Web processing machine equipped with ultrasonic sealer

Abstract

To provide a machine for converting a web into a pouch or a bag comprising a wrap seal by using an ultrasonic sealer.SOLUTION: In certain examples, a machine that forms a web into bags or pouches includes a sealing section through which the web is conveyed in a machine direction. The sealing section is configured to form a wrap seal in the web and has an input end configured to receive the web which has a first web section and a second web section. An ultrasonic sealer with a horn and an anvil defines a nip therebetween through which the first web section passes. The ultrasonic sealer is configured to form the wrap seal in the first web section. The anvil is positioned between the first web section and the second web section. An output end is configured to dispense the web with the wrap seal formed therein.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - Reference to Related Applications This disclosure claims priority based on U.S. Provisional Patent Application No. 63 / 181,475, filed on April 29, 2021, the disclosure of which is incorporated herein in its entirety.

[0002] This disclosure relates to machines for converting webs, and more particularly, to machines for converting a web into a pouch or bag having a lap seal using an ultrasonic sealer.

Background Art

[0003] The following U.S. patents are incorporated herein by reference in their entirety.

[0004] U.S. Patent No. 7,191,575 discloses a vertical form - fill - seal continuous pouch machine having a forming tube.

[0005] U.S. Patent No. 8,029,428 discloses a machine and method for manufacturing bags from a web by moving from an input section to a rotating drum and an output section.

[0006] U.S. Patent No. 10,946,591 discloses a method and apparatus for making bags or pouches. Seals can be formed using an ultrasonic sealer, and different seal patterns can be utilized.

Summary of the Invention

[0007] This summary is provided to introduce a selection of concepts that are further described below in the detailed description of the invention. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0008] In a particular example, a machine for forming a web into a bag or pouch includes a sealing section through which the web is conveyed in the direction of the machine. The sealing section has an input end configured to receive a web having a first web section and a second web section, and is configured to form a wrap seal on the web. An ultrasonic sealer having a horn and an anvil defines a nip between them through which the first web section passes. The ultrasonic sealer is configured to form a wrap seal on the first web section. The anvil is positioned between the first web section and the second web section. The output end is configured to distribute the web formed therein as the wrap seal is distributed.

[0009] Various other features, purposes, and advantages will become clear from the following description, along with the drawings.

[0010] This disclosure will be described with reference to the following figures. The same numbering is used throughout the drawings to refer to similar features and components. [Brief explanation of the drawing]

[0011] [Figure 1] This is a perspective view of an exemplary machine in this disclosure.

[0012] [Figure 2] This is another perspective view of the machine shown in Figure 1.

[0013] [Figure 3] This is a schematic diagram of a web folded for wrapping and sealing.

[0014] [Figure 4] This is a perspective view of an exemplary arm assembly supporting an anvil in this disclosure.

[0015] [Figure 5] Figure 4 is a perspective view of the arm assembly interacting with the material web. [Figure 6]A perspective view of the arm assembly of FIG. 4 interacting with a web of material.

[0016] [Figure 7] A side view of the arm assembly shown in FIG. 6.

[0017] [Figure 8] An end view of the arm assembly shown in FIG. 6 having a web of material.

[0018] [Figure 9] A schematic view of an exemplary seal station of the present disclosure.

[0019] [Figure 10] A perspective view of an exemplary arm assembly.

[0020] [Figure 11] Another perspective view of the arm assembly of FIG. 10.

[0021] [Figure 12] A side view of the arm assembly of FIG. 10.

[0022] [Figure 13] An end view of the arm assembly of FIG. 10.

[0023] [Figure 14] A cross-sectional view of the arm assembly of FIG. 10 taken along line 14-14 of FIG. 12.

[0024] [Figure 15] A perspective view of an exemplary anvil.

[0025] [Figure 16] A cross-sectional view of the anvil of FIG. 15.

[0026] 5] [Figure 17]This is a magnified view of the anvil in Figure 15, located within line 17-17 in Figure 16.

[0027] [Figure 18] Another illustrative perspective of an anvil.

[0028] [Figure 19] This is a magnified view of the anvil in Figure 18, located within the line 19-19 in Figure 18.

[0029] [Figure 20] This is a cross-sectional view of the anvil in Figure 18 at one of the grooves located approximately at the line 20-20 in Figure 19.

[0030] [Figure 21] Another illustrative perspective of an anvil.

[0031] [Figure 22] Figure 21 is an end view of the anvil.

[0032] [Figure 23] This is a magnified view of the anvil in Figure 21, located within line 23-23 in Figure 22.

[0033] [Figure 24] This is a schematic diagram showing a partial cross-section of the web.

[0034] [Figure 25] This is a schematic diagram of an exemplary control system in this disclosure. [Modes for carrying out the invention]

[0035] Known web processing machines convert web, which is typically supplied as a continuous sheet of material from a web supply roll, into pouches or bags. The machine may be a continuous motion machine, an intermittent motion machine, or a hybrid machine having features of both continuous and intermittent motion machines.

[0036] A continuous motion machine conveys a web at a constant speed, and various actions are performed on or against the web as the machine conveys the web through the machine. The machine can further perform various actions or operations on the web to create a bag or pouch. For example, the machine can use a sealer to form one or more seals on the web in order to form a pouch or bag at least partially. The machine can also heat the web with a heater, cool the web with a cooler, attach an insert (e.g., a zipper) to the web, cut the web with a knife or cutter, and / or perforate the web with a perforator. The machine may include a rotating drum and / or shuttle that moves the sealer components so that there is no relative motion between the web and the sealer components.

[0037] Alternatively, an intermittent motion machine moves and stops the web so that one or more actions can be performed on the web when it stops. For example, when the web stops, a sealer can form a seal on the web. The web is then moved forward and stopped again so that different actions can be performed on the web.

[0038] When forming a pouch or bag, the machine (such as the continuous-motion or intermittent-motion machine described above) forms one or more seals in the web. Each individual bag or pouch contains one or more seals, and each bag or pouch typically has an unsealed opening into which an object, such as food, is placed. After the object is placed in the bag or pouch, the machine can then form an additional seal in the web or add a closing mechanism such as a zipper to close the opening and completely seal the object inside the bag or pouch.

[0039] A wrap seal is a seal commonly formed on a web when forming a bag or pouch. To form a wrap seal, the machine transports the web from a feed roll through a folding station that folds the opposing sides of the web toward each other in a cross direction. Note that the cross direction is opposite to each other and lateral (e.g., perpendicular) to the machine direction (the machine direction and cross direction will be further explained below). Thus, the opposing sides of the web overlap each other so that the web folds into the shape of a continuous tube. In this shape, a portion of the inner surface of the web overlaps a portion of the outer surface of the web.

[0040] The folded web is transported to a downstream sealing station where a lap seal is formed by sealing or bonding the overlapping sides of the web to each other. Known machines include sealing components such as a heated sealing bar that forms the lap seal on the folded web. Through research and experimentation, the inventors recognized that machines using heated seal bars to form lap seals require preheating the seal bar to the desired sealing temperature, and further require a large amount of energy to maintain the desired sealing temperature while the machine is operating and forming the seal. Furthermore, the inventors recognized that other machines for forming seals often include multiple sealers, further including cooling devices, cooling sections for cooling the seals, and / or may require a compressed air system for cooling the formed seal and / or the surrounding web. Thus, the inventors have developed an improved machine that forms lap seals on a web with good seal strength at a lower energy cost, and the forming does not require a cooling device or cooling area for cooling the seal, allowing the machine to have a smaller footprint and shorter web path than conventional machines. It should be noted that the shorter web path can improve web handling and reduce web waste. The inventors have also developed a machine that requires little maintenance, has minimal start-up time requirements, allows for real-time seal adjustment, allows for seal customization, and / or improves machine efficiency. Accordingly, the inventors have developed the machine and sealing station (as well as their features and components) of the present disclosure.

[0041] Figures 1 and 2 show an exemplary sealing station 30 of the present disclosure, which is part of an exemplary machine 10 of the present disclosure. Machine 10 may include other sections or stations 11, 12, 15 ( schematically shown in Figure 9) upstream and / or downstream of the sealing station 30 (e.g., input station, output station, cutting station, folding station 15). Note that machine 10 defines a machine direction (see arrow MD extending longitudinally along machine 10) which is the direction in which the web 20 is transported through machine 10 from upstream to downstream. Intersecting directions (see arrow CD) as referred hereafter herein are opposite directions that are lateral (e.g., perpendicular) to the machine direction MD. Some features of machine 10 are described below in specific spatial relationships to one another (e.g., vertically spaced and longitudinally offset), but note that these spatial relationships are not intended to limit the orientation of machine 10 or its components to any particular limited orientation. For example, depending on the specific application of the machine 10, the machine 10 can be reversed, or its machine direction can be oriented vertically, in contrast to the machine direction and orientation of the machine 10 shown in the figures of this disclosure.

[0042] Machine 10 includes a folding station 15 that folds the opposing sides 21 and 22 of the web 20 toward each other in a cross direction CD such that the sides 21 and 22 (Figure 3) overlap each other. Note that the folding station 15 is not fully shown in Figures 1 and 2, although Figure 2 shows the approximate location of the folding station 15. The folding station 15 may include any suitable folding components such as plates, angles, and blocks configured to fold the web 20. In one example, the folding station 15 includes folding components on each side of the web 20 such that the sides of the web fold inward in a cross direction toward the center of the web 20 as the web 20 is transported along the folding components. In one example, the web 20 enters the folding station as a flat sheet and exits the folding station (after the folding components have folded the sides of the web 20) having the shape of a continuous tube (see Figure 3) and an elliptical cross-section.

[0043] Figure 3 shows a cross-sectional view of the web 20 as it is being transported downstream of the folding station 15. Here, the folded web 20 is in the shape of a continuous tube (for example, the web 20 has a tubular shape and a substantially elliptical cross-section; see Figure 3). Sides 21 and 22 overlap each other (see also Figure 3) and are part of the first web section 41 of the web 20, where a lap seal is formed. If the web 20 is in the shape of a continuous tube, it includes a second web section 42 opposite the first web section 41. Part of the inner surface 23 of the web 20 overlaps with or is adjacent to part of the outer surface 24. Note that in certain examples, as shown in Figure 3, the second side surface 22 is above the first side surface 21. However, in other examples, the machine 10 may be configured such that the first side surface 21 is above the second side surface 22.

[0044] A roller system having one or more rollers 17 (Figures 2 and 9) transports the folded web 20 from the folding station 15 through the sealing station 30 downstream in the machine direction MD. The roller system may include idler rollers, guide rollers, tension rollers, drive rollers, driven rollers, or other rollers known in the art for collectively transporting and supporting the web 20 within the machine 10. The roller system may be configured to maintain tension in the web 20 as it is transported through the sealing station 30. Note that other rollers (not shown) of the roller system may be located in the sealing station 30 and / or other stations upstream and / or downstream of the sealing station 30.

[0045] The sealing station 30 is configured to form a lap seal on the web 20 by sealing the overlapping sides 21, 22 of the web 20 to each other. Referring to the exemplary web 20 shown in Figure 3, the inner surface 23 near the second side 22 of the web 20 is sealed to the outer surface 24 near the first side 21 of the web 20. As further described herein, the lap seal is formed on the web 20 using an ultrasonic sealer 50 that applies ultrasonic energy, vibration energy, and / or compressive force to the web 20, thereby forming a lap seal on the web 20.

[0046] The sealing station 30 has an upstream input first end (the “input end” in the claims) 31 that receives the web 20 from the folding station 15, and an opposite downstream output second end (the “output end” in the claims) 32 that distributes the web 20 with the lap seal formed. A first frame (the “frame” in the claims) 33 extends in the cross direction CD and is spaced perpendicularly from the web 20. The first frame 33 is for supporting an arm assembly 60 perpendicularly to the web 20, and the arm assembly 60 holds the anvil 52 of the ultrasonic sealer 50. In a particular example, the arm assembly 60 is a cantilever beam with one end coupled to the first frame 33 and the other opposite end (e.g., the end that holds the anvil 52) suspended freely. The first frame 33 includes one or more mounting holes 34 so that the arm assembly 60 is attached to the first frame 33 and movable in the cross direction CD. In other examples, the first frame 33 may have rails with channels (not shown) that facilitate the cross-directional movement of the arm assembly 60 along the first frame 33. In other examples, the arm assembly 60 is coupled to the first frame 33 via dovetail wedges, linear rails, and / or shaft slides. Note that in certain examples, the arm assembly 60 and / or horn 51 can be moved manually by an operator or automatically by an actuator (not shown) of the machine 10.

[0047] The second frame 35 is positioned downstream of the first frame 33 in the machine direction MD. The second frame 35 is for vertically supporting the horn 51 of the ultrasonic sealer 50 relative to the web 20 and anvil 52, which are held by the arm assembly 60. The second frame 35 and / or the horn 51 are movable in the cross direction CD, and in one example, the second frame 35 and / or the horn 51 are moved in the first cross direction CD1 (Figure 2) so that the horn 51 is positioned perpendicular to the anvil 52. Note that Figure 1 shows the second frame 35 having frame components that are coupled to and support the horn 51 relative to the web 20 and anvil 52. These frame components are offset from the horn 51 in the first cross direction CD1 and / or vertically from the horn 51. A pair of finishing rollers 36 are positioned downstream of the second frame 35, and the finishing rollers 36 are for finishing the lap seal as described below.

[0048] Referring here to Figures 4-8, the arm assembly 60 includes a first arm 61 detachably coupled to a first frame 33, and a second arm 62 extending laterally and mechanically MD relative to the first arm 61. Figure 4 shows the web 20 spaced apart from the arm assembly 60, Figure 5 shows the web 20 partially engaged with the arm assembly 60, and Figure 6 shows the web 20 fully engaged with the arm assembly 60 such that the anvil 52 is within a gap 29 (Figure 7) defined by the web 20. Figures 4-8 and the interaction between the web 20 and the arm assembly 60 will be described in more detail below. Furthermore, Figures 4 to 8 show a large space between the horn 51 and the anvil 52 so that the features and components of the arm assembly 60 are clearly shown, but it should be noted that the space between the horn 51 and the anvil 52 can vary (for example, 1.0 mm between the horn 51 and the anvil 52, 8.0 mm between the horn 51 and the anvil 52) and can be determined based on various factors during the setup and operation of the machine 10 (e.g., web thickness, pattern on the anvil 52). In addition, Figures 11 to 14 show a similar exemplary arm assembly 60 isolated from the machine 10 and the web 20.

[0049] The first arm 61 is cantilevered from the first frame 33 toward the web 20 and may include a portion extending generally in the machine direction MD. Thus, in a particular example, the arm assembly 60 is a cantilever beam coupled to the first frame 33 via the first arm 61. The first arm 61 includes one or more fasteners 63 (see Figure 2) for coupling the first arm 61 to the first frame 33. The fasteners 63 can be any suitable components such as clamps or threaded nuts and bolts. The fasteners 63 are removed so that an operator can move the first arm 61 and the arm assembly 60 along the first frame 33 in one of the intersecting directions CD and re-couple the first arm 61 to the first frame at a desired position corresponding to a desired position on the anvil 52. In a particular example, the machine 10 includes one or more actuators for moving the arm assembly 60 relative to the first frame 33. In these examples, the operator does not need to manually engage the arm assembly 60 and / or any fasteners 63 in order to move the arm assembly 60.

[0050] The second arm 62 is cantilevered and connected to the first arm 61, extending along the web 20 in the machine direction MD. Specifically, the second arm 62 has an input first end 64 connected to the first arm 61 and an opposite second end 65 downstream of the first end 64 in the machine direction MD. The second arm 62 includes a first side surface 71, an opposite second side surface 72, and a body 73. The channel 66 is defined near the first end 64 of the second arm 62, and the opening 69 is defined on the first side surface 71 of the second arm 62. Note that the guide surface 67 defines the channel 66 at least partially and is spaced apart from the first arm 61 (see Figures 4 and 10). During the operation of the machine 10 (further described herein), the first side surface 21 of the web 20 is conveyed in the machine direction MD through the opening 69 and the channel 66, and further along the upper surface 77 of the main body 73. The guide surface 67 is spaced apart from the first arm 61 (see Figure 4).

[0051] The first arm 61 is coupled to the second side 72 of the second arm 62 (see Figure 4) via a coupling section 68 of the second arm 62. The coupling section 68 is located at the first end 64 of the second arm 62. During the operation of the machine 10, the second side 22 of the web 20 is transported along the coupling section 68 and further along the upper surface 77 of the body 73 in the machine direction MD.

[0052] The second end 65 of the second arm 62 has a notch 74 (see Figure 8) into which the anvil 52 is received and held. The bore 75 (Figure 4) extends between the sides 71, 72 of the second arm 62 and the notch 74 so that a shaft, pin, or rod (not shown) can be inserted through the bore 75, the channel 66, and the anvil 52. Thus, the pin or rod connects the anvil 52 to the second arm 62 and allows the anvil 52 to rotate around an axis 78 (Figures 4 and 7) that passes through the center of the bore 75. The shaft, pin, or rod can be removed so that the operator can replace the anvil 52 with a different anvil 52. For example, the anvil 52 may be replaced with a different anvil 52 having a different seal pattern or profile, as further described herein. Note that in other examples, the anvil 52 does not rotate (for example, the anvil 52 is stationary relative to the second arm 62).

[0053] It should be noted that in certain cases, the anvil 52 may generate heat during operation (for example, friction between the anvil 52 and the web 20 may be generated by heat), and therefore it may be necessary to cool the anvil 52 to ensure that the lap seal is properly formed on the web 20. However, the body 73 of the second arm 62 is close to the anvil 52 and / or coupled to the anvil 52 via pins and acts as a heat sink for the anvil 52. Thus, heat can flow from the anvil 52 to the second arm 62, and the second arm 62 may include one or more cooling components configured to remove or dissipate the heat that the second arm 62 receives from the anvil 52. In one example, the cooling component is a channel extending along the outer surface of the second arm 62 through which air flows to cool the second arm 62. In another example, the cooling component is a conduit within the second arm 62 through which air or fluid is carried to cool the second arm 62. In one example, the air is compressed air supplied from an air pump (not shown).

[0054] Referring specifically to Figure 9, the arm assembly 60 is shown by a dashed line, and the sides 21, 22 and the second web section 42 are shown by solid lines. The lap seal is formed on the web 20 along the sealing surface 54, which is shown by a dashed line in Figure 9. The outer circumference of the roller 17 upstream of the sealer 50 is offset in a first direction from the sealing surface 54 (see arrow M), and the outer circumference of the upper finishing roller 36 is also offset in a first direction from the sealing surface 54 (see arrow N).

[0055] As described above, the web 20 is transported in the machine direction MD through a sealing station 30 where a wrap seal is formed on the web 20. As the web 20 is transported along the arm assembly 60, each side 21, 22 and the second web section 42 of the web 20 are transported simultaneously along separate paths extending between the upstream roller 17 (see point P) and the horn 51 and anvil 52 (see point Q). Specifically, the first side 21 is transported along the first path, the second side 22 is transported along the second path, and the second web section 42 is transported along the third path. In certain cases, the lap seal is properly formed by the sealer 50, and these components (the first side 21, the second side 22, and the second web section 42 of the web 20) are not offset from one another when the lap seal is formed on the web 20, such that the length of the first side 21 of the web 20 in the mechanical direction MD of the first path is equal to the length of the second side 22 of the web 20 in the mechanical direction MD of the second path, and equal to the length of the second web section 42 in the mechanical direction MD of the third path. If the lengths of the first side 21 in the first path, the second side 22 in the second path, and / or the second web section 42 in the third path are not equal, the lap seal may not be properly formed on the web 20, and the web 20 may contain wrinkles, creases, or other undesirable features that adversely affect the lap seal strength and / or aesthetic appearance of the bag. Thus, the surface and curved edges of the arm assembly 60 are designed such that the lengths of the first side surface 21 in the first path and the second side surface 22 in the second path are equal to each other.

[0056] Returning to Figures 4-6, an exemplary sequence of operations for properly positioning the web 20 through the sealer 50 around the arm assembly 60 is described below. Figure 4 shows the web 20 spaced apart from the arm assembly 60 and extending between the roller at the upstream end 31 and the roller at the downstream end 32 of the sealing station 30 (e.g., roller 17 in Figure 9). The web 20 is in the shape of a flat, continuous tube as shown in Figure 3. Referring to Figure 5, in order to engage the web 20 with the arm assembly 60, the operator first stops the transport of the web 20, and then the operator pulls the second side 72 of the web 20 around the second side 22 of the second arm 62 (see arrow P in Figure 5). Thus, the second side 22 of the web 20 extends along the body 73 of the second arm 62, and the second arm 62 and anvil 52 are partially within the gap 29 defined by the folded web 20 (see also Figures 3 and 8). Note that in Figure 5, a portion of the arm assembly 60 covered by the second side 22 of the web 20 is shown by a dashed line.

[0057] Next, the operator similarly pulls the first side surface 21 of the web 20 around the first side surface 71 of the second arm 62 so that the first side surface 21 of the web 20 extends along the guide surface 67 and the top surface 77 through the channel 66 and the opening 69 (see arrow Q in Figure 6). Thus, the second arm 62 and the anvil 52 are within the gap 29, and the web 20 engages properly with the arm assembly 60 to form a lap seal on the web 20 (see also Figure 8). Note that in Figure 6, the portion of the arm assembly 60 covered by the sides 21, 22 of the web 20 is shown by a dashed line. Furthermore, note that the sides 21, 22 may be in a first orientation relative to each other, where the second side surface 22 is closer to the horn 51 than the first side surface 21 (see Figure 8), or in an alternative second orientation where the first side surface 21 is closer to the horn 51 than the second side surface 22. The first or second orientation is selected by the operator, and the selection may depend on the material properties of the web 20.

[0058] When the operator restarts the machine 10, the second arm 62 and anvil 52 remain within the gap 29 (for example, the web 20 moves around the second arm 62 and anvil 52), while the sides 21 and 22 of the web 20 are transported along the second arm 62. Figure 7 shows the interaction between the web 20 and the arm assembly 60 while the web 20 is being transported in the machine direction MD. The portion of the arm assembly 60 covered by the web 20 is shown by a thin solid line, and the horn 51 is spaced apart from the web 20 for clarity.

[0059] Referring now to Figure 8, an end view of the second arm 62, anvil 52, and horn 51 is shown. Note that line 8-8 in Figure 6 is the approximate location of the end view shown in Figure 8. Also note that Figure 8 shows the web 20 spaced apart from the horn 51 and anvil 52, but during operation there is either less space between these components or just enough space between them to allow the sides 21, 22 of the web 20 to pass through. In certain examples, the horn 51 is moved to a certain position relative to the anvil 52 by an actuator (not shown), such as a servo motor. The distance between the outer circumferential surfaces of the horn 51 and the anvil 52 can vary, and in certain examples, the distance between the outer circumferential surfaces of the horn 51 and the anvil 52 depends on the thickness of the web 20 and the material parameters (e.g., thickness) of the lap seal formed on the web 20. In certain examples, the horn 51 and / or anvil 52 can be gradually moved toward each other, thereby positioning the horn 51 and anvil 52 relative to each other. In one example, the spacing or distance between the horn 51 and anvil 52 (e.g., the vertical height of the nip defined between the horn 51 and anvil 52) is selected by the operator based on any number of factors such as the web thickness, the web material, and / or the parameters of the desired lap seal (e.g., the thickness of the lap seal, the desired seal strength), and the spacing remains constant while the machine 10 is in operation.

[0060] In another example, while the web 20 is being transported through the nip, the distance between the horn 51 and the anvil 52 can be changed automatically and / or dynamically to maintain a desired pressure on the web 20 and properly form a lap seal. Changing the distance automatically and dynamically takes into account variations in the material of the web 20 (e.g., variations in thickness) so that a lap seal is properly formed on the web. In this example, a sensor (not shown) is configured to sense the pressure applied to the web 20 by the horn 51 and the anvil 52. An actuator (not shown; e.g., a pneumatic piston, a servo motor) coupled to the anvil 52 is controlled by a controller (further described herein) based on a signal received from the sensor, and the actuator moves the horn 51 relative to the anvil 52, thereby maintaining the desired pressure on the web 20.

[0061] The horns 51 and anvils 52 define a nip 79 between them through which the sides 21, 22 and the first web section 41 are conveyed. As the sides 21, 22 of the web 20 are conveyed through the nip, the horns 51 and anvils 52 compress the sides 21, 22 between them (note that Figure 8 shows the sides 21, 22 spaced apart from each other for clarity). This causes the horns 51 and anvils 52 to cooperate in forming a lap seal on the web 20. In one example, the horns 51 and anvils 52 form the lap seal by sealing the inner surface 23 near the second side 22 of the web 20 to the outer surface 24 near the first side 21 of the web 20. The horns 51 and anvils 52 rotate relative to each other, continuously forming a lap seal on the web 20 as the web 20 is continuously conveyed through the nip. Thus, the lap seal on the web 20 extends in the machine direction MD downstream of the sealer 50. In certain examples, the horn 51 and / or anvil 52 may be rotated by an actuator (e.g., a motor). In other examples, the web 20 rotates the horn 51 and / or anvil 52 as it is transported between the horn 51 and anvil 52.

[0062] The horn 51 receives ultrasonic energy from an ultrasonic energy generator or source (not shown) so that the horn 51 vibrates. The vibration of the horn 51 relative to the anvil 52 imparts energy to the sides 21, 22 of the web 20 as it is transported between the horn 51 and the anvil 52. The anvil 52 may include a pattern that imparts a pattern to the lap seal formed on the web 20 (e.g., the size and shape of the lap seal). However, in other examples, the anvil 52 does not have a pattern, and instead its outer surface is smooth. Note that in certain examples, by applying ultrasonic energy to the web 20 via the horn 51, portions of the web 20 that fuse or seal together to form a lap seal are melted. In one example, when ultrasonic energy is applied to the web 20 via the horn 51, the molten material fuses together, melting the inner surface 23 and outer surface 24 so that a lap seal is formed on the web 20. In certain examples, the application of ultrasonic energy is configured so that the surfaces 38 (Figure 3) opposite the inner surface 23 and outer surface 24 do not inadvertently bond to other surfaces of the web 20. For example, these surfaces 38 do not adhere to the second web section 42.

[0063] Furthermore, it should be noted that the second web section 42 (see Figure 3) remains separated from the lap seal by cantilevering the second arm 62 and anvil 52 in the gap 29 defined by the web 20 via the first arm 61 and the first frame 33. That is, the second arm 62 and anvil 52 maintain the separation between the second web section 42 and the sides 21, 22. Note that in certain examples, the second arm 62 and anvil 52 are spaced vertically above the second web section 42. Those skilled in the art will recognize that if the anvil 52 is positioned outside the gap 29, the sealer 50 may inadvertently form a lap seal between the first web section 41 (e.g., sides 21, 22) and the second web section 42. To avoid this potential problem, the anvil 52 is positioned within the gap 29 formed by the web 20.

[0064] Optionally, after the lap seal has formed on the web 20, the finishing roller 36 (see Figure 9) defines a nip through which the web 20 with the lap seal is conveyed. The finishing roller 36 is configured to compress the lap seal between the finishing rollers, thereby finishing the lap seal (as described below).

[0065] Here, referring to Figures 15 to 24, exemplary anvils 52 are shown. Each anvil 52 has a central bore 81 and one or more surfaces extending along the circumference of the anvil 52. The anvil 52 has an outer surface 82 and a sealing surface 83 that is raised relative to the outer surface 82. The sealing surface 83 at least partially defines the size and shape of the lap seal formed on the web 20 when the horn 51 and the anvil 52 cooperate to form the lap seal (as described above). A transition surface 84 extends between the outer surface 82 and the sealing surface 83, and the transition surface 84 provides a smooth transition between the outer surface 82 and the sealing surface 83. The transition surface 84 advantageously prevents the web 20 from tearing, notching, cutting, or rupturing when the lap seal is formed on the web 20. The transition surface 84 can further smooth the surfaces 23, 24 of the web 20 near the lap seal.

[0066] The outer diameter E1 of the anvil 52 varies and can be based on the application of the machine 10, the specific material properties of the web 20, the desired properties of the lap seal, and / or the location of the lap seal on the web 20. In one example, the outer diameter of the anvil 52 is 0.9843 inches. In another example, the outer diameter of the anvil 52 is 1.9685 inches. The outer diameter may also be in the range of 0.10 inches to 4.0 inches, preferably 0.8 inches to 2.5 inches. In certain examples, an anvil 52 with a smaller outer diameter can be used, and the lap seal is formed near the outer edge of the web 20. In other examples, an anvil with a larger outer diameter can be used to form the lap seal near the center of the web 20 (see Figure 2 showing the outer edge 26 and center 27 of the web 20).

[0067] Referring specifically to Figures 18-20, an exemplary pattern 86 is included in the anvil 52 for forming a lap seal on the web 20. Pattern 86 includes recessed grooves 87 within the sealing surface 83 and the transition surface 84. The grooves 87 are arranged in a "hatching" pattern. When ultrasonic energy is applied to surfaces 23, 24 via the horn 51, the web 20 melts (as described above), and the molten material flows into the grooves 87. As the web 20 and lap seal are transported downstream of the horn 51 and the anvil 52, the anvil 52 rotates so that the material in the grooves 87 moves with the lap seal (for example, the material in the grooves 87 is part of the lap seal that exits the grooves 87). Thus, the lap seal contains material arranged in a pattern corresponding to pattern 86 on the anvil 52. Refer to Figure 20 showing the web 20 having the pattern corresponding to groove 87. Note that the sides 21, 22 and grooves of the web 20 are spaced apart from each other for clarity.

[0068] In certain examples, the finishing roller 36 is configured to compress a lap seal having a pattern within it (as described above with respect to Figures 18-20). In this example, a portion of the molten web 20 to form the lap seal is still malleable, and therefore the finishing roller 36 compresses these materials (e.g., the material is compressed and crushed) into a more nearly flat and smooth profile (see Figure 24). In certain examples, the lap seal is an impermeable or lockup seal.

[0069] Figures 21–23 show another exemplary pattern 86 according to this disclosure, in which grooves 87 intersect each other and the grooves 87 are rhombic or "X" patterned. In certain examples, the anvil 52 has multiple patterns 86 aligned along the outer circumference of the anvil 52. Thus, a single anvil can be used to form different lap seals on the web 20. The anvil 52 can be "inverted" or moved in the intersecting direction CD to change the lap seal formed on the web 20. In certain examples, the anvil 52 has one or more annular channels (not shown) that allow air to flow along the anvil 52, thereby allowing the anvil 52 to be cooled. The annular channels can also receive bands or O-rings.

[0070] It should be noted that in certain examples, the sealer 50 can cause a specific portion of the web 20 to melt into a portion of the groove 87 defined in the transition surface 84, and / or to flow further in the intersecting direction CD, or to "seep out". In this example, the material melting into the transition surface 84 helps to form a transition zone to the next lap seal of the adjacent unsealed web 20. This transition region reduces or minimizes stress points between the lap seal and the adjacent unsealed web 20, thereby reducing or minimizing accidental tearing of the lap seal from the adjacent unsealed web 20. The finishing roller 36 can compress the material within the transition zone, thereby creating a flatter or smoother profile of the transition zone.

[0071] The shape, width, and / or depth of the groove 87 can vary and can have any width or depth. Note that Figure 20 shows the web 20 spaced apart from the groove 87 for clarity, and that portions of the web 20 are shown spaced apart from each other for clarity. For example, the groove 87 may be straight or curved. The width W1 of the groove 87 (Figure 20) can range from 0.001 to 0.020 inches, in one example the width W1 is 0.008 inches. The depth W2 of the groove 87 (Figure 20) can range from 0.0001 to 0.0010 inches, in one example the depth W2 is 0.004 inches. Note that in certain examples the width W1 may correspond to the radius of the groove 87. The groove 87 has a top 88 and a bottom 89, and a rounded edge 90 near the bottom 89. Therefore, the width and / or depth of the grooves can vary (for example, groove 87 may have a width of 0.008 inches at its top 88 and a width of 0.004 inches at its bottom 89). While groove 87 is described above, it should be noted that pattern 86 may include raised or recessed dots and / or other shapes based on the lap seal formed on the web 20. Furthermore, it should be noted that in certain examples, pattern 86 may exclude grooves.

[0072] Figure 25 shows an exemplary control system 300 for machine 10. The control system 300 is for controlling the operation and characteristics of machine 10 and the various components described above. The control system 300 includes a controller 301 having memory and a processor. The controller 301 communicates with the various components of machine 10 via a wired or wireless link 305. The controller 301 receives input from a user interface device 310 configured to allow an operator to input data into the system 300. The operator can input data such as the material forming the web 20, the ultrasonic energy that must be applied to the horn to form the seal, and the speed of machine 10. The controller 301 also communicates with a roller system 311 or conveyor that transports the web 20 and the actuators described above. In addition, one or more sensors 315 are configured to communicate with the controller 301 and transmit data to the controller 301. In some examples, mechanical adjustments determine the distance between the horn 51 and the anvil 52. In one example, sensor 315 can detect the presence of a web within the machine 10, communicate this to controller 301, and activate the ultrasonic generator. In another example, a sensor inside the ultrasonic generator / controller is configured to detect ultrasonic energy and / or vibrations being output by the horn 51 or pressure and transmit horn output data. If the horn output data is below the threshold output required to form the desired seal, controller 301 communicates with the ultrasonic energy generator to increase the ultrasonic energy supplied to the horn 51, thereby increasing the ultrasonic energy, vibration, and / or pressure applied to the web 20 by the horn 51. In one example, controller 301 is configured to stop the machine 10 if sensor 315 detects that no layer or side of the web 20 is present.

[0073] In a specific example, the machine forms a web into a bag or pouch. The machine includes a sealing section through which the web is conveyed in the direction of the machine. The sealing section is configured to form a wrap seal on the web, and the web has a first web section and a second web section. The input end is configured to receive the web. The ultrasonic sealer has a horn and an anvil that define a nip through which the first web section passes. The ultrasonic sealer is configured to form a wrap seal on the first web section, and the anvil is positioned between the first web section and the second web section. The output end is configured to distribute the web formed therein as the wrap seal is distributed.

[0074] In certain examples, the first web section includes opposing sides of the web that overlap each other. In certain examples, the web is transported continuously through the seal section, and the ultrasonic sealer continuously forms a wrap seal on the web. In certain examples, the web received through the input end has a tubular shape with an elliptical cross-section and a defined gap between the first web section and the second web section. The anvil is located within the gap, and each of the first and second web sections advances along both sides of the anvil, respectively.

[0075] In a particular example, the web is transported through a machine toward the machine, and the machine includes a folding station upstream of the sealing station. The folding station is configured to fold each side of the web in opposite intersecting directions so that both sides of the web overlap each other, and the first web section includes the overlapping sides of the web. In a particular example, the folding station is configured to fold the web into a tubular shape. In a particular example, the folding station is configured to fold the web so that a gap is defined by the web, and the anvil is positioned within the gap.

[0076] In certain examples, the web defines a gap between a first web section and a second web section, and the anvil is within the gap as the web is transported through the seal section, with the first and second web sections moving along both sides of the anvil. In certain examples, the seal section includes a frame extending in a cross direction which is lateral to the machine direction, and the frame cantilever-supports the anvil within the gap. For example, an arm assembly is a cantilever beam attached to the first frame, and the arm assembly cantilever-supports the anvil within the gap.

[0077] In certain examples, the machine includes a roller system configured to transport the web in the direction of the machine. In certain examples, the web is transported through the machine in the direction of the machine, and the seal section further includes an arm assembly configured to extend in the direction of the machine such that the arm assembly extends between a first web section and a second web section, thereby holding the anvil. In certain examples, the seal section may include a frame that extends transversely in the direction of the machine and is spaced away from the web such that the frame supports the arm assembly relative to the web.

[0078] In a specific example, the machine forms a web into a bag or pouch. The web is folded so that the first side and the opposite second side of the web overlap each other, such that the web has a first web section including a first side and a second side, a second web section on the opposite side, and a defined gap between the first and second web sections. The machine includes an ultrasonic sealer having a horn and anvil collectively configured to form a lap seal on the first web section as the web is conveyed through the machine in the machine direction. The frame extends in a direction perpendicular to the machine direction and is spaced apart from the web. An arm assembly is coupled to the frame and cantilevered within the gap, thereby supporting the anvil in the gap between the first and second web sections.

[0079] In certain examples, the web has an elliptical cross-section. In certain examples, the arm assembly is movable in a cross direction along the frame so that the anvil can be repositioned relative to the horn. In certain examples, the arm assembly defines a first arm coupled to the frame, a second arm extending in the machine direction and holding the anvil, and a channel between the first and second arms. The web is transported in the machine direction along the arm assembly such that a first side of the web passes through the channel. In certain examples, the first side of the web is transported along a first path along the arm assembly, and the second side of the web is transported along a second path along the arm assembly before a lap seal is formed on the web. In certain examples, the arm assembly has a first arm coupled to the frame and a second arm extending in the machine direction and holding the anvil. The second arm includes a cooling component configured to cool the arm and thereby the anvil.

[0080] This specification cites several references. The cited references are incorporated herein by reference in their entirety. If there is any discrepancy between the definition of a term in this specification and the definition in the cited references, that term should be interpreted according to the definition provided herein.

[0081] Certain terms are used in this specification for the sake of brevity, clarity, and understanding. Such terms are used for illustrative purposes and are intended to be interpreted broadly; therefore, no unnecessary limitations beyond the requirements of the prior art should be inferred therefrom. Different apparatuses, systems, and method steps described herein may be used alone or in combination with other apparatuses, systems, and methods. Various equivalents, substitutions, and modifications are expected to be possible within the scope of the appended claims.

[0082] The functional block diagrams, operation sequences, and flow diagrams provided in the figures represent exemplary architectures, environments, and methodologies for implementing novel embodiments of this disclosure. For the sake of simplicity, methodologies included herein may be in the form of functional diagrams, operation sequences, or flow diagrams, and may be described as a series of operations, but it should be understood and recognized that methodologies are not limited by the order of operations, as some operations may, accordingly, occur in a different order than those shown and described herein, and / or concurrently with other operations. For example, those skilled in the art will understand and recognize that methodologies may alternatively be represented as a series of interrelated states or events, such as a state diagram. Furthermore, not all operations exemplified in the methodologies are required for novel embodiments.

[0083] This specification uses examples to disclose the present invention in its best mode and to enable those skilled in the art to construct and use the present invention. The patentable scope of the present invention is defined by the claims and may include other embodiments that those skilled in the art may conceive. Such other embodiments are intended to be within the claims if they have structural elements that are not different from the language of the claims, or if they include equivalent structural elements that are substantially different from the language of the claims.

Claims

1. A machine for forming a web into a bag or pouch, A sealing station in which the web is conveyed in the direction of the machine, wherein the sealing station is configured to form a wrap seal on the web, An input terminal configured to receive the web having a first web section and a second web section, An ultrasonic sealer having a horn and an anvil defining a nip between which a first side and a second side of the first web section pass, wherein the ultrasonic sealer is configured to form the lap seal on the first side and the second side of the first web section, and the anvil is positioned between the first web section and the second web section passing below the ultrasonic sealer, The sealing station comprises an output terminal configured to distribute the web formed inside the wrap seal, The web defines a gap between the first web section and the second web section, and as the web is transported through the sealing station, the anvil is in the gap, and each of the first web section and the second web section moves along both sides of the anvil. A machine in which the sealing station includes a frame extending in a direction perpendicular to the direction of the machine, the frame cantilevering the anvil within the gap.

2. The machine according to claim 1, wherein the first web section includes a first side and a second side of the web that overlap each other.

3. The machine according to claim 1, wherein the web is continuously conveyed through the sealing station, and the ultrasonic sealer continuously forms the wrap seal on the web.

4. The machine according to claim 1, wherein the web received via the input terminal has a tubular shape with an elliptical cross-section and a defined gap between the first web section and the second web section, the anvil is located in the gap, and each of the first web section and the second web section advances along both sides of the anvil, respectively.

5. The web is transported through the machine in the direction of the machine, and the machine, A folding station upstream of the sealing station, the folding station further comprises a folding station configured to fold the first side and the second side of the web in opposite intersecting directions such that the first side and the second side of the web overlap each other. The machine according to claim 1, wherein the first web section includes the overlapping first and second sides of the web.

6. The machine according to claim 5, wherein the folding station is configured to fold the web into a tubular shape.

7. The machine according to claim 5, wherein the folding station is configured to fold the web such that a gap is defined by the web, and the anvil is positioned within the gap.

8. The machine according to claim 1, further comprising a roller system configured to transport the web in the direction of the machine.

9. The machine according to claim 1, wherein the web is transported through the machine in the direction of the machine, and the sealing station further comprises the arm assembly, which is configured to extend in the direction of the machine such that the arm assembly extends between the first web section and the second web section, thereby holding the anvil.

10. The machine according to claim 9, wherein the sealing station further comprises a frame extending in the lateral machine direction and spaced apart from the web, the frame supporting the arm assembly relative to the web.

11. A machine for forming a web into a bag or pouch, wherein the first side and the opposite second side of the web are folded overlapping each other such that the web has a first web section including a first side and a second side, a second web section on the opposite side, and a defined gap between the first web section and the second web section, and the machine An ultrasonic sealer having a horn and anvil jointly configured to form a wrap seal on a first web section as the web is conveyed through the machine in the direction of the machine, A frame extending in a direction perpendicular to the machine direction and spaced apart from the web, A machine comprising: an arm assembly coupled to the frame and cantilevered within the gap, thereby supporting the anvil within the gap between the first web section and the second web section.

12. The machine according to claim 11, wherein the web has an elliptical cross-section.

13. The machine according to claim 11, wherein the arm assembly is movable along the frame in the intersecting direction so that the anvil can be repositioned relative to the horn.

14. The arm assembly comprises a first arm coupled to the frame, a second arm extending in the machine direction and holding the anvil, and a channel between the first arm and the second arm. The machine according to claim 11, wherein the web is transported along the arm assembly in the direction of the machine such that the first side surface of the web passes through the channel.

15. The machine according to claim 14, wherein the first side of the web is transported along a first path along the arm assembly, and the second side of the web is transported along a second path along the arm assembly before the wrap seal is formed on the web.

16. The machine according to claim 11, wherein the arm assembly comprises a first arm coupled to the frame and a second arm extending in the direction of the machine and holding the anvil, the second arm comprising a cooling component configured to cool the second arm, thereby cooling the anvil.

17. A machine for making bags from a web having a first web section and a second web section, A sealing station through which the web is transported, the sealing station comprising an ultrasonic sealer having a horn, and an anvil defining a nip between which a first side and a second side of the first web section pass, such that the ultrasonic sealer is configured to form a lap seal therein, the anvil being positioned between the first web section and the second web section passing below the ultrasonic sealer, The sealing station is a machine that includes a frame on which the anvil is cantilevered so that the anvil is positioned between the first web section and the second web section.

18. The machine according to claim 17, wherein the web is continuously conveyed in the machine direction through the sealing station such that the horn and the anvil continuously form the lap seal on the first web section.

19. The machine according to claim 17, further comprising a roller system configured to transport the web through the sealing station.

20. The machine according to claim 17, wherein a folding station is further configured upstream of the sealing station, the folding station being configured to fold the web such that the first web section is on the opposite side of the second web section and the web has a tubular shape.

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