Automated bagging machine for forming side seals

Abstract

An automated bagging machine includes a frame, a roller coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends. The roller is configured to rotate about the longitudinal axis. The bagging machine further includes a seal bar coupled to the frame and having a first drive mechanism configured to axially drive the seal bar toward the roller, a heat member configured to heat the seal bar, and a blade, and a second drive mechanism configured to drive rotation of the roller. When the first drive mechanism drives the seal bar toward the roller, the roller and the seal bar are configured to engage with film moved through the machine and form a side seal along an edge of the film.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 771,442, filed on Mar. 13, 2025, the entire contents of which are incorporated by reference herein.FIELD

[0002] The application relates to machines, and more specifically, to automated bagging machines that form bags with side sealed edges.BACKGROUND

[0003] Automated bagging machines are widely used to form plastic film into bags and fill them with materials such as ice, food products, mulch, soil, rock, ice melt, fertilizers, and other loose goods. Automated bagging machines commonly employ different sealing methods to close plastic film bags, such as edge seals or side seals. Edge seals (e.g., burn seals) are typically formed by pressing a heated seal bar against a stationary surface, creating a narrow seal along the outer edge of the bag. While effective, this method can concentrate wear on specific areas and may limit seal strength, particularly in applications requiring wider, more durable seals.SUMMARY

[0004] In one aspect, the invention provides an automated bagging machine including a frame, a roller coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends, wherein the roller is configured to rotate about the longitudinal axis, a seal bar coupled to the frame and including a first drive mechanism configured to axially drive the seal bar toward the roller, a heat member configured to heat the seal bar, and a blade, and a second drive mechanism configured to drive rotation of the roller, wherein when the first drive mechanism drives the seal bar toward the roller, the roller and the seal bar are configured to engage with film moved through the machine and form a side seal along an edge of the film.

[0005] In another aspect, the invention provides an automated bagging machine including a frame, a guide assembly configured to direct film along a path through the bagging machine, a seal bar coupled to the frame and including a drive mechanism and a heat member, and a cylindrical roller removably coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends, wherein the roller is configured to rotate about the longitudinal axis to engage the film during a sealing operation, and wherein the roller includes a base, a first layer surrounding the base, and a second layer surrounding the first layer.

[0006] In yet another aspect, the invention provides an automated bagging machine including a frame, a roller coupled to the frame and rotatable about a longitudinal axis, wherein the roller is configured to engage a film, a seal bar coupled to the frame and movable toward the roller to press the film against the roller and form a seal in the film, a drive mechanism configured to drive rotation of the roller, and a bearing coupled between the roller and the drive mechanism, wherein the bearing is configured to drive incremental rotation of the roller about the longitudinal axis in a first direction and inhibit rotation of the roller in a second direction.

[0007] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of an automated bagging machine according to one aspect of the invention.

[0009] FIG. 2 is another perspective view of the automated bagging machine of FIG. 1.

[0010] FIG. 3 is a perspective view of a roller assembly of the automated bagging machine of FIG. 1.

[0011] FIG. 4 is a cross-sectional view of the roller assembly of FIG. 3.

[0012] FIG. 5 is a top cross-sectional view of the roller assembly of FIG. 3.

[0013] FIG. 6 is a partial cross-sectional view of the automated bagging machine of FIG. 1, illustrating a portion of the roller assembly and a seal bar assembly.

[0014] FIG. 7 is another partial cross-sectional view of the automated bagging machine of FIG. 1, illustrating a portion of the roller assembly.

[0015] FIG. 8 is a cross-sectional view of the seal bar assembly of the automated bagging machine of FIG. 1.

[0016] FIG. 9 is another cross-sectional view of the seal bar assembly of FIG. 8.

[0017] FIG. 10 is an exploded view of a portion of the seal bar assembly of FIG. 8, illustrating a seal bar and a blade.

[0018] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Use of "including" and "comprising" and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of "consisting of" and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Unless specified or limited otherwise, the terms “mounted,”“connected,”“supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.DETAILED DESCRIPTION

[0019] FIGS. 1-2 illustrate an automated bagging machine 10 operable to form plastic film bags, receive and load pre-measured bulk material into the bags, and seal the bags closed. The automated bagging machine 10 includes a bag forming unit 100 to form the plastic film bags. In the illustrated embodiments, the bags are shaped and sized to hold ice. However, the bags may accommodate bulk materials such as, for example, ice, mulch, sawdust, grain, etc.

[0020] With continued reference to FIGS. 1-2, the bag forming unit 100 includes a main frame 104 supporting a guide assembly 108, a roller assembly 112, a seal bar assembly 116, and an air blower assembly 120. The bag forming unit 100 guides a roll of plastic film (not shown) through the bagging machine 10, cuts the film into individual bags, and seals a side surface of each of the bags. Together, the guide assembly 108, the roller assembly 112, the seal bar assembly 116, and the air blower assembly 120 work in a coordinated cycle, ensuring continuous, accurate positioning and sealing of the film.

[0021] The guide assembly 108 includes the roll of plastic film supported on the automated bagging machine 10, and a guide 124 that directs the film along a predetermined path through the bag forming unit 100. A first drive mechanism (e.g., motor, pneumatic cylinder, etc.) (not shown) drives the plastic film, automatically advancing the film through the bag forming unit 100. The guide 124 ensures proper alignment and tension of the film as it moves through the machine 10. Specifically, the guide 124 includes a first stage 128 and a second stage 132. The first stage 128 includes two parallel wire frames 136, and the second stage 132 includes two parallel guards 140. A narrow gap 144 between the frames 136 and the guards 140 forms the path for the film, ensuring smooth film movement during operation.

[0022] With reference to FIGS. 3-4, the roller assembly 112 includes a roller 148, a second drive mechanism 152, and a bearing 156. The roller 148 is substantially cylindrical and is configured to abut against the film as it moves through the bag forming unit 100. The roller includes a first distal end 148a, a second distal end 148b opposite the first distal end 148a, and a longitudinal axis 150 (FIG. 4) extending through the distal ends 148a, 148b. The first distal end 148a is coupled to an upper edge 104a of the main frame 104 of the machine 10, and the second distal end 148b is coupled to a lower edge 104b of the main frame 104 of the machine 10.

[0023] With reference to FIGS. 4-5, the roller 148 is concentrically structured with multiple layers. A core of the roller 148 includes a rigid cylindrical base 160 that provides structural support and stability. Surrounding the base 160 is a low-durometer elastomeric pad 164, which is designed to conform slightly under pressure to create uniform sealing contact, as discussed in more detail below. The outermost layer is a PTFE coating 168 that encases the elastomeric pad 164, preventing material adhesion and minimizing heat-related wear. More specifically, the coating 168 is composed of Teflon™; however, other types of coatings may alternatively or additionally be applied. An idler shaft 170 extends from the first distal end 148a of the roller 148, and a drive shaft 172 extends from the second distal end 148b of the roller 148The idler shaft 170 is fixed relative to the roller 148, such that the roller 148 is rotatable relative to the idler shaft 170, whereas the drive shaft 172 rotates with the roller 148. The roller 148 is coupled to the bearing 156, which is coupled to the second drive mechanism 152.

[0024] With reference to FIGS. 3-4 and 7, the second drive mechanism 152 controls rotation of the roller 148 about the longitudinal axis 150. In the illustrated embodiments, the second drive mechanism 152 is a pneumatic cylinder. However, other drive mechanisms, such as a motor, may be implemented. More specifically, the second drive mechanism 152 operates the bearing 156 to ensure precise, incremental rotation. Specifically, the bearing 156 is a one-way roller bearing that operates like a ratchet and pawl mechanism. During each cycle, the second drive mechanism 152 engages, advancing the roller 148 by an adjustable set increment. The bearing 156 prevents backward movement, ensuring unidirectional rotation of the roller 148 about the longitudinal axis 150. The bearing 156 is configured such that each engagement shifts the surface of the roller 148 to a new contact point with the seal bar assembly 116. This prevents repeated wear on the same section of the roller 148, helps maintain consistent sealing performance, and extends the longevity of the roller 148.

[0025] With reference to FIGS. 6-7, the roller 148 is removably coupled to the main frame 104 of the machine 10. Specifically, the roller 148 includes a first quick-release coupling mechanism 178 (FIG. 6) positioned on the idler shaft 170 and a second quick-release coupling mechanism 182 (FIG. 7) positioned on the drive shaft 172. The first coupling mechanism 178 includes a detent pin 186, a cable 190, and a fastener 194. The pin 186 extends through the idler shaft 170 and the fastener 194 couples to the seal bar assembly 116. The cable 190 extends between and couples the pin 186 and the fastener 194. To remove the first distal end 148a of the roller 148 from the main frame 104, the operator pulls the pin 186, disengaging a ball detent and allowing the pin 186 to be extracted from the idler shaft 170.

[0026] The second coupling mechanism 182 includes a fastener 198 (e.g., a clevis pin) and a pin 202 (e.g., a hairpin cotter pin). The fastener 198 extends through the drive shaft 172 and a portion of the lower edge 104b of the main frame 104. The pin 202 is inserted through an end of the fastener 198, securing the fastener 198 in place on the drive shaft 172. To remove the second distal end 148b of the roller 148 from the main frame 104, the operator pulls the pin 202, which disengages the fastener 198, allowing the operator to remove the fastener 198 and free the roller 148 from the drive shaft 172. Once both coupling mechanisms 178, 182 are disengaged, the roller 148 can be lifted out of place for maintenance or replacement.

[0027] With reference to FIGS. 8-9, the seal bar assembly 116 is positioned adjacent to and opposite the roller assembly 112. The seal bar assembly 116 includes a seal bar 206 (FIG. 10), a heated cartridge 210, or heat member, a third drive mechanism 212, or air cylinder, and a blade 214 (FIG. 10). As shown in FIG. 10, the seal bar 206 is generally elongate and rectangular, including a flat sealing surface 218 configured to engage the film against the roller 148 to form a seal. The seal bar 206 includes a first portion 206a, a second portion 206b, and two extruded bars 220 coupled to the first and second portions 206a, 206b. The extruded bars 220 securely clamp the blade 214 to the seal bar 206, as discussed in more detail below. The bars 220 are composed of aluminum and include a coating composed of PTFE (e.g., Teflon). The seal bar 206 additionally includes two guide plates 224, one positioned on each side of the seal bar portions 206a, 206b. The guide plates 224 provide structural support and stable movement of the blade 214 during the cutting process, insulate sides of the seal bar 206, and aid in clamping and controlling the film prior to a cutting operation, as discussed in more detail below.

[0028] The cartridge 210 is a heated cartridge in the form of a wire and includes a connector 222. A distal end of the cartridge 210 is coupled to the connector 222, which serves as an interface between the cartridge 210 and an external power supply 228. The cartridge 210 operates using electrical resistance heating and is monitored and regulated by a thermocouple. The connector 222 includes electrical terminals linking the cartridge 210 to a power supply 228. However, in alternative embodiments, different types of cartridges and heat sources may be implemented (e.g., heated air, oil, or another thermal fluid).

[0029] With reference to FIG. 8, the air cylinder 212 is adjacent to the seal bar 206 and acts as a pneumatic actuator that controls movement of the seal bar 206. When pressurized, the air cylinder 212 extends a piston, axially driving the seal bar 206 toward the roller 148 during a sealing operation. More specifically, the seal bar assembly 116 includes two parallel guide rods 230 positioned between the air cylinder 212 and the seal bar 206. The guide rods 230 ensure stable, linear movement, preventing misalignment or tiling as the seal bar 206 moves. The air cylinder 212 applies a force greater than that of internal spring-loaded devices 232 (FIGS. 8-9) within the seal bar 206, compressing the spring-loaded devices 232 until the seal bar 206 reaches the roller 148. The spring-loaded devices 232 then determine the final sealing force, allowing controlled engagement between the seal bar 206, the film, and the roller 148 to ensure consistent sealing performance. Once the sealing process is complete, the air cylinder 212 retracts, pulling the seal bar 206 away from the film and resetting the air cylinder 212 for the next cycle. In the illustrated embodiments, the drive mechanism 212 is an air cylinder. However, other drive mechanisms, such as a motor, may be implemented.

[0030] With reference to FIG. 10, the blade 214 is a cutting element integrated into the seal bar 206 and configured to sever the film along the sealed seam. More specifically, the blade 214 is positioned within an elongate slot formed by the bars 220. The slot extends along a length of the seal bar 206, aligning the blade 214 with the sealing surface 218 to facilitate simultaneous sealing and cutting in a single operation. The blade 214 includes a sharp edge designed to cut the film immediately before a seal is formed, ensuring a clean separation of individual bags. More specifically, the blade 214 is positioned slightly forward of the seal bar 206, such that when the seal bar 206 moves forward, the blade 214 advances through the film against the surface of the roller 148.

[0031] In some embodiments, the seal bar 206 may be removable from the main frame 104. Specifically, the seal bar 206 includes fasteners 234 (e.g., clevis pins and retaining pins) coupling the seal bar 206 to the main frame 104. In the illustrated embodiments, the seal bar 206 includes four fasteners 234. However, the seal bar 206 may include fewer or additional fasteners 234. To remove the seal bar 206, the operator disconnects the air cylinder 212 and removes the fasteners 234 from the seal bar 206. Once the fasteners 234 are removed, the seal bar 206 and the cartridge 210 can be lifted out of place for maintenance or replacement.

[0032] With reference to FIGS. 1 and 8, the air blower assembly 120 is positioned immediately adjacent to and downstream of the roller assembly 112 and the seal bar assembly 116. The air blower assembly 120 facilitates bag separation. Specifically, the air blower assembly 120 includes an air nozzle 238 (FIG. 8) configured to direct a controlled burst of air at the newly formed bag. This airflow acts to gently push the bag away from the sealing area, preventing the heat-softened film from inadvertently re-adhering. The air blower assembly 120 operates in a timed sequence to ensure that the air burst occurs immediately after the sealing and cutting process is complete. The air blower assembly 120 is mounted on a support 242, allowing fine-tuning of the airflow direction and intensity based on the film type and sealing conditions.

[0033] During operation, the first drive mechanism drives the film through the guide 124, moving the film along the predetermined path toward the roller assembly 112. Before the film engages the roller 148, the second drive mechanism 152 drives the roller 148, such that the roller 148 rotates incrementally to allow the roller 148 to release heat and to place the roller 148 at a different position from the previous cycle. The bearing 156 ensures that each increment is precise.

[0034] Once the film is indexed and engaged with the roller 148, the air cylinder 212 activates and extends the seal bar 206 toward the film and roller 148, bringing the sealing surface 218 toward the film. Specifically, the guide plates 224, which protrude from the seal bar 206, engage and clamp the film against the roller 148. The guide plates 224 then stop moving while the portions 206a, 206b and the bars 220 of the seal bar 206 continue to extend toward the film. As the portions 206a, 206b and the bars 220 reach the film, the sealing surface 218 contacts the film and the blade 214 cuts through the film, causing the roller 148 to slightly deflect. As the blade 214 cuts through the film, now cut into two pieces, a forward piece having a trailing edge and a rearward piece having a leading edge. The seal bar 206 continues pinching both pieces of the film between the sealing surface 218 of the seal bar 206 and the roller 148. The roller 148 conforms to the surface of the seal bar 206, ensuring uniform pressure across the film. The pressure, along with the heat from the cartridge 210, form the side seal on trailing edge of the forward piece of the film and another side seal on the leading edge of the rearward piece of the film, thereby facilitating formation of a bag by the forward piece and a bag by the rearward piece. The pressure applied between the seal bar 206 and the roller 148 tapers off due to the radius of the roller 148, creating a tapered side seal. The side seal includes a length of approximately 8-inches. However, in some embodiments, the side seal may include a greater or smaller length.

[0035] During the sealing operation, the air cylinder 212 continues to exert force on the roller 148. Specifically, the spring-loaded devices 232 coupled to the seal bar 206 measure how much force the seal bar 206 exerts onto the roller 148. Once the force reaches a predetermined threshold value (and / or once a predetermined time has been reached), the spring-loaded devices 232 cause the air cylinder 212 to retract, pulling the seal bar 206 away from the newly sealed film. Immediately following the retraction of the seal bar 206, the air blower assembly 120 is activated. The air nozzle 238 directs a burst of air at the film piece, preventing the heat-softened film from accidentally re-adhering to itself and keeping the two sides of the bag separated. Once the bag is moved out of engagement with roller 148 and the seal bar 206, the second drive mechanism 152 partially rotates the roller 148, and the next cycle is initiated. Therefore, the process repeats, continuously forming, cutting, and sealing new bags.

[0036] While the above description focuses on forming side seals, in some embodiments, the automated bagging machine 10 may be configured to form seals along other edges of the film, such as top or bottom edges, to accommodate different bag configurations and sealing requirements.

[0037] The automated bagging machine 10 provides several key advantages over traditional models. First, the roller 148 creates a tapered, wider seal. The cylindrical shape of the roller 148 ensures that pressure is applied gradually across the film due to the flat surface of the seal bar 206 contacting the cylindrical outer surface of the roller 148 during seal formation, resulting in a tapered side seal. This gradual transition in pressure creates a stronger and more consistent seal, enhancing the durability and integrity of the bag. Moreover, the use of a side seal, rather than an edge seal, provides superior sealing integrity, resulting in a stronger bond.

[0038] Furthermore, the removable roller 148 and / or seal bar 206 allows for easy maintenance and replacement, reducing downtime and improving overall machine efficiency. The PTFE coating 168 on the roller 148 serves as a release agent, preventing material adhesion and protecting the roller 148 from potential damage caused by the blade 214 during the sealing and cutting process. Finally, the bearing 156 ensures precise, incremental rotation of the roller 148, preventing wear on the same section of the roller 148 and maintaining consistent sealing performance over time.

[0039] Various disclosures are set forth in the following claims.

Examples

Embodiment Construction

[0019]FIGS. 1-2 illustrate an automated bagging machine 10 operable to form plastic film bags, receive and load pre-measured bulk material into the bags, and seal the bags closed. The automated bagging machine 10 includes a bag forming unit 100 to form the plastic film bags. In the illustrated embodiments, the bags are shaped and sized to hold ice. However, the bags may accommodate bulk materials such as, for example, ice, mulch, sawdust, grain, etc.

[0020]With continued reference to FIGS. 1-2, the bag forming unit 100 includes a main frame 104 supporting a guide assembly 108, a roller assembly 112, a seal bar assembly 116, and an air blower assembly 120. The bag forming unit 100 guides a roll of plastic film (not shown) through the bagging machine 10, cuts the film into individual bags, and seals a side surface of each of the bags. Together, the guide assembly 108, the roller assembly 112, the seal bar assembly 116, and the air blower assembly 120 work in a coordinated cycle, ensuri...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 771,442, filed on Mar. 13, 2025, the entire contents of which are incorporated by reference herein.FIELD

[0002] The application relates to machines, and more specifically, to automated bagging machines that form bags with side sealed edges.BACKGROUND

[0003] Automated bagging machines are widely used to form plastic film into bags and fill them with materials such as ice, food products, mulch, soil, rock, ice melt, fertilizers, and other loose goods. Automated bagging machines commonly employ different sealing methods to close plastic film bags, such as edge seals or side seals. Edge seals (e.g., burn seals) are typically formed by pressing a heated seal bar against a stationary surface, creating a narrow seal along the outer edge of the bag. While effective, this method can concentrate wear on specific areas and may limit seal strength, particularly in applications requiring wider, more durable seals.SUMMARY

[0004] In one aspect, the invention provides an automated bagging machine including a frame, a roller coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends, wherein the roller is configured to rotate about the longitudinal axis, a seal bar coupled to the frame and including a first drive mechanism configured to axially drive the seal bar toward the roller, a heat member configured to heat the seal bar, and a blade, and a second drive mechanism configured to drive rotation of the roller, wherein when the first drive mechanism drives the seal bar toward the roller, the roller and the seal bar are configured to engage with film moved through the machine and form a side seal along an edge of the film.

[0005] In another aspect, the invention provides an automated bagging machine including a frame, a guide assembly configured to direct film along a path through the bagging machine, a seal bar coupled to the frame and including a drive mechanism and a heat member, and a cylindrical roller removably coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends, wherein the roller is configured to rotate about the longitudinal axis to engage the film during a sealing operation, and wherein the roller includes a base, a first layer surrounding the base, and a second layer surrounding the first layer.

[0006] In yet another aspect, the invention provides an automated bagging machine including a frame, a roller coupled to the frame and rotatable about a longitudinal axis, wherein the roller is configured to engage a film, a seal bar coupled to the frame and movable toward the roller to press the film against the roller and form a seal in the film, a drive mechanism configured to drive rotation of the roller, and a bearing coupled between the roller and the drive mechanism, wherein the bearing is configured to drive incremental rotation of the roller about the longitudinal axis in a first direction and inhibit rotation of the roller in a second direction.

[0007] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of an automated bagging machine according to one aspect of the invention.

[0009] FIG. 2 is another perspective view of the automated bagging machine of FIG. 1.

[0010] FIG. 3 is a perspective view of a roller assembly of the automated bagging machine of FIG. 1.

[0011] FIG. 4 is a cross-sectional view of the roller assembly of FIG. 3.

[0012] FIG. 5 is a top cross-sectional view of the roller assembly of FIG. 3.

[0013] FIG. 6 is a partial cross-sectional view of the automated bagging machine of FIG. 1, illustrating a portion of the roller assembly and a seal bar assembly.

[0014] FIG. 7 is another partial cross-sectional view of the automated bagging machine of FIG. 1, illustrating a portion of the roller assembly.

[0015] FIG. 8 is a cross-sectional view of the seal bar assembly of the automated bagging machine of FIG. 1.

[0016] FIG. 9 is another cross-sectional view of the seal bar assembly of FIG. 8.

[0017] FIG. 10 is an exploded view of a portion of the seal bar assembly of FIG. 8, illustrating a seal bar and a blade.

[0018] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Use of "including" and "comprising" and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of "consisting of" and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Unless specified or limited otherwise, the terms “mounted,”“connected,”“supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.DETAILED DESCRIPTION

[0019] FIGS. 1-2 illustrate an automated bagging machine 10 operable to form plastic film bags, receive and load pre-measured bulk material into the bags, and seal the bags closed. The automated bagging machine 10 includes a bag forming unit 100 to form the plastic film bags. In the illustrated embodiments, the bags are shaped and sized to hold ice. However, the bags may accommodate bulk materials such as, for example, ice, mulch, sawdust, grain, etc.

[0020] With continued reference to FIGS. 1-2, the bag forming unit 100 includes a main frame 104 supporting a guide assembly 108, a roller assembly 112, a seal bar assembly 116, and an air blower assembly 120. The bag forming unit 100 guides a roll of plastic film (not shown) through the bagging machine 10, cuts the film into individual bags, and seals a side surface of each of the bags. Together, the guide assembly 108, the roller assembly 112, the seal bar assembly 116, and the air blower assembly 120 work in a coordinated cycle, ensuring continuous, accurate positioning and sealing of the film.

[0021] The guide assembly 108 includes the roll of plastic film supported on the automated bagging machine 10, and a guide 124 that directs the film along a predetermined path through the bag forming unit 100. A first drive mechanism (e.g., motor, pneumatic cylinder, etc.) (not shown) drives the plastic film, automatically advancing the film through the bag forming unit 100. The guide 124 ensures proper alignment and tension of the film as it moves through the machine 10. Specifically, the guide 124 includes a first stage 128 and a second stage 132. The first stage 128 includes two parallel wire frames 136, and the second stage 132 includes two parallel guards 140. A narrow gap 144 between the frames 136 and the guards 140 forms the path for the film, ensuring smooth film movement during operation.

[0022] With reference to FIGS. 3-4, the roller assembly 112 includes a roller 148, a second drive mechanism 152, and a bearing 156. The roller 148 is substantially cylindrical and is configured to abut against the film as it moves through the bag forming unit 100. The roller includes a first distal end 148a, a second distal end 148b opposite the first distal end 148a, and a longitudinal axis 150 (FIG. 4) extending through the distal ends 148a, 148b. The first distal end 148a is coupled to an upper edge 104a of the main frame 104 of the machine 10, and the second distal end 148b is coupled to a lower edge 104b of the main frame 104 of the machine 10.

[0023] With reference to FIGS. 4-5, the roller 148 is concentrically structured with multiple layers. A core of the roller 148 includes a rigid cylindrical base 160 that provides structural support and stability. Surrounding the base 160 is a low-durometer elastomeric pad 164, which is designed to conform slightly under pressure to create uniform sealing contact, as discussed in more detail below. The outermost layer is a PTFE coating 168 that encases the elastomeric pad 164, preventing material adhesion and minimizing heat-related wear. More specifically, the coating 168 is composed of Teflon™; however, other types of coatings may alternatively or additionally be applied. An idler shaft 170 extends from the first distal end 148a of the roller 148, and a drive shaft 172 extends from the second distal end 148b of the roller 148The idler shaft 170 is fixed relative to the roller 148, such that the roller 148 is rotatable relative to the idler shaft 170, whereas the drive shaft 172 rotates with the roller 148. The roller 148 is coupled to the bearing 156, which is coupled to the second drive mechanism 152.

[0024] With reference to FIGS. 3-4 and 7, the second drive mechanism 152 controls rotation of the roller 148 about the longitudinal axis 150. In the illustrated embodiments, the second drive mechanism 152 is a pneumatic cylinder. However, other drive mechanisms, such as a motor, may be implemented. More specifically, the second drive mechanism 152 operates the bearing 156 to ensure precise, incremental rotation. Specifically, the bearing 156 is a one-way roller bearing that operates like a ratchet and pawl mechanism. During each cycle, the second drive mechanism 152 engages, advancing the roller 148 by an adjustable set increment. The bearing 156 prevents backward movement, ensuring unidirectional rotation of the roller 148 about the longitudinal axis 150. The bearing 156 is configured such that each engagement shifts the surface of the roller 148 to a new contact point with the seal bar assembly 116. This prevents repeated wear on the same section of the roller 148, helps maintain consistent sealing performance, and extends the longevity of the roller 148.

[0025] With reference to FIGS. 6-7, the roller 148 is removably coupled to the main frame 104 of the machine 10. Specifically, the roller 148 includes a first quick-release coupling mechanism 178 (FIG. 6) positioned on the idler shaft 170 and a second quick-release coupling mechanism 182 (FIG. 7) positioned on the drive shaft 172. The first coupling mechanism 178 includes a detent pin 186, a cable 190, and a fastener 194. The pin 186 extends through the idler shaft 170 and the fastener 194 couples to the seal bar assembly 116. The cable 190 extends between and couples the pin 186 and the fastener 194. To remove the first distal end 148a of the roller 148 from the main frame 104, the operator pulls the pin 186, disengaging a ball detent and allowing the pin 186 to be extracted from the idler shaft 170.

[0026] The second coupling mechanism 182 includes a fastener 198 (e.g., a clevis pin) and a pin 202 (e.g., a hairpin cotter pin). The fastener 198 extends through the drive shaft 172 and a portion of the lower edge 104b of the main frame 104. The pin 202 is inserted through an end of the fastener 198, securing the fastener 198 in place on the drive shaft 172. To remove the second distal end 148b of the roller 148 from the main frame 104, the operator pulls the pin 202, which disengages the fastener 198, allowing the operator to remove the fastener 198 and free the roller 148 from the drive shaft 172. Once both coupling mechanisms 178, 182 are disengaged, the roller 148 can be lifted out of place for maintenance or replacement.

[0027] With reference to FIGS. 8-9, the seal bar assembly 116 is positioned adjacent to and opposite the roller assembly 112. The seal bar assembly 116 includes a seal bar 206 (FIG. 10), a heated cartridge 210, or heat member, a third drive mechanism 212, or air cylinder, and a blade 214 (FIG. 10). As shown in FIG. 10, the seal bar 206 is generally elongate and rectangular, including a flat sealing surface 218 configured to engage the film against the roller 148 to form a seal. The seal bar 206 includes a first portion 206a, a second portion 206b, and two extruded bars 220 coupled to the first and second portions 206a, 206b. The extruded bars 220 securely clamp the blade 214 to the seal bar 206, as discussed in more detail below. The bars 220 are composed of aluminum and include a coating composed of PTFE (e.g., Teflon). The seal bar 206 additionally includes two guide plates 224, one positioned on each side of the seal bar portions 206a, 206b. The guide plates 224 provide structural support and stable movement of the blade 214 during the cutting process, insulate sides of the seal bar 206, and aid in clamping and controlling the film prior to a cutting operation, as discussed in more detail below.

[0028] The cartridge 210 is a heated cartridge in the form of a wire and includes a connector 222. A distal end of the cartridge 210 is coupled to the connector 222, which serves as an interface between the cartridge 210 and an external power supply 228. The cartridge 210 operates using electrical resistance heating and is monitored and regulated by a thermocouple. The connector 222 includes electrical terminals linking the cartridge 210 to a power supply 228. However, in alternative embodiments, different types of cartridges and heat sources may be implemented (e.g., heated air, oil, or another thermal fluid).

[0029] With reference to FIG. 8, the air cylinder 212 is adjacent to the seal bar 206 and acts as a pneumatic actuator that controls movement of the seal bar 206. When pressurized, the air cylinder 212 extends a piston, axially driving the seal bar 206 toward the roller 148 during a sealing operation. More specifically, the seal bar assembly 116 includes two parallel guide rods 230 positioned between the air cylinder 212 and the seal bar 206. The guide rods 230 ensure stable, linear movement, preventing misalignment or tiling as the seal bar 206 moves. The air cylinder 212 applies a force greater than that of internal spring-loaded devices 232 (FIGS. 8-9) within the seal bar 206, compressing the spring-loaded devices 232 until the seal bar 206 reaches the roller 148. The spring-loaded devices 232 then determine the final sealing force, allowing controlled engagement between the seal bar 206, the film, and the roller 148 to ensure consistent sealing performance. Once the sealing process is complete, the air cylinder 212 retracts, pulling the seal bar 206 away from the film and resetting the air cylinder 212 for the next cycle. In the illustrated embodiments, the drive mechanism 212 is an air cylinder. However, other drive mechanisms, such as a motor, may be implemented.

[0030] With reference to FIG. 10, the blade 214 is a cutting element integrated into the seal bar 206 and configured to sever the film along the sealed seam. More specifically, the blade 214 is positioned within an elongate slot formed by the bars 220. The slot extends along a length of the seal bar 206, aligning the blade 214 with the sealing surface 218 to facilitate simultaneous sealing and cutting in a single operation. The blade 214 includes a sharp edge designed to cut the film immediately before a seal is formed, ensuring a clean separation of individual bags. More specifically, the blade 214 is positioned slightly forward of the seal bar 206, such that when the seal bar 206 moves forward, the blade 214 advances through the film against the surface of the roller 148.

[0031] In some embodiments, the seal bar 206 may be removable from the main frame 104. Specifically, the seal bar 206 includes fasteners 234 (e.g., clevis pins and retaining pins) coupling the seal bar 206 to the main frame 104. In the illustrated embodiments, the seal bar 206 includes four fasteners 234. However, the seal bar 206 may include fewer or additional fasteners 234. To remove the seal bar 206, the operator disconnects the air cylinder 212 and removes the fasteners 234 from the seal bar 206. Once the fasteners 234 are removed, the seal bar 206 and the cartridge 210 can be lifted out of place for maintenance or replacement.

[0032] With reference to FIGS. 1 and 8, the air blower assembly 120 is positioned immediately adjacent to and downstream of the roller assembly 112 and the seal bar assembly 116. The air blower assembly 120 facilitates bag separation. Specifically, the air blower assembly 120 includes an air nozzle 238 (FIG. 8) configured to direct a controlled burst of air at the newly formed bag. This airflow acts to gently push the bag away from the sealing area, preventing the heat-softened film from inadvertently re-adhering. The air blower assembly 120 operates in a timed sequence to ensure that the air burst occurs immediately after the sealing and cutting process is complete. The air blower assembly 120 is mounted on a support 242, allowing fine-tuning of the airflow direction and intensity based on the film type and sealing conditions.

[0033] During operation, the first drive mechanism drives the film through the guide 124, moving the film along the predetermined path toward the roller assembly 112. Before the film engages the roller 148, the second drive mechanism 152 drives the roller 148, such that the roller 148 rotates incrementally to allow the roller 148 to release heat and to place the roller 148 at a different position from the previous cycle. The bearing 156 ensures that each increment is precise.

[0034] Once the film is indexed and engaged with the roller 148, the air cylinder 212 activates and extends the seal bar 206 toward the film and roller 148, bringing the sealing surface 218 toward the film. Specifically, the guide plates 224, which protrude from the seal bar 206, engage and clamp the film against the roller 148. The guide plates 224 then stop moving while the portions 206a, 206b and the bars 220 of the seal bar 206 continue to extend toward the film. As the portions 206a, 206b and the bars 220 reach the film, the sealing surface 218 contacts the film and the blade 214 cuts through the film, causing the roller 148 to slightly deflect. As the blade 214 cuts through the film, now cut into two pieces, a forward piece having a trailing edge and a rearward piece having a leading edge. The seal bar 206 continues pinching both pieces of the film between the sealing surface 218 of the seal bar 206 and the roller 148. The roller 148 conforms to the surface of the seal bar 206, ensuring uniform pressure across the film. The pressure, along with the heat from the cartridge 210, form the side seal on trailing edge of the forward piece of the film and another side seal on the leading edge of the rearward piece of the film, thereby facilitating formation of a bag by the forward piece and a bag by the rearward piece. The pressure applied between the seal bar 206 and the roller 148 tapers off due to the radius of the roller 148, creating a tapered side seal. The side seal includes a length of approximately 8-inches. However, in some embodiments, the side seal may include a greater or smaller length.

[0035] During the sealing operation, the air cylinder 212 continues to exert force on the roller 148. Specifically, the spring-loaded devices 232 coupled to the seal bar 206 measure how much force the seal bar 206 exerts onto the roller 148. Once the force reaches a predetermined threshold value (and / or once a predetermined time has been reached), the spring-loaded devices 232 cause the air cylinder 212 to retract, pulling the seal bar 206 away from the newly sealed film. Immediately following the retraction of the seal bar 206, the air blower assembly 120 is activated. The air nozzle 238 directs a burst of air at the film piece, preventing the heat-softened film from accidentally re-adhering to itself and keeping the two sides of the bag separated. Once the bag is moved out of engagement with roller 148 and the seal bar 206, the second drive mechanism 152 partially rotates the roller 148, and the next cycle is initiated. Therefore, the process repeats, continuously forming, cutting, and sealing new bags.

[0036] While the above description focuses on forming side seals, in some embodiments, the automated bagging machine 10 may be configured to form seals along other edges of the film, such as top or bottom edges, to accommodate different bag configurations and sealing requirements.

[0037] The automated bagging machine 10 provides several key advantages over traditional models. First, the roller 148 creates a tapered, wider seal. The cylindrical shape of the roller 148 ensures that pressure is applied gradually across the film due to the flat surface of the seal bar 206 contacting the cylindrical outer surface of the roller 148 during seal formation, resulting in a tapered side seal. This gradual transition in pressure creates a stronger and more consistent seal, enhancing the durability and integrity of the bag. Moreover, the use of a side seal, rather than an edge seal, provides superior sealing integrity, resulting in a stronger bond.

[0038] Furthermore, the removable roller 148 and / or seal bar 206 allows for easy maintenance and replacement, reducing downtime and improving overall machine efficiency. The PTFE coating 168 on the roller 148 serves as a release agent, preventing material adhesion and protecting the roller 148 from potential damage caused by the blade 214 during the sealing and cutting process. Finally, the bearing 156 ensures precise, incremental rotation of the roller 148, preventing wear on the same section of the roller 148 and maintaining consistent sealing performance over time.

[0039] Various disclosures are set forth in the following claims.

Examples

Embodiment Construction

[0019]FIGS. 1-2 illustrate an automated bagging machine 10 operable to form plastic film bags, receive and load pre-measured bulk material into the bags, and seal the bags closed. The automated bagging machine 10 includes a bag forming unit 100 to form the plastic film bags. In the illustrated embodiments, the bags are shaped and sized to hold ice. However, the bags may accommodate bulk materials such as, for example, ice, mulch, sawdust, grain, etc.

[0020]With continued reference to FIGS. 1-2, the bag forming unit 100 includes a main frame 104 supporting a guide assembly 108, a roller assembly 112, a seal bar assembly 116, and an air blower assembly 120. The bag forming unit 100 guides a roll of plastic film (not shown) through the bagging machine 10, cuts the film into individual bags, and seals a side surface of each of the bags. Together, the guide assembly 108, the roller assembly 112, the seal bar assembly 116, and the air blower assembly 120 work in a coordinated cycle, ensuri...

Claims

1. An automated bagging machine comprising: a frame;a roller coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends, wherein the roller is configured to rotate about the longitudinal axis;a seal bar coupled to the frame and includinga first drive mechanism configured to axially drive the seal bar toward the roller,a heat member configured to heat the seal bar, anda blade, anda second drive mechanism configured to drive rotation of the roller;wherein when the first drive mechanism drives the seal bar toward the roller, the roller and the seal bar are configured to engage with film moved through the machine and form a side seal along an edge of the film.

2. The automated bagging machine of claim 1, wherein the roller is removably coupled to the frame.

3. The automated bagging machine of claim 1, wherein the seal bar is removably coupled to the frame.

4. The automated bagging machine of claim 1, further comprising a ratchet and a pawl coupled to the second drive mechanism, wherein the ratchet and the pawl are configured to drive incremental rotation of the roller about the longitudinal axis.

5. The automated bagging machine of claim 1, wherein an outer surface of the roller includes a PTFE coating.

6. The automated bagging machine of claim 1, wherein the blade is positioned forward of the seal bar such that that the blade cuts the film before a seal is formed.

7. The automated bagging machine of claim 1, wherein the side seal is tapered along the edge of the film.

8. An automated bagging machine comprising: a frame;a guide assembly configured to direct film along a path through the bagging machine;a seal bar coupled to the frame and including a drive mechanism and a heat member; anda cylindrical roller removably coupled to the frame and including a first end, a second end opposite the first end, and a longitudinal axis extending through the first and second ends;wherein the roller is configured to rotate about the longitudinal axis to engage the film during a sealing operation, andwherein the roller includes a base, a first layer surrounding the base, and a second layer surrounding the first layer.

9. The automated bagging machine of claim 8, wherein the first layer is an elastomeric pad and the second layer is a PTFE coating.

10. The automated bagging machine of claim 8, wherein the first layer is substantially deformable during sealing.

11. The automated bagging machine of claim 8, wherein the drive mechanism is a first drive mechanism, and wherein the automated bagging machine further comprises a second drive mechanism configured to drive rotation of the roller, wherein the second drive mechanism includes an idler shaft coupled to the first end of the roller, and a drive shaft coupled to the second end of the roller.

12. The automated bagging machine of claim 11, wherein the roller includes a first coupling mechanism coupled to the idler shaft, and a second coupling mechanism coupled to the drive shaft.

13. The automated bagging machine of claim 12, wherein the first coupling mechanism includes a pin extending through the idler shaft, a fastener coupled to the seal bar, and a cable extending between the pin and the fastener.

14. The automated bagging machine of claim 12, wherein the second coupling mechanism includes a fastener extending through the drive shaft and the frame, and a pin extending into the fastener.

15. An automated bagging machine comprising: a frame;a roller coupled to the frame and rotatable about a longitudinal axis, wherein the roller is configured to engage a film;a seal bar coupled to the frame and movable toward the roller to press the film against the roller and form a seal in the film;a drive mechanism configured to drive rotation of the roller; anda bearing coupled between the roller and the drive mechanism, wherein the bearing is configured to drive incremental rotation of the roller about the longitudinal axis in a first direction and inhibit rotation of the roller in a second direction.

16. The automated bagging machine of claim 15, wherein the bearing is a one-way bearing.

17. The automated bagging machine of claim 15, wherein the drive mechanism is a pneumatic cylinder.

18. The automated bagging machine of claim 15, wherein the drive mechanism actuates the bearing such that the roller advances between sealing operations of the seal bar.

19. The automated bagging machine of claim 15, wherein the roller and the seal bar are configured to engage with the film and form a side seal along an edge of the film.

20. The automated bagging machine of claim 15, wherein the bearing includes a ratchet and a pawl coupled to the drive mechanism, wherein the ratchet and the pawl are configured to drive incremental rotation of the roller about the longitudinal axis.

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