Product packaging system and method

Abstract

Packaging systems and methods supply dunnage products to a dispensing assembly for dispensing from a supply source to a selected one of a plurality of packaging stations. The dispensing assembly includes a closed dispensing path, at least one dunnage carrier configured to transport dunnage products along the dispensing path, a plurality of control surfaces, and a dunnage deflector at each packaging station. Each control surface has a plurality of cam paths. The dunnage carrier includes at least one cam follower configured to engage a selected one of the cam paths. The dunnage deflector is selectively operable to engage the dunnage product in the dunnage carrier to direct the cam follower onto a selected cam path to transport the dunnage product to a selected one of the packaging stations.

Description

Technical Field

[0001] This invention relates to a product packaging system, and more particularly to a padding conveying mechanism for use with a padding changer in the packaging system. Background Technology

[0002] When products are transported from one location to another, they are typically transported in containers with protective packaging materials. Containers can be cardboard boxes. Protective packaging materials can be plastic air cushions, paper pads, foam pads, or other elastic materials.

[0003] A cushioning converter or changer can be used to convert raw materials (such as paper sheets, plastic sheets, or foam) into cushioning products or padding mats. The changer typically discharges the cushioning product through an outlet into a transition zone (such as a holding or temporary storage zone) in a predetermined discharge direction, from which the cushioning product can then be removed for insertion into containers for packaging purposes. Summary of the Invention

[0004] This invention relates to a system and method for supplying and distributing padding products to multiple packaging stations. The system features a padding product supply and distribution assembly, and multiple packaging stations, combined to provide a packaging system and method with advantages over existing packaging arrangements. Specifically, an exemplary packaging system includes supplied padding products, multiple packaging stations, and a distribution assembly that selectively distributes the padding products from a supply source to a selected packaging station, maintaining automatic supply of padding products to the packaging station. The distribution assembly includes: one or more padding carriers that transport the padding products from the supply source to the selected packaging station; and a control surface having a cam path that engages with a cam follower on the padding carrier to control the opening and closing of the padding carrier for retrieving and storing the padding products without requiring power to the padding carrier. When the cam follower engages the cam path, movement of the padding carrier causes it to open or close against a biasing force, thereby simplifying the distribution assembly.

[0005] Describing the claims, an exemplary packaging system includes at least one supply source of padding product, multiple packaging stations, and a dispensing assembly that selectively dispenses the padding product from the supply source to a selected packaging station among the packaging stations. The dispensing assembly includes a closed dispensing path, at least one padding carrier, multiple control surfaces, and a padding deflector. The at least one padding carrier is configured to transport the padding product along the dispensing path, and the padding deflector is located at each of the supply source and each packaging station. Each control surface has multiple cam paths, and one of the control surfaces is positioned adjacent to each packaging station. The padding carrier includes at least one cam follower configured to engage a selected cam path among the cam paths. The padding deflector at each packaging station is selectively operable to engage the padding product in the padding carrier to guide the cam follower of the padding carrier onto the selected cam path to transport the padding product to the selected packaging station. The control surfaces are also positioned adjacent to the supply source.

[0006] In one or more embodiments, the system further includes a controller that selectively controls a pad deflector at each packaging station to distribute pad products to a selected packaging station.

[0007] In one or more embodiments, the dispensing component includes a conveyor that defines a dispensing path and is capable of transporting at least one padding carrier along the dispensing path.

[0008] In one or more embodiments, the distribution path is raised above the packaging station.

[0009] In one or more embodiments, the padding deflector at each packaging station is selectively movable between an extended position and a retracted position away from the extended position for engaging the padding product in the padding carrier.

[0010] In one or more embodiments, the supply of padding material includes a converter that transforms sheet material into a padding product having a lower density than the sheet material.

[0011] In one or more embodiments, the converter is a cushioning converter capable of converting kraft paper into cushioning padding products.

[0012] In one or more embodiments, the converter is mounted on a stand in an elevated position.

[0013] In one or more embodiments, at least one packaging station includes a receiver for receiving and storing the padding product before it is needed.

[0014] In one or more embodiments, each packaging station includes a receiver for receiving and storing padding products before they are needed.

[0015] In one or more embodiments, the receiver has an opening on one side near the bottom surface of the receiver to facilitate the removal of the padding product in the order it is supplied to the receiver.

[0016] An exemplary packaging method includes the following steps: (a) supplying padding products from a supply source; (b) transporting the padding products from the supply source along a distribution path via a distribution component, wherein a plurality of packaging stations are arranged along the distribution path; and (c) controlling elements of the distribution component to deliver the padding products to a selected packaging station among the plurality of packaging stations.

[0017] In one or more embodiments, the transport step includes transporting the padding product in a clamping device mounted to the conveyor.

[0018] In one or more embodiments, the transport step includes: automatically opening a clamping device having a pair of jaws to receive padding product between the jaws as the conveyor moves the clamping device past the outlet of the supply source; and automatically closing the clamping device to capture the padding product between the jaws as the conveyor moves the clamping device past the supply source.

[0019] In one or more embodiments, the transport step includes automatically opening the clamping device as the conveyor moves the clamping device past a selected packaging station.

[0020] In one or more embodiments, the control step includes controlling a cushioning deflector at each of a plurality of adjacent packaging stations to move between an extended position and a retracted position to control the orientation of the cushioning product as it is transported through each packaging station.

[0021] In one or more embodiments, the control step includes controlling a pad deflector at each of a plurality of adjacent packaging stations to move between an extended position and a retracted position to control the orientation of the pad product and the clamping device as the pad product is transported through each packaging station, wherein the clamping device includes a cam follower that interacts with a cam path on a cam surface at each packaging station, the cam path controlling whether the clamping device moves to an open position.

[0022] In one or more embodiments, the supply step includes converting the sheet material into a padding product having a lower density than the sheet material.

[0023] In one or more embodiments, the conversion step includes converting kraft paper into a cushioning padding product.

[0024] In one or more embodiments, the conveying step includes storing the padding product in a receiver at a selected packaging station. Attached Figure Description

[0025] Figure 1 This is a front perspective view of an exemplary packaging system.

[0026] Figure 2 yes Figure 1 A magnified view of a part of the system.

[0027] Figure 3 yes Figure 1 A cross-sectional view of an exemplary padding conversion machine for the system.

[0028] Figure 4 It shows in Figure 1 The rear perspective view of the padding carrier used in the system shown.

[0029] Figure 5 It is in an operable configuration. Figure 4 A perspective view of a portion of the padding support of the system shown.

[0030] Figure 6 It is in a separate configuration Figure 4 A perspective view of a portion of the padding support.

[0031] Figure 7 yes Figure 1 A rear stereoscopic view of a portion of the system shown.

[0032] Figure 8 yes Figure 7 A right-side perspective view of a portion of the system shown.

[0033] Figure 9 yes Figure 7 A front stereoscopic view of a portion of the system shown.

[0034] Figure 10 yes Figure 1 The left perspective view of the padding conversion machine shown.

[0035] Figure 11 yes Figure 8 The system shown is a right-side perspective view, with the hollow padding support near the guide surface.

[0036] Figure 12 yes Figure 11 The left perspective view of the system shown shows the padding carrier engaging the guide surface.

[0037] Figure 13 yes Figure 12The left perspective view of the system shown, in which the padding carrier is located... Figure 12 The guide surface is located further downstream of the guide surface in the middle.

[0038] Figure 14 yes Figure 13 The rear perspective view of the system shown.

[0039] Figure 15 yes Figure 10 The right-side perspective view of the system shown shows the padding carrier being opened to capture the padding product.

[0040] Figure 16 yes Figure 10 The left perspective view of the system shown shows the padding carrier closing after passing through a guide surface without padding products.

[0041] Figure 17 yes Figure 10 The left perspective view of the system shown.

[0042] Figure 18 yes Figure 10 The left-side perspective view of the system shown shows the padding carrier closed to capture the padding product.

[0043] Figure 19 yes Figure 18 The left perspective view of the system shown shows the padding carrier transporting the padding product from the padding transfer machine.

[0044] Figure 20 This is a left-side perspective view of the padding carrier that transports padding products to the packaging station.

[0045] Figure 21 yes Figure 11 The system shown is a right-side perspective view, in which the padding carrier is close to the guide surface during the transport of the padding product.

[0046] Figure 22 yes Figure 15 The system shown is a right-side perspective view, in which the padding carrier approaches the outlet of the padding converter while transporting the padding product.

[0047] Figure 23 yes Figure 16 The system shown is a right-side perspective view, in which the padding carrier bypasses the outlet of the padding converter while transporting the padding product.

[0048] Figure 24 This is a right-side perspective view of the padding carrier that transports padding products to the packaging station.

[0049] Figure 25 yes Figure 1A top-down perspective view of the packaging station section of the system.

[0050] Figure 26 yes Figure 25 A front perspective view of the guide surface at the packaging station shown.

[0051] Figure 27 yes Figure 26 The front perspective view of the guide surface at the packaging station shown, with an empty padding carrier.

[0052] Figure 28 yes Figure 26 The front perspective view of the guide surface at the packaging station shown, where the padding carrier transports the padding product to the packaging station.

[0053] Figure 29 yes Figure 26 The front perspective view of the guide surface at the packaging station shown, in which the padding carrier transports the padding product.

[0054] Figure 30 yes Figure 29 An alternative front perspective view of the guide surface at the packaging station shown, in which the padding carrier transports the padding product.

[0055] Figure 31 yes Figure 30 An enlarged view of the padding support shown.

[0056] Figure 32 It was through Figure 27 The guide surface shown is in the front perspective view of the empty pad carrier in a closed configuration. Detailed Implementation

[0057] This invention generally provides a packaging system and method for supplying padding products to multiple packaging stations. See the accompanying drawings for details, first referring to... Figure 1 and Figure 2 An exemplary packaging system 100 includes a supply source 102 of dunnage product 104, a plurality of packaging stations 106, and a dispensing assembly 110 that selectively dispenses the dunnage product 104 from the supply source 102 to selected packaging stations among the packaging stations 106. The dispensing assembly 110 includes one or more dunnage carriers 112 (… Figure 4 The padding carrier 112 is configured to travel along a closed distribution path and transport padding product 104 along the closed distribution path. The supply source 102 and packaging station 106 of padding product 104 are arranged along the distribution path.

[0058] The dispensing assembly 110 also includes a plurality of control surfaces 114 at the supply source 102 and at each packaging station 106, the plurality of control surfaces 114 cooperating with the padding carrier 112 to control the retrieval and storage of padding product 104 as the padding carrier 112 moves along the dispensing path. The system 100 may also include a controller 120 that selectively directs the dispensing assembly 110 to deliver padding product 104 to the packaging station 106, or directs the supply source 102 to provide padding product 104 for transport, or a combination thereof.

[0059] The supply source 102 of the padding product 104 in the illustrated embodiment includes a padding converter 122, such as a converter commonly referred to as a cushioning converter. Cushioning converters have been used to convert sheet-like raw materials (such as paper) into a padding product or pad with a lower density than the original sheet-like raw material. An exemplary raw material is kraft paper. The resulting pads are typically relatively lightweight and have a relatively lower density than the raw materials used to manufacture them.

[0060] The cross-section of the exemplary padding converter 122 is in Figure 3 The diagram shows and includes a forming assembly 124 through which sheet material is advanced via a feed assembly 126. An exemplary sheet material is kraft paper, which may be fan-folded and provided to the padding converter in a rectangular stack. Pulling the sheet material through the forming assembly 124 causes the sheet material to wrinkle and causes the lateral edges to rotate inward to form a cushioning strip 128 having a lower density than the sheet material. The feed assembly 126 typically also engages with or otherwise acts on the wrinkled material to hold overlapping layers of the wrinkled material together to maintain the shape of the cushioning strip 126. Downstream of the forming assembly 124 and the feed assembly 126, a cutting assembly 130 cuts padding product 104 of the desired length from the cushioning strip 128.

[0061] The illustrated padding converter 122 produces padding products 104 having length, width, and thickness dimensions, with the length dimension being significantly larger than the width or thickness dimension. The converter discharges the padding products 104 longitudinally (generally in a first direction parallel to the length dimension) through an outlet 132 of the padding converter 122 in a generally horizontal discharge direction, wherein a shelf 134 presents and supports the padding products 124 for retrieval by one of the padding carriers 112 of the dispensing assembly 110. The padding converter 122 is mounted on a frame or stand 136 such that the padding products 104 are discharged at a convenient height for retrieval by the dispensing assembly 110 from the supply source 102.

[0062] The supply source 102 for padding product 104 is not limited to the use of paper padding or the types of cushioning pads described above. In alternative embodiments, different types of padding converters can be used to produce other types of padding, including gap-filling, cushioning, or blocking and supporting padding made of one or more of air bladders, foam-filled blocks or bags, paper tape, foam peanuts, etc. The supply source 102 for padding product 104 does not necessarily need to include a padding converter. For example, one or more padding converters can be remotely positioned to produce padding product 104 subsequently transported to supply source 102. In this case, supply source 102 would include a padding product storage element and a dispenser for dispensing padding product 104 via an outlet for retrieval by dispensing assembly 110.

[0063] return Figure 2 Each packaging station 106 includes a receiver 140 for receiving cushioning pads or other padding products 104 from the dispensing assembly 110 for subsequent use by the packaging machine. Each packaging station 106 will typically additionally or alternatively include a packaging surface (not shown) for supporting a container into which the padding product 104 will be placed by the packaging machine, or the padding product will be dispensed directly into the container without the packaging machine. Exemplary packaging surfaces may be provided by a workbench or conveyor belt. The receiver 140 will typically be located in an elevated position above the packaging surface, and the dispensing assembly 110 will be located above the receiver 140.

[0064] The receiver 140 shown in the figure has one or more openings 142 on its bottom facing one side, which make it easier for the packaging machine to retrieve the padding product 104 from the receiver 140. The receiver 140 can be considered as part of the dispensing assembly 110 or the packaging station 106.

[0065] The dispensing assembly 110 dispenses padding products 104 supplied by supply source 102 to packaging station 106. To achieve this, the dispensing assembly 110 may include a conveyor 146 that defines a dispensing path for the padding products 104 and transports the padding products 104 along the dispensing path. The conveyor 146 transports one or more padding carriers 112 in a conveying direction (generally referred to as the downstream direction). The upstream direction is opposite to the downstream direction. In the illustrated embodiment, when viewed from above, the conveyor 146 is an overhead conveyor, and the downstream direction is clockwise around the dispensing path.

[0066] One or more padding carriers 112 are configured to travel along a distribution path defined by conveyor 146 and are configured to retrieve padding products 104 from outlet 132 of supply source 102, transport and then release the padding products 104 at one of a plurality of packaging stations 106. Figures 4-6In the exemplary embodiment shown, each padding carrier 112 is connected to a section of conveyor 146 via a bracket 150 mounted to conveyor 146 and one or more magnetic elements 152 coupled to the padding carrier 112, to facilitate moving the padding carrier 112 to or removing the padding carrier 112 from conveyor 146 for adjustment, repair, or replacement. The illustrated embodiment employs two magnetic elements 152 arranged at right angles to each other. Magnets fixed to the conveyor or to the bracket 150, or a combination thereof, may be used. In the illustrated embodiment, a flexible belt 153 also facilitates securing the padding carrier 112 to conveyor 146 as a spare for the magnetic elements 152. Other fastening methods may be used to secure the padding carrier 112 to the bracket 150 or conveyor 146.

[0067] Each padding carrier 112 includes a mechanism for retrieving padding products, such as the gripping device 154 shown in the figure. The gripping device 154 may also be referred to as a gripper and is similar to a pair of pliers. The gripping device 154 thus includes a pair of arms, at least one of which rotates about a pivot axis 156. When mounted to a conveyor 146, the pivot axis 156 is generally oriented parallel to the direction of movement (downstream) of the conveyor. The arms of the gripping device 154 include a pair of control portions 160 and a pair of grippers 162. The control portions 160 are like the restraint or handle portions of the pliers, extending from one side of the pivot axis 156, and the grippers 162 extend from the opposite side of the pivot axis 156. The control portions 160 are used to control the gripping device 154 and specifically control the movement of the grippers 162. The pivot 156 allows the clamping device 154 to move between a closed position and an open position. In the closed position, the distal ends of the clamps 162 are brought close together to hold the padding product 104 between the distal ends of the clamps 162. In the open position, the distal ends of the clamps 162 are further spaced apart to transport the padding product 104 to one of the packing stations 106 or to be ready to receive the padding product 104 at the outlet 132 of the supply source 102.

[0068] Therefore, the illustrated clamping device 154 uses a squeezing motion to engage and hold the padding product 104 between the distal ends of the grippers 162. The grippers 162 can also be referred to as arms, hands, or fingers, and their distal ends move toward and away from each other to grasp, hold, and release the padding product 104 between them. The distal ends of the grippers 162 may be provided with engagement surfaces to facilitate gripping the padding product 104, such engagement surfaces being, for example, a selected surface texture or material, an element of the perforated padding product 104, or an opening coupled to a vacuum source to hold the padding product 104 with suction, or other features facilitating gripping the padding product 104.

[0069] In the illustrated clamping device 154, the distal ends of the jaws 162 are connected by a flexible element 164 extending between the distal ends of the jaws 162. The flexible element 164 bends around a central portion 166 when the jaws 162 are in the closed position. Thus, the jaws 162 and the flexible element 164 form an opening in which the padding product 104 can be received and held for transport. As the jaws 162 move to the open position, the flexible element 164 straightens, and when the flexible element 164 is straightened between the jaws 162, the central portion 164 thereby facilitates the ejection of the padding pad 104 from the clamping device 154.

[0070] The illustrated clamping device 154 is biased to the closed position by a biasing element 170 (such as one or more springs or other elastic materials or structures). This allows the clamping device 154 to hold the padding product 104 during transport without any active energy requirements. Only energy is needed to move the gripper 162 to the open position against the action of the biasing element 170, and this energy can be provided by the movement of the conveyor 146, as discussed below. Alternative biasing elements 170 can be used to bias the clamping device 154 to the open or closed position.

[0071] Alternative types of clamping devices can be used instead of the clamping device 154 illustrated in the padding carrier 112. Furthermore, the padding carrier 112 can include alternative methods for receiving the padding product 104 at the outlet 132 of the supply source 102, holding the padding product 104 for transport, and releasing or distributing the padding product 104 at the packaging station 106. For example, a smaller, flowable padding product can be supplied in the carrier, and the clamping device 154 will transport the carrier along with the padding product on the conveyor 146.

[0072] Turn Figures 7-23The conveyor 146 not only transports the padding carrier 112 along the distribution path but also provides power to resist the action of the biasing element 170 to open the clamping device 154. In other words, movement of the padding carrier 112 is used to open the clamping device 154 to retrieve the padding product 104 from the outlet 132 of the supply source 102 and to store the padding product 104 at a selected packaging station 106. To achieve opening the clamping device 154, the distribution assembly 110 uses a control surface 114, which is positioned at each packaging station 106 adjacent to the conveyor 146 and adjacent to the outlet 132 of the supply source 102. A control portion 160 of the clamping device 154 is configured to engage the control surface 114 and move along the control surface 114 as the conveyor 146 advances the padding carrier 112. For this purpose, the distal end of the control portion 160 may be fitted with a bearing or a rotating bushing comprising a bushing made of a low-friction material. The interaction between the control section 160 and the control surface 114 controls the clamping device 154 and its open position. Figure 15 ) and closing position ( Figure 12 The movement between the grippers 162 and the control surface 114 defines the path used as a cam (also referred to as the cam path), and the control portion 160 acts as a cam follower to achieve the desired pivoting movement of the grippers 162. By using the control surface 114, no active power mechanism is required on each pad carrier 112 to open and close the grippers 154 as it moves between the open and closed positions.

[0073] Depending on whether the clamping device 154 needs to be in an open or closed position, each control surface 114 provides multiple paths for the control portion 160 of the clamping device 154. These paths may be defined by grooves, recesses, or protrusions that receive or otherwise engage the distal end of the control portion 160 of the clamping device 154 as the conveyor 146 moves the pad carrier 112 past the control surface 114. These paths may also be referred to as cam paths or cam tracks. In the illustrated embodiment, each control surface 114 includes three paths that approach and branch off to separate or converge the distal end of the control portion 160 or bring the distal ends of the control portion 160 together and thus move the gripper 162 between a closed and open position.

[0074] To control which paths the control section 160 takes on the control surfaces 114, a bypass arm 176 is installed in front of each control surface 114 adjacent to the conveyor 146. The bypass arm 176 is positioned to engage the padding product 104 held in the clamp 162 as the padding carrier 112 moves past it. The bypass arm 176 influences the orientation of the clamping device 154 by engaging the padding product 104. The bypass arm 176 may alternatively be referred to as a padding influencer or padding guide. The bypass arm 176 is installed upstream of and in front of the control surfaces 114 such that the padding carrier 112 passes over the bypass arm 176 before the control surfaces 114.

[0075] In the illustrated embodiment, a control surface 114 is mounted on the inside of a conveyor 146, and a bypass arm 176 is mounted on the outside of the conveyor 146. The inside of the conveyor 146 is inside the closed dispensing path defined by the conveyor 146, and the outside of the conveyor 146 is opposite to the outside of the closed dispensing path defined by the conveyor 146. The bypass arm 176 interacts with the padding product 102 held by the clamping device 154 to rotate the clamping device 154 about a pivot axis 156, and thus guides the control portion 160 of the clamping device 154 to engage the control surface 114, such that the control portion 160 and the control surface 114 move the clamping device 154 to a desired position.

[0076] If the padding carrier 110 holds the padding product 104 as it approaches the supply source 102, then the clamping device 154 should remain in the closed position. The clamping device 154 does not need to open (move to the open position) to release the padding product 104 at the supply source 102. The clamping device 154 does not need to move to the open position to receive the padding product 104 from the supply source 102. Therefore, the bypass arm 176 guides the padding carrier 112 to move past the supply source 102 while holding the padding product 104 and keeping the clamping device 154 in the closed position (see [link to relevant documentation]). Figures 21-23 As the pad carrier 112 travels past the bypass arm 176, the bypass arm 176 engages the pad product 104. This causes the clamping device 154 to rotate about the pivot axis 156 to a rotational orientation and guides the two control portions 160 into a common bypass path on the control surface 114. In the illustrated embodiment, the bypass path is the uppermost path. The bypass path allows the clamping device 154 to remain in the closed position as the pad carrier 112 passes the outlet 132 of the supply source 102.

[0077] This rotational orientation of the clamping device 154 positions the control portion 160 vertically above the gripper 162, such that the padding product 102 held in the gripper 162 passes below the shelf 134 at the outlet 132 of the supply source 102. When the control portion 160 leaves the control surface 114, the control surface 114 can guide or allow the control portion 160 to rotate the clamping device 154 away from the rotational orientation, placing the control portion 160 in a generally horizontal, non-rotating, default, or transport orientation as the padding carrier 110 transports the padding product 102 forward to a selected packaging station in the packaging station 106.

[0078] If the padding carrier 110 is empty and there is no padding product 104 when it approaches the supply source 102, the clamping device 154 needs to be in the open position to retrieve the padding product 104 from the supply source 102. The padding carrier 112 travels past the bypass arm 176, which does not rotate the clamping device 154 to a rotational orientation. The bypass arm 176 is positioned to engage the padding product 104 held in the jaws 162 of the clamping device 154, or to engage the upper jaw 162 of the clamping device 154 (raised if there is padding product 104 between the upper and lower jaws 162). Therefore, the absence of padding product 104 means that the padding carrier 112 is not affected by the bypass arm 176.

[0079] The illustrated clamping device 154 includes two control portions 160: a first control portion or first cam follower 190 and a second control portion or second cam follower 192. When the system 100 wants to open the gripper 162 (moving the gripper 162 of the clamping device 154 to the open position), as the control portion 160 engages the control surface 114, the control surface 114 separates the control portions 190 and 192 and guides them into different paths. The first control portion 190 (lower control portion) generally travels along a path parallel to the direction of travel (downstream direction). In the illustrated embodiment, this path is generally horizontal. The second control portion 192 (upper control portion) (whose distal end is spaced apart from the distal end of the first control portion 190) engages the control surface 114 such that the second control portion 192 follows another path. This path is generally located between the horizontal path and the uppermost path (bypass path), and can therefore be referred to as an intermediate path. The paths of the first control section 190 and the second control section 192 branch vertically, such that at least one of the grippers 162 of the gripping device 154 rotates about the pivot axis 156 to move the gripping device 154 to the open position.

[0080] In the open position, the clamping device 154 is ready to receive the padding product 104 from the outlet 132 of the supply source 102. As the padding carrier 110 passes the outlet 132 of the supply source 102, the control surface 114 brings the paths of the control portions 190, 192 together, allowing the flexible element 164 to move the jaws 162 together, capturing the padding product 104 (if present) on the shelf 134 at the outlet 132 of the supply source 102. In the illustrated embodiment, the intermediate path ends abruptly, allowing the biasing element 170 to quickly return the jaws 162 of the clamping device 154 to the closed position and capture the padding product 104 in the opening of the clamping device 154 between the jaws 162.

[0081] In the illustrated embodiment, the control surface 114 at the supply source 102 is located on a bend in the conveyor 146 and follows the bend of the conveyor 146. In other words, the control surface 114 is parallel to the distribution path defined by the conveyor 146. If the conveyor 146 is straight near the supply source 102, the control surface 114 will also be straight. In the illustrated configuration, vertical displacement of the path defined by the control surface 114 is used to move the clamping device 154 from a closed position to an open position. The curvature of the control surface 114 does not affect whether the clamping device 154 is in the open or closed position as the control surface 114 follows the path of the conveyor 154. The control surface is also curved relative to the pivot axis 156, allowing the control portion 160 to engage different paths of the control surface without constraint. The distance between the control surface 114 and the pivot axis 156 is typically based on the length of the control portion 160 relative to the pivot axis 156. The different lengths of the first control portion 190 and the second control portion 192 can also be used in conjunction with the features of the control surface 114 to guide one of the desired portions of the first control portion 190 and the second control portion 192 in a funnel-like or otherwise manner to the desired path.

[0082] See now Figures 21-32 Conveyor 146 and padding carrier 112 transport padding product 104 to a selected packaging station among packaging stations 106. Operating similarly to control surface 114 at supply source 102, at control surface 114 adjacent to each packaging station 106, first control portion 190 and second control portion 192 can be guided onto vertically branching paths to open gripper 162. However, at the selected packaging station 106, gripping device 154 moves to the open position to release padding product 104 and transport padding product 104 to packaging station 106. In the illustrated embodiment, when gripping device 154 moves to the open position causing gripper 162 to separate, padding product 104 falls into receiver 140. In other words, gravity transports padding product 104 from padding carrier 112 to packaging station 106.

[0083] However, considering their different functions, the control surface 114 at each packaging station 106 is configured slightly differently from the control surface 114 at the supply source 102. Opening the gripping mechanism 154 when it is simultaneously in its generally horizontal transport orientation works well for receiving and capturing the padding product 104 at the outlet 132 of the supply source 102, and also allows the padding product 104 to fall from the gripping mechanism 154 into the receiver 140 at the packaging station 106. However, it is more definite to transport the padding product 104 to the packaging station 106 by rotating the gripping mechanism 154 to open the gripper 162 while facing downwards. In other words, besides controlling whether the gripping device 154 is in the open or closed position, the system 100 can use the bypass arm 176 and the control surface 114 to control the rotational orientation of the gripping device 154.

[0084] At each packaging station 106, the bypass arm 176 is typically controlled by a controller 120, which controls actuators to move the bypass arm 176 between an extended transport position and a retracted bypass position. The bypass arm 176 retracts, unlike the control surface 114 at supply source 102, so that it will not engage the padding product 104 if it is not being transported to packaging station 106. In this case, the control sections 160 all pass through control surface 114 along a common bypass path, and the clamping device 154 remains in the closed position without changing its orientation. The bypass path in control surface 114 at packaging station 106 is horizontal and parallel to the distribution path and conveyor 146.

[0085] However, if the padding product 104 is to be transported to the packaging station 106, the controller 120 moves the bypass arm 114 to an extended transport position. This can be achieved by an actuator 196 (such as a solenoid or pneumatic or electric motor or other power source). If the clamping device 154 holds the padding product 104, the padding product 104 will engage the bypass arm 176, causing the clamping device 154 to rotate about the pivot axis 156 to a rotational orientation. In the rotational orientation, the control portions 160 of the clamping device 154 (specifically, the first control portion 190 and the second control portion 192) engage corresponding branched paths on the control surface 114 at the packaging station 106. The control surface 114 at the packaging station 106 typically has only two paths: the aforementioned bypass path and the control path branching from the bypass path. A funnel or other guiding feature guides the second control portion 192 to the path that branches vertically from the bypass path engaged by the first control portion 190. As the first control section 190 and the second control section 192 follow their respective paths and separate vertically, the gripper 162 of the clamping device 154 moves to the open position to release the padding product 104. In the rotational orientation, the open mouth of the gripper 162 of the clamping device 154 faces downward and is below horizontal, and gravity pulls the padding product 104 out of the clamping device 154 to fall into the receiver 140, thereby transporting the padding product to the packaging station 106.

[0086] If the bypass arm 176 is in the extended transport position but the clamping device 154 is not holding the padding product 104, or if the bypass arm 176 is in the retracted bypass position, the padding carrier 112 passes through the bypass arm 176 without changing its orientation, and the control sections 190, 192 both traverse the bypass path. Therefore, the controller 120 can control the bypass arm 176 at each packaging station 106 to bypass one or more packaging stations 106 and transport the padding product 104 at subsequent packaging stations 106. Conversely, since the padding carrier 112 only bypasses the supply source 102 when transporting the padding product 104, the bypass arm 176 adjacent to the control surface 114 at the supply source 102 can remain in the extended position.

[0087] Each packing station 106 may also include a sensor 200 to detect how full adjacent receivers 140 are. The sensor 200 outputs a signal to the controller 120. Based on the signal from the sensor 200, the controller 120 may control the bypass arm 114 associated with the packing station 106 to move to an extended position, thereby "requesting" the delivery of the next padding product 104 transported by the padding carrier 112 to the packing station 106. To ensure that packing stations 106 on distribution paths further from the supply source 102 of the padding product 104 do not lack padding product 104, the controller 120 may control the bypass arm 176 at each packing station 106 to ensure equitable distribution of padding product 104 to the packing station 106. Therefore, alternative control methods are also conceivable, and controller 120 can control the corresponding bypass arm 176 to allow the padding carrier 112 to bypass one or more packaging stations 106 without transporting padding product 102, such as transporting padding product 106 to the packaging station 106 with the least amount of padding product 106 in its receiver 140 or to the packaging station 106 that consumes padding product 104 the fastest. Signals from sensor 200 can indicate that receiver 140 at a particular packaging station 106 is not full or empty and requires padding product 104. Signals from sensor 200 can alternatively indicate the degree of fullness of receiver 140 or simply whether receiver 140 is full enough to enable the detection of padding product 104 in receiver 140.

[0088] Controller 120 (in) Figure 1 (Illustrated schematically) The elements of the dispensing assembly 110 selectively dispense the padding product 104 to the corresponding packaging station 106. The controller 120 can then control the feeder 102 to supply the padding product 104 to the dispensing assembly 110 and control the dispensing assembly 110 to provide the padding product 104 to each packaging station 106. The supply source 102 can also operate independently of the controller 120, providing the padding product 104 so that the padding product 104 is always available at the outlet 132 once the previously supplied padding product 104 has been removed. Although the controller 120 typically operates without interaction from the packaging machine, input and output devices (such as a keyboard and display) can be provided, for example, to allow the packaging machine to access information from the controller 120 and to provide a way to input information to the controller 120. As another example, instead of a sensor in the controller receiver 140 informing when additional padding product 104 is needed, the packaging machine can use a foot pedal or other type of switch to signal to the controller 120 that packaging station 106 needs more padding product 104, and the controller 120 can then control the required delivery. Therefore, the controller 120 helps automate much of the packaging system 100.

[0089] Controller 120 is an electronic device or system that manages and controls the operation of other devices (such as conveyor 146, bypass arm 176, and supply source 102) in packaging system 100. Controller 120 may include components such as a microprocessor, memory, one or more input / output interfaces, and circuitry and software. A computer with a central processing unit, memory, and dedicated software can be used as the controller 120 to control the operating elements of packaging system 100.

[0090] In summary, supply source 102 provides a first padding product 104 at outlet 132. For example, a padding converter can convert raw material into a padding product, which is supported at outlet 132 on shelf 134. Conveyor 146 moves an empty padding carrier 112 along a distribution path to supply source 102. As padding carrier 112 approaches supply source 102, control portion 160 of clamping device 154 engages control surface 114 near supply source 102, and first control portion 190 and second control portion 192 separate as they travel along separate paths defined by control surface 114, thereby moving clamping device 154 to an open position. As the padding carrier 112 moves along the control surface 114 and passes the outlet 132 of the supply source 102, the path of the control surface allows control sections 190, 192 to rejoin, allows the clamping device 154 to return to the closed position, captures the padding product 104 on the shelf 134 at the outlet 132 of the supply source 132, and carries the padding product 104 away from the outlet 132 along the distribution path. The controller 120 controls the bypass arm 176 to transport the padding product to a selected packaging station among the packaging stations 106. At the packaging station 106 to be bypassed, the bypass arm 176 retracts, and the conveyor 146 moves the padding carrier 112 through the packaging station 106 without changing its orientation.

[0091] When the padding carrier 112 reaches the selected packaging station 106, the extended bypass arm 176 engages the padding product 104 and causes the gripper 154 to rotate about the pivot axis 156, thereby causing the jaws 162 and the padding product 104 to rotate downwards. The control portion 160 of the gripper 154 engages the control surface 114 near the selected packaging station 106, and the first control portion 190 and the second control portion 192 are guided onto a branched path. The branched path opens the jaws 162, moves the gripper 154 to the open position, allows the padding product 104 to fall out of the gripper 104, and transports the padding product 104 to the packaging station 106. The padding product 104 will fall into the receiver 140, and when the packaging machine is ready, the packaging machine will withdraw the padding product 104 through the opening 142 in the receiver for use in packaging containers for one or more objects for transport. The conveyor 146 continues to move the pad carrier 112 along the distribution path and returns to the supply source 102 to retrieve another pad product 104, continuing the process.

[0092] As understood from the foregoing, an exemplary method for supplying padding products from a supply source to multiple packaging stations includes the following steps: (i) transporting the padding products from an outlet of the supply source; (ii) moving a padding carrier along a distribution path passing through the outlets of the supply source and the multiple packaging stations; (iii) controlling the movement of the padding carrier between an open position and a closed position by means of interaction between the padding carrier and a control surface installed near each of the multiple packaging stations along the distribution path at the supply source and the multiple packaging stations; and (iv) selectively controlling the path defined by the control surface by a control arm associated with the padding carrier to move the padding carrier to an open position or a closed position at each of the supply source and the multiple packaging stations.

[0093] In summary, the exemplary packaging system 100 and method supply padding product 104 to a dispensing assembly 110 for dispensing from a supply source 102 to a selected packaging station among a plurality of packaging stations 106. The dispensing assembly 110 includes a closed dispensing path, at least one padding carrier 112 configured to transport the padding product 104 along the dispensing path, a plurality of control surfaces 114, and a padding deflector or bypass arm 176 at each packaging station 106. Each of the control surfaces 114 has a plurality of cam paths. The padding carrier 112 includes at least one cam follower or control portion 160 configured to engage a selected cam path on the control surface 114. The padding deflector 176 is selectively operable to engage the padding product 104 in the padding carrier 112 to guide the cam follower 160 onto the selected cam path to deliver the padding product 104 to the selected packaging station 106.

[0094] Although the invention has been shown and described with respect to a particular embodiment, equivalent changes and modifications will be made by those skilled in the art upon reading and understanding this specification and the accompanying drawings. In particular, regarding the various functions performed by the foregoing entities (parts, components, devices, compositions, etc.), unless otherwise stated, the terminology used to describe such entities (including references to “device”) is intended to correspond to any entity performing the specified function of the said entity (i.e., functionally equivalent), even if structurally not equivalent to the disclosed structures performing the functions of the exemplary embodiments of the invention illustrated herein.

Claims

1. A packaging system comprising: at least one supply of dunnage product; a plurality of packaging stations; and a dispensing assembly that selectively dispenses the dunnage product from the supply into a selected one of the packaging stations; wherein the dispensing assembly includes an enclosed dispensing path, at least one dunnage carrier configured to transport the dunnage product along the dispensing path, a plurality of control surfaces, and a dunnage deflector at the supply and at each of the packaging stations; wherein each of the control surfaces has a plurality of cam paths, and one of the control surfaces is positioned adjacent the supply and adjacent each of the packaging stations; wherein the dunnage carrier includes at least one cam follower configured to engage a selected one of the cam paths; wherein the dunnage deflector at each of the packaging stations is selectively operable to engage the dunnage product in the dunnage carrier to direct the cam follower of the dunnage carrier onto the selected one of the cam paths to transport the dunnage product into the selected one of the packaging stations.

2. The system of claim 1, further comprising a controller that selectively controls the dunnage deflector at each of the packaging stations to dispense the dunnage product into the selected one of the packaging stations. the dispensing assembly includes a conveyor that defines the dispensing path and is capable of transporting the at least one dunnage carrier along the dispensing path.

3. The system of claim 1 or any preceding claim, wherein, the dispensing path is elevated above the packaging stations.

4. The system of claim 1 or any preceding claim, wherein, the dunnage deflector at each of the packaging stations is selectively movable between an extended position for engaging the dunnage product in the dunnage carrier and a retracted position away from the extended position.

5. The system of claim 1 or any preceding claim, wherein, the supply of dunnage includes a converter that converts a sheet stock into a dunnage product having a lower density than the sheet stock.

6. The system of claim 1 or any preceding claim, wherein, the converter is a cushion converter capable of converting Kraft paper into a cushion dunnage product.

7. The system of claim 6, wherein, the converter is mounted on a gantry in an elevated position.

8. The system of claim 6, wherein, at least one of the packaging stations includes a receptacle for receiving and storing dunnage product therein prior to a need.

9. The system of claim 1 or any preceding claim, wherein, each of the packaging stations includes a receptacle for receiving and storing dunnage product therein prior to a need.

10. The system of claim 1 or any preceding claim, wherein, the receptacle has an opening on a side proximate a bottom surface of the receptacle to facilitate removal of dunnage product in an order in which the dunnage product was supplied into the receptacle.

11. The system of claim 10, wherein, 12. A method of packaging comprising the steps of: supplying dunnage product from a supply; transporting the dunnage product from the supply along a dispensing path via a dispensing assembly, wherein a plurality of packaging stations are arranged along the dispensing path; controlling elements of the dispensing assembly to transport the dunnage product to a selected one of the plurality of packaging stations. ​ 13. The packaging method of claim 12, wherein, The transporting step includes transporting the dunnage product in a clamping device mounted to the conveyor.

14. The packaging method according to claim 12 or any one of claims 12 to 13, wherein, The transporting step includes automatically opening the clamping device having a pair of jaws to receive a dunnage product between the pair of jaws as the conveyor moves the clamping device past the outlet of the supply and automatically closing the clamping device to capture the dunnage product between the pair of jaws as the conveyor moves the clamping device past the supply.

15. The packaging method according to claim 12 or any one of claims 12 to 14, wherein, The transporting step includes automatically opening the clamping device as the conveyor moves the clamping device past the selected packaging station.

16. The packaging method according to claim 13 or any one of claims 13 to 15, wherein, The controlling step includes controlling a dunnage deflector adjacent each packaging station of the plurality of packaging stations to move between an extended position and a retracted position to control the orientation of the dunnage product as the dunnage product is transported past each packaging station.

17. The packaging method according to claim 13 or any one of claims 13 to 16, wherein, The controlling step includes controlling a dunnage deflector adjacent each packaging station of the plurality of packaging stations to move between an extended position and a retracted position to control the orientation of the dunnage product and the clamping device as the dunnage product is transported past each packaging station, wherein the clamping device includes a cam follower that interacts with a cam path on a cam surface at each packaging station that controls whether the clamping device moves to an open position.

18. The packaging method according to claim 12 or any one of claims 12 to 17, wherein, The supplying step includes converting a sheet stock into the dunnage product, the dunnage product having a lower density than the sheet stock.

19. The packaging method of claim 18, wherein, The converting step includes converting Kraft paper into a cushion dunnage product.

20. The packaging method according to claim 12 or any one of claims 12 to 19, wherein, The transporting step includes transporting the dunnage product in a clamping device mounted to the conveyor. The transporting step includes automatically opening the clamping device having a pair of jaws to receive a dunnage product between the pair of jaws as the conveyor moves the clamping device past the outlet of the supply and automatically closing the clamping device to capture the dunnage product between the pair of jaws as the conveyor moves the clamping device past the supply. The transporting step includes automatically opening the clamping device as the conveyor moves the clamping device past the selected packaging station. The controlling step includes controlling a dunnage deflector adjacent each packaging station of the plurality of packaging stations to move between an extended position and a retracted position to control the orientation of the dunnage product as the dunnage product is transported past each packaging station. The controlling step includes controlling a dunnage deflector adjacent each packaging station of the plurality of packaging stations to move between an extended position and a retracted position to control the orientation of the dunnage product and the clamping device as the dunnage product is transported past each packaging station, wherein the clamping device includes a cam follower that interacts with a cam path on a cam surface at each packaging station that controls whether the clamping device moves to an open position. The supplying step includes converting a sheet stock into the dunnage product, the dunnage product having a lower density than the sheet stock. The converting step includes converting Kraft paper into a cushion dunnage product. The transporting step includes transporting the dunnage product in a clamping device mounted to the conveyor. The transporting step includes automatically opening the clamping device having a pair of jaws to receive a dunnage product between the pair of jaws as the conveyor moves the clamping device past the outlet of the supply and automatically closing the clamping device to capture the dunnage product between the pair of jaws as the conveyor moves the clamping device past the supply.

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