Packaging material forming apparatus, and method of using the same

Abstract

Packaging material is often used to protect goods in transit. Paper is environmentally less damaging than plastics but the machines used to make the packaging material are relatively large. This specification describes apparatus to form packaging material that is relatively simple and small in size. The apparatus is for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll and includes a cutting mechanism 140 comprising a first reciprocating blade 310 and a second reciprocating blade 320. The reciprocating blades 310, 320 may be arranged to cut the packaging material in two separate strokes, thus allowing for a small and lightweight motor to be used, thereby minimising the size and weight of the overall apparatus and reducing the likelihood of the cutting mechanism 140 jamming.

Description

[0001] The present invention relates generally to a packaging material forming apparatus and a method of producing packaging material and finds particular, although not exclusive, utility in producing lengths of paper cushioning material.

[0002] It is known to provide an apparatus and method for forming packaging material for use with a feedstock of pre-folded paper, as disclosed in UK Patent GB2508267B. However, the cutting mechanism used in this machine comprises a single reciprocating blade and a stationary blade, with the packaging material passing between the two blades. An entire width of the packaging material is then crushed and cut with each stroke of the single reciprocating blade. As such, the cutting mechanism is prone to jamming, since the entire width of the packaging material is cut by a single reciprocating blade. This large reciprocating blade also requires a heavy-duty motor, the size of which limits the compactness of the overall machine. Document GB 2 549 257 A discloses a dunnage forming machine comprising a cutting mechanism which comprises a stationary blade and a first and a second reciprocating blade, which blades are pivotable relative to the stationary blade. The blades being driven by drive cogs which are coupled such that they rotate concurrently, wherein the blades cut the dunnage at the same time. For a business with relatively little space a smaller, lighter and more compact machine which has relatively simple construction and operation is desirable. Furthermore, as the machine may undergo intensive use, it is also desirable to have a machine that is less prone to jamming when cutting the formed packaging material.

[0003] In a first aspect, the present invention provides packaging material forming apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is arranged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together, and wherein both of the rollers in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another, the apparatus further comprising a cutting mechanism for cutting the partially crushed linear tubular paper form into desired lengths, wherein: the cutting mechanism comprises a stationary blade, a first reciprocating blade, and a second reciprocating blade; the first reciprocating blade and / or the second reciprocating blade are pivotable relative to the stationary blade; the first reciprocating blade is driven by a first drive cog, and the second reciprocating blade is driven by a second drive cog; the first drive cog and the second drive cog are coupled to one another such that they rotate concurrently; and the coupling of the first drive cog and the second drive cog is achieved via a drive belt, and the drive belt is removable and / or adjustable, such that the first drive cog and the second drive cog may be rotated independently of one another, thereby enabling alteration of a phase difference between movement of the first connecting rod and the second connecting rod, thereby altering a phase difference between movement of the first reciprocating blade and the second reciprocating blade.

[0004] The pre-folded paper may have a width of 600mm (when unfolded), with one edge folded over 175mm from one linear side and the other edge folded over 175mm from the other opposite linear side such that the two edges overlap by 100mm. The paper may be initially folded flat having a width of 250mm. The roll of paper may be 300m long.

[0005] The former may be inserted into the folded paper such that as the paper moves across the former, into the apparatus, the portions of paper forming the two side folds are pushed away from the base portion of the paper to create the tubular form.

[0006] The first reciprocating blade and the second reciprocating blade may be arranged to cut a first portion and a second portion of a width of the partially crushed linear tubular paper form. In this way, the cutting mechanism may be less prone to jamming, because less force is exerted by the extruded paper form onto the cutting edges of the reciprocating blades. The first reciprocating blade and the second reciprocating blade may be arranged to cut in two distinct strokes. This may render a light duty motor suitable for driving the cutting mechanism, thereby minimising the size and weight of the cutting mechanism and consequently the packaging material forming apparatus.

[0007] A portion of the width of the paper form cut by the first reciprocating blade may overlap with a portion of the width of the paper form cut by the second reciprocating blade, such that a portion of the width of the paper form may be cut by both blades.

[0008] The first reciprocating blade and the second reciprocating blade may each have at least one sharp edge. Sharp may mean any profile effective for cutting the partially crushed linear tubular paper form. Sharp may mean that the at least one edge is a right angle. The use of right-angled blades may mean that minimal maintenance and / or sharpening is required, which may therefore increase the longevity of the cutting mechanism. The blades may be made from metal, for example flat ground machine steel.

[0009] The second set of rollers may be arranged to produce the crimp along the middle of the partially crushed tubular paper form in the direction of feeding through the machine. This crimp or seal may be effected by the teeth squeezing the paper between them. The seal may be effected between the two linear edges of the paper and the base portion of the paper such that a cross-section of the resultant packaging material is an approximate figure of eight with two cushion-like forms, one either side of a crimped middle section.

[0010] The apparatus may further comprise two rotatable rollers upon which the roll of paper may rest and rotate. The rollers may be freely rotatable.

[0011] The apparatus may comprise a frame and either or both of the first and second set of rollers may be resiliently mounted to the frame such that they are movable relative to it to accommodate the irregularities of the tubular paper form. The resilience may be achieved by using springs or other such resilient mountings between brackets, retaining a shaft upon which the rollers are mounted, and the frame.

[0012] The radial outer surfaces of both of the rollers in the first set may be milled. In this regard, the term "milled" may mean a series of grooves, or a pattern of raised pimples. The milling may aid the initial feeding of the paper into the apparatus as it may more easily "grab" the end of the paper and pull it through. Furthermore, it may assist in maintaining the rate of entry of paper into the apparatus.

[0013] The apparatus may further comprise a cowling being arranged to accept the paper after it has been fed through the former and direct it to between the first set of rollers which are located immediately downstream thereof; the cowling having sides which taper inwardly so as to reduce the width of the paper as it passes therethrough.

[0014] The sides of the cowling are closer together at the downstream end compared to the upstream inlet to inwardly reduce the width of the tubular paper form to approximately 130 mm. In other words, the cowling may be funnel-shape.

[0015] The paper may be cut between the stationary and reciprocating blades.

[0016] The stationary blade may have at least one sharp edge. Sharp may mean any profile effective for cutting the partially crushed linear tubular paper form. Sharp may mean that the at least one edge is a right angle. The stationary blade may be made from metal, for example flat ground machine steel.

[0017] The first reciprocating blade and / or the second reciprocating blade may be pivotable relative to the stationary blade. In this way, the cutting motion of the reciprocating blades may pivot from an outside edge of the paper form towards the centre of the paper form, thereby resembling a scissor action. Accordingly, each reciprocating blade may incrementally cut the paper form from an outside edge towards the centre, leading to reduced force on the cutting mechanism and a lower likelihood of jamming. In the construction wherein only the first reciprocating blade may be pivotable relative to the stationary blade, it will be appreciated that the second reciprocating blade may move linearly relative to the stationary blade, such that the second reciprocating blade may incrementally cut the paper form from an outside edge of the paper form towards the centre of the paper form. Similarly, in the construction wherein only the second reciprocating blade may be pivotable relative to the stationary blade, it will be appreciated that the first reciprocating blade may move linearly relative to the stationary blade, such that the first reciprocating blade may incrementally cut the paper form from an outside edge of the paper form towards the centre of the paper form.

[0018] Motion of the first drive cog may be transferred to the first reciprocating blade via a first crank and first connecting rod, and motion of the second drive cog may be transferred to the second reciprocating blade via a second crank and second connecting rod.

[0019] The cutting action of each blade may be staggered by varying degrees. The staggering of the cutting action may be varied to suit the particular type of packaging material being produced. Removable may mean that the drive belt may be partially, or entirely removable from the drive cogs. Adjustable may mean that the drive belt may be extendable, such that the drive cogs may be rotated independently of one another while the drive belt is extended in position. The drive belt may then be retractable such that it retracts back to fitting around the drive cogs once adjustment is complete.

[0020] The first reciprocating blade, the second reciprocating blade and the stationary blade may each have a cutting edge, and the cutting edges of the first reciprocating blade and the second reciprocating blade may be arranged immediately adjacent to the cutting edge of the stationary blade. In this way, the movement of the reciprocating blades across the edge of the stationary blade may create a shearing action, thereby effectively cutting the partially crushed linear tubular paper form therebetween.

[0021] The resultant packaging material may be dispensed via a dispensing chute. This may be located downstream of the cutting mechanism.

[0022] The apparatus may further comprise sensing means for sensing the presence or absence of packaging material in the chute, and a PCU for controlling the first and second sets of rollers and the cutting mechanism.

[0023] The PCU may control the first and second sets of rollers by controlling a drive motor. The PCU may be programmed to stop the first and second sets of rollers before operating the cutting mechanism.

[0024] The PCU may operate the first and second of rollers to produce packaging material when the sensor senses the absence of packaging material in the dispensing chute. In this respect, the apparatus may not be producing packaging material when the sensor senses the presence of packaging material in the chute. In this way, a user may withdraw each length of packaging material, as required, without having to manually control the apparatus and without the apparatus producing more packaging than is immediately necessary. The apparatus may produce packaging material on demand and as required.

[0025] The PCU may be programmed to produce a predetermined number of individual lengths of packaging material; the dimension of each length also being predetermined.

[0026] The PCU may be programmed and the apparatus arranged such that a user is presented with various lengths to choose from and / or various numbers of lengths to select. The apparatus may include buttons assigned with these choices for ease of operability.

[0027] In a second aspect, the invention provides a method of producing packaging material comprising the steps of providing a packaging material forming apparatus according to the first aspect; providing a roll of pre-folded paper; feeding the free end of the paper through the former and between the first set of rollers; the former partially opening the folded paper into a linear tubular form, and operating the apparatus such that the first set of rollers rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together; and cutting the partially crushed linear tubular paper form into desired lengths.

[0028] In this method the two outside corners of the free end of the roll of pre-folded paper may be cut-off prior to being fed through the former and between the first set of rollers such that the free end of the paper is separated into three separate sheets.

[0029] A packaging material forming apparatus may be provided for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is arranged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together, and wherein both of the rollers in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another, the apparatus further comprising a cutting mechanism for cutting the partially crushed linear tubular paper form into desired lengths, wherein the cutting mechanism comprises a pivotable reciprocating blade and a fixed cutting surface.

[0030] It is to be understood that the packaging material forming apparatus may be operated using the same method as described in relation to the second aspect. It will be understood that the features described with regard to the first and second aspects may equally be used with, and / or apply to, the packaging forming apparatus.

[0031] The fixed cutting surface may be a planar and / or profiled sheet of material positioned substantially adjacent to the pivotable reciprocating blade, such that the paper form is arranged to pass between the pivotable reciprocating blade and the fixed cutting surface before the paper form is cut. The fixed cutting surface may be a stationary blade.

[0032] The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for the sake of example only, without limiting the scope of the invention as defined by the claims.

[0033] The reference figures quoted below refer to the attached drawings. Figure 1 is a schematic side overview of part of one example of the apparatus; Figure 2 is a schematic side view of part of the apparatus of Figure 1; Figure 3 is a cross-sectional side view of one example of the pre-folded paper; Figure 4 is a perspective view of the former of Figure 3 on its own; Figure 5 is a perspective view of the former of Figure 4 together with a portion of the pre-folded paper having been opened by the former; and Figure 6 is a perspective schematic view of one example of the apparatus, including a cutting mechanism.

[0034] The present invention will be described with respect to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. Each drawing may not include all of the features of the invention and therefore should not necessarily be considered to be an embodiment of the invention. In the drawings, the size of some of the elements may be exaggerated and not drawn to scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.

[0035] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other sequences than described or illustrated herein.

[0036] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other orientations than described or illustrated herein.

[0037] It is to be noticed that the term "comprising", used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression "a device comprising means A and B" should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0038] Reference throughout this specification to "an embodiment" or "an aspect" means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the present invention. Thus, appearances of the phrases "in one embodiment", "in an embodiment", or "in an aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different embodiments or aspects.

[0039] Similarly, it should be appreciated that in the description various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Moreover, the description of any individual drawing or aspect should not necessarily be considered to be an embodiment of the invention. Rather, as the following claims reflect, inventive aspects lie in fewer than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.

[0040] Furthermore, while some embodiments described herein include some features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form yet further embodiments, as will be understood by those skilled in the art.

[0041] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practised without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

[0042] In the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

[0043] The use of the term "at least one" may mean only one in certain circumstances.

[0044] The principles of the invention will now be described by a detailed description of at least one drawing relating to exemplary features of the invention. It is clear that other arrangements can be configured according to the knowledge of persons skilled in the art without departing from the underlying concept or technical teaching of the invention, the invention being limited only by the terms of the appended claims.

[0045] In Figure 1, an apparatus 10 for producing packaging material, or dunnage, using a rugation process, from paper or similar material, is shown in schematic form. The figure does not include all of the various elements such as electric motors, instead showing only the key features.

[0046] A frame 20 includes a support 40 at one upper end for holding a pre-folded roll of paper 30. The roll may rotate on an axle (not shown) passing through its centre, the axle being supported by the support 40. Alternatively, the roll of paper may rest on parallel rollers (not shown) without a central axle / spindle. This improves the ease with which the roll of paper may be replaced. An end of the paper 35 is led from the roll 30 over two individual tensioning rollers 50 so that the paper 35 may be fed horizontally into the main part 200 of the apparatus. Before it enters this main part 200 it passes between two further rollers 60 acting as guides.

[0047] The paper then passes through and around a former 80 which expands the pre-folded paper 35 from a substantially flat web into a substantially linear tubular form. The former is described with reference to Figures 4 and 5 in more detail below.

[0048] The substantially tubular form has a base 36 and two sides 37, 38 which extend from the base 35 up, around and over the base to form the sides and top of the tubular form.

[0049] The linear centre of the tubular form of paper 35 then passes between two rollers 100 which squeeze together the top and bottom surfaces of the centre of the tubular form to create two cushion-like forms either side of a substantially flat compressed strip running in the direction of the linear length of the paper 110.

[0050] The rollers 100 may be more wheel-like in form having a thickness in the range of 10mm to 20mm and a diameter in the range of 100mm to 200mm. The outer circumferential surface of the rollers may be milled or include dimples. The rollers may comprise metal.

[0051] The paper 35 is propelled through this first set of rollers 100 at a speed in the range of 10 to 50 metres per minute.

[0052] The paper 110 then passes between a second set of rollers which are rotating at a speed approximately half the speed of rotation of the first set of rollers such that the paper exits the second set of rollers in the range 5 to 25 metres per minute.

[0053] Due to this speed reduction the paper 35 is crumpled between the first and second sets of rollers such that its longitudinal linear length is reduced.

[0054] Each of the second set of rollers 120 includes teeth, the two sets of teeth interlocking during rotation. The teeth are rounded in a sinusoidal manner so that they do not puncture, rip or tear the paper. The interaction of the two sets of teeth help to seal the central, previously compressed, strip such that it does not separate.

[0055] The second set of rollers 120 may have a thickness in the range of 20mm to 50mm and a diameter in the range of 100mm to 200mm. The rollers may comprise metal.

[0056] The resultant paper form 130 is thus comprised of linearly crumpled paper having two cushion-like forms either side of a central compressed and sealed strip.

[0057] This dunnage 130 may then be cut into required length by a cutting mechanism 140, described in more detail below. The dunnage 130 may be used as packaging to prevent goods from being damaged in transit.

[0058] The resultant paper may be dispensed via a dispensing chute (not shown) provided downstream of the cutting mechanism.

[0059] With the roll of paper 30 located above the frame 20 and the apparatus 10 being relatively simple; it is possible to produce packaging material with equipment that occupies a relatively small space.

[0060] Figure 2, shows the main part 20 of the apparatus comprising a frame 23. The paper 35 enters the apparatus in the direction 200 on the right and exits on the left in the direction 201. The frame supports a lower first roller 100A and a lower second roller 120A. A support 24 extends from approximately the centre of the lower part of the frame 23 upwardly and a pivot point is provided towards the top thereof. From this pivot point 27, two arms 28 extend one rearwardly towards the first set of rollers 100 and one forwardly towards the second set of rollers 120. At the end of the rearwardly extending arm 28, the upper first roller 100B is pivotally connected. Similarly, at the end of the forwardly extending arm 28, the upper second roller 120B is pivotally connected.

[0061] These upper first 100B and second 120B rollers may thus move up and down relative to the fixed lower first 100A and second 120A rollers. This movement allows for the crumpled paper 110 to pass through the second set of rollers 120A, 120B without blocking occurring.

[0062] The upper first 100B and second 120B rollers are biased downwardly against the upper side of the frame 23 by individual coil springs 29 the force of each being adjustable via a threaded bar 25 as will be understood by the skilled person. This ensures good traction between the upper and lower rollers.

[0063] Although not shown, it will be understood that a motor is used to drive the rollers. A gear system may be employed to drive the first and second sets of rollers at different speeds.

[0064] Figure 3 shows a cross-section of the pre-folded paper 35. It comprises a single laminar sheet wherein the two longitudinal edges have been folded over the central portion 36. One edge has been folded over initially and then the other folded over such that an upper portion 38 overlies a middle portion 37 which, in turn, overlies the lower portion 36. The figure shows the paper slightly opened for the sake of clarity. In reality the paper 35 will feed off the roll 30 with tight folds such that the upper portion 38 will be substantially immediately above and on the middle portion 37 which will be substantially immediately above and on the lower portion 36.

[0065] With the initial paper roll 30 being provided in this way the amount of space required is minimised.

[0066] Figures 4 and 5 show the former 80 which is used to open the folded paper into an approximate tubular form. The former 80 comprises two lobes 81, 82, located one at either end of a first rectilinear bar 83. The lobes 81, 82 each comprise a cylinder with a dome shape at either longitudinal end. A second rectilinear bar 84 is provided extending from one lobe 81 towards the other lob 82, parallel with, but slightly spaced from the first rectilinear bar 83. This second bar 84 does not extend all the way to the lobe 82. Rather, it turns through 90 degrees and extends upwardly 85. This upwardly extending bar is only partially shown in Figure 4. The direction of its extent is indicated by broken lines. It is used to affix the former to the apparatus 10. The upwardly extending bar 85 is located closer to the lobe 82 than the lobe 81 from which it extends. This allows for upwardly extending bar 85 to be located approximately at the position of the longitudinal edge of the upper portion 38 of paper.

[0067] In use, the former 80 is arranged such that the direction of the movement of the paper 35 as it passes past the former 80 is substantially perpendicular to the axis of the two rectilinear bars 83, 84.

[0068] The paper 35 passes the former such that the lower portion 36 passes underneath the first rectilinear bar 83, the middle portion 37 passes between the first and second rectilinear bars 83, 84, and the upper portion 38 passes over the upper second rectilinear bar 84.

[0069] The former is positioned inside the folded paper 35 such that as the paper passes past the former 80 the two lobes move the paper into an approximate tubular form 90. The upwardly extending bar 85 allows the paper to pass it by extending beyond the longitudinal edge of the upper portion 38 as may be more clearly seen in Figure 5.

[0070] The resultant tubular form of paper 90 includes enlarged cushion like forms 33, 34 each around the lobes 81, 82.

[0071] For an initial feeding of the paper 35 into the apparatus 10, the longitudinal end of the paper 35 is trimmed with scissors such that a substantially triangular shape is formed. In other words the two outer corners are cut off. This leaves the three leaves (upper 38, middle 37, and lower 36) substantially separate with no connecting folds at the sides. This allows the three separate leaves 36, 37, 38 to be fed under, between and over the two rectilinear bars 83, 84 without having to pull the folded paper open so as to fit around the lobes 81, 82. The paper is then fed manually to the first set of rollers 100 which when rotating pull the paper into the apparatus 10. The paper is then automatically pulled around the lobes as it progresses into the apparatus such that the folded flat paper form is opened into the approximate tubular form.

[0072] In Figure 6, a partial view of one example of the apparatus including a cutting mechanism 140 is shown. The cutting mechanism 140 comprises a first reciprocating blade 310, a second reciprocating blade 320 and a stationary blade 330. The stationary blade 330 extends substantially horizontally across an upper portion of the cutting mechanism 140, from a left-hand side of the cutting mechanism 140 to a right-hand side of the cutting mechanism 140. The first reciprocating blade 310 is pivotally mounted adjacent to the stationary blade 330 at a pivot point 340 located near the left-hand edge of the stationary blade 330. The second reciprocating blade 320 is pivotally mounted adjacent to the stationary blade 330 at a pivot point 350 located near the right-hand edge of the stationary blade 330.

[0073] The first 310 and second 320 reciprocating blades each include a pivot point 340, 350, thereby pivotally mounting them to the pivot points 340, 350. Each blade comprises a cutting edge 315, 325 on its upper surface arranged to pass over the stationary cutting blade 330. The stationary blade 330 has a cutting edge 335 along its lower edge.

[0074] Below the cutting edge 335 of the stationary blade 330, an outward facing surface of the interlocking teeth of the second 120 set of rollers can be seen. The finished paper form would therefore pass out of the figure, towards the direction of the viewer. The first reciprocating blade 310 and second reciprocating blade 320 may move toward and away from the stationary blade 330 such that the finished crumpled dunnage which passes between the blades parallel to the cutting edge 335 of stationary blade 330 is cut into desired lengths.

[0075] Towards the base of the cutting mechanism 140 are arranged two drive cogs 370, 390. Each drive cog includes a crank, arranged as a pin 365, 385, extending from the face of each drive cog 365.

[0076] Connecting rods 360, 380 are arranged to connect each drive cog 370, 390 via their respective cranks 365, 385 to each respective blade 310, 320. Each connecting rod 360, 380 is pivotably attached to each blade. Accordingly, in use, as each drive cog rotates, each connecting rod is driven up and down reciprocatively to thus move each blade 310, 320 up and down reciprocatively so that they partially rotate back and forth about their pivot points 340, 350. This movement ensures that the cutting edge 315, 325 of each pivotable blade 310, 320 moves across, and against, the cutting edge 330 of the stationary blade to thereby cut the paper emerging from withing the apparatus. It will be understood that the cut starts at both outer edges of the crimped paper and travels towards the centre. The cutting edge 315, 325 of each pivotable blade 310, 320 has a length that is at least as long, or longer, than half the width of the paper at the point of being cut such that the cutting edges 315, 325 may overlap, in use. The speed of reciprocation of the blades is arranged such that the blades do not impede the flow of crimped paper from the machine. However, it is also contemplated that the motion of the paper may be stopped briefly while it is cut.

[0077] Either or both of the drive cogs 370, 390 are driven by a motor (not shown), which may be the same motor as which drives the first 100 and second 120 sets of rollers. The drive cogs 370, 390 are shown coupled together via drive belt 395, although it is to be understood that if both drive cogs are driven no drive belt is required.

[0078] The drive belt 395 includes an interior ribbed profile corresponding to an exterior toothed profile on each of the drive cogs 370, 390. In this way, the drive belt 395 connects the two drive cogs 370, 390 such that they may rotate in unison. The rotation of the drive cogs 370, 390.

[0079] The relative rotational position of the drive cogs 370, 390 may be varied by removing the drive belt 395, rotating one or both of the drive cogs 370, 390, and replacing the drive belt 395. In this way, an offset may be introduced between the pivoting cutting action of the first reciprocating blade 310 and the second reciprocating blade 320. Alternatively, the drive belt 395 may be extendable, thereby allowing for adjustment of the offset between the rotational position of the drive cogs 370, 390 by extending the drive belt 395 to separate its ribs from the teeth on the drive cogs 370, 390, and rotating one or both of the drive cogs 370, 390 to a different relative position. The drive belt 395 may then be retractable such that it retracts back so its ribs again engage with the teeth on the drive cogs 370, 390 once adjustment is complete. The drive belt 395 is supported at its lower edge by a support roller 400.

[0080] The first 100 and second 120 sets of rollers may be stopped when the cutting mechanism is required to cut the paper.

[0081] In an alternative version, only one cutting blade may be provided (not shown). This single blade is provided with a length such that it extends across the entire width of the paper as it emerges. The single blade may reciprocate, and be driven to reciprocate, in the same manner as described above with regard to the two blade alternative.

Claims

1. Packaging material forming apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former (80) for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers (100, 120) for moving the tubular paper form through the apparatus, wherein the first set of rollers (100) is arranged to rotate at a speed greater than the second set of rollers (120) to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers (120) being arranged to crimp the two linear sides of the paper together, and wherein both of the rollers (100, 120) in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another, the apparatus further comprising a cutting mechanism (140) for cutting the partially crushed linear tubular paper form into desired lengths, wherein: the cutting mechanism (140) comprises a stationary blade (330), a first reciprocating blade (310), and a second reciprocating blade (320); the first reciprocating blade (330) and the second reciprocating blade (320) are pivotable relative to the stationary blade (330); the first reciprocating blade (310) is driven by a first drive cog (370), and the second reciprocating blade (320) is driven by a second drive cog (390); the first drive cog (370) and the second drive cog (390) are coupled to one another such that they rotate concurrently; and the coupling of the first drive cog (370) and the second drive cog (390) is achieved via a drive belt (395), and the drive belt (395) is removable and / or adjustable, such that the first drive cog (370) and the second drive cog (390) may be rotated independently of one another, thereby enabling alteration of a phase difference between movement of the first connecting rod (360) and the second connecting rod (380), thereby altering a phase difference between movement of the first reciprocating blade (310) and the second reciprocating blade (320).

2. The apparatus of claim 1, wherein the second set of rollers (120) is arranged to produce the crimp along the middle of the partially crushed tubular paper form in the direction of feeding through the machine.

3. The apparatus of any preceding claim, further comprising two rotatable rollers upon which the roll of paper may rest and rotate.

4. The apparatus of any preceding claim, comprising a frame (20) and wherein either or both of the first and second set of rollers (100, 120) are resiliently mounted to the frame (20) such that they are movable relative to it to accommodate the irregularities of the tubular paper form.

5. The apparatus of claim 1, further comprising a cowling being arranged to accept the paper after it has been fed through the former (80) and direct it to between the first set of rollers (100) which are located immediately downstream thereof; the cowling having sides which taper inwardly so as to reduce the width of the paper as it passes therethrough.

6. The apparatus of claim 1, wherein motion of the first drive cog (370) is transferred to the first reciprocating blade (310) via a first crank (365) and first connecting rod (360), and motion of the second drive cog (390) is transferred to the second reciprocating blade (320) via a second crank (385) and second connecting rod (380).

7. The apparatus of any preceding claim, wherein the first reciprocating blade (310), the second reciprocating blade (320) and the stationary blade (330) each have a cutting edge (315, 325, 335), and the cutting edges (315, 325) of the first reciprocating blade (310) and the second reciprocating blade (320) are arranged immediately adjacent to the cutting edge (335) of the stationary blade (330).

8. The apparatus of any preceding claim, further comprising sensing means for sensing the presence or absence of packaging material in a dispensing chute, and a PCU for controlling the first and second sets of rollers (100, 120) and the cutting mechanism (140).

9. The apparatus of claim 8, wherein the PCU operates the first and second sets of rollers (100, 120) to produce packaging material when the sensor senses the absence of packaging material in the dispensing chute.

10. The apparatus of either one of claims 8 and 9, wherein the PCU is programmed to produce a predetermined number of individual lengths of packaging material; the dimension of each length also being predetermined.

11. A method of producing packaging material comprising the steps of providing a packaging material forming apparatus according to any preceding claim; providing a roll of pre-folded paper; feeding the free end of the paper through the former (80) and between the first set of rollers (100); the former (80) partially opening the folded paper into a linear tubular form, and operating the apparatus such that the first set of rollers (100) rotate at a speed greater than the second set of rollers (120) to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers (120) being arranged to crimp the two linear sides of the paper together; and cutting the partially crushed linear tubular paper form into desired lengths.

12. The method of claim 11, wherein the two outside corners of the free end of the roll of pre-folded paper are cut-off prior to being fed through the former (80) and between the first set of rollers (100) such that the free end of the paper is separated into three separate sheets.

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