System and method for stacking a continuous web of fan-folded sheet material

Abstract

1. A system (1) for stacking a fanfolded continuous web (M) of indefinite length sheet material, such as corrugated cardboard, comprising: a feeder having means for guiding the continuous web (M) in a longitudinal direction (L); a crease processing device (2) downstream of the feeder for forming transverse creases (C) in the continuous web (M) spaced at a constant longitudinal pitch (K) to define a series of adjacent partitions (P); a folding device (14) downstream of the crease processing device (2) for progressively and alternately fanfolding the adjacent partitions (P) along the creases (C); and a recovery device (39) for recovering the folded web (M) into a stack of adjacent partitions (P), wherein the recovery device (39) includes vertically extending supports (40) for holding the stack of adjacent fanfolded partitions (P). A dynamic cutting unit (52) is mounted at the top of the support post (40) and acts on the adjacent partition (P) at the top of the stack as it moves along, following the stack formation without stopping the folder (14). A method for stacking a continuous fanfolded web (M) of sheet material, such as corrugated cardboard of indefinite length.

Description

Technical Field

[0001] The present invention is generally found to have applications in the field of packaging, and more particularly relates to a system for stacking a continuous web of fan-folded (zigzagged) sheet material of variable length.

[0002] The present invention also relates to a method for stacking a continuous web of fan-folded corrugated cardboard of variable length.

Background Art

[0003] It has long been known that sheet materials, typically corrugated cardboard, are used in the manufacture of box-shaped packages in the form of a web of sheet material that is folded into a fan-fold arrangement to reduce bulk and facilitate handling.

[0004] In fact, the raw sheet material is initially provided as a continuous web of a continuous sheet material of variable length, similar in form to a continuous strip of an old dot matrix printer, i.e., consisting of a series of adjacent portions or compartments of equal size, which are known as partitions, separated by fold lines and folded alternately one on top of the other to form a stack of overlapping partitions.

[0005] Stacks of equal or different sizes are loaded into the magazine of an automatic or semi-automatic machine or equipment for manufacturing boxes of the desired size.

[0006] To obtain a stack, a continuous web first undergoes a process of forming transverse fold lines with respect to the longitudinal direction of the continuous web, which is usually done by a creaser equipped with at least two opposing pressure rollers for forming creases on both sides of a continuous web dividing adjacent partitions, as described, for example, in Japanese Utility Model Publication No. 49-031775 or U.S. Patent No. 2012 / 021886.

[0007] Once a crease or fold is formed, the web undergoes a fanfold process, which involves alternately folding adjacent partitions so that one is on top of the other, then stacking them in a final output unit and cutting them to a desired or standard height, as described, for example, in International Publication No. 2013 / 132325 or U.S. Patent No. 7402130.

[0008] Next, the fanfold stack of sheet material is loaded into one or more storage magazines of the cutting and creasing machine, from which the partitions are continuously unfolded and transported to the cutting and creasing units, which then form a single sheet (blanket) that will be assembled into a box.

[0009] German Patent No. 102012020943 discloses an apparatus for folding and stacking a continuous web to form a flat partition, the apparatus comprising a feeder for feeding strips of sheets and a plurality of support components guided along annular guides for supporting the strips at fold lines.

[0010] Furthermore, the support components have individual actuation control units and can be displaced perpendicular to the feed direction of a continuous web.

[0011] Specifically, a continuous web is oriented horizontally to the feeder and stacked horizontally on a conveyor belt, which is adapted to temporarily support and move the stack of fan-folded sheet material away from the device.

[0012] One drawback of this known system is that the crease is formed on only one side of the strip, and the support component always supports the strip from the bottom. This, along with the continuous changes in the feed speed of the support component, can cause press wrinkles to form within the strip.

[0013] Furthermore, the support components protrude in a cantilevered manner, retract laterally, and slide outward from the fold line. This reduces the feed speed, which significantly impacts the overall operating speed of the device.

[0014] Another drawback of this known system is that once a continuous web is folded, the conveyor belt supports the stack along only one side of the stack and along one of the series of fold lines, which can lead to deformation due to the stack's own weight and the formation of further press wrinkles.

[0015] European Patent No. 2409939 discloses a folding device comprising a latching member guided to displace the corrugated web at a fold. A further latching member is guided independently of the former latching member and transported along the corrugated web at another fold located upstream of the former fold.

[0016] Furthermore, a collection device is positioned downstream of a folding device that stacks corrugated cardboard webs, which are folded along creases to form a stack.

[0017] One drawback of this known folding device is that the latching member acts only on one side of the corrugated web for every two fold lines, making it impossible to avoid the formation of press wrinkles near the first latching member.

[0018] Furthermore, the feed speed is limited by the complexity of the mechanism that moves the independent latch member components, which are driven by an annular belt or chain.

[0019] A further drawback is that each time a stack needs to be cut within the retrieval device, the feed speed of a continuous web is reduced to allow the partition to be cut above the stack. [Overview of the project] [Problems that the invention aims to solve]

[0020] In view of the prior art, the technical problem addressed by the present invention is to enable cutting a continuous web to form a stack without slowing down or stopping the folding device, while avoiding the formation of press wrinkles. [Means for solving the problem]

[0021] The object of the present invention is to overcome the drawbacks discussed above by providing a highly efficient and cost-effective system and method for stacking fanfolded continuous webs of sheet material of variable length, such as corrugated cardboard.

[0022] A particular object of the present invention is to provide a system, as discussed above, that can minimize the formation of press wrinkles near the fold line and avoid the need to slow down or stop the folding device.

[0023] Another object of the present invention is to provide a system, as considered above, that enables the rapid stacking of a continuous web without the constraints of cutting the top-level partition of the stack.

[0024] A further object of the present invention is to provide a system as contemplated above that can be easily adapted to a continuous web of various widths.

[0025] Another object of the present invention is to provide a system as contemplated above that can vertically align both sides of a stack.

[0026] As will be further clarified below, these and other objects are met by a system for stacking a fan-folded continuous web of variable-length sheet material, such as cardboard, as defined in claim 1.

[0027] The system includes a feeding device having means for guiding a continuous web longitudinally, a creasing device located downstream of the feeding device for forming transverse creases spaced at a constant longitudinal pitch on the continuous web to define a series of adjacent partitions, and a folding device located downstream of the creasing device for progressively and alternately fan-folding the adjacent partitions along the creases.

[0028] A collecting device is also provided for collecting the folded and stacked webs of adjacent partitions, the device including vertically extending posts for holding a stack of adjacent fan-folded partitions.

[0029] According to a particular aspect of the present invention, a dynamic cutting unit is attached to the top of the post and operates while moving to the topmost adjacent partitions of the stack while following stack formation without stopping the folding device.

[0030] Due to this in-motion cutting operation of the cutting unit, the stack formation process can be followed while maintaining a substantially horizontal plane on which the continuous web lies above the stack unchanged, thereby avoiding the need to slow down or stop the folding device.

[0031] Advantageously, the column comprises a first stack support rack and a second stack support rack, as well as stack unloading units mounted on the column on their respective lifting carriages designed to move vertically along the column, and a cutting unit mounted on the transverse end of the first support rack and movable along substantially horizontal transverse guide means.

[0032] Furthermore, the cutting unit includes a blade, an opposing blade, and a belt and pulley type motorized drive mechanism adapted to move the cutting blade around its own axis and the transverse moving carriage of the cutting unit simultaneously.

[0033] This arrangement allows the top adjacent partition of the stack to be acted upon as it moves vertically during stacking, thereby avoiding the formation of press wrinkles and the need to slow down or stop the folding device.

[0034] The present invention also relates to a method for stacking a continuous web of fanfolded sheet material, such as corrugated cardboard of variable length according to the present invention, as defined in claim 11.

[0035] Preferred embodiments of the present invention are as defined in the dependent claims.

[0036] Further features and advantages of the present invention will become clearer from a detailed description of a system for stacking continuous webs of non-limiting sheet materials of variable length, such as fan-folded corrugated cardboard, which will be illustrated with the help of the accompanying drawings as an example. [Brief explanation of the drawing]

[0037] [Figure 1] A side view of the system of the present invention. [Figure 2] This is a top view of the system of the present invention. [Figure 3] This is a perspective view of the system of the present invention. [Figure 4] Figure 3 is a cross-sectional view of the system. [Figure 5] Figure 1 is a perspective view of the recovery device of the system. [Figure 6] Figure 5 is a top view of the recovery device. [Figure 7] Figure 5 is a side view of the recovery device. [Figure 8] Figure 5 is a perspective view of the details of the recovery device. [Figure 9] Figure 5 is a close-up view of the details of the recovery device. [Figure 10] Figure 5 is a perspective view of the apparatus at different operating steps. [Figure 11] Figure 5 is a perspective view of the apparatus at different operating steps. [Figure 12] This is a side view of the apparatus in Figure 5 at different operating steps. [Figure 13] This is a side view of the apparatus in Figure 5 at different operating steps. [Figure 14] Figure 5 is a perspective view of the apparatus at different operating steps. [Figure 15] Figure 5 is a perspective view of the apparatus at different operating steps. [Figure 16] This is a side view of the apparatus in Figure 5 at different operating steps. [Figure 17] This is a side view of the apparatus in Figure 5 at different operating steps. [Figure 18] Figure 5 is a perspective view of the apparatus at different operating steps. [Figure 19] Figure 5 is a perspective view of the apparatus at different operating steps. [Figure 20] This is a side view of the apparatus in Figure 5 at different operating steps. [Figure 21] This is a side view of the apparatus in Figure 5 at different operating steps. [Modes for carrying out the invention]

[0038] In particular, referring to the drawings, a system is shown, designated by the number 1 overall, in which sheet materials of varying lengths, such as a continuous web M of corrugated cardboard that has been fan-folded, are stacked.

[0039] As is publicly known, a continuous web M is substantially longitudinal and has a bottom side S1, a top side S2, and longitudinal side edges B, and includes a predetermined maximum width E determined by the distance of the longitudinal side edges B.

[0040] As best illustrated in Figures 1 to 4, System 1 includes a frame that defines a vertical center plane π and a feeder (not shown) that has means for guiding a continuous web M along a longitudinal direction L parallel to the vertical center plane π.

[0041] The crease processing device 2 is also located downstream of the feed device and is adapted to form transverse creases C spaced at a constant longitudinal pitch K on a continuous web M, defining a series of adjacent partitions P.

[0042] The crease processing device 2 may include two crease processing rollers 6', 6'' having tools configured to alternately form creases C on the bottom side S1 and the top side S2 of a continuous web M in order to form a "Z" fold.

[0043] Therefore, at the output of the crease processing device 2, the web M will have alternating creases C1 formed on the bottom surface S1 for folding the web M upward and creases C2 formed on the top surface S2 for folding the web M downward.

[0044] Conveniently, System 1 includes a folding device 14 located downstream of the crease processing device 2 for progressively and alternately fanfolding adjacent partitions P along the crease C.

[0045] As best shown in the drawings, downstream of the folding device 14, system 1 includes a retrieval device 39 for retrieving the folded web M and stacking adjacent partitions P.

[0046] The retrieval device 39 includes vertically extending support columns 40 that hold the stack of adjacent partitions P that have been fan-folded by the folding device 14.

[0047] The support column 40 includes a plurality of upright members 41 fixed to the ground G, and a plurality of crossing members 42 adapted to reinforce the support column 40 and to form compartments 43 for holding stacks.

[0048] As best shown in Figures 5 to 8, the first stack support rack 44, the second stack support rack 45, and the stack unloading unit 46 are attached to the support column 40.

[0049] Specifically, the first support rack 44 and the second support rack 45 include a plurality of arms 47 offset transversely at a predetermined pitch, and the discharge unit 46 includes a closed-loop conveyor belt 48 for temporarily supporting the stack and moving it transversely away from the support column 40.

[0050] Furthermore, the first support rack 44 and the second support rack 45 are each attached to a first lifting carriage 49 and a second lifting carriage 50 that are vertically movable along the support column 40, and the lifting carriages 49 and 50 are attached to the first transverse ends 44' and 45' of the first support rack 44 and the second support rack 45, respectively.

[0051] Similarly, the unloading unit 46 is attached to a third lifting carriage 51, which is movable vertically along a vertical support 40, allowing the unloading unit 46 to be moved downward when a stack is formed, while the substantially horizontal plane Q with a continuous web M laid over the stack remains unchanged, as best shown in Figures 10 to 17.

[0052] Of course, appropriate vertical sliding means, not shown in the illustration, are mounted along the vertical range of the support column 40, allowing the lifting carriages 49, 50, and 51 to move vertically independently.

[0053] According to a unique aspect of the present invention, the dynamic cutting unit 52 is mounted on the top of the support column 40 and operates while moving to the adjacent partition P at the top of the stack, following the stack formation without stopping the folding device 14.

[0054] Therefore, multiple stacks can be obtained from a single web M without slowing down or stopping the crease processing device 2 and / or the folding device 14, as further described below.

[0055] As best shown in Figures 8 and 9, the dynamic cutting unit 52 is mounted to the second transverse end 44" of the first support rack 44 facing the stack and includes a fourth carriage 53 designed to move along a substantially horizontal transverse guide means 54.

[0056] The cutting unit 52 includes circular cutting blades 55 facing the opposing blades 56 to cut a continuous web M, and these blades are inclined at a predetermined angle so as to cut through adjacent partitions P at the top of the stack.

[0057] Furthermore, a belt and pulley-type motorized drive mechanism 57 is provided to move the cutting blade 55 around its own axis and the fourth carriage 53 along the transverse guide mechanism 54 simultaneously.

[0058] As shown in Figures 10 to 17, in order to facilitate stack tracking, the first lifting carriage 49 and the second lifting carriage 50 each include substantially longitudinal guide means 58 to selectively move the first support rack 44 and the second support rack 45 toward the stack and temporarily support the stack once adjacent partitions P are disconnected.

[0059] Next, the continuous web M is cut in transit, and this cut is made just before the first carriage 44 and the second carriage 45 move toward the holding section 43 to support the stack that is being formed.

[0060] As best shown in Figures 14 to 21, the stack immediately after cutting is supported by support racks 44, 45, which follow the formation of the stack while maintaining a plane Ω that keeps a continuous web M constant over it for the time required for the unloading unit 46 to climb the corresponding vertical sliding means to unload the previous stack out of the support column 40 and to retrieve the stack.

[0061] Next, the first support rack 44 and the second support rack 45 move away from the holding section 43 along the longitudinal guide means 58 to unload the stack onto the unloading unit 46.

[0062] In addition, to facilitate the alignment of the creases C1 and C2 of each stack, the support column 40 includes a first 59 and a second substantially vertical leveling plate 60 for vertically aligning the crease C2 on the top side S2 and the crease C1 on the bottom side S1, respectively.

[0063] Preferably, the first support rack 44 is removed from the stack before the stack formed on the discharge unit 46 is discharged, while the second support rack 45 is pushed toward the first support rack 44 and the stack is held horizontally immobile by the leveling plates 59, 60, as shown in Figures 14 to 17.

[0064] In a further embodiment, the present invention relates to a method for stacking a continuous web M of a sheet material, for example, a corrugated cardboard of variable length having a bottom side S1, a top side S2, and longitudinal side edges B, which has been fan-folded.

[0065] This method, The steps include providing a feeder for feeding a continuous web M in the longitudinal direction L, In order to form transverse creases C spaced at a constant longitudinal pitch K on a continuous web M, a crease processing device 2 is provided downstream of the feed device, and adjacent partitions P are defined. The step of providing a folding device 14 downstream of the crease processing device 2 in order to progressively and alternately fanfold adjacent partitions P along the crease C, A recovery device 39 for recovering the folded web M is provided downstream of the folding device 14, and a stack of overlapping adjacent partitions P is formed. The steps include providing a vertically extending support column 40 within the recovery device 39 to hold the stack of fan-folded adjacent partitions P, The steps include providing a first stack support rack 44 and a second stack support rack 45, a stack unloading unit 46, and a dynamic cutting unit 52 for cutting at least one adjacent partition P of the stack within the recovery device 39, The crease processing device 2 alternately forms creases C1 and C2 on the bottom side S1 and top side S2 of a continuous web M, Steps include operating the folding device 14, The first support rack 44 and the second support rack 45 are moved horizontally toward the stack and vertically toward the stack unloading unit 46, thereby allowing the folding device 14 to follow the formation of the stack without stopping it. The steps include activating the dynamic cutting unit 52 while it is moving to interact with the topmost adjacent partition P of the stack, thereby avoiding the need to stop the folding device 14, The steps include: stacking the stack onto the unloading unit 46, Includes.

[0066] It will be understood from the above that the system and method of operation for stacking a continuous web of fan-folded sheet material according to the present invention will satisfy the intended purpose, namely, that it will be possible to form a stack without press creases and without slowing down or stopping the folding device.

[0067] The system and operating method of the present invention are subject to numerous modifications and variations within the scope of the concept of the present invention disclosed in the appended claims.

[0068] The system and operating method of the present invention have been described with particular reference to the accompanying drawings, but the numbers referenced in this disclosure and claims are used solely to make the present invention easier to understand and are not intended to limit the claims in any way.

[0069] Wherever there is a reference in this specification to “one embodiment,” “embodiment,” or “some embodiments,” this indicates that a particular characteristic, structure, or component described is included in at least one embodiment of the subject matter of the present invention.

[0070] Furthermore, these specific characteristics, structures, or components may be combined together by any suitable method to provide one or more embodiments. [Industrial applicability]

[0071] Since this invention can be manufactured on an industrial scale in a factory that processes sheet materials into packaging, it has potential applications in industrial fields.

Claims

1. A feeder having means for guiding a continuous web (M) in the longitudinal direction (L), A crease processing device (2) located downstream of the feed device defines a series of adjacent partitions (P) by forming transverse creases (C) spaced apart at a constant longitudinal pitch (K) on the continuous web (M), To progressively and alternately fanfold adjacent partitions (P) along the crease (C), a folding device (14) is located downstream of the crease processing device (2), A retrieval device (39) that collects the folded web (M) and stacks it in the adjacent partition (P), Includes, The recovery device (39) includes vertically extending support columns (40) for holding the stack of fan-folded adjacent partitions (P), The dynamic cutting unit (52) is attached to the top of the support column (40) and acts on the adjacent partition (P) at the top of the stack as it moves, following the stack formation without stopping the folding device (14). A system (1) for stacking a continuous web (M) made of irregularly sized sheet material such as corrugated cardboard, which has been fan-folded, The system (1) is characterized in that a first stack support rack (44), a second stack support rack (45), and a stack unloading unit (46) are attached to the support column (40).

2. The system according to claim 1, characterized in that the first stack support rack (44) and the second stack support rack (45) are attached to a first lifting carriage (49) and a second lifting carriage (50) that are vertically movable along the vertically extending support column (40), and the first lifting carriage (49) and the second lifting carriage (50) are attached to the first transverse ends (44', 45') of the first stack support rack (44) and the second stack support rack (45).

3. The system according to claim 2, characterized in that the stack unloading unit (46) is attached to a third lifting carriage (51) that is vertically movable along the vertically extending support column (40).

4. The system according to claim 3, wherein the dynamic cutting unit (52) is attached to a second transverse end (44") of the first stack support rack (44) and includes a fourth carriage (53) adapted to move along a substantially horizontal transverse guide means (54) and a circular cutting blade (55) facing a counter blade (56) for cutting the continuous web (M).

5. The system according to claim 4, further comprising a belt and pulley type motorized drive mechanism (57) adapted to move the cutting blade (55) around its own axis and the fourth carriage (53) along the transverse guide means (54) simultaneously.

6. The system according to claim 2, wherein the first lifting carriage (49) and the second lifting carriage (50) each include substantially longitudinal guide means (58) adapted to selectively move the first stack support rack (44) and the second stack support rack (45) toward the stack to temporarily support the stack once the adjacent partition (P) is cut, and to follow the formation of the stack without stopping the folding device (14).

7. The system according to claim 1, characterized in that the first stack support rack (44) and the second stack support rack (45) include a plurality of arms (47) that are offset transversely by a predetermined pitch.

8. The system according to claim 1, wherein the stack unloading unit (46) includes a closed-loop conveyor belt (48) which is adapted to temporarily support the stack and move it transversely away from the support column (40).

9. The crease processing apparatus (2) processes the bottom side (S) of the continuous web (M). １ ) and top side (S ２ The structure is configured to alternately form creases on the bottom surface (S １ ) Crease (C １ ) and the top surface (S ２ ) Crease (C ２ The system according to claim 1, characterized by including first (59) and second substantially vertical leveling plates (60) that vertically align the two.

10. A method for stacking sheet materials such as a continuous web (M) of corrugated cardboard of varying lengths, which has been fan-folded, The steps include providing a feeding device for feeding a continuous web (M) in the longitudinal direction (L), A crease processing device (2) is provided downstream of the feed device in order to form transverse creases (C) spaced at a constant longitudinal pitch (K) on the continuous web (M), and the adjacent partitions (P) are defined. The step of providing a folding device (14) located downstream of the crease processing device (2) in order to progressively and alternately fanfold adjacent partitions (P) along the crease (C), A retrieval device (39) for retrieving the folded web (M) is provided downstream of the folding device (14), and a stack of overlapping adjacent partitions (P) is formed. The steps include providing a vertically extending support column (40) within the recovery device (39) to hold the stack of adjacent partitions (P) that have been fan-folded, The steps include providing a first stack support rack (44) and a second stack support rack (45), a stack unloading unit (46), and a dynamic cutting unit (52) for cutting at least one adjacent partition (P) of the stack within the recovery device (39), The first stack support rack (44) and the second stack support rack (45) are moved horizontally toward the stack and vertically toward the stack unloading unit (46), thereby allowing the folding device (14) to follow the formation of the stack without stopping it. The steps include: operating the dynamic cutting unit (52) while it is moving to interact with the uppermost adjacent partition (P) in the stack, thereby avoiding the need to stop the folding device (14); The steps include: loading the stack onto the stack unloading unit (46); Methods that include...

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