DEVICE AND METHOD FOR PRODUCING FILLING MATERIAL

Description

[0001] The present invention relates to a device and a method for producing packing material. Such devices and methods have long been known in the art. This type of packing material is used, for example, in cardboard boxes to protect goods being shipped or to fill empty spaces so that the contents of a larger box do not move around too much. Devices of this type are known in the art. They typically have guide cams with interconnected mechanisms, including a feed mechanism that advances a paper strip and a stamping mechanism that cuts the paper into strips and presses these cut strips through dies.These devices, which are known according to the applicant's internal prior art, have proven their worth, but have the disadvantage that, especially at higher throughput rates, coupling and the provision of guide curves have a speed-limiting effect.

[0002] WO 2011 / 025614 A1 describes a method and apparatus for manufacturing packaging cushioning. US 5,257,492 describes a method and apparatus for manufacturing packaging material from a ribbon-like material with a conveying device and a cutting device, wherein paper strips are deformed by rotating rollers.

[0003] EP 2 719 528 A1 describes a device for manufacturing a paper cushioning product with a discharge channel that conveys cut-off paper sections to a discharge opening, wherein this channel is designed such that a user cannot reach a cutting mechanism through it. US 2009 / 0082187 A1 describes a device for manufacturing packaging material in which material is compressed in one direction and then bonded to a carrier.

[0004] The present invention is therefore based on the objective of providing a method and a device that allow for a higher throughput. These objectives are achieved according to the invention by the subject matter of the independent claims. Advantageous embodiments and further developments are the subject of the dependent claims.

[0005] The invention relates to a device for producing filling material according to claim 1.

[0006] The advantage here is that the drives can be controlled independently of each other. By using separate drives, it is possible to eliminate the need for a mechanical coupling between the transport and pressing processes. This allows for more precise control and significantly increases throughput rates. Specifically, the use of different drives enables considerably better coordination than the guide curves known in the prior art or, more generally, in the case of a mechanical coupling.

[0007] Advantageously, at least one of the two drives is an electric motor, and in particular a servo motor. Preferably, there is no mechanical coupling between the first transport device and the pressing device. Preferably, however, the corresponding drives are controlled in coordination with each other.

[0008] In a further advantageous embodiment, the pressing device has a pressing body which presses the strips through the dies to produce the filling material. This filling material consists of curved material scraps, for example, curved paper scraps or the like. Advantageously, the material to be conveyed is paper or cardboard. However, it could also be a plastic material or, more generally, a recyclable material. In another advantageous embodiment, the dies have a cross-shaped cross-section. This can, in particular, be a cross with curved arms. Such a die produces the corresponding filling material in a particularly advantageous manner.

[0009] In another advantageous embodiment, the pressing device moves a press ram essentially perpendicular to the conveying direction of the material.

[0010] Advantageously, the device comprises at least two punches, which are preferably coupled to each other or which preferably press different strips through the dies synchronously. Advantageously, the device comprises at least four and advantageously at least six such punches. These punches can, for example, be arranged side by side in groups of two and preferably also be attached to a common punch carrier, which presses these punches against the material to produce the filler material.

[0011] In a further advantageous embodiment, the device has an insertion opening and, in particular, an insertion slot, which also aligns the direction of movement of the filling material, more precisely the paper strip. This insertion slot is preferably arranged upstream of the first transport unit. Furthermore, it would also be possible to connect lateral guide elements to this insertion slot, which prevent the paper from deviating laterally from its transport direction or drifting off course. Such lateral guide elements can be adjustable, for example, to allow the device to be adapted to different widths of the material strip.

[0012] In a further advantageous embodiment, the device also has a guide device for guiding the punches and / or for guiding the punch movement.

[0013] It is advantageous to couple the movement of the first cutting unit with a movement of the punch or press unit. This makes it possible that when the press unit is moved towards the transported paper material, the material is cut first, and then the individual strips are pressed through the dies.

[0014] In another advantageous embodiment, a cutting element and / or several cutting elements are arranged between individual pressing devices.

[0015] In a further advantageous embodiment, the device has a second conveying unit, which is arranged downstream of the first conveying unit along the conveying direction and which is also suitable and intended for transporting the elongated material along the predetermined conveying direction. Preferably, the second conveying unit also has its own drive. This independent drive can be controlled separately from the first drive mentioned above. Thus, it is also possible for these two drives to convey the material at different times or for different periods. Therefore, the device preferably has at least three drives, and in particular, three independent drives.

[0016] In a further advantageous embodiment, a buffer zone is arranged between the first and second conveying units, which can accommodate varying quantities of the elongated material belt. This buffer zone can, for example, be a simple empty section through which the material passes, and in which more or less of the material can be accommodated.

[0017] Advantageously, the material belt is deflected in this buffer area. Preferably, the material belt can move freely in this buffer area. Therefore, the material in this area is preferably not in contact with transport or guiding elements such as rails, rollers, or the like. Preferably, the material belt is deflected at least once in this area. Preferably, the material belt is deflected at least once by at least 40°, more preferably by at least 60°, more preferably by at least 100°, and particularly preferably by at least 140°. Preferably, the material belt is deflected at least twice in this area. Preferably, the material belt is also deflected at least by 40°, more preferably by at least 60°, more preferably by at least 100°, and particularly preferably by at least 140° during the second deflection. Preferably, the material belt is conveyed at least section by section in a horizontal direction.The material belt is therefore preferably conveyed in a serpentine fashion within the aforementioned buffer zone. However, it would also be possible to arrange buffering elements, such as so-called dancer rollers, within the buffer zone.

[0018] This approach makes it possible for the two conveying systems to operate independently of each other; for example, if only the first conveying system is in operation, the buffer is emptied, whereas if only the first conveying system is in operation, it is merely refilled.

[0019] In a further advantageous embodiment, at least one conveying device is suitable and designed to convey the material strip in a timed manner. Advantageously, both conveying devices are suitable and designed to convey the material strip in a timed manner. In this way, the overall production process can be accelerated, since, for example, a pressing operation can be carried out during downtime.

[0020] In a further advantageous embodiment, the device has a plurality of cutting elements arranged one behind the other along the conveying direction, each of which is suitable and intended to cut the material in the direction deviating from the conveying direction.

[0021] As mentioned above, this is preferably a direction perpendicular to the conveying direction. This method, especially in conjunction with intermittent operation, allows a large number of strips to be cut and then pressed through the die using the ram. For example, four, six, or eight pieces of filler material can be produced in a single pressing operation.

[0022] Advantageously, the device has a receiving container for holding the filling material. This receiving container can directly receive the filling particles pressed through the die.

[0023] In a further advantageous embodiment, the device has at least one control unit for controlling the drives of the first conveying device and the pressing device, wherein these drives are controlled such that the strips of material are pressed through the dies while the strips are not conveyed in the conveying direction. This means that the strip is conveyed to a position, then cut while stationary, and in the next step the bodies or the filling material are pressed out of the strip.

[0024] In a further advantageous embodiment, the device has a second cutting device which cuts the material strip in a direction that deviates by no more than 30° from the conveying direction. Advantageously, this cutting device cuts the material strip precisely within the conveying device or at an angle that deviates by no more than 10°, preferably no more than 5°, from the conveying direction. In a further advantageous embodiment, the cutting device is a movable cutting blade, for example, a rotatable cutting blade. This can, for example, be arranged centrally within a width of the material strip and cut it into two parallel strips extending in the conveying direction. Preferably, the second cutting device is arranged upstream of the first cutting device.This means that, preferably, the material strip is first cut in its direction of extension, and then perpendicular to it. In a further preferred embodiment, the second cutting device also has a drive device, such as, but not exclusively, an electric motor.

[0025] Preferably, however, the drive of the pressing device is coupled with the drive of the first cutting device.

[0026] In a further advantageous embodiment, at least one conveying device has a conveying roller which transports the material belt in the conveying direction. For example, the first conveying device can have two conveying rollers which work together and push the belt between them.

[0027] In a further advantageous embodiment, the second conveying device also has a conveying roller. An additional counter plane can be arranged, along which the material belt is conveyed by this conveying roller. For example, the material belt can slide relative to a counter plane and be pushed along this counter plane by the corresponding second conveying roller. This counter plane can also have rollers by means of which the material is conveyed. These rollers can be passive.

[0028] In addition, the device can have lateral guide elements that ensure essentially straight-line transport or transport in which the paper strip cannot deviate laterally from its transport path. These lateral guide devices can, for example, be designed as lateral rails. In this way, it is ensured that the material strips cannot be displaced laterally, at least in a direction perpendicular to the material strip and, in particular, also horizontally.

[0029] The arrangement of the second cutting device in the aforementioned conveyor level is advantageous.

[0030] In a further advantageous embodiment, at least one conveying device has two rollers, i.e., a roller and a counter roller. These can be spaced apart from each other, particularly for inserting the material strip. In this way, the material strip can first be threaded in, and then the rollers can be put into operation, i.e., enable the conveying of the material strip.

[0031] In a further advantageous embodiment, the device has a support on which at least the first conveying device and the second conveying device are arranged. For example, a support plate can be provided on which both the drives for the conveying rollers and the drives for the pressing device are arranged.

[0032] In another advantageous embodiment, the pressing device has a worm motor or a motor that is geared down to achieve the pressing movement.

[0033] In a further advantageous embodiment, the device includes a transmitting device which is suitable and intended for transmitting data characteristic of the device. This data may, for example, be characteristic of the operation of the device. Preferably, the transmitting device is suitable and intended for wireless transmission of this data.

[0034] Preferably, the data are selected from a group of data that are characteristic of an operating time of the device, that are characteristic of a material processed by the device, that are characteristic of an aging and / or wear state of the device and / or components of the device, that are characteristic of fault states of the machine, and the like.

[0035] In addition, the transmitter can also transmit data indicating the replacement of machine parts and / or wear parts. For example, information can be sent indicating that a user has replaced a specific wear part, such as a die. The corresponding times of such replacements can also be transmitted. This allows the manufacturer to monitor the proper replacement of components.

[0036] This allows the machine manufacturer to react very quickly to any errors that may occur. It also enables the machine manufacturer to quickly identify potential sources of error.

[0037] Preferably, this transmitting device communicates with a control unit of the device. This control unit can output the relevant data to the transmitting device. Preferably, the transmitting device is a GSM module. However, data transmission via secure connections, such as VPN lines, is also possible. Alternatively, the data could be transmitted over the internet. In another preferred embodiment, the device also includes sensor devices suitable and / or intended for detecting machine states. These could include, for example, temperatures, torques, or similar parameters. Such data can also be output via the transmitting device.

[0038] In another preferred embodiment, the device includes a storage unit that records data characteristic of the device's operation (such as the data mentioned above). This enables long-term monitoring of the device. The data stored by this storage unit can also be transmitted by the transmitting device.

[0039] In another preferred embodiment, a control device is designed such that it only allows the device to operate if data transmission via the transmitting device is also enabled. If, for any reason, the transmission of data by the transmitting device is interrupted, the control device can halt the device's operation and / or prevent the machine from starting.

[0040] It is also possible that, in the event of an interruption in transmission by the transmitting device, a warning message is first issued to a machine operator, and only after a certain period of time is the operation of the device stopped. Preferably, the transmitting device includes a transmitting element such as a transmitting antenna. It would be possible, for example, for the device's operation to be interrupted if the transmitting antenna is removed. For instance, mechanical interruption elements, such as switches, could be provided that shut down the device when the transmitting antenna is removed. Alternatively, detection devices could be provided that detect the absence of data communication and shut down the device accordingly.

[0041] It is possible for the transmitting device to transmit data continuously, but it would also be possible for data to be transmitted in a timed manner, or at specific defined intervals. For example, a log containing data could be transmitted at regular intervals.

[0042] In a further advantageous embodiment, the device also includes a receiving unit suitable and intended for receiving signals and / or data. For example, control data can be transmitted to the device, such as a software update. Advantageously, the receiving unit is also suitable and intended for receiving data wirelessly.

[0043] The present invention further relates to a method for producing filling material and in particular for producing filling material from paper or cardboard or similar recyclable materials according to claim 11.

[0044] Advantageously, the drive for the pressing device and the drive for the conveying device are sequentially synchronized. Preferably, the material strips are pressed through the dies while the material belt is stationary in the conveying direction.

[0045] Advantageously, the material strip is buffered in at least one section of the device, i.e., a different amount of material strip is accommodated.

[0046] In another preferred method, the material belt is conveyed by two successive conveying devices, wherein these two conveying devices are operated independently of each other and preferably cause the material belt to be conveyed at least temporarily at different times.

[0047] In another preferred method, the material belt is conveyed in a timed manner.

[0048] Advantageously, the material strip is also cut in another cutting direction, which runs in particular in the extension direction of the material strip.

[0049] Preferably, the material strip is cut with cuts that are at least temporarily perpendicular to each other.

[0050] Further advantages and embodiments can be seen from the attached drawings: Fig. 1 shows an overall view of a device 1 according to the invention; Fig. 2 shows a view of a cutting and pressing unit for the in Figure 1 Device shown; Fig. 3 a further more detailed representation of the device shown in Figure 2 device shown; Fig. 4 a top view along line DD from Figure 2 ; Fig. 5 a representation along line CC from Figure 3 ; Fig. 6 a representation of the cutting device; and Fig. 7 a representation of the back side of the device according to the invention.

[0051] Figure 1Figure 1 shows a representation of a device 1 according to the invention for producing filling material. A carrier roller 25 is provided, on which a paper material 20 is stored and from which the paper material 20 is unwound. The paper material is preferably in strip form. Reference numeral 2 designates a first transport device, which serves to transport the paper strip 20 here in the X direction. This transport device has two transport rollers 32 and 34, of which, however, preferably only one roller is driven. A corresponding drive device, such as an electric motor, is not shown. These rollers 32 and 34 can be tensioned against each other by means of a pretensioning device (not shown) in order to guide the paper material securely. It would also be possible for these two rollers to be temporarily spaced apart from each other, for example, to allow a material strip to be threaded through.

[0052] Reference numeral 4 designates a second transport device, which, as explained below, is also suitable and intended for transporting the paper tape in direction X. This second transport device 4 has a driven transport roller 42 and a counter roller 44. Preferably, one of these two rollers is again driven by a drive (not shown). Reference numeral 46 designates a support surface on which the paper tape 20 rests and along which it can be moved.

[0053] Reference numeral 6, in its entirety, designates a cutting device used for cutting the material strip. This cutting device comprises three cutting elements 62, 64, and 66.

[0054] Reference numeral 12 designates, in its entirety, a pressing device suitable and intended for pressing individual strips of material through dies. This pressing device has a drive 24. This drive has a drive wheel 52, which drives a rack 54 and moves it downwards in the Y direction to achieve the pressing action.

[0055] Figure 2 shows a detailed representation of the in Figure 1The device shown depicts the three dies 82, 84, and 86 through which the material strips are pressed. A second cutting device 18 is also shown, which cuts the paper material in the transport direction X, specifically into two essentially parallel strips. These strips are then cut again in the transverse direction by the cutting device 6 and subsequently pressed through the dies. In this way, six filler pieces can be produced in one pressing operation.

[0056] The reference symbol PB designates a buffer zone of the material conveyor belt. This zone is located between the first and second conveying units. It can be seen that the material is conveyed in this zone in a serpentine pattern. If, for example, the second conveying unit 4 is stationary and the second conveying unit 2 continues to move, the buffer zone PB will also continue to fill. Conversely, this buffer zone is emptied when the first conveying unit 2 is stationary and only the second conveying unit 4 is moving.

[0057] Reference numeral 70 designates a carrier on which three press bars 72, 74 and 76 are arranged. These serve – as mentioned above – to press the paper material, already cut in the longitudinal and transverse directions, through the individual matrices 82, 84 and 86.

[0058] Figure 3Figure 1 shows a further detailed representation of a device according to the invention. The individual cutting elements 62, 64, and 66 are also shown here, which cut the material in a direction perpendicular to the plane of the figure. Reference numerals 68 denote guide elements or counter-cutting elements, which serve to guide the cutting elements. Reference numeral 65 denotes pre-tensioning devices with which the guide elements 68 are pre-tensioned, here in the Figure 3 to the right - that is, in the direction of the respective cutting element - they are pre-tensioned.

[0059] Figure 4 shows a view along line DD in Figure 2 Here, the three matrices 82, 84, and 86 can be seen, each with cross-shaped openings (for clarity, only openings 82a and 82b are shown). The roller 44 is also visible, which, in conjunction with the one in Figure 3The roller 42 shown serves to convey the paper strip, as does the counter-pressure roller 16, which, together with the cutting roller 18, serves to cut the paper strip in the transport direction X. The counter-pressure roller 16 has a slot 16a into which the cutting edge of the cutting roller 18 can penetrate.

[0060] Figure 5 shows a view along line CC from Figure 3Here, a cutting element 62 is shown, as well as the guide element 68, which also serves as a counter-cutting element. To perform the cutting process, the cutting element 62 is moved downwards in the Y direction. More precisely, this is a pivoting movement of the cutting elements, which also has a component in this Y direction. The dies 82 are also visible. Reference numeral 24 indicates a drive motor that drives a gear 52 via a reduction gear, and this in turn drives the rack 54. A press body is arranged on this rack, which presses the paper strips through the die. In addition, the drive motor also drives the cutting element 62 via a drive linkage 56. Thus, there is a mechanical coupling between the movement of the press body and the movement of the cutting elements.However, it is also conceivable that these movements can be adjusted relative to each other, i.e., it can be set when the cutting process is finished before the pressing process begins.

[0061] Figure 6Figure 1 shows a detailed representation of the cutting device 6. The individual cutting elements 62, 64, and 66 are shown, as well as two counter-cutting strips 68 and the preloading devices or springs 65, which force the respective counter-cutting strips 68 toward their associated cutting elements 62, 64, and 66. The reference numeral 60 designates a support on which the cutting elements 62, 64, and 66 are arranged. It can be seen that the cutting elements 62, 64, and 66 do not move precisely in the Y direction, but are pivoted about a rotational axis D. This ensures that the cut is not made simultaneously at all points, but rather proceeds from the inside out in the aforementioned transverse direction Z.

[0062] Figure 7Figure 1 shows a rear view of the device according to the invention. Reference numeral 50 refers to a control device that controls the individual drives of the device 1. This control device is arranged on the rear side of the carrier 30, i.e., on the side opposite the actual device. Preferably, this control device controls all drives responsible for the transport and pressing processes.

[0063] Reference numeral 100 designates a control device for controlling the apparatus 1. This control device can control the individual drives, such as the drives of the transport equipment. Reference numeral 18 designates a transmitter suitable for the wireless output of data and / or signals. This transmitter 14 can also be in communication with the control device and receive data from it.

[0064] The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided they are novel, individually or in combination, over the prior art. It is further noted that the individual figures also describe features that may be advantageous in and of themselves. The skilled person will immediately recognize that a specific feature described in a figure may be advantageous even without adopting additional features from that figure. Furthermore, the skilled person will recognize that advantages may also arise from a combination of several features shown in individual or different figures. Reference symbol list

[0065] D Rotary axis P Buffer area X Direction Y Direction Z Transverse direction 1 Device 2 First transport device / conveyor device 4 Second transport device / conveyor device 6 Cutting device 12 Pressing device 14 Transmitting device 16 Counter-pressure roller 16a Slot in counter-pressure roller 18 Cutting device / Cutting roller 20 Paper material / Paper tape / Material tape / Elongated material 24 Drive / Drive motor 25 Carrier roller 26 Conveyor roller 30 Carrier 32 Transport roller 34 Transport roller 42 Transport roller 44 Counter roller 46 Support surface 50 Control device 52 Drive wheel / Gear 54 Rack 56 Drive linkage 62 Cutting element 64 Cutting element 65 Pre-tensioning devices 66 Cutting element 68 Guide element / Counter-cutting strip 70 Carrier 72 Press bar 74 Press bar 76 Press bar 82Matrix 84Matrix 86Matrix 100Control device

Claims

1. Apparatus for producing filling material, having a first conveying device (2) which is suitable and intended for conveying an elongate material strip (20) along a predetermined conveying direction (X), and having a first cutting device (6) which is suitable and intended for cutting the material strip (20) into strips in a direction which deviates from the conveying direction (X), and having a pressing device (12) which presses these strips through dies (82, 84, 86) in order to produce the filling material from these strips, wherein different drives (24) are provided at least for the pressing device (12) and the conveying device (2) and the dies have a cross-shaped cross-section and the pressing device moves a pressing punch substantially perpendicular to the conveying direction of the material.

2. Apparatus (1) according to claim 1, characterized in that the apparatus (1) has a second conveying device (4) which is arranged along the conveying direction (X) after the first conveying device (2) and which is also suitable and intended for transporting the elongated material (20) along the predetermined conveying direction.

3. Apparatus (1) according to claim 2, characterized in that a buffer area (PB) is arranged between the first conveying device (2) and the second conveying device (4), which can accommodate different quantities of the elongated material belt (20).

4. Apparatus (1) according to at least one of the preceding claims, characterized in that at least one conveying device (2, 4) is suitable and intended for conveying the material belt (20) in a clocked manner.

5. Apparatus (1) according to at least one of the preceding claims, characterized in that the apparatus (1) has a plurality of cutting elements (62, 64, 66) arranged one behind the other along the conveying direction (X), which cutting elements are each suitable and intended for cutting the material belt in the direction (Y) deviating from the conveying direction (X).

6. Apparatus (1) according to at least one of the preceding claims, characterized in that the apparatus has at least one control device (50) for controlling the drives of the first conveying device (2) and the pressing device (12), which controls these drives in such a way that the tape strips are pressed through the dies (82, 84, 86) while the tape strips are not conveyed in the conveying direction (X).

7. Apparatus (1) according to at least one of the preceding claims, characterized in that the apparatus (1) has a second cutting device (18) which cuts the material belt (20) in a direction which does not deviate by more than 30° from the conveying direction (X).

8. Apparatus (1) according to at least one of the preceding claims, characterized in that at least one conveying device (2, 4) has a conveyor roller (32, 42) which conveys the material belt (20) in the conveying direction (X).

9. Apparatus (1) according to at least one of the preceding claims, characterized in that the apparatus (1) has a carrier (30) on which at least the first conveying device (2) and the pressing device (12) are arranged.

10. Apparatus (1) according to at least one of the preceding claims, characterized in that the apparatus has a transmitting device which is suitable and intended for transmitting data characteristic of the apparatus and / or an operation of the apparatus (1).

11. Method for producing filling material, wherein a material belt (20) is transported by a first conveying device (2) in a conveying direction (X) and strips of material are cut off from the material belt by a first cutting device along a first cutting direction (Y) which deviates from the conveying direction (X) and these strips of material are pressed through dies (82, 84, 86) in order to produce the filling material, wherein the conveying device (2) and the pressing device are driven by different drives (24) and the dies have a cross-shaped cross-section and the pressing device moves a pressing punch substantially perpendicular to the conveying direction of the material.