristics.

[0065] Reference Figure 1 , the front wall 34 of the accumulation box 12 has a lip 54 formed on its upper end. The front wall 34 is shorter than the first and second side walls 30, 32 of the box 12, that is, the front wall 34 has a smaller vertical dimension. The lip 54, the first and second side walls 30, 32, and the top 39 define an opening 56 adjacent to the channel 48. When the pillow 20 reaches the top of the channel 48, it passes through the opening 56 and into the interior volume 40 of the box 12.

[0066] The pillows 20 can fall downward due to gravity upon entering the interior space. As described above, the first and second side walls 30, 32 are spaced apart by a distance approximately equal to the maximum width 19 of the pillows 20, such that the first and second side walls 30, 32 constrain the pillows from twisting or otherwise rotating about the longitudinal axis of the chain 22 of pillows 20. Because each pillow 20 is connected to its adjacent pillow 20 by a web 24, each pillow 20 can rotate relative to its adjacent pillow 20 about a transverse axis passing through its associated web 24. Thus, the chain 22 of pillows 20 can reverse direction upon placement within the accumulation bin 12. Typically, the chain 22 will fall randomly, forming a series of repeating S-shapes as the pillows 20 fill the interior volume 40. Lateral (ie, transverse) constraints imposed on the chain 22 by the first and second side walls 30 , 32 of the box 12 keep the chain 22 from becoming twisted or tangled, or otherwise occupying a position or orientation that would prevent the chain 22 from being smoothly fed into the transfer unit 14 .

[0067] The device 10 also includes a sensor 56 configured to sense the height level of the pillows 20 within the accumulation box 12. Figure 1. Sensor 56 may be, for example, an optical sensor. Alternatively, other types of sensors may be used. Sensor 56 is communicatively coupled to control unit 58 of apparatus 10. Control unit 58 is configured to activate air circulation device 50 when sensor 56 indicates that the height level of pillows 20 is below a predetermined threshold (e.g., below the line of sight of sensor 56). When activated, air circulation device 50 feeds additional pillows 20 into interior volume 40 of bin 12 in the manner described above. Upon receiving an indication from sensor 56 that the height level of pillows 20 has reached the predetermined threshold, control unit 58 deactivates air circulation device 50.

[0068] Alternatively or additionally, the device 10 may be configured with conditions that allow an operator to activate and deactivate the air circulation device 50 so that the operator can manually adjust the height level of the pillows 20 within the box 12 .

[0069] The transfer unit 14 is mounted on the accumulation box 12, as can be seen in Figure 1 The transfer unit 12 has a modular configuration that allows the transfer unit 14 to be installed in and removed from the accumulation box 12 as a separate, self-contained cartridge or unit. Figure 1 and Figure 3 The transfer unit 14 includes: a first side panel (not shown); a second side panel 61; a rotating structure in the form of a paddle wheel 62; and a motor 64. The first side panel and the second side panel 61 are securely mounted on the frame 37 of the accumulation box 12 near the lower end of the accumulation box 12, wherein the first side panel is disposed adjacent to the first side wall 30, and the second side panel 61 is disposed adjacent to the second side wall 32.

[0070] If you can Figure 3 , the control unit 58 is mounted on the outwardly facing side of the second side panel 61. The first and second side panels 61 are spaced apart by approximately the same distance as the first and second side walls 30, 32, i.e., the first and second side panels 61 are spaced apart by a distance that is approximately equal to the maximum width 19 of the pillow 20.

[0071] like Figure 3 As shown in FIG, the motor 64 is securely mounted on the inwardly facing side of the second side panel 61 and is located within the interior volume 40 of the box 12. The paddle wheel 62 is mounted on a shaft (not shown) for rotation. The shaft is securely mounted on the inwardly facing side of the second side panel 62.

[0072] The motor 64 is a servo motor. Other types of motors, such as stepper motors, may be used in alternative embodiments. The motor 64 drives the paddle wheel 62 to rotate, wherein torque is transmitted from the motor 64 to the paddle wheel 60 via a drive belt (not shown) or other suitable means.

[0073] Reference Figure 2 and Figure 3 , the paddle wheel 62 includes a hub in the form of a drum 70. The paddle wheel 62 also includes six propulsion members in the form of paddles or blades 72 securely mounted on the drum 70. The drum 70 is mounted on its support shaft via bearings (not shown) that facilitate rotation of the drum 70 relative to the shaft. The paddle wheel 62 is coupled to a drive belt via pulleys (not shown) that are securely mounted on the ends of the drum 70. In alternative embodiments, the hub may be configured as an axle or other structure configured to support and carry the blades 72, and the rotating structure may have a form different from that of the paddle wheel 62. In other alternative embodiments, the blades 72 may be directly connected to each other without a hub.

[0074] The blades 72 are configured to move the chain 22 of pillows 20 by engaging the pillows 20 via valleys 25 formed between the inflated portions 23 of adjacent pillows 20. More specifically, each blade 72 engages with the web-connected portion 24 between the pillows 20, and each blade 72 pushes the inflated portion 23 of the pillow 20 adjacent to the upstream side of the blade 72 as the paddle wheel 62 rotates.

[0075] The blades 72 are fixed to the drum 70 so that each blade 72 extends tangentially from its point of attachment to the outer surface of the drum 70, as can be seen in FIG. Figure 2 Thus, each blade 72 is offset by approximately 90 degrees from a direction orthogonal to the location on the outer surface of the drum 70 to which the blade 72 is attached, causing the blade 71 to tilt away from the direction of rotation of the paddle wheel 62. Figure 17 As can be seen, the front side of each blade 72 is inclined at an angle 202 relative to the second portion 84 of the second guide member 78, and the rear side of each blade 72 is inclined at a supplementary angle 200 relative to the second portion 84 of the second guide member 78, wherein angle 202 is less than angle 200.

[0076] In alternative embodiments, the blades 72 may have a different Figure 2 For example, in an alternative embodiment, the blades 72 may extend in a direction normal to the adjacent surface of the drum 70. In other alternative embodiments, the blades 72 may extend at an angle between corresponding angles associated with the normal direction and the tangential direction to the adjacent surface of the drum 70.

[0077] The paddle wheel 62 is depicted as having six blades 72 for illustrative purposes only. The optimal number of blades 72 may vary depending on a variety of factors, such as the distance between adjacent webs 24 within a chain 22 of the pillow 20; and whether the blades 72 are to engage every web 24 along the chain 22, every other web 24, every other web 24, or some other multiple of a web 24. Thus, alternative embodiments may be configured with fewer than six or more than six blades 72.

[0078] In alternative embodiments, the pushing member may have a configuration other than the blade 72. For example, the pushing member may be configured as a rod, reed, brush, wire, or other structure capable of pushing the pillow chain 22, as discussed herein, without damaging the pillows 20 or webs 24.

[0079] Reference Figure 2 and Figure 3 The transfer unit 14 further includes a first guide 76 and a second guide 78. The first guide 76 and the second guide 78 are secured to the first side panel 60 and the second side panel 61 via mounting members 79 extending between the first side panel 60 and the second side panel 61. The first guide 76 and the second guide 78 guide the pillow chain 22 into and around the paddle wheel 62 and out of the transfer unit 14. The first guide 76 and the second guide 78 can be formed from a flexible plastic material. In alternative embodiments, the first guide 76 and the second guide 78 can be formed from other materials.

[0080] A first guide 76 is located near the bottom of the transfer unit 14 and is configured as a ramp that lifts the chain 22 of the pillow 20 as it approaches the paddle wheel 62 , helping to ensure that the chain 22 is properly positioned to engage or be entrained by the paddle wheel 62 .

[0081] The second guide 78 has a first portion 80 that surrounds the motor 64 of the transfer unit 14, thereby preventing contact between the chain 22 and the motor 64. Moreover, the first portion 80 helps guide the chain 22 of the pillow 20 as the chain 22 of the pillow 20 approaches the paddle wheel 62. More specifically, the first portion 80 is spaced apart from the first guide 76 such that the first portion 80 and the first guide 76 define a path or channel 82 that constrains the pillow 20 from above and below as the chain 22 approaches the paddle wheel 62 in a manner that helps ensure proper engagement between the chain 22 and the paddle wheel 62. Figure 2 Channel 82 can be seen in FIG.

[0082] The second guide 78 has a second portion 84 that is adjacent to the first portion 80. The second portion 84 extends above and around the paddle wheel 62 and then extends downward in a generally vertical direction. The second portion 84 has a curved section that is configured to push the pillow 20 inward toward the rotational centerline of the paddle wheel 62, thereby urging the pillow 20 to remain in contact with the rotating paddle wheel 62. The second portion 84 also includes a vertical section that guides the pillow chain 22 toward an exit 86 at the bottom of the transfer unit 14 after the chain 22 has been transported around the paddle wheel 62, as shown in FIG. Figure 2 and Figure 3 As shown in .

[0083] If you can Figure 2 , the length of each blade 72 is selected so that interference occurs between the blade 72 and the second portion 84 of the second guide 78 as the blade 72 rotates past the second portion 84. The blade 72 can be formed of a material, such as plastic, that allows the blade 72 to flex in response to the interference and is sufficiently flexible to avoid damage to the web 24 as the outer ends or tips of the blades 72 contact the web 24 when the web 24 becomes trapped between the tips of the blades 72 and the second portion 84 of the second guide 78.

[0084] As described above, the pillow chain 22 is fed into the accumulation box 12 via the passage 48 and is accumulated within the accumulation box 12 in a random or semi-random series of folds, with the chain 22 prevented from twisting or rotating about its centerline by the restraint of the pillows 20 by the first and second side walls 30, 32. During startup of the apparatus 10, an operator manually feeds the leading pillow 20 of the pillow chain 22 through the passage 82 defined within the transfer unit 14 and between the paddle wheel blades 72 located immediately downstream of the passage 82. The operator has access to the pillow chain 22 and the paddle wheel 62 through an access opening and an access door 90 incorporated into the first and second side walls 30, 32, as shown with respect to the second side wall 32. Figure 3 As shown in .

[0085] A random or semi-random series of pleats can maintain the pillow chain 22 in a structured arrangement. Figure 1 As shown in FIG, the majority of the pillow chain 22 falls into the accumulation bin 12 in a uniform layer, the length of the uniform layer being substantially equal to the distance between the front wall 34 and the rear wall 36. This structural arrangement prevents the pillow chain 22 from wrinkling, twisting, bundling, knotting, or tangling. Furthermore, the uniform layer ensures that the height of the pillow chain 22 increases at a relatively predictable rate and in a predictable manner, which facilitates programming, for example, for dispensing a predetermined number of pillows. This structural arrangement also reduces system downtime because the pillow inflation and sealing device 8 does not need to be shut down to untie the pillow chain 22.

[0086] During the feeding and loading process, the operator may press a "load" button (not shown) or other input device communicatively coupled to the control unit 58. The load button generates an input that, when received by the control unit 58, causes the control unit 58 to activate the motor 64, thereby causing the motor 64 to slowly rotate the paddle wheel 62 so that at least the leading pillow 20 can be captured by the paddle wheel 62. During the feeding and loading process, the operator does not need to index the pillows 20 to the paddle wheel 62 because the paddle wheel 62 naturally establishes the order during the loading process by virtue of the spacing between the blades 72 and maintains the one-to-one correspondence between the blades 72 and the pillows 20 throughout the operation of the device 10.

[0087] As described above, the device 10 can be activated by an operator depressing a foot pedal or other input device; or the device 10 can be activated upon receiving an external command requesting a specific number of pillows 20 to be dispensed. Upon activation, the device 10 sends an input to the motor 64 that causes the motor 64 to start at its normal speed. The motor 64 rotates the paddle wheel 62 via a drive belt. Figures 1 to 3 From the perspective of FIG, the paddle wheel 62 rotates in a clockwise direction. The blade 72 located downstream or behind the leading pillow 20 pushes the inflated portion 23 of the leading pillow 20, causing the leading pillow 20 to rotate with the paddle wheel 62.

[0088] Furthermore, the adjacent downstream blade 72 engages the web 24 just behind or downstream of the leading pillow 20. As described above, the length of the blade 72 and the spacing between the drum 70 and the second guide 78 cause the blade 72 to flex as it drags the web 24 along the adjacent surface of the second guide 78. For example, the material, flexibility, length, or a combination thereof of the blade 72 can generate a force, such as friction, between the tip of the blade 72 and the web 24 (which becomes trapped between the tip of the blade 72 and the second guide 78), allowing the blade 72 to drag the web 24 in the direction of rotation of the blade 72. The positive contact between the blade 72 and the web 24 and the resulting drag on the web 24 further encourage the pillow chain 22 to rotate with the paddle wheel 62. Moreover, the pulling of the blades 72 against the webs 24 assists the paddle wheel 62 in conveying the chain 22 when one or more pillows 20 are fully or partially deflated, flattened, or otherwise in some other defective condition, so that the blades 72 cannot propel those particular pillows 20 by acting on the inflated portions 23 of those pillows 20. In the disclosed embodiment, it will be appreciated that this pulling action of the blades 72, along with the ability of the paddle wheel 62 to accommodate five pillows 20 simultaneously, enables the paddle wheel 62 to continue conveying the chain 22 when three or more consecutive pillows 20 are not properly inflated, such as when the pillows are punctured or otherwise not fully inflated. (When one or more pillows 20 are not properly inflated, the force exerted by the blades 72 on the properly inflated pillows within the dispensing unit 14 also assists in advancing the chain 22.)

[0089] Alternative embodiments of the transfer unit 14 can be configured to simultaneously accommodate more or fewer than five pillows 20. Moreover, the blades 72 can be configured to be sufficiently flexible to allow the blades 72 to pass over the pillows 20 within the transfer unit 14 without damaging the pillows 20 if the chain 22 of the pillows 20 becomes jammed and cannot advance through the transfer unit 14. The optimal degree of flexibility for the blades 76 depends on the stiffness of the pillows 20, which can vary with factors such as the inflation pressure of the pillows 20, the material from which the pillows 20 are formed, and so forth.

[0090] The rotation of the pillow chain 22 with the rotating paddle wheel 62 eventually causes the next or second pillow 20 in the chain 22 to contact the paddle wheel 62 (if the second pillow 20 has not previously contacted the paddle wheel 62 during the loading process). In particular, the spacing between the blades 72 is such that the next pillow 20 is entrained between the blade 72 disposed immediately behind the leading pillow 20 and the blade 72 disposed adjacent to and downstream of the blade 72. Moreover, the two adjacent blades 72 (between which the second pillow 20 is now captured) contact respective web portions 22 immediately upstream and downstream of the second pillow portion 20. Entrainment of subsequent pillows 20 in the chain 22 by the blades 72 continues in this manner as the paddle wheel 62 continues to rotate and draw additional pillows 20 from the accumulation box 12, causing the respective positions of the pillows 20 and blades 72 to be automatically indexed, as can be seen in FIG. Figure 2 In alternative embodiments, the number and spacing of the blades 72 on the drum 70 may be varied so that two or more pillows 20 are captured in the spaces between adjacent blades 72 .

[0091] In the transfer unit 14, the spacing between the tips of the blades 76 can be approximately equal to the length of the pillows 20. In alternative embodiments, where two or more pillows 20 can be accommodated between adjacent blades 76, the spacing between the blade tips can be approximately equal to the combined length of the pillows. The spacing between the blade tips can be a function of the thickness of the pillows 20. For example, the maximum thickness of the pillows 20 can be approximately equal to 50% of the spacing between the blade tips. In other embodiments, this percentage can range from approximately 10% to approximately 80%. The maximum thickness of the pillows 20 should be large enough relative to the spacing between the blade tips to allow the blades 76 to flex when engaged with the pillows 20, but not so large that the pillows become trapped between adjacent blades 72. In alternative embodiments, the spacing between the blade tips can vary from these values.

[0092] The interaction between each blade 76 and the web 22 depends, in part, on the physical properties of the web 22. For example, a relatively stiff or inflexible pillow 20 or a relatively heavy pillow 20 may require that the flexibility of the blade 76 be relatively low to help ensure that the blade 76 can exert sufficient force on the pillow 20 to advance the web 22 without causing the blade 76 to advance over or jump over the pillow 20. Conversely, a relatively flexible pillow 20 may require that the flexibility of the blade 76 be relatively high to help ensure that the blade 76 can flex sufficiently to avoid puncturing or otherwise damaging the pillow 20.

[0093] Moreover, a relatively thick and flexible pillow 20 may necessitate a greater flexibility of the blade 76 and / or a greater angle of the blade 76 relative to the direction of rotation of the blade 76 to help increase the contact area between the blade 76 and the pillow 20 so that the force exerted by the blade 76 on the pillow 20 is exerted over a relatively large area on the pillow.

[0094] The paddle wheel 62 continues to pull or draw the accumulated pillow chain 22 from the interior volume 40 of the accumulation box 12, with the first guide 76 and the first portion 80 of the second guide 78 guiding the chain 22 to the paddle wheel 62. The aforementioned constraint of the pillow 20 by the first side wall 30 and the second side wall 31 can help ensure that the chain 22 does not become tangled and is fed to the paddle wheel 62 in a jam-free manner.

[0095] Reference Figure 2 , the pillow 20 is guided in a curved path and maintained in contact with the paddle wheel 62 by the circular segment of the second portion 84 of the guide 78. The chain 22 of the pillow 20 eventually reaches the vertical segment of the segment portion 84, at which point the chain 22 travels downward. The chain 22 then exits the transfer unit 14 through the exit 86. When the operator releases the foot pedal, or when a predetermined number of pillows 20 have been dispensed from the dispensing unit 14, the control unit 58 deactivates the motor 64.

[0096] The device 10 also includes a wiper that helps separate the pillow 20 from its adjacent blade 72 in the event that the pillow 20 adheres to the blade 72 due to static friction or other factors. The wiper can be, for example, a brush 88, such as Figure 2 As shown in . A brush 88 is mounted on the first side panel 60 or the second side panel 61 adjacent to the outlet 86. The brush 88 extends upward so that the upwardly oriented bristles of the brush 88 contact each blade 72 as the blade 72 rotates past the brush 88. The brush 88 is inclined in a downward direction, that is, in the direction of movement of the chain 22. The brush 88, including its bristles, is configured to have sufficient rigidity to prevent the pillow 20 from moving along with its associated blade 72 if the pillow 20 fails to separate from the blade 72 when the blade 72 approaches the outlet 86 and begins to rotate in an upward direction away from the outlet 86. The brush 88 is flexible enough to avoid damaging the pillow 20. In alternative embodiments, the anti-sticking device can be a tab, a reed, or other device having the above-mentioned characteristics.

[0097] The device 10 also includes another anti-reverse feature that prevents the pillow chain 22 from moving upstream (i.e., in a direction opposite to the direction in which the chain 22 is fed by the transfer unit 14) away from the paddle wheel 62 after the motor 64 is deactivated and the paddle wheel 62 is no longer pulling the chain 22 of pillows 20 in the downward direction. The anti-reverse feature can be, for example, a brush 90 mounted on the first or second side panel 61 just upstream of the first guide 76 and angled upward in the downward direction. Figure 2 . The brush 90, including its upwardly oriented bristles, is configured to be flexible enough to allow the pillow 20 to pass over the brush 90 as the pillow 20 travels downstream toward the paddle wheel 62, while being rigid enough to prevent the chain 22 from moving in an upward direction when the paddle wheel 62 is not rotating. In alternative embodiments, the anti-reversal feature may be a tab, a reed, or other device having the aforementioned characteristics.

[0098] In alternative embodiments of the apparatus 10, the transfer unit 14 can be configured to move the web 22 linearly or in another non-rotational manner. In such embodiments, the rotating structure of the transfer unit 14 (e.g., the paddle wheel 62) can be replaced by a structure that moves the web 22 in a linear or non-rotational direction.

[0099] The separation unit 16 is located just downstream of the outlet 86 and automatically separates the string of dispensed pillows 20 from the rest of the chain 22. Alternative embodiments of the device 10 may be configured without the separation unit 16.

[0100] In embodiments without a separating unit 16, an operator can manually tear the string of dispensed pillows 20 from the remainder of the chain 22. The webs 24 of the chain 22 used in such embodiments may include perforations that permit the webs 24 to be torn without deflation or otherwise damaging the adjacent inflated portions 23 of the pillows 20. Due to the reverse-angled orientation of the blades 72 of the paddle wheel 26, the blade 72 that contacts the particular web 24 to be torn is angled away from the direction in which the chain 24 is pulled by the operator to tear the web 24. Thus, the pulling force will drive the tip of that particular blade 72 further toward the underlying web 24 and the lower surface of the second guide 82. The friction created between the blade 72, web 24, and second guide 82, combined with the deactivated motor 64, causes a braking or ratcheting force that holds the paddle wheel 62 and entrained web 24 in place as the web 24 is torn across its perforations, which in turn allows an operator to quickly and easily retrieve a string of dispensed pillows 20 in embodiments not equipped with a separation unit 16.

[0101] The separation unit 16 automatically separates the string of pillows 20 from the remainder of the chain 22 of pillows 20 after the string of pillows 20 has been dispensed. Figure 2 and Figure 3 As seen in FIG, the separation unit 16 is mounted directly below the transfer unit 14 so that the pillows 20 can pass through the separation unit 16 when leaving the transfer unit 14 through the outlet 86 .

[0102] Reference Figures 6 to 16 The separation unit 16 comprises an actuator 100 and a press in the form of a pressure rod 102 connected to the actuator 100. The actuator 100 may be, for example, a pneumatic actuator. The actuator 100 is configured to cause the pressure rod 102 to Figure 6 and Figure 12 The first or retracted position shown in Figure 9 and Figure 16 , and moves linearly between the second or extended position shown in FIG.

[0103] The separation unit 16 also includes an anvil 104 and a protective element in the form of a guard or cover 108. The cover 108 is mounted on the anvil 104 and is configured to Figures 6 to 8 and Figures 12 to 15 The first or safe position shown in Figure 9 and Figure 16 1 and 2. The cover 108 is linearly translated relative to the anvil 104 between the second or retracted position shown in FIG. The cover 108 is biased toward its safe position by a spring (not shown).

[0104] The separation unit 16 also comprises a cutting device in the form of a hot wire or cutting wire 110. Figure 10 and Figure 11 The cutting wire 110 is mounted on the anvil 104. During operation, when the web 24 of the pillow chain 22 is brought into contact with the cutting wire 110, the cutting wire 110 generates heat, which severs the web 24 of the pillow chain 22, as shown in FIG. Figure 10 In alternative embodiments, other types of cutting devices, such as flat film heaters, may be used in place of the cutting wire 110. In other alternative embodiments, the cutting device may be a sharp blade.

[0105] The separation unit 16 further comprises a bottom guard 140 comprising a movable portion 142 and a stationary portion 144. Figure 3 、 Figure 4 as well as Figures 7 to 9The movable portion 142 is connected to the actuator 100 so that the movable portion 142 translates linearly with the actuator 100 and the pressure rod 102. The stationary portion 144 is connected to the frame 37 so that the movable portion 142 can slide relative to the stationary portion 144 when the movable portion 142 translates linearly, as can be seen in FIG. Figures 7 to 9 It can be seen in.

[0106] When the pressure lever 102 and the cover 108 are in their respective retracted positions, the pressure lever 102 is spaced apart from the cover 108 such that the pressure lever 102 and the cover 108 define an opening 111 , as shown in FIG. Figure 12 The opening 111 is aligned with the outlet 68 in the transfer unit 14 so that the string of pillows 20 dispensed by the transfer unit 14 passes through the opening 111 when leaving the transfer unit 14. (For clarity, the Figure 6 A string of pillows 20 is shown in FIG. Figures 7 to 10 The string of pillows 20 is not shown). The pressure rod 102 pushes the specific web portion 24 to be cut into the cutting line 110 when moving from the retracted position to the extended position, as shown in FIG. Figure 10 As shown in FIG, the web portion 24 is caused to be cut by the heated cutting line 110, as shown in FIG. Figure 11 As shown in Figure 10 As can be seen in FIG, the restraint of the web 24 by the U-shaped member 116 of the pressure member 102 and the cover 108 can cause the web 24 to undergo some stretching before being cut. The separation unit 16 can include a fan (not shown) or other necessary means to help ventilate fumes and odors that may be generated by the heating of the web 24.

[0107] The control unit 58 is configured to activate the motor 56 of the dispensing unit 14 so that the paddle wheel 62 will rotate by specific angular increments according to and corresponding to the number of pillows 20 to be dispensed. For example, the paddle wheel 62 rotates approximately 60 degrees when one pillow is to be dispensed, approximately 120 degrees when two pillows are to be dispensed, approximately 180 degrees when three pillows 20 are to be dispensed, and so on.

[0108] The transfer unit 14 includes the necessary items to help ensure that the particular web 24 to be cut is aligned with the pressure bar 102 and the cutting line 110. For example, the transfer unit 14 includes six magnets 112 mounted at equally spaced angular increments on the side of the drum 70 of the paddle wheel 62. Figure 2 The magnets 112 are depicted in FIG. The transfer unit 14 also includes a magnetic switch (not shown) that generates an output when the magnetic switch is aligned with one of the magnets 112. The magnets 112 and the magnetic sensor are positioned so that when any magnet 112 is aligned with the magnetic switch, the web 24 of the pillow chain 22 will be aligned with the pressure bar 102 and the cutting line 110, as shown in FIG. Figure 2 and Figure 10 . Thus, magnet 112 and the magnetic switch serve as a means for indexing the angular position of paddle wheel 62 with the position of pressure bar 102 and the position of cut line 110 at the beginning of a dispensing cycle so that when paddle wheel 62 has dispensed the desired number of pillows 20, the particular web 24 to be cut will be aligned with pressure bar 102 and cut line 110. The software in controller 58 may also facilitate targeted adjustment of web 24 by allowing the operator to adjust a “home offset” parameter through a control interface with controller 58.

[0109] Control unit 58 includes a "home" switch that, when pressed by the operator, causes control unit 58 to activate motor 64 of transfer unit 14 to slowly rotate paddle wheel 62 until one of magnets 112 comes into alignment with the magnetic sensor. Thus, control unit 58, magnet 112, and magnetic switch act as a servo control system that allows operator 23 to "home" or "rehome" paddle wheel 62. The home or rehome operation can be performed at startup of device 10, or whenever the angular position of paddle wheel 62 has drifted from its correctly indexed position at the beginning of a dispensing cycle.

[0110] The cover 108 defines a narrow passage 113, as can be seen in Figure 10 and Figure 11 As can be seen in Figures 6 to 8 As can be seen in FIG, when the cover 108 is in the safety position, the cutting line 110 is positioned within the channel 113 such that the cutting line 110 is enclosed on three sides by the cover 108. When the cover 108 is enclosed within the channel 113, the likelihood of an operator coming into contact with the cutting line 110 is very low. Thus, the cover 108 acts as a safety device, which minimizes the likelihood of an operator or other person accidentally coming into contact with the heated cutting line 110. When the cover 108 is moved to the retracted position, as shown in FIG. Figures 9 to 11 As shown, the cover 108 no longer covers the cut line 110 , and the cut line 110 may sever the web 24 when the web 24 is brought into contact with the cut line 110 . Figure 10 and Figure 11 The web portion 24 is shown immediately before and after being cut or severed by the cutting line 110, respectively.

[0111] The pressure bar 102 includes a body 114 and a U-shaped member 116. The U-shaped member is mounted on the body 114 so that the U-shaped member 116 faces the cutting line 110 and the cover 108. Figure 10As can be seen in FIG, as the pressure rod 102 moves toward the extended position, the U-shaped member 116 is configured to contact the front or exposed end of the cover 108 at locations above and below the channel 113. Continued movement of the pressure rod 102 toward its extended position causes the U-shaped member 116 to push the cover 108 toward its retracted position against the spring biasing the lower cover 108. At the point when the pressure rod 102 reaches its extended position, as shown in FIG. Figure 9 、 Figure 10 and Figure 15 , the U-shaped member 116 has pushed the cover 108 completely into the retracted position, and the U-shaped member 116 spans the cutting line 110. Thus, although the cover 108 has been retracted away from the cutting line 110, people are still protected from inadvertently touching the cutting line 110 because the cutting line 110 is now covered by the U-shaped member 116.

[0112] Reference Figures 12 to 16 The separation unit 16 further comprises two control elements, for example in the form of locking arms 120, which are mounted on opposite sides of the cover 108. A first end of each arm 120 is coupled to the cover 108 so that the arm 120 can be moved relative to the cover 108. Figure 12 and Figure 13 The first or locked position shown in Figure 15 and Figure 16 , rotates between the second or unlocked position shown in FIG.

[0113] Each arm 120 has a slot 122 formed therein. The slot 122 has an elongated first portion 124 extending from a position near the second end of the arm 120 and a second portion 126 adjacent to the first portion 124. The second portion 126 is downwardly inclined and is at an angle of, for example, about 127 degrees from the first portion 124.

[0114] Each arm 120 has a catch 128 formed thereon proximate a first end of the arm 120. When the arm 120 is in its first or locked position, each catch 128 is configured to engage a corresponding flange or lip 130 located on a side of the anvil 104, as shown. Figures 12 to 14 The engagement of each catch 128 and its corresponding lip 130 prevents the cover 108 from moving from its secure position to its retracted position, helping to ensure that the cutting line 110 always remains at least partially covered and out of easy reach of the operator or other personnel.

[0115] The arms 120 are configured such that the catch 128 of each arm 120 disengages from its corresponding lip 130 when the pressure bar 102 moves from its retracted position toward its extended position. In particular, the pressure bar 102 includes two rollers 132 located on opposite sides of the pressure bar 102. Each roller 132 is positioned within the slot 122 of the corresponding arm 120. Figure 12 As shown in FIG, when the pressure bar 102 is in its retracted position, the roller 132 is located in the first portion 124 of the slot 122. Movement of the pressure bar 102 toward its extended position causes the attached roller 132 to translate relative to the arm 120 within the first portion 124 of the slot 122. Figure 14 As shown in FIG, continued movement of the pressure bar 102 toward its extended position eventually causes the roller 132 to reach the second portion 126 of the slot 122. Once the roller 132 enters the second portion 126, further movement of the pressure bar 102, combined with the downwardly angled orientation of the second portion 126, creates a cam effect that causes the arm 120 to rotate in a clockwise direction, as can be seen in FIG. Figure 14 and Figure 15 At the point where the U-shaped member 116 of the pressure rod 102 initially contacts the cover 108, as shown in FIG. Figure 15 As shown in FIG, the rotation of the arm 120 lifts the catch 128 away from its corresponding lip 130, thereby unlocking the cover 108 and allowing the cover 108 to move toward its retracted position in response to the continued movement of the pressure bar 102 toward its extended position. At this time, the continued movement of the pressure bar 102 toward its extended position causes the attached arm 120 to move, thereby moving the cover 108 into the retracted position within the anvil 104, as shown in FIG. Figure 16 As shown in .

[0116] During operation, the transfer unit 14 dispenses a string of pillows 20 through the outlet 86 by rotation of the paddle wheel 62. The length of the string is determined automatically by the control unit 58 or by the amount of time the operator has depressed the foot pedal or other actuating means of the device 10. The pillows 20, upon exiting the transfer unit 14, travel downwardly into the opening 111 defined by the pressure rod 102 and the cover 108 while the pressure rod 102 and the cover 108 are in their respective retracted positions, as shown. Figure 6 and Figure 12 The angular position of the paddle wheel 62 is indexed to the position of the pressure bar 102 and the position of the cut line 110 so that the particular web 24 to be cut is aligned with and positioned between the pressure bar 102 and the cut line 110 .

[0117] At this time, the control unit 58 activates the actuator 100 of the separation unit 16. Figure 7 、 Figure 13 and Figure 14As shown, the actuator 100 drives the pressure rod 102 toward the web 24. The U-shaped member 116 of the pressure rod 102 then contacts the web 24, which becomes clamped between the U-shaped member 116 and the cover 108, as can be seen in FIG. Figure 10 As the U-shaped member 116 is about to push the web portion 24 into the cover 108, the arm 120 has rotated to its unlocked position by interacting with the roller 132, as shown in FIG. Figure 15 As shown in .

[0118] Further movement of the pressure rod 102 toward the cover 108 causes the cover 108 to retract into the anvil 104, as in Figure 9 and Figure 16 Once the cover 108 has been retracted, the cutting line 110 is no longer disposed within the channel 113 in the cover 108, and the web 24 can come into contact with the cutting line 110 as it is pushed toward the cutting line 110 by the U-shaped member 116 of the pressure bar 102. Additionally, as the pressure bar 102 contacts the cover 108, the web 24 can be pulled and stretched toward the cutting line 110 between the prongs of the U-shaped member 116, as shown. Figure 10 As shown in .

[0119] Contact between the web 24 and the cutting line 110 cuts or severing the web 24, separating the string of dispensed pillows 20 from the remainder of the chain 22. Figure 11 At this point, the pressure lever 102 is in its extended position, and the cover 108 is in its retracted position, as shown in FIG. Figure 9 and Figure 16 As shown in .

[0120] Furthermore, when a cutting or severing action is performed to separate the string of pillows 20 from the rest of the chain 22, the controller 56 generates an output that causes the paddle wheel 62 to rotate slightly in a direction opposite to the dispensing direction (i.e., opposite to the direction in which the paddle wheel 62 is rotated to dispense the string). The reverse rotation of the paddle wheel 62 provides mechanical assistance in separating the string of pillows 20 from the rest of the chain 22. The reverse rotation also minimizes contact between the pillows 20 and the hot cutting line 110 by withdrawing the newly formed leading edge of the pillow chain 22 from the contact area of ​​the cutting line 110, thereby preventing the leading edge from adhering to the cutting line 100 and causing operational congestion in the device 10.

[0121] The string of pillows 20 is held in place after separation from the rest of the chain 22 by the U-shaped member 116 of the pressure bar 102 acting on the cover 108 so that the string of pillows remains suspended from the cutting unit 16, as shown. Figure 11, as shown in FIG. An operator or a separate automated device can easily remove a dispensed string of pillows 20 from the separation unit 16 by pulling on the dispensed string of pillows 20. Control unit 58 can command actuator 100 to move pressure rod 102 to its retracted position at the start of the next dispensing cycle, preparing separation unit 16 to receive the next string of pillows 20 to be dispensed from transfer unit 14. More specifically, in this operating mode, the start of the next or subsequent cycle for dispensing strings of pillows 20 to an operator or another automated device will cause actuator 100 to retract before the dispensing process begins. As described above, the next cycle can be initiated by an operator input to controller 58 via an input device such as a foot pedal, button, etc. The next cycle can also be initiated by a signal sent to device 10 from another automated device, or by another form of input provided to device 10.

[0122] Alternatively, the operator may select an operating mode in which the control unit 58 causes the actuator 100 to retract the pressure rod 102 immediately after the web 24 has been severed, causing the string of pillows 20 to fall freely from the separation unit 16 .

Claims

1. An apparatus for dispensing pillows for product packaging, each of the cushioning pillows comprising a first portion and a second portion, the second portions each having a thickness less than that of the first portion, the second portions of adjacent pillows abutting one another to form a continuous web of the pillows, the web defining peaks coinciding with locations of maximum thickness of the first portions and valleys located between the peaks, the apparatus comprising: A transfer unit, comprising at least one pushing member; wherein: The pushing member is configured to engage the web of the pillow such that the pushing member draws the web of the pillow into the transfer unit and moves the web of the pillow through the transfer unit toward an exit of the transfer unit, and The pushing member is inclined away from a rotational direction of the pushing member.

2. The device according to claim 1, wherein The pushing member includes a blade. The device according to claim 1 , further comprising a plurality of pushing members.

4. The device according to claim 1, wherein: The transfer unit further includes a hub; The pushing member is mounted on the hub; and The pushing member extends in a direction substantially tangential to an outer surface of the hub.

5. The device according to claim 1, wherein The transfer unit further includes a guide configured to guide the web of pillows along a path.

6. The device according to claim 5, wherein: The front side of the pushing member is configured to contact the pillow and advance the pillow; The front side of the pushing member is inclined at a first angle relative to an adjacent portion of the guide; The rear side of the pushing member is inclined relative to an adjacent portion of the guide at a second angle that is a supplementary angle to the first angle; and The first angle is smaller than the second angle.

7. The device according to claim 5, wherein The guide member comprises: a curvilinear portion configured to guide the web of the pillow along a curvilinear path; and A vertical portion is adjacent to the curvilinear portion and is configured to guide the web of the pillow to the outlet.

8. The device according to claim 5, wherein When the pushing member moves through the guide, the guide interferes with the pushing member.

9. The device according to claim 8, wherein The urging member is configured to flex in response to interference between the urging member and the guide.

10. The device according to claim 9, wherein The pushing member and the guide are configured such that a second portion of the pillow is entrained between a tip of the pushing member and the guide as the pushing member moves past the guide.

11. The device according to claim 3, wherein The spacing between the tips of adjacent pushing members is substantially equal to the length of the pillow.

12. The apparatus according to claim 5, wherein: The guide member is a second guide member; The dispensing unit further includes a first guide; The first guide and the second guide are configured to guide the web of the pillow toward the pushing member; the first guide and the second guide are spaced apart from one another by a spacing that ensures proper engagement of the web of pillow within the transfer unit; and The second guide is configured as a ramp that raises the web of the pillow as the second guide guides the web of the pillow along the path.

13. The apparatus according to claim 1, wherein: The pushing member is configured to advance the web of the pillow in a first direction, and The dispensing unit also includes an anti-reverse feature configured to inhibit movement of the web of the pillow in a second direction opposite to the first direction.

14. The device according to claim 13, wherein The anti-reversal feature includes a brush.

15. The device according to claim 1, wherein The dispensing unit also includes a wiper configured to contact the pillow and separate the pillow from the pushing member as the pushing member and the pillow rotate past the wiper.

16. The device according to claim 15, wherein The wiper includes a brush.

17. The apparatus of claim 1, further comprising a holding box, wherein The pushing member is configured to engage the web of the pillow when the pushing member is rotated such that the pushing member draws the web of the pillow from the holding box into the transfer unit.

18. The device according to claim 18, wherein The transfer unit is configured to be mounted on and removed from the holding box as a modular unit.

19. The device according to claim 17, wherein The holding box includes a door configured to provide access to an interior volume of the holding box and to the transfer unit.

20. The device according to claim 1, wherein The pillow is an inflatable pillow.

21. The device according to claim 20, wherein One or more of the pillows are not properly inflated.

22. The device according to claim 1, wherein The transfer unit is further configured to simultaneously engage two or more of the pillows.

23. The device according to claim 1, wherein The transfer unit is further configured to dispense a predetermined number of pillows.

24. The apparatus according to claim 1, wherein The pushing member is further configured to avoid damaging the web of the pillow while drawing the web of the pillow into and through the transfer unit.

25. An apparatus for dispensing pillows for product packaging, each of the cushioning pillows comprising a first portion and a second portion, the second portions each having a thickness less than that of the first portion, the second portions of adjacent pillows abutting one another to form a continuous web of the pillows, the web defining peaks coinciding with locations of maximum thickness of the first portions and valleys located between the peaks, the apparatus comprising: A separation unit configured to receive a web of packaging articles, wherein the separation unit comprises: anvil, a cover mounted on the anvil and configured to move relative to the anvil between a first position and a second position of the cover, a press movable between a first position and a second position of the press; and a cutting device mounted on the anvil and configured to sever the second portion of the pillow upon contact therewith, wherein: When the cover is in the first position of the cover, the cover at least partially encloses the cutting device; The press is configured to move the cover from the first position of the cover to the second position of the cover and push the web into the cutting device when the press is moved from the first position of the press to the second position of the press, and When the cover is in the second position of the cover, the press is configured to at least partially enclose the cutting device.

26. The device according to claim 25, wherein The cutting device comprises a cutting wire.

27. The apparatus of claim 25, further comprising a control element coupled to the cover and configured to rotate relative to the cover between a first position and a second position of the control element; wherein: The control element is configured to engage the anvil when the control element is in the control element's first position; and Engagement of the control element and the anvil prevents movement of the cover from the first cover position to the second cover position.

28. The apparatus according to claim 26, wherein The control element includes a locking arm including a latch configured to engage the anvil when the control element is in the control element's first position.

29. The apparatus of claim 28, wherein: The press includes rollers; the locking arm having a slot formed therein, and the slot being configured to receive the roller; the roller translates within the slot as the press moves from a first position of the press to a second position of the press; and The slot is configured such that translation of the roller within the slot causes the control element to rotate relative to one another between a first position and a second position of the control element.

30. The apparatus of claim 29, wherein: The slot includes a first portion extending in a first direction and a second portion extending in a second direction different from the first direction; and The slot is further configured such that translation of the roller within the second portion of the slot urges the control element from the first position of the control element to the second position of the control element.

31. The apparatus according to claim 25, wherein When the cover is in the second position of the cover, the cover does not enclose the cutting device.

32. The apparatus of claim 25, wherein: The cover defines a channel configured to receive the cutting device when the cover is in the cover's first position.

33. The apparatus according to claim 32, wherein The press comprises a body and a U-shaped member mounted on the body and facing the cutting device and the cover, wherein the U-shaped member is configured to contact ends of the cover at positions above and below the channel when the press moves from a first position of the press to a second position of the press.

34. The apparatus according to claim 33, wherein The U-shaped member is configured to pull and stretch the second portion of the pillow between the prongs of the U-shaped member when the press is moved from the first position of the press to the second position of the press.

35. The apparatus of claim 34, wherein: The U-shaped member is further configured to at least partially enclose the cutting device when the cover is in the second position of the cover.

36. The apparatus of claim 34, wherein: The U-shaped member and the cover are also configured to contact and clamp the second portion of the pillow at locations above and below the channel.

37. The apparatus of claim 25, wherein: The separation unit further includes an actuator configured to move the press between a first position of the press and a second position of the press.

38. The apparatus of claim 37, further comprising a transfer unit comprising a pushing member and a motor, the motor being configured to move the pushing member during operation, wherein: the pushing member being configured to engage the web of the pillow such that the pushing member draws the web of the pillow into the transfer unit and moves the web of packaged articles along a path within the transfer unit and out of an exit of the transfer unit; the press bar and the cover defining an opening configured to receive a web of the pillow when the press is in the press's first position; and The opening defined by the press and the cover is located directly below the outlet of the transfer unit.

39. The apparatus of claim 38, wherein: The apparatus further includes a control unit communicatively coupled to the motor; and The control unit and the motor are configured to position the pushing member in a plurality of predetermined positions where one of the second portions of the pillow is aligned with the press and the cutting device.

40. The apparatus of claim 39, wherein: The transfer unit further includes a hub, a plurality of pushing members mounted on the hub; a plurality of magnets mounted on the hub; and a sensor; the sensors and the magnets being configured such that the sensors are aligned with corresponding ones of the magnets when the push member is positioned in a predetermined angular position; the sensor being configured to generate an output indicating when the sensor is aligned with either of the magnets; and The control unit and the motor are further configured to position the pushing member such that one of the magnets is aligned with the sensor.

41. The apparatus according to claim 40, wherein The control unit and the motor are configured to reverse the rotation direction of the hub when or after the cutting device severs the web portion of the pre-inflated pillow.

42. The apparatus according to claim 41, wherein The control unit and the motor are further configured to reverse the rotation direction of the hub when or after the cutting device severs the web portion of the packaging product so that contact between the leading edge of the packaging product web and the cutting device is minimized.

43. An apparatus for dispensing pillows for product packaging, each of the cushioning pillows comprising a first portion and a second portion, the second portions each having a thickness less than that of the first portion, the second portions of adjacent pillows abutting one another to form a continuous web of the pillows, the web defining peaks coinciding with locations of maximum thickness of the first portions and valleys located between the peaks, the apparatus comprising: a holding box defining an interior volume configured to receive the web of the pillow; a duct defining a channel configured to receive a web of the pillow and direct the web of the pillow in a first direction to an interior volume of the holding box; an air circulation device in fluid communication with the channel and configured to direct air into the channel at a pressure and flow rate sufficient to move a web of packaging articles through the channel in the first direction during operation; and An anti-reverse feature is mounted within the channel and is configured to inhibit movement of the web of the pillow in a second direction opposite the first direction.

44. The device according to claim 43, further comprising a transfer unit comprising a pushing member, wherein The pushing member is configured to engage the web of the pillows such that the pushing member draws the web of the pillows from the holding box into the transfer unit and advances the web of packaged articles within the transfer unit toward an outlet of the transfer unit.

45. The apparatus of claim 43, wherein: The pipe is mounted on an outer surface of the holding box; and The conduit and an outer surface of the holding box define the passage.

46. ​​The apparatus of claim 45, wherein The anti-reversal feature includes a tab.

47. The apparatus of claim 43, wherein: The interior volume of the holding box has a width substantially equal to the maximum width of the packaged articles.

48. The apparatus of claim 43, wherein: the holding box including a first side wall and a second side wall, the first side wall and the second side wall being separated by a distance, the distance defining a width of an interior volume of the holding box; and Significant movement of the pillow within the holding box in the width direction of the pillow is restricted by the first side wall and the second side wall.

49. The apparatus of claim 43, wherein: The channel has a width that is approximately equal to the maximum width of the pillow.

50. The apparatus of claim 43, wherein The channel has a substantially vertical orientation.

51. The apparatus of claim 43, wherein: The channel has a cross-sectional dimension that is approximately equal to the thickness and maximum width of the packaged article.

52. The apparatus of claim 43, wherein: The air circulation device is one of a fan and a blower.

53. The apparatus of claim 43, wherein: The box is configured such that the web of the pillow falls toward the bottom of the holding box and folds over itself after entering the holding box.

54. The apparatus of claim 53, wherein: The box is also configured such that the web of the pillows folds in a random pattern after entering the holding box.

55. The apparatus of claim 43, wherein The packaging product is an inflatable pillow.

56. The apparatus of claim 55, wherein: Also included is an inflation and sealing machine positioned relative to the holding box such that the web of pillows exits the inflation and sealing machine at a point below the bottom of the holding box, wherein the inflation and sealing machine is configured to form a web of inflatable pillows and feed the web into the holding box.

57. The apparatus of claim 43, further comprising a conveyor positioned below a bottom portion of the holding box.

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