Method for the production of packaging cushions and associated production line
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- G KRAFT MASCHINENBAU CO WITH LTD LIABILITY
- Filing Date
- 2020-06-10
- Publication Date
- 2026-07-16
AI Technical Summary
Existing packaging cushions made of plastic are environmentally incompatible and their production is more expensive compared to cardboard counterparts, which require multiple folds and are less efficient in absorbing impact energy.
A method and production line that uses a cardboard web fed continuously through a conveyor belt, scored with parallel grooves for easier folding, folded symmetrically into a U-profile, glued, and cut to form cardboard packaging cushions without manual intervention, ensuring high production efficiency and environmental compatibility.
The method allows for high-volume, automated production of cardboard packaging cushions with improved impact energy absorption, reducing environmental impact and production costs while maintaining efficiency.
Smart Images
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Abstract
Description
[0001] The present application relates to a method for producing packaging cushions from a cardboard web according to claim 1. Furthermore, the present application relates to a production line for producing a plurality of packaging cushions according to claim 11.
[0002] A cardboard web is a web of material made from cardboard, the length of which is significantly greater than its width. The cardboard web is typically formed from several layers of paper of varying thicknesses, so that the cardboard is essentially a paper with a comparatively large thickness. In particular, the thickness of the cardboard can be at least 2 mm, preferably at least 3 mm. The width of a typical cardboard web suitable for the production of packaging cushions is typically in the range of 10 cm to 50 cm, while the length of the cardboard web is generally at least 30 m, preferably at least 50 m. In any case, the length of the cardboard web significantly exceeds its width, preferably by at least a factor of 20, more preferably by at least a factor of 30, and further preferably by at least a factor of 50.
[0003] Packaging cushions are used to protect the goods being packaged from damage, particularly from impacts. This applies, for example, to the packaging of flat, sheet-like goods, such as those made from engineered wood panels used in the furniture industry. Such goods are especially susceptible to damage during delivery from bumps or knocks, which can significantly impair the overall appearance of the package. Therefore, it is typically recommended to protect these items with packaging cushions that, for example, wrap around the edges of the package. In the event of a bump or knock, the cushions absorb the impact energy and prevent deformation of the package and its contents.The packaged goods themselves are therefore protected from the respective impact energy. State of the art
[0004] In the prior art, packaging cushions made of plastic are particularly well-known and can be manufactured industrially with great ease. Due to the numerous possibilities for adjusting the stiffness and thus the damping properties of such packaging cushions, these plastic packaging cushions are widely used.
[0005] However, such packaging cushions have the disadvantage of being significantly less environmentally friendly compared to packaging cushions made of cardboard. The use of plastic packaging cushions should therefore be reduced and, if possible, completely avoided. The same applies to the use of even a small amount of plastic in packaging cushions that are otherwise made of cardboard.
[0006] Accordingly, packaging cushions made entirely of cardboard are already known. However, these are disadvantageous in that their production is more complex compared to typical plastic cushions, since the cardboard usually has to be folded multiple times to create a cushion that is technically capable of absorbing impact energy and dissipating it through deformation. Task
[0007] The present application is therefore based on the task of providing a method by which packaging cushions made of cardboard can be manufactured more easily compared to the prior art. Solution
[0008] The underlying problem is solved according to the invention by the method of claim 1. Advantageous embodiments are described in the dependent claims.
[0009] The method according to the invention provides that the cardboard web is guided along a production line by means of a feeding device and manipulated in several process steps, so that packaging cushions are ultimately formed. The feeding device can in particular be formed by a conveyor belt by means of which the cardboard web is guided in a feed direction along the production line, preferably whereby the feed direction does not change during the process.
[0010] In a first process step, the cardboard web, preferably unfolded, is fed to a creasing unit by means of the feed device. This unit is designed to provide the cardboard web with a plurality of grooves extending parallel to the feed direction. The grooves are arranged parallel to each other and serve to weaken at least one upper layer of the cardboard web, thereby imprinting fold lines onto the web. These fold lines have the effect of making the cardboard web more prone to creasing than areas that have not been previously scored by the creasing unit. The fold lines thus form "designed crease points" where the cardboard web will crease as soon as a force acting perpendicular to a plane of the cardboard is applied to a specific section of the web.Advantageously, the grooves are made symmetrically with respect to a longitudinal axis of the cardboard web, so that a left and a right half of the cardboard web can be folded symmetrically to each other.
[0011] Following the creasing unit, the cardboard web is guided along a folding unit, which allows the cardboard web to be folded multiple times. For this purpose, opposite edges of the cardboard web are folded towards each other several times in opposite directions. A particularly advantageous method of achieving this is explained separately below.
[0012] The folded cardboard web is then fed to a gluing unit, which continuously introduces an adhesive into the gap between the folded edge strips of the cardboard web as the web is advanced. The gluing unit can, in particular, comprise at least one, preferably two, nozzles through which a preferably flowable and / or sprayable adhesive, for example in the form of paper glue, is applied. After the application of the adhesive, the two edge strips are pressed together under pressure, so that the adhesive comes into contact with the opposing surfaces of the edge strips and the edge strips are thus bonded together. The cardboard web then exists in the form of a rigid cushioning strip that cannot unfold on its own in the absence of external forces.
[0013] Finally, the cushioning strip is fed to a cutting device, which cuts it to length perpendicular to its feed direction. In this way, individual packaging cushions are successively cut from the cushioning strip. While the cushioning strip is preferably in the form of a continuous strip, produced by the production line, the final conversion into individual packaging cushions takes place by cutting the strip to length as described. The individual length of each packaging cushion is particularly easy to adjust by making the cut at the desired point on the cushioning strip, guided by the cutting device.
[0014] The method according to the invention has many advantages. In particular, it enables the production of a large number of packaging cushions by means of a conveyor belt production process, in which a respective cardboard web is processed continuously, preferably at a constant speed. In other words, the cardboard web does not have to stop at any time, so that the cardboard web is not fed to individual processing units at intervals, but is guided continuously along processing units that process the cardboard web as it moves towards the cushioning strip and finally the packaging cushions. This type of procedure is particularly advantageous with regard to the overall output of the production line. In other words, the method according to the invention allows the production of a particularly large number of individual packaging cushions in a specific period of time.
[0015] Another significant advantage is that the production of the packaging cushions can be fully automated. This means that no direct intervention by at least one machine operator is required for the production of the packaging cushions. In particular, no manual intervention on the packaging cushion itself or the underlying cardboard web is necessary. Employee involvement in the production of the packaging cushions is therefore limited to maintenance work and any necessary repairs.
[0016] In a particularly advantageous embodiment of the method according to the invention, in a first folding step, the folding device folds upwards in a clockwise direction relative to a plane of the cardboard web, in the feed direction, and extending from an associated left side edge of the cardboard web to a first fold line facing the left side edge. Simultaneously, partially overlapping, or subsequently, as a further component of the first folding step, an outer section in the right side edge of the cardboard web, extending from an associated right side edge of the cardboard web to a first fold line facing the right side edge, is folded upwards in a counterclockwise direction relative to the plane of the cardboard web. The outer sections of the cardboard web are then each in an upright position.The cardboard web, which previously lay flat on the feed device, is thus transformed, in cross-section, into a U-profile during the entire first folding step. Advantageously, the folding angle in the folding step, by which the outer sections are folded upwards relative to the cardboard plane, is between 80° and 100°, preferably between 85° and 95°, and more preferably 90°.
[0017] In a second folding step performed by the folding device, the outer sections, which are currently in their upright position, are then folded further, each time in the same direction as the first folding step. In other words, the outer section on the left (when viewed in the feed direction) is folded further clockwise, and the outer section on the right (when viewed in the feed direction) is folded further counterclockwise. This can again be done simultaneously, partially overlapping, or sequentially. The folding is carried out in such a way that the outer sections are each folded onto a surface of the remaining cardboard web. As a result, the cardboard web then has opposing, double-layered edge strips. Advantageously, these edge strips do not abut each other directly, but rather define a space between them in which the cardboard web is only a single layer.Advantageously, the width of the free space corresponds at least essentially to twice the thickness of the cardboard web.
[0018] In a third folding step, which is carried out by means of the folding device according to the preferred embodiment of the method according to the invention, the edge strips are each folded upwards towards each other relative to the plane of the cardboard, with the folding again taking place in accordance with the respective folding direction of the previous folding steps. Advantageously, the cardboard web, which previously lay flat on the feed device, is present at the end of the third folding step in the form of a rectangular (unglued) cushioning strip, which can in particular be solid, i.e., has no planned cavities between individual cardboard sections.
[0019] Advantageously, during the third folding step, both edge strips are folded upwards by a maximum of 85°, preferably a maximum of 80°, relative to the plane of the cardboard, in accordance with their direction of folding. This ensures that the edge strips together define a gap at their upper ends and, in particular, do not yet come into direct contact with each other. In this state, the still-unfinished cushioning strip has an approximately V-shape. This allows an adhesive to be introduced into the aforementioned upper gap by means of the adhesive device, which follows the folding device. Only after the adhesive has been introduced are the edge strips finally pressed together as described above and thus bonded, thereby completing the cushioning strip.
[0020] Furthermore, the method according to the invention can be particularly advantageous if the two folded edge strips are kept apart by means of a separating element during their feeding to the adhesive device. This separating element ensures that a gap remains between the opposing surfaces of the edge strips, into which the adhesive can be applied as explained above.
[0021] As already indicated above, the method according to the invention is particularly advantageous when the cardboard web is guided along the production line without interruption by means of the feed device. In particular, the cardboard web should not be stopped during the process, and preferably also not be slowed down.
[0022] Advantageously, the feed unit is operated at a constant feed rate. This can be in a range between 15 m / min and 35 m / min, preferably between 20 m / min and 30 m / min. This feed rate provides sufficient output of packaging cushioning while ensuring good processing of the cardboard web along the production line. In particular, this feed rate allows the cushioning strip to be cut to length using the cutting device without having to stop the feed unit.
[0023] For this purpose, it is particularly advantageous if the cutting device includes a cutting blade that can be inserted and retracted perpendicular to the feed direction of the cardboard web into a cross-section of the cushioning strip. The cutting blade can be pneumatically driven. When using such a cutting device, the cushioning strip is essentially "chopped off," with the cutting process occurring so quickly that the cushioning strip preferably does not need to be slowed down or stopped. Any "run-up" of the cushioning strip against the cutting blade of the cutting device can then be disregarded due to the high cutting speed.
[0024] The method according to the invention is particularly advantageous when a total of six grooves are introduced into the cardboard web using the creasing device. Regardless of the number of grooves, it is further advantageous if the grooves are introduced symmetrically into the surface of the cardboard web with respect to a longitudinal axis. In this way, the cardboard web can be folded symmetrically with respect to the longitudinal axis, starting from both of its side edges, so that the resulting cushioning strip and the packaging cushions produced therefrom are mirror-symmetrical with respect to a central plane of symmetry. The combination of such a configuration with the introduction of a total of six grooves allows the cardboard web to be folded three times per side, so that the finished packaging cushion thus has a total of six folds.
[0025] As already indicated above, it can be particularly advantageous if the cardboard web is processed in such a way that a solid cushioning strip, and thus solid packaging cushioning, is ultimately produced, which has no structural voids. Accordingly, it is particularly advantageous if the folding lines are introduced into the cardboard web by means of the creasing device in such a way that, as a result of its manipulation by the folding device, the cardboard web is folded into a solid cushioning strip. The folding lines are preferably designed such that the transformation of the originally unfolded cardboard web into the solid cushioning strip is achieved by means of a total of six folds, which are further preferably divided into three folding steps carried out symmetrically from both side edges of the cardboard web.
[0026] Furthermore, the method according to the invention can be particularly advantageous if the individual packaging cushions are tilted 90° about their longitudinal axis to one side by means of a tilting device. This can be particularly advantageous with regard to further processing of the packaging cushions, especially when integrated into a fully automated packaging process, depending on the orientation in which the packaging cushions are ultimately incorporated into packaging and applied to the respective packaged goods.
[0027] The underlying problem is solved from a device engineering perspective by means of a production line with the features of claim 11. Advantageous embodiments are described in the dependent claims.
[0028] The production line according to the invention is suitable for the uninterrupted and preferably fully automatic production of a large number of packaging cushions from a continuous cardboard web, i.e., without the direct intervention of at least one machine operator. For this purpose, the production line comprises a feed device by means of which the cardboard web can be moved along the production line in a feed direction. The feed device can, in particular, be formed by a conveyor belt onto which the cardboard web can be placed. Specifically, the feed device extends along a straight line so that the cardboard web is continuously guided straight and thus not deflected. Furthermore, the production line comprises a creasing device by means of which a plurality of fold lines can be embossed onto the cardboard web, oriented parallel to the feed direction.Furthermore, the production line includes at least one folding device by which the cardboard web can be folded, in particular by which opposing side edges of the cardboard web can be folded towards each other multiple times in opposite directions. In this way, the cardboard web can be folded into a cushioning strip. The folding device can, in particular, comprise several folding stages, as explained in more detail below. The production line also includes a gluing device by which the folded edge strips of the cardboard web can be glued together, thus forming the cushioning strip. Finally, a cutting device is connected downstream of the gluing device by which individual packaging cushions can be successively cut from the cushioning strip.
[0029] The inventive method described above is particularly easy to carry out using the production line according to the invention. The resulting advantages have already been outlined above. In particular, it is possible to produce packaging cushions made entirely of cardboard, enabling large-scale production within a short period of time. The finished packaging cushions are preferably completely free of plastics and thus offer an advantage in terms of environmental compatibility compared to conventional plastic packaging cushions.
[0030] In an advantageous embodiment of the production line according to the invention, the folding device comprises three folding stages. By means of a first switching stage, two opposing outer sections of the cardboard web can be folded upwards in opposite directions relative to a plane of the cardboard web. The outer sections each extend from one of the side edges of the cardboard webs to a respective first fold line facing that side edge.
[0031] To perform the folding, it is particularly advantageous if the folding device, in its first stage, has at least one elongated folding element by means of which at least one of the outer sections of the cardboard web can be subjected to a force such that it folds upwards along the fold line relative to the plane of the cardboard web. Such a folding element can be designed, in particular, to receive the respective side section starting from its unfolded state and to apply at least a force component to the outer section that causes a torque about the first fold line. Advantageously, the folding element acts in such a way that the effective force acting on the outer section is perpendicular to a surface of the outer section. It is particularly advantageous if the folding element is designed to follow the folding movement of the outer section.It is important to note that with each folding step, the effective width of the cardboard webs decreases, as a portion of the webs is moved out of the plane of the cardboard. Given this, for the continuous production of packaging cushions, it is advantageous if the folding element—viewed in the feed direction of the cardboard webs—extends towards a central area of the web, so that the folding element follows the folding of the outer section. A corresponding design is illustrated in particular by the embodiment shown below.
[0032] Furthermore, it can be particularly advantageous if the folding device in the first folding stage is symmetrical and thus comprises at least two folding elements, each assigned to one of the outer lateral sections of the cardboard web. Advantageously, the folding elements extend together along a first folding path assigned to the first folding stage. This allows the cardboard web to be folded synchronously at both lateral edges as it is guided along the first folding stage, so that the opposing outer sections of the cardboard web are folded upwards in opposite directions. As explained above, the folding elements extend along the folding path and conically towards each other in the direction of the central area of the cardboard web, thus ensuring continuous engagement of the folding elements with the respective outer section.
[0033] The folding elements can, in particular, comprise elongated guide rods with a round cross-section. Furthermore, it is conceivable that the folding elements have a plurality of rollers that interact with a respective section of the cardboard web, allowing the cardboard web to roll along the rollers as it is guided along the corresponding folding path. The rollers are also capable of applying a force to the respective section of the cardboard web to produce the desired fold. Compared to a folding element in the form of a guide rod, such a folding element with a plurality of rollers offers the advantage that the cardboard web is subjected to less cleaning force as it is guided along the respective folding stage of the folding device.
[0034] In an advantageous embodiment of the production line according to the invention, in which the folding device comprises three folding stages, the outer sections folded upwards in the first folding stage can be folded over by means of the second switching stage of the folding device in such a way that the outer sections are folded over onto a surface of the remaining cardboard web, and the cardboard web subsequently forms opposing, double-layered edge strips. Advantageously, the second folding stage is equipped with at least one folding element, and preferably at least two folding elements are present, which are arranged symmetrically to each other along a folding section of the second folding stage and each is assigned to an edge strip. The folding elements can be designed, in particular, as described above, i.e., for example, in the form of elongated guide rods and / or with a plurality of rollers.As explained above, it is particularly advantageous if the respective folding element extends towards a longitudinal axis of the cardboard web when viewed in the feed direction, in order to follow the cardboard web during its folding, since the effective width of the latter decreases during each fold.
[0035] Using the third folding stage of the folding device, the previously formed edge strips can finally be folded upwards relative to the cardboard plane, again following the same folding direction as before. It is also advantageous in the third folding stage if the folding device includes folding elements as described above.
[0036] In a further advantageous embodiment of the production line according to the invention, it comprises at least one separating element by means of which the folded edge strips are kept apart, at least in an upper end region. This is advantageous insofar as an adhesive is to be introduced between the edge strips by means of the adhesive device, so that the folded edge strips can be bonded to one another. For this purpose, it is necessary that a gap exists between the edge strips into which the adhesive can be introduced. By means of the separating element, it can be ensured that this gap exists and that the surfaces of the edge strips facing each other do not unintentionally come into contact with one another.
[0037] To securely bond the edge strips together after the adhesive has been applied, the bonding device advantageously includes at least one pressure element by means of which the two edge strips can be pressed against each other. The pressure element can, in particular, comprise two corresponding pressure rollers that together define a gap. The gap is dimensioned such that the formed cushion strip is compressed as it is guided along the pressure element, with the opposing surfaces of the two edge strips being pressed against each other.
[0038] Furthermore, such a production line can be particularly advantageous if it includes a cutting device upstream of the creasing unit, by means of which the cardboard web can be cut in its longitudinal direction and thereby separated into at least two individual cardboard webs. The use of such a cutting device enables the parallel production of packaging cushions, with the separated cardboard webs being processed individually. The processing can differ, particularly with regard to the configuration of the packaging cushions to be produced, so that, for example, packaging cushions of different lengths can be manufactured, such as for use with a rectangular panel component whose length exceeds its width.The “long packaging cushions” can then be used particularly well to protect the longitudinal edges of the panel component and the “short packaging cushions” to protect the transverse edges of the panel component.
[0039] Finally, such a production line can be particularly advantageous if its cutting unit includes a cutting blade that can be inserted and retracted perpendicular to the feed direction of the cardboard web into a cross-section of the cushioning strip. Such a cutting blade can, for example, be a metallic blade, preferably driven by a pneumatic drive. With such a drive, the cutting unit can be inserted into the cross-section of the cushioning strip more easily and abruptly, so that a portion of the packaging cushion can be "cut off" from the strip. List of characters
[0040] The invention is explained in more detail below with reference to an exemplary embodiment shown in the figures. These show: Fig. 1: An isometric view of a production line according to the invention, Fig. 2: A grooving device of the production line according to Fig. 1, Fig. 3: A first folding stage of a folding device of the production line according to Fig. 1, Fig. 4: A second folding stage of the folding device of the production line according to Fig. 1, Fig. 5: A drying section of the production line according to Fig. 1, Fig. 6: A detail of a cutting device of the production line according to Fig. 1, Fig. 7: A schematic isometric representation of a cardboard strip to be folded, Fig. 8: The cardboard web according to Fig. 6, wherein outer sections are folded upwards after passing through a 1st folding stage, Fig. 9: The cardboard web according to Fig. 7, wherein the outer sections are folded over to form an edge strip after passing through a 2nd folding stage, Fig. 10: The cardboard web according to Fig. 8, wherein the edge strips are folded towards each other to form a cushion strip, and Fig. 11: A graphic illustration of the entire folding process of a cardboard web.
[0041] An embodiment of a production line according to the invention 1 , which in the Fig. 1 to Fig. As shown in section 6, it includes a feed device. 4 , which is designed in the form of a conveyor belt. By means of the feed device 4 is one in Fig. 7 cardboard strips shown 3 in a conveyance direction 5 movable and thus along the production line 1 manageable. The cardboard web 3It is virtually endless here. Thus, its length is significantly greater than its width. 29 , so that from a cardboard strip 3 a variety of packaging cushions 2 It can be manufactured. Along the production line 1 will the cardboard web 3 , which are fed into the production line 1 in an unfolded, flat state, first by means of a Fig. 2 shown groove device 6 "grooved", so that in the cardboard web 3 a total of six fold lines 7 The fold lines are formed. 7 are relative to a longitudinal axis 32 the cardboard track 3 Arranged symmetrically. From opposite side edges. 9 , 10 out in the direction of the longitudinal axis 32 Viewed, the cardboard web 3 after passing through the grooving device 6 Therefore, pairs of first, second, and third fold lines7 on. By means of the grooving device 6 will the cardboard web 3 , which in the example shown is formed from several layers of paper glued together, is cut on the surface and thereby weakened, so that, in a sense, predetermined creases are created at which the cardboard web 3 in the course of an applied folding force that is perpendicular to a cardboard plane 20 It works. These grooves form the aforementioned fold lines within the meaning of the present application. 7 , along which the cardboard web 3 It folds and is therefore foldable. After these fold lines are introduced... 7 into the cardboard web 3 is it particularly easy to use the cardboard web 3 using the folding device 8 to fold in the desired way.
[0042] The grooving device 6 , which are located in a feed area 22 the production line 1The arrangement includes a plurality of grooved discs. 28 , each with two grooved edges 41 exhibit the grooving device shown here. 6 is suitable for creating a total of twelve grooves in the cardboard web 3 to introduce. The grooved cardboard strip 3 It is then separated in the middle using a cutting device not shown in the figures, resulting in two separate cardboard strips. 3 half the width. Explanation of the further production line. 1 The following always refers to one of these two cardboard webs. 3 The use of an originally wider cardboard web 3 , which is then divided, offers the possibility of doubling production capacity. Furthermore, it is possible to use packaging cushions. 2to produce cushions of varying lengths simultaneously. This is useful for packaging a wide variety of goods, as these are typically rectangular, allowing for the creation of cushioning. 2 for one long side and other (namely shorter) packaging cushions 2 required for one short side of the respective packaged goods.
[0043] Following the insertion of the fold lines 7 using the grooving device 6 as well as the separation will each cardboard web 3 by means of a folding device 8 towards a cushion strip 13 folded. The folding mechanism 8 This includes a total of three folding stages. 15 , 16 , 17 , which one after the other along the production line 1 to be traversed. The folding steps 15 , 16 , 17 are suitable for the cardboard web 3 to the upholstery strip13 to fold.
[0044] In the example shown, the first folding step 15 the folding mechanism 8 a total of three folding elements 34 , 35 , 36 which can be particularly well illustrated by Fig. 3 result. The folding elements 34 , 35 , 36 are in the production line shown here 1 related to a respective cardboard web 3 arranged symmetrically on both sides, so that during the guiding of the cardboard web 3 along the first folding step 15 both opposing outer sections 18 , 19 the cardboard track 3 They are folded simultaneously and in the same way, but in opposite directions. The following explanation details the individual folding elements. 34 , 35 , 36 refers only to one side of the cardboard web 3, i.e., concerning the folding of the outer section 18 The explanations apply analogously to the similarly designed folding elements of the first folding stage. 15 on the opposite side of the cardboard web 3 with the other outer section 19 to apply.
[0045] The folding elements 34 , 35 , 36 Each unit comprises an elongated, straight roller carrier which includes a number of rollers. These rollers are freely rotatable on the roller carrier, so that the cardboard web 3 , which along the respective folding element 34 , 35 , 36 is guided along, and can roll off the rollers opposite the respective roller carrier. The individual folding elements 34 , 35 , 36 They are each arranged in a twisted position relative to each other with respect to their respective longitudinal axes.
[0046] Thus, the first folding element is 34 oriented in such a way that the rollers are on the outer section 18 the cardboard track 3 "from below", i.e. perpendicular to the plane of the cardboard 20 grasp. As can be seen from the presentation of Fig. 3 results in the first folding element 34 one in the feed direction 5 rising orientation. The folding element 34 is therefore suitable for the assigned outdoor section 18 on its underside 39 to pick up and lift easily. Since the cardboard web 3 the fold lines described above 7 This lifting of the outer section results in 18 to the fact that the outer section 18 opposite an adjacent area of the cardboard web 3 It is folded upwards. The outer section is then folded upwards. 18 in a sense, around a fold line. 7defined axis of rotation relative to the rest of the cardboard web 3 rotated. This inevitably results in a change in the effective width. 33 the cardboard track 3 compared to an original width 29 reduced, while their effective height increases. Accordingly, it is advantageous if the folding elements 34 , 35 , 36 related to the feed direction 5 are slightly oriented inwards, i.e., towards a central area 37 the cardboard track 3 extend. In this way, the folding elements 34 , 35 , 36 in a sense, the folding movement of a respective section of the cardboard web 3 updated.
[0047] Following the first folding element 34 The already partially folded outer section will 18 to the second folding element 35handed over, which - as explained above - is opposite the first folding element 34 is twisted around a longitudinal axis. This offers the advantage that the roller carrier of the second folding element 35 the rollers arranged on it are also in a position opposite the first folding element 34 can accommodate the changed orientation, so that the rollers can now follow the slightly inclined outer section. 18 the cardboard track 3 This provides better support and allows the desired folding movement to continue. In particular, the running surfaces of the rollers are at least essentially parallel to the underside of the respective outer section. 18 , 19 arranged. Also the second folding element 35 is opposite to the feed direction 5 inclined orientation, so that during the guiding of the cardboard web 3 along the first folding step 15 the outer section 18further upwards, referring to the remaining cardboard web 3 is folded.
[0048] Finally, the cardboard web 3 to the third folding element 36 transferred, which in the same way with respect to its longitudinal axis compared to the previous folding element 34 , 35 is twisted. The roller support of the third folding element. 36 is oriented in such a way that the rollers arranged on it are at least essentially rotatable about a vertical axis of rotation and thus the guide surfaces of the rollers are suitable for guiding the outer section 18 the cardboard track 3 to support it laterally. The third folding element 36 is also related to the feed direction 5 laterally towards the central area 37 the cardboard track 3 inclined, so that by the action of the third folding element 36 the outer section 18 up to a folding angle27 at 90° to the plane of the cardboard 20 It can be folded in a twisted, upright position.
[0049] The first folding stage 15 the folding mechanism 8 is finished as soon as the outer sections 18 , 19 each has reached its upright position as a result of the aforementioned folding movements, in which, in the present example, it is each by a folding angle 27 at 90° to the plane of the cardboard 20 are folded upwards. This state is particularly evident from the following: Fig. 8.
[0050] Then the cardboard web 3 to a second folding stage 16 the folding mechanism 8 handed over. This is particularly evident from the following: Fig. 4. The second folding stage 16 comprises a total of two folding elements 38 , which here are formed by elongated round bars. These round bars are oriented in such a way relative to the feed direction. 5the cardboard track 3 oriented so that they point towards the central area 37 the cardboard track 3 They extend towards each other and are slightly inclined downwards. In this way, a distance is created between the corresponding folding elements. 38 along the second folding stage 16 gradually reduced. The inclination of the folding elements 38 The downward combination with their orientation towards each other has the technical effect that the folded outer sections 18 , 19 the cardboard track 3 The cardboard strip will be folded further, following its original folding pattern. 3 along their second fold lines 7 bent, as can be seen particularly well from the illustration according to Fig. 8 results. The folding elements 38 This leads, in a sense, to the fact that the outer sections 18 , 19are forced further towards each other inwards and downwards, whereby the resulting pressure on the outer sections 18 , 19 The applied folding force causes the described further folding. As soon as the cardboard web 3 the second folding stage 16 What happened is the outer sections 18 , 19 completely on a surface 21 the cardboard track 3 folded over so that the cardboard web 3 henceforth a double-layered border strip on their opposite edges 12 forms. This state of the cardboard web 3 is particularly good based on Fig. 9 recognizable.
[0051] Finally, the production line shown here is used 1 the cardboard track 3 by means of a third folding step 17 towards the desired upholstery strip 13 folded. For this purpose, the previously formed edge strips are folded. 12following their respective previous folding direction, they were folded further towards each other, with the edge strips 12 each along the third fold lines 7 the cardboard track 3 be folded up. The fold lines 7 In the example shown, they are embedded in the cardboard web in such a way as to 3 It was suggested that during the folding up of the edge strips 12 a space between the facing end faces 25 the edge strip 12 remaining free space 40 is completely filled. In this way, the finished padding strip 13 , which is particularly well illustrated here by Fig. 10 results in no structural cavities and is therefore solidly constructed. The folding up of the edge strips 12 by means of the third folding stage 17This is achieved similarly to the first folding stage by means of appropriately oriented folding elements, which here are formed by roller carriers with rollers arranged on them.
[0052] In the example shown, the third folding step 17 the folding mechanism 8 designed in such a way that they form the edge strips 12 the cardboard track 3 not yet fully folded upwards, i.e. the surfaces facing each other 23 the edge strip 12 not yet bringing them into direct contact with each other. A folding angle of the edge strips 12 opposite the original cardboard level 20 Therefore, the angle here is less than 90°, for example 85°. In this way, the area between the edge strips remains... 12 first a gap 24 , which is characterized in particular by Fig. This results in 11. The underlying consideration is that, in order to permanently fix the finished upholstery strips, 13the two edge strips 12 They are glued together by applying an adhesive, so that the finished upholstery strip 13 cannot develop independently in an unintentional way.
[0053] Accordingly, the production line according to the invention has 1 via an adhesive device 11 , by means of which the said adhesive is applied between the edge strips 12 , namely into the described gap 24 , can be applied. The adhesive device 11 is immediately the third folding stage of the folding device 8 assigned. Here it interacts with a stationary separating element, not shown in the figures, which is located between the edge strips. 12 is arranged and helps to ensure that they are not unintentionally introduced before being fed to the adhesive device 11 are pressed against each other and thereby the gap space 24is sealed. The separating element can be wedge-shaped in particular, thus sealing the edge strips. 12 reliably keep them apart. Using the adhesive device 11 The adhesive is then applied to the gap. 24 introduced, whereupon the edge strips 12 They are pressed against each other by means of appropriate pressure rollers under pressure, so that the surfaces 23 the edge strip 12 come into direct contact with each other and stick together.
[0054] Following the adhesive setup 11 The now finished upholstery strip 13 , as he looks Fig. 10 results, along a drying section 26 guided along which the adhesive can dry and develop its bonding effect. Finally, the previously endless strip of padding is... 13 a cutting device 14supplied by means of the cushion strips 13 cut through and thus individual packaging cushions 2 to be manufactured. The cutting device 14 In the example shown, this includes an area above the padding strip. 13 arranged cutting blade that cuts into the cross-section of the cushion strip by means of a pneumatic drive 13 It can be inserted, which effectively "chopps off" the latter. The individual packaging cushions 2 This method allows for the particularly simple production of packaging cushions in any desired length, which can also be used to manufacture other packaging cushions. 2 only the programming of the cutting device 14 needs to be changed.
[0055] One special feature of the production line shown here is... 1 following the cutting device 14 Furthermore, a tilting device 30, by means of which the pre-cut packaging cushions 2 around their longitudinal axis 31 They can be "tipped over". Initially, the packaging cushions are lying flat. 2 still in their orientation according to the representation in Fig. 10 before. For further automated processing of the packaging cushions 9 , particularly in the context of a process for the fully automated packaging of goods, it can be advantageous if the packaging cushions 2 in relation to their “standing position” according to Fig. 10 are placed in a "lying position". This is because the packaging cushions 2 , particularly during the packaging of flat goods such as furniture panels, the tilting device is applied in its horizontal position along the edges of the respective goods. 30 This therefore contributes to the fact that the packaging cushions 2They can then be processed further immediately without manual intervention, for example using a gripper robot.
[0056] As a result, it is possible to use the production line according to the invention. 1 It is particularly easy to use a wide variety of packaging cushions. 2 to be manufactured fully automatically and exclusively using cardboard made from paper. A special feature here is that the production line according to the invention... 1 continuously, that is, in particular without stopping the feed mechanism 4 , can be operated. In this process, the cardboard web is used. 3 Driven at a constant feed rate of, for example, 25 m / min. Manual intervention by a machine operator on the production line. 1 or other personnel are not required. Instead, the packaging cushions 2 Fully automated production. Stopping the feed unit 4is also for the purpose of cutting the upholstery strip to length 13 not necessary, as the insertion of the cutting blade of the cutting device 14 so quickly that the padding strip 13 in this case, it does not significantly interfere with the cutting blade. Reference symbol list 1 production line 2 packing pads 3 cardboard strips 4 Feed device 5 Feed direction 6 Grooving device 7 fold line 8 Folding mechanism 9. Side margin 10 side margin 11 Adhesive device 12 edge strips 13 upholstery strips 14 Cutting device 15 first folding stage 16 second folding stage 17 third folding stage 18 Exterior section 19 Exterior section 20 cardboard levels 21 surface 22 Feed area 23 Surface 24 gap space 25 Front 26 Drying section 27 folding angles 28 Grooved disc 29 width 30 Tilting device 31 Longitudinal axis 32 Longitudinal axis 33 effective width 34 folding elements 35 folding elements 36 folding elements 37 Middle range 38 folding elements 39 Underside 40 free space 41 Grooved edge
Claims
[1] Method for producing packaging cushions (2) from a cardboard web (3), wherein the cardboard web (3) is guided by means of a feed device (4) in a feed direction (5) along a production line (1) and is successively manipulated by means of the following method steps in such a way that packaging cushions (2) are produced: a) The cardboard web (3) is fed to a creasing device (6) and is creasing by means of the creasing device (6) parallel to the feed direction (5) so that folding lines (7) are embossed on the cardboard web (3). b) The grooved cardboard web (3) is guided along a folding device (8), during which opposite side edges (9, 10) of the cardboard web (3) are folded towards each other several times in the opposite folding direction. c) The folded cardboard web (3) is fed to an adhesive device (11) by means of which, as the cardboard web (3) is advanced, an adhesive is continuously introduced into a gap (24) between edge strips (12) of the cardboard web (3) folded towards one another, and the two edge strips (12) are then pressed against one another and glued together in this way, so that the cardboard web (3) is henceforth in the form of a solid cushioning strip (13). d) The cushioning strip (13) is fed to a cutting device (14) by means of which the cushioning strip (13) is cut to length transversely to its feed direction and in this way individual packaging cushions (2) are continuously cut from the cushioning strip (13). [2] Method according to claim 1, characterized by that the cardboard web (3) is folded several times by means of the folding device (8) in the following folding steps: i) Two mutually opposite outer sections (18, 19) of the cardboard web (3), each extending from one of the side edges (9, 10) of the cardboard web (3) to a respective facing first fold line (7), are folded upwards in opposite folding directions relative to a cardboard plane (20) of the cardboard web (3), so that the outer sections (18, 19) are each in a raised position; ii) The outer sections (18, 19) in the raised position are further folded over - each following a folding direction of the first folding step - so that the outer sections (18, 19) are folded over onto a surface (21) of the remaining cardboard web (3) and the cardboard web (3) henceforth forms opposing, double-layered edge strips (12); iii) The edge strips (12) are folded upwards towards each other relative to the cardboard plane (20), each following a folding direction of the second folding step. [3] Method according to claim 2, characterized by that the outer sections (18, 19) are folded up in the first folding step by a folding angle (27) between 80° and 100°, preferably between 85° and 95°, more preferably 90°, relative to the cardboard plane (20). [4] Method according to one of claims 2 or 3, characterized by that the two edge strips (12) are folded up in the third folding step by a folding angle of maximum 85°, preferably maximum 80°, relative to the cardboard plane (20). [5] Method according to one of claims 2 to 4, characterized by that the two folded-up edge strips (12) are kept at a distance by means of a separating element during their feeding to the adhesive device (11), so that an unintentional pressing of the gap (24) present between the mutually facing surfaces (23) of the edge strips (12) is prevented. [6] Method according to one of the preceding claims, characterized bythat the cardboard web (3) is guided along the production line (1) without interruption by means of the feed device (4). [7] Method according to claim 6, characterized by that the feed device (4) is operated at a constant feed speed, preferably at a feed speed in the range between 15 m / min and 35 m / min, preferably between 20 m / min and 30 m / min. [8] Method according to one of the claims, characterized by that the creasing device (6) creates a total of six grooves in the cardboard web (3). [9] Method according to one of the claims, characterized by that the folding lines (7) are introduced into the cardboard web (3) in such a way as to match a width (29) of the latter that the cardboard web (3) is processed into a solid cushioning strip (13) as a result of its manipulation by means of the folding device (8) and the gluing device (11). [10] Method according to one of the claims, characterized bythat the separated packaging cushions (2) are tilted to one side by 90° around their longitudinal axis (31) by means of a tilting device (30). [11] Production line (1) for the uninterrupted production of a plurality of packaging cushions (2) from a continuous cardboard web (3), comprising - a feed device (4) by means of which the cardboard web (3) can be moved in a feed direction (5) along the production line (1), - a creasing device (6) by means of which a plurality of folding lines (7) oriented parallel to the feed direction (5) can be impressed on the cardboard web (3), - at least one folding device (8) by means of which opposite side edges (9, 10) of the cardboard web (3) can be folded several times towards each other in opposite folding directions, so that the cardboard web (3) can be folded towards a cushioning strip (13), - an adhesive device (11) by means of which edge strips (12) of the cardboard web (3) folded towards one another can be glued to the cushioning strip (13), - a cutting device (14) by means of which individual packaging cushions (2) can be successively separated from the cushioning strip (13). [12] Production line (1) according to claim 11, characterized by that the folding device (8) comprises three folding stages (15, 16, 17), wherein by means of a first folding stage (15) two mutually opposite outer sections (18, 19) of the cardboard web (3), each extending from one of the side edges (9, 10) of the cardboard web (3) to a respective first folding line (7), can be folded upwards in opposite folding directions relative to a cardboard plane (20) of the cardboard web (3), so that the outer sections (18, 19) are each in a raised position, wherein by means of a second folding stage (16) the upstanding outer sections (18, 19) - each following a folding direction of the first folding stage (15) - can be further folded in such a way that the outer sections (18, 19) are folded over onto a surface (21) of the remaining cardboard web (3) and the cardboard web (3) henceforth forms opposing, double-layered edge strips (12), wherein by means of the third folding stage (17) the edge strips (12) - each following a folding direction of the second folding stage (16) - can be folded upwards relative to the cardboard plane (20). [13] Production line (1) according to claim 12, characterized by a separating element by means of which the folded-up edge strips (12) can be kept at a distance so that an unintentional pressing of a gap (24) present between the mutually facing surfaces (23) of the edge strips (12) is prevented. [14] Production line (1) according to one of claims 11 to 13, characterized byin that the folding device (8) has at least two folding elements (34, 35, 36) which are arranged symmetrically to a longitudinal axis (32) of the cardboard web (3) and extend along a folding step (15) of the folding device (8), wherein the folding elements (34, 35, 36) each cooperate - viewed in the feed direction (5) of the cardboard web (3) - with a laterally outer section of the cardboard web (3), wherein the folding elements (34, 35, 36) - viewed over a section of the folding step (15) - are oriented so as to run towards one another in the direction of a central region (37) of the cardboard web (3). [15] Production line (1) according to one of claims 11 to 14, characterized by that the cutting device (14) comprises a cutting knife which can be inserted into a cross-section of the cushioning strip (13) and retracted again perpendicular to the feed direction (5) of the cardboard web (3).