Bagging machine with multiple-force actuator and mechanically-actuated grippers

Abstract

Bagging machines (18) include a sealing mechanism (20, 250) having a sealing bar (24) and a pressure plate (23) movable in relation to the sealing bar so that the pressure plate and the sealing bar can apply pressure to a sealing area on an envelope to form a closure seal. The bagging machines can include a high-force actuator (30) and a low-force actuator (28) configured to apply different levels of force to the sealing bar dependent upon the position of the sealing bar in relation to the pressure plate. The bagging machines also can include one or more grippers (105) that separate the upper ends of the envelope walls to provide access to an interior pocket of the envelope. The grippers can be configured to disengage from their drive mechanism upon encountering an obstruction in their movement into and out of contact with the envelope walls.

Description

Docket No. 194313.18202BAGGING MACHINE WITH MULTIPLE-FORCE ACTUATOR AND MECHANICALLY-ACTUATED GRIPPERSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application No. 63 / 687,194, filed August 26, 2024, the disclosure of which is incorporated by reference herein in its entirety.BACKGROUND

[0002] Automated bagging machines are in widespread use for packaging small to mediumsize items in shipping containers such as envelopes. The shipping containers, e.g., envelopes, may be provided to the bagging machine as a web of interconnected envelopes. The bagging machine is configured to open each envelope so that the item to be packaged can be loaded into an interior pocket of the envelope. After the item has been loaded, the bagging machine can close the envelope and form a closure seal that seals the envelope shut so that the item is retained within the envelope. The loaded and sealed envelope then may be separated from the web on a manual basis, or automatically by provisions on the bagging machine.

[0003] Automated bagging machines, however, can present hazards to individuals operating such machines. For example, the process of closing and sealing the envelope typically involves pressing portions of the opposing envelope walls against each other with substantial force while applying heat thereto, to form a closure seal on the envelope. Inadvertent contact with the heating element or inadvertently placing one’s fingers or hands between the pressing elements can result in serious injury.

[0004] Also, the web typically is pulled through the bagging machine at a relatively high rate of speed. Thus, the various mechanisms that direct and otherwise handle the web within the bagging machine may be susceptible to jamming or to becoming obstructed, which can interfere with the efficient operation of the bagging machine and the formation of a properly sealed envelope, and can result in damage to the web or the bagging machine itself.SUMMARY

[0005] In one aspect of the disclosed technology, a bagging machine includes a sealing mechanism that includes a pressure plate and a sealing bar opposing the pressure plate by an1175705203Docket No. 194313.18202 envelope-receiving space. The bagging machine also includes a pressure-plate linkage associated with the pressure plate to move the pressure plate between an open position at a distance from the sealing bar that allows loading of an envelope that is received in the envelope-receiving space, an intermediate position spaced nearer to the sealing bar than at the open position, and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of the envelope.

[0006] The bagging machine further includes an actuator mechanism. The actuator mechanism that includes a low-force actuator configured to drive the pressure-plate linkage to move the pressure plate between the open and intermediate positions via a first force and a high-force actuator that is disengaged from the pressure-plate linkage at the open position of the pressure plate, and that is engaged with the pressure-plate linkage between the intermediate and sealing positions of the pressure plate to drive the pressure-plate linkage to move the pressure plate from the intermediate position to the sealing position via a second force that is greater than the first force.

[0007] In another aspect of the disclosed technology, the high-force actuator is incapable of applying force to the pressure plate when the high-force actuator is disengaged from the pressure-plate linkage.

[0008] In another aspect of the disclosed technology, the high-force actuator is disengaged from the pressure-plate linkage between the intermediate and open positions of the pressure plate.

[0009] In another aspect of the disclosed technology, the pressure-plate linkage is engaged with the pressure-plate linkage only between the intermediate and sealing positions of the pressure plate.

[0010] In another aspect of the disclosed technology, the pressure plate is spaced from the sealing bar by about 14 inch or less when the pressure plate is in the intermediate position.

[0011] In another aspect of the disclosed technology, the second force is at least two times greater than the first force.

[0012] In another aspect of the disclosed technology, the second force is at least five times greater than the first force.2175705203Docket No. 194313.18202

[0013] In another aspect of the disclosed technology, the high-force actuator includes a spiral cam configured to provide an elevated mechanical advantage to drive the pressure-plate linkage compared to the low-force actuator.

[0014] In another aspect of the disclosed technology, the high-force actuator includes a cam, and an actuator member coupled to the cam and configured to rotate the cam. The cam includes a curvilinear first camming surface coupled to the pressure-plate linkage when the pressure plate moves from the intermediate position to the sealing position The first camming surface is configured to exert the second force on the pressure-plate linkage.

[0015] In another aspect of the disclosed technology, the first camming surface is configured so that the second force increases as the pressure plate moves from the intermediate position to the sealing position.

[0016] In another aspect of the disclosed technology, a radius of curvature of the first camming surface decreases along a length of the camming surface.

[0017] In another aspect of the disclosed technology, the cam is configured to rotate between a first angular position at which the pressure plate is located in the intermediate position and a first end portion of the camming surface is coupled the pressure plate linkage and a second angular position at which the pressure plate is located in the sealing position and a second end portion of the camming surface is coupled the pressure plate linkage. The radius of curvature of the first camming surface at the second end portion of the camming surface is less than the radius of curvature of the first camming surface at the first end portion of the camming surface.

[0018] In another aspect of the disclosed technology, the pressure-plate linkage is configured to disengage from the cam as the pressure plate moves from the intermediate position and toward the open position.

[0019] In another aspect of the disclosed technology, the cam includes a curvilinear second camming surface coupled to the pressure-plate linkage when the pressure plate moves from the sealing position to the intermediate position. The second camming surface is configured to exert a third force on the pressure-plate linkage. The third force drives the pressure-plate linkage to move the pressure plate from the sealing position to the intermediate position.

[0020] In another aspect of the disclosed technology, the first and second camming surfaces partially define a recess configured to receive a portion of the pressure-plate linkage when the pressure plate moves between the intermediate and open positions.3175705203Docket No. 194313.18202

[0021] In another aspect of the disclosed technology, the low-force actuator is configured to remain deactivated, and engaged with the pressure-plate linkage as the pressure plate moves between the intermediate and sealing positions.

[0022] In another aspect of the disclosed technology, the closure seal is formed from a heat- sealable material. The sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar, and the heating element is configured to heat the heat- sealable material when the pressure plate is in the sealing position.

[0023] In another aspect of the disclosed technology, the bagging machine further includes a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

[0024] In another aspect of the disclosed technology, a bagging machine includes a sealing mechanism that includes a sealing bar and pressure plate. The pressure plate is movable with respect to the sealing bar between an open position at a distance from the sealing bar that allows loading of an envelope that is received in an envelope-receiving space and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of a first envelope.

[0025] The bagging machine further includes a gripper mounted to the pressure plate and configured to move from an open position to a gripping position to grip an upper edge of a front wall of the first envelope sufficiently to pull the envelope open, a gripper drive drivingly engaged with the gripper to drive the gripper to the gripping position, and a coupling between the gripper drive and the gripper that is configured to disengage the gripper from the gripper drive in response to a predetermined force resisting movement of the gripper to the gripping position, causing the gripper to release the front wall.

[0026] In another aspect of the disclosed technology, the coupling is configured couple the gripper to the gripper drive as the pressure plate is moved to the open position of the pressure plate and the envelope is loaded in the envelope-receiving space.

[0027] In another aspect of the disclosed technology, the gripper is configured to rotate between the open and gripping positions of the gripper. The gripper drive includes a rotatable4175705203Docket No. 194313.18202 gripper drive shaft and the coupling is configured to releasably couple the gripper to the gripper drive shaft in rotation.

[0028] In another aspect of the disclosed technology, the gripper drive further includes a gripper coupler mounted on the gripper drive shaft and configured to rotate with the gripper drive shaft and the coupling is configured to releasably couple the gripper to the gripper coupler in rotation via the gripper coupler.

[0029] In another aspect of the disclosed technology, the coupling is configured to rotationally decouple the gripper from the gripper coupler upon the predetermined force resisting movement of the gripper to the gripping position.

[0030] In another aspect of the disclosed technology, the gripper is configured to slide in relation to the gripper coupler in response to the predetermined force resisting movement of the gripper to the gripping position.

[0031] In another aspect of the disclosed technology, the gripper is configured to rotationally decouple from the gripper coupler and a rotation angle of the gripper relative to the gripper coupler is limited by a stop.

[0032] In another aspect of the disclosed technology, the rotation angle is limited to 15 degrees or less.

[0033] In another aspect of the disclosed technology, the coupling is a magnetic coupling including a first magnet mounted on the gripper, and a second magnet mounted on the gripper coupler.

[0034] In another aspect of the disclosed technology, a magnetic attraction between the first and second magnets is sufficiently high to allow the gripper drive to drive the gripper to the gripping position and sufficiently low to allow the gripper to disengage from the gripper drive in response to the predetermined force resisting movement of the gripper to the gripping position.

[0035] In another aspect of the disclosed technology, the magnetic attraction between the first and second magnets is sufficiently high to couple the gripper drive to the gripper as the pressure plate is moved to the open position of the pressure plate and the envelope is loaded within the envelope-receiving space with the gripper gripping the upper edge of the front wall of the envelope.

[0036] In another aspect of the disclosed technology, the gripper has a backing surface located within a magnetic field of the first magnet, the gripper coupler has a backing surface located5175705203Docket No. 194313.18202 within a magnetic field of the second magnet, and the backing surface of the gripper is driven into contact with the backing surface of the gripper coupler by magnetic attraction between the first and second magnets.

[0037] In another aspect of the disclosed technology, the first magnet is driven toward the second magnet as the gripper is driven to the gripping position.

[0038] In another aspect of the disclosed technology, an outer surface of the gripper drive shaft has a polygonal shape and the gripper coupler has an inner surface configured to engage the outer surface of the gripper drive shaft.

[0039] In another aspect of the disclosed technology, a shape the inner surface of the gripper matches the polygonal shape of the outer surface of the gripper drive shaft.

[0040] In another aspect of the disclosed technology, the outer surface of the gripper drive shaft has a hexagonal shape.

[0041] In another aspect of the disclosed technology, the gripper is further configured to move from the open to the gripping position of the gripper to grip the upper edge of the front wall of the envelope sufficiently to pull the envelope open as the pressure plate moves toward the open position of the pressure plate.

[0042] In another aspect of the disclosed technology, the gripper includes a tab configured to facilitate manual application of a force to the gripper sufficient to disengage the gripper from the gripper drive.

[0043] In another aspect of the disclosed technology, the closure seal is formed from a heat- sealable material. The sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar. The heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

[0044] In another aspect of the disclosed technology, the bagging machine further includes a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

[0045] In another aspect of the disclosed technology, a bagging machine includes a sealing mechanism that includes a sealing bar and a pressure plate. The pressure plate is movable with respect to the sealing bar between an open position at a distance from the sealing bar that allows 6175705203Docket No. 194313.18202 loading of an envelope that is received in an envelope-receiving space and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of a first envelope.

[0046] The bagging machine further includes a gripper mounted to the pressure plate and configured to move from an open position to a gripping position to grip an upper edge of a front wall of the first envelope sufficiently to pull the envelope open and a gripper drive configured to move the gripper between the open and gripping positions of the gripper and actuated by the movement of the pressure plate with respect to the sealing bar.

[0047] In another aspect of the disclosed technology, the gripper drive is configured to move the gripper between the open and gripping positions of the gripper based on a position of the pressure plate with respect to the sealing bar.

[0048] In another aspect of the disclosed technology, the gripper drive includes a drive cam, a follower, a gripper actuator, and a rotatable gripper drive shaft. The gripper is mounted to the gripper drive shaft and is configured to rotate with the gripper drive shaft between the open and gripping positions of the gripper. The gripper actuator engages the follower and is configured to displace the follower in response to the movement of the pressure plate with respect to the sealing bar. The follower is coupled to the drive cam and the gripper driveshaft is fixed to the drive cam so that the displacement of the follower causes the drive cam to rotate the gripper drive shaft.

[0049] In another aspect of the disclosed technology, the gripper actuator includes a closed track defining a passage configured to receive the follower. At least a portion of the closed track is curved so that relative movement between the follower and the gripper actuator displaces the follower in a direction other than a direction of travel of the pressure plate between the open and sealing positions of the pressure plate.

[0050] In another aspect of the disclosed technology, the direction other than a direction of travel of the pressure plate between the open and sealing positions of the pressure plate is a direction orthogonal to the direction of travel of the pressure plate between the open and sealing positions of the pressure plate.

[0051] In another aspect of the disclosed technology, the gripper actuator is stationary in relation to the pressure plate as the pressure plate moves between the open and sealing positions of the pressure plate.7175705203Docket No. 194313.18202

[0052] In another aspect of the disclosed technology, the passage has a linear portion and a curvilinear portion and the follower is displaced in the direction other than a direction of travel of the pressure plate between the open and sealing positions of the pressure plate when the follower moves within the curvilinear portion of the passage.

[0053] In another aspect of the disclosed technology, the gripper drive further includes a drive body coupled to the pressure plate so that the drive body moves with the pressure plate. The gripper actuator is coupled to the drive body and is configured to move linearly in relation to the drive body and the drive body is configured to displace the gripper actuator in relation to the follower as the pressure plate approaches the sealing position of the pressure plate.

[0054] In another aspect of the disclosed technology, the gripper is further configured to move from the open position to the gripping position of the gripper to grip the upper edge of the front wall of the envelope sufficiently to pull the envelope open as the pressure plate moves toward the open position of the pressure plate.

[0055] In another aspect of the disclosed technology, the closure seal is formed from a heat- sealable material. The sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar and the heating element is configured to heat the heat- sealable material when the pressure plate is in the sealing position.

[0056] In another aspect of the disclosed technology, the bagging machine further includes a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

[0057] In another aspect of the disclosed technology, a bagging machine includes a sealing bar and a pressure plate. The pressure plate is movable with respect to the sealing bar between an open position at a distance from the sealing bar that allows loading of a first envelope that is received in an envelope-receiving space and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of the first envelope. The bagging machine further includes a biasing member configured to bias the sealing bar toward the pressure plate.

[0058] In another aspect of the disclosed technology, the biasing member is configured to establish a sealing pressure on the closure by the pressure plate and the sealing bar when the pressure plate is pushed against the sealing bar.8175705203Docket No. 194313.18202

[0059] In another aspect of the disclosed technology, the bagging machine further includes a guide block fixed to a frame of the bagging machine, a guide pin fixed to the sealing bar and extending through the guide block. The guide pin engages the sealing bar so that the sealing bar is suspended from the guide pin and the biasing member is positioned between the guide block and the sealing bar so that the biasing member biases the sealing bar away from the guide block.

[0060] In another aspect of the disclosed technology, the biasing member includes a spring.

[0061] In another aspect of the disclosed technology, the spring is positioned around the guide pin.

[0062] In another aspect of the disclosed technology, the bagging machine further includes a restraint fixed to the guide pin and configured to restrain the guide pin from exiting the guide block.

[0063] In another aspect of the disclosed technology, the sealing bar is configured to move on the pin in relation to the frame.

[0064] In another aspect of the disclosed technology, the closure seal is formed from a heat- sealable material. The sealing bar further includes a heating element associated with the pressure plate and / or the sealing bar and the heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

[0065] In another aspect of the disclosed technology, the bagging machine further includes a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

[0066] In another aspect of the disclosed technology, the sealing guard includes a biasing member configured to bias the heating element toward the extended position and the bias of the biasing member configured to bias the heating element toward the extended position is less than the bias of the biasing member configured to bias the sealing bar toward the pressure plate.

[0067] In another aspect of the disclosed technology, a bagging machine is configured for use with a web of interconnected envelopes. The bagging machine includes a sealing mechanism that includes a sealing bar and a pressure plate. The pressure plate is movable with respect to the sealing bar between an open position at a distance from the sealing bar that allows loading of a first envelope that is received in an envelope-receiving space and a sealing position in which the 9175705203Docket No. 194313.18202 pressure plate is pressed against the sealing bar to form a closure seal of the envelope. The bagging machine further includes a web separator configured to separate a portion of the first envelope from a portion of an adjacent second envelope on the web as the sealing bar moves toward the sealing position.

[0068] In another aspect of the disclosed technology, the web separator is coupled the pressure plate so that the web separator moves with the pressure plate.

[0069] In another aspect of the disclosed technology, the web separator is configured to separate the portion of the first envelope from the portion of the second envelope prior to formation of the closure seal.

[0070] In another aspect of the disclosed technology, the portion of the first envelope is adjacent a side of the first envelope and the portion of the second envelope is adjacent a side of the second envelope.

[0071] In another aspect of the disclosed technology, the web separator includes a perforation breaker configured to break one or more perforations located on the web between the first envelope and the second envelope as the sealing bar moves toward the sealing position to separate the portion of the first envelope from the portion of the second envelope.

[0072] In another aspect of the disclosed technology, the perforation breaker includes a breaking element and a holding member. The breaking element is configured to break the one or more perforations as the sealing bar moves toward the sealing position. The holding member is configured to hold a portion of the second envelope in place as the breaking element breaks the one or more perforations.

[0073] In another aspect of the disclosed technology, the holding member is configured to hold a portion of the second envelope in place as the breaking element breaks the one or more perforations.

[0074] In another aspect of the disclosed technology, the breaking element is configured move in relation to the holding member as the breaking element breaks the one or more perforations.

[0075] In another aspect of the disclosed technology, the web separator further includes a breaker plate defining a breaker cavity therein and the breaker cavity is configured to receive a portion of the breaking element as the breaking element breaks the one or more perforations.

[0076] In another aspect of the disclosed technology, the breaker plate is mounted above the sealing bar.10175705203Docket No. 194313.18202

[0077] In another aspect of the disclosed technology, the perforation breaker further includes a spring associated with the holding member and biasing the holding member toward the sealing bar.

[0078] In another aspect of the disclosed technology, the perforation breaker further includes a spring associated with the breaking element and biasing the breaking element toward the sealing bar and the spring associated with the breaking element is stiffer than the spring associated with the holding member.

[0079] In another aspect of the disclosed technology, the breaking element includes a forward surface, and an upper surface adjoining the forward surface. The forward surface is oriented at an acute angle in relation to the upper surface, the forward surface and the upper surface define a forward edge of the breaking element, and the forward edge of the breaking element is configured to break the one or more perforations as the sealing bar moves toward the sealing position.

[0080] In another aspect of the disclosed technology, the closure seal is formed from a heat- sealable material. The sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar and the heating element is configured to heat the heat- sealable material when the pressure plate is in the sealing position.

[0081] In another aspect of the disclosed technology, he bagging machine further includes a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.BRIEF DESCRIPTION OF THE DRAWINGS

[0082] The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

[0083] FIG. l is a top-right perspective-view of an embodiment of a bagging machine;

[0084] FIG. 2 is a partial front view of a web of envelopes for use in the bagging machine shown in FIG. 1 ;11175705203Docket No. 194313.18202

[0085] FIG. 3 is a magnified partial front view of an alternative embodiment the web of envelopes shown in FIG. 2;

[0086] FIG. 4 is top-front perspective-view of an envelope after being loaded, sealed and separated from web by the bagging machine shown in FIG. 1;

[0087] FIG. 5 is a top-left side-view of an alternative embodiment of a sealing mechanism of the bagging machine shown in FIG. 1;

[0088] FIG. 6 is magnified partial top-left side-view of the sealing mechanism shown in FIG.5, depicting a cam and follower when a transverse member of is in an intermediate position;

[0089] FIG. 7 is magnified partial top-left perspective-view of the sealing mechanism shown in FIG. 5, depicting the cam and follower when the transverse member is in a sealing position;

[0090] FIG. 8 is a top-front perspective view of an alternative embodiment of the sealing mechanism, an alternative embodiment of a gripper drive and grippers, an alternative embodiment of a suction cup, and the addition of web separators in the form of perforation breakers to the bagging machine shown in FIG. 1;

[0091] FIG. 9 is a partial right-rear perspective-view of the transverse member of the sealing mechanism shown in FIG. 8, depicting the perforation breaker and the gripper in a gripping position;

[0092] FIG. 10 is a partial top-left perspective-view of the peroration breaker shown in FIG. 9, in contact with the web;

[0093] FIG. 11 is a partial top-right side-view of the gripper drive shown in FIG. 8, depicting the grippers in the gripping position;

[0094] FIG. 12 is a partial top-left perspective-view of the gripper drive and sealing mechanism shown in FIG. 8, depicting the gripper partially open and a pressure plate of the sealing mechanism in an intermediate position;

[0095] FIG.13 is a partial top-left perspective-view of the gripper drive and sealing mechanism shown in FIG. 8, depicting the gripper in an open position and the pressure plate in the sealing position;

[0096] FIG.14 is a right-rear perspective-view of a break-away gripper coupling of gripper drive shown in FIG. 8;

[0097] FIG. 15 is a partial top-left perspective-view of an envelope-receiving space of the bagging machine shown in FIG. 1, depicting the grippers in a gripping position;12175705203Docket No. 194313.18202

[0098] FIG. 16 is a partial left-rear perspective view of the envelope-receiving space of the bagging machine shown in FIG. 1, depicting the grippers in an open position;

[0099] FIG. 17 is a magnified partial right-rear perspective view of the gripper and a suction cup of the bagging machine shown in FIG. 1 ; and

[0100] FIG. 18 is a diagrammatic view of various electrical and electronic components of embodiments of the bagging machine of the present disclosure.DETAILED DESCRIPTION

[0101] The inventive concepts are described with reference to the attached figures, wherein like reference numerals represent like parts and assemblies throughout the several views. Several aspects of the inventive concepts are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the inventive concepts. One having ordinary skill in the relevant art, however, will readily recognize that the inventive concepts can be practiced without one or more of the specific details or with other methods. In other instances, well- known structures or operation are not shown in detail to avoid obscuring the inventive concepts.

[0102] Packaging containers can include parcel packaging and other containers to package items. Packaging containers are configured to contain and hold an item, typically enclosing the item, during shipping or storage of the item. Parcel packaging is configured for shipping and / or storing products, such as for storage in warehouse or retail shelves and displays. Examples of parcel packaging include flexible shipping containers such as envelopes, which can have varying degrees of flexibility and typically are used to ship or mail small or relatively flat items or smaller items around which the walls of the envelope can conform. Flexible shipping containers such as envelopes can be padded or non-padded, can be made of materials such as paper and flexible cardboard, can be configured with or without sidewalls or gussets, and can include larger envelopes such as mailers. Examples of parcel packaging can include bags, such as paper or poly bags, which can have a self-sealing capability and are typically used to ship small to medium-sized items.

[0103] Referring to FIGS. 1-4, a bagging machine 18 facilitates the loading and sealing of preformed envelopes 52 (the bagging machine 18 is shown with certain elements removed for clarity). The envelopes 52 can be supplied to the bagging machine 18 as a continuous web 50 of 13175705203Docket No. 194313.18202 interconnected envelopes 52. The envelopes 52 are configured to contain and hold an item 103 to be packaged, allowing the item 103 to be mailed or shipped. Examples of envelopes 52 suitable for use as the envelopes 52 are disclosed, for example, in U.S. Application No. 18 / 920,740, filed October 18, 2024 and titled “BAGGING MACHINE WITH BREAKING ELEMENT AND FLATTENER ASSEMBLY,” the contents of which are incorporated by reference herein in their entirety.

[0104] The bagging machine 18 can be used with different types of flexible shipping containers such as envelopes having single ply walls or double-ply walls with, or without padding, insulating, and / or expandable material disposed between the plies of the walls. Alternative embodiments of the bagging machine 18 can be configured to receive and operate on an individual mailer or other individual shipping containers that are not connected to other similar mailers or other containers as in the continuous web 50.

[0105] The bagging machine 18 is configured to receive the web 50 of preformed envelopes 52; to form an opening 53 in each envelope 52 to provide access an envelope pocket 55 defined by opposing walls of the envelope 52 so that the item 103 to be packaged can be loaded into the envelope pocket 55; to seal the loaded envelope 52; and to separate the sealed envelope 52 from the web 50.

[0106] The web 50 can be formed from two sheets of paper or other material joined along the respective side edge portions thereof by longitudinally extending inter-wall seals 131 shown in FIG. 2. The overlapping sheets form a front wall 57 and an opposing rear wall 59 of each envelope 52 as shown in FIG. 2 and FIG. 1, respectively. In alternative embodiments, the web 50 can be formed from a single sheet of C-folded material, with the overlapping side edge portions of the sheet fixed to each other by a single inter- wall seal 131. The web 50 can be formed, for example, from regular kraft paper. The web 50 can be formed from other types of paper including, for example, extensible paper; and from materials other than paper including, for example, polyethylene or other types of plastic film, in the alternative.

[0107] Referring to FIG. 2, a plurality of transversely extending inter- wall seals 129 are formed between the sheets of the web 50. Each inter-wall seal 129 corresponds to a bottom of a respective envelope 52.

[0108] Regions of weakness can be formed in the web 50, between each of the individual envelopes 52. The regions of weakness can be located adjacent to, and downstream of each 14175705203Docket No. 194313.18202 inter- wall seal 129 on the web 50. (The downstream direction, as denoted by arrow 83 in FIG. 1, corresponds to the direction in which the web 50 is drawn through the bagging machine 18). The regions of weakness can be formed, for example, as a series of perforations 56 that extend transversely across the opposing front and rear walls 57, 59 of each envelope 52, between the inter-wall seals 131 of the web 50. The regions of weakness can be formed in other ways, such as a score line, in the alternative.

[0109] A cut 58 can be formed in the front wall 57 of each envelope 52. The cut 58 can be located adjacent to, and downstream of the series of perforations 56. The cut 58 can be spaced from the perforations 56 in the longitudinal direction of the web 50 by, for example, about 1 / 8 inch to about 3 / 16 inch. The cut 58 can be, for example, a kiss cut. The cut 58 permits the front wall 57 to be drawn away from the rear wall 59, to facilitate formation of the opening 53 in the envelope 52. In alternative embodiments, the cut 58 and the perforations 56 can be formed at the same longitudinal location along the envelope 52 (in which case the front wall 57 would not include the perforations 56).

[0110] A sealing material in the form of a closure-sealing element 54 is disposed on an inwardly facing surface of the front wall 57 adjacent to, and downstream of the cut 58. The closure-sealing element 54 can be disposed on an inwardly facing surface of the rear wall 59 instead of, or in addition to, the front wall 57. The closure-sealing element 54 can be a heat- activatable material in the form of a heat sealable material or a hot-melt adhesive that, upon being heated and pressed, forms a closure seal 61 that adheres the front wall 57 and the rear wall 59 of the envelope 52 to each other, thus maintaining the opening 53 in a closed state. The closure sealing element 54 can be a pressure-sensitive adhesive, a cold glue, a cohesive material, or other type of material in the alternative. The closure sealing element 54 is depicted as being spaced from the adjacent portions of the inter- wall seals 131. The closure sealing element 54 can adjoin the inter-wall seals 131 in alternative embodiments of the envelope 52.[0U1] Also, the closure seal 61, along with the and the inter-wall seals 129, 131, form a portion of a pocket border that completely circumscribes the envelope pocket 55 to retain the item 103 within the envelope pocket 55. Thus, prior to formation of the closure seal 61, the envelope pocket 55 is closed on three sides and open on the fourth side, with the fourth side being closed upon formation of the closure seal 61. The closure-sealing element 54 and the15175705203Docket No. 194313.18202 adjacent portions of the front wall 57 and the rear wall 59 define a sealing region on the envelope 52.

[0112] The heat-activatable material can be, for example, a heat sealable material. Heat sealable materials are pre-applied on the opposing surfaces of the substrates that are to be sealed together, typically as a coating applied to each surface. In some embodiments, the heat sealable material can be applied as a tape. The heat sealable material, after application, typically is solid in form.

[0113] An example of a heat sealable coating material is a weldable polymer provided in a thickness and with a composition such that upon applying sufficient heat to the coating and pressure to the substrates to pressure the opposing coatings against each other, the heat sealable material of the coatings melts and becomes welded together upon cooling, thereby forming a heat-seal of one substrate to the other. Typical heat sealable coatings are made of thermoplastics. The heat sealable material on the opposing surfaces of the substrates typically is identical. In some embodiments, non-identical materials can be used in the coating provided the materials are similar enough such that the materials can melt and combine to become welded together upon cooling.

[0114] In some embodiments, the heat-sealable material can include emulsion-based polymers and polymer dispersions. The one or more polymers can include one or more of vinyl acetate ethylene, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetate copolymers, polyvinyl alcohol copolymers, dextrin stabilized polyvinyl acetate, vinyl acetate copolymers, ethylene copolymers, vinylacrylic, styrene acrylic, acrylic, styrene butyl rubber, polyurethane, polyolefins, and biodegradable materials (e.g., cellulose and starch). For example, the heat-activatable material can be a polyvinyl alcohol (PVOH) coating. In some applications, the PVOH can be coated with polyethylene (PE) or polylactic acid (PLA) to prevent the PVOH from sticking, or from absorbing moisture which causes sticking.

[0115] In some embodiments, the heat-sealable material can include a polyolefin-based dispersion. The polyolefin dispersion can include polyethylene and / or polypropylene, thermoplastic polymers, polymeric stabilizing agents including at least one polar polymer, water, and / or other suitable polyolefin dispersions. A suitable polyolefin dispersion can include, for example, HYPOD™, available from Dow Chemical, or other suitable polyolefin dispersions.16175705203Docket No. 194313.18202

[0116] In some embodiments, the heat-sealable material can be water-based. The water-based heat-sealable material may include a water-based polymer. The use of a water-based heat- sealable material can enhance the recyclability of the packaging material, such as the web 50, since the water-based heat-sealable material can be dissolved and separated easily from the paper pulp during the recycling process.

[0117] Other types of heat-activatable materials, such as a hot-melt adhesive, can be used in lieu of a heat-sealable material adhesive in alternative embodiments. Hot-melt adhesives can have minimal, or no tackiness at room temperature, and do not need to be covered by a release layer before being sealed. Some hot-melt adhesives can be tacky at room temperature and need to be covered by a release layer before being sealed.

[0118] Hot-melt adhesives are thermoplastic polymers that are solid at room temperature, become molten when heated to an activation temperature above their softening point, and resolidify upon loss of heat at a temperature below a solidifying point, which may be the same as or different than the activation temperature, increasing in strength as they re-solidify. Most hot- melt adhesives, upon melting into a molten state and re-solidifying, do not undergo any chemical reaction such as cross-linking or removal of a carrier, e.g., evaporation of water. Thus, hot-melt adhesives typically can be reactivated, i.e., re-melted and re-solidified, after initially being applied to a substrate.

[0119] The hot-melt adhesive, after being applied to the surface to be bonded, can be in a low- tackiness state in which it has a low, or no tackiness in a lower range of temperatures. The hot- melt adhesive is applied hot, and cools and cures in the converting process. The hot-melt adhesive is reactivated by re-heating the hot-melt adhesive up to an activation temperature within a lower range of temperatures. This lower range of application temperatures in some embodiments, for example, is below about 140 °F. In other embodiments, for example, the lower range of temperatures is below about 120 °F, below about 125 °F, or below about 130 °F.

[0120] The re-heating of the hot-melt adhesive to the activation temperature causes the hot- melt adhesive to become molten. The subsequent cooling of the hot-melt adhesive, in combination with the application of pressure, causes the hot-melt adhesive to bond to the opposing surface, forming a seal between the surfaces.

[0121] As another example, the heat-activatable material can be an expandable material that expands when subjected to an elevated temperature. The expandable material, when expanded, 17175705203Docket No. 194313.18202 can provide an additional cushioning effect to the envelopes 52. For example, an expandable material can be provided by depositing an expansion element on to the surface of a fluid adhesive. When activated, the expansion element creates voids in the adhesive, producing a foamed adhesive. Microspheres fdled with a gas, such as nitrogen, for example, can be used as the expansion element. When heated, such as by subjecting the microspheres to microwave or other radiation, the expandable material expands and can provide a cushioning effect.

[0122] The above details of the envelope 52 are presented for illustrative purposes only. The bagging machine 18 can be used to load and seal other types of envelopes.

[0123] Referring to FIGS. 1, 8, and 13, the bagging machine 18 is configured to operate in repetitive cycles in which the bagging machine 18 opens an envelope 52 to allow an item 103 to be placed inside the envelope pocket 55, closes the envelope 52, seals the envelope 52, separates the envelope 52 form the web 50, and advances another envelope 52 into position to repeat the cycle.

[0124] A sealing cycle for an individual envelope 52 can begin after an operator (or a suitable automated device) has placed an item 103 in the pocket 55 of the envelope 52 by way of the envelope opening 53. The envelope 52 being loaded is located at the downstream end of the web 50 and is held open by grippers 105 of the bagging machine 18. The grippers 105 are mounted on a transverse member 22 of a sealing mechanism 20 of the bagging machine 18 and are rotatable in relation to the transverse member 22 between an open position and a gripping position. (As discussed below, the bagging machine 18 can be equipped with an alternative embodiment of the grippers 105 in the form of grippers 202, shown in FIG. 1. As also discussed below, the bagging machine 18 can be equipped with alternative embodiments of the sealing mechanism 20 in the form of a sealing mechanism 250 and a sealing mechanism 300, shown in FIGS. 1 and 8, respectively.)

[0125] The envelope opening 53 had been formed at the conclusion of the previous sealing cycle by a suction cup 120 (discussed below), the grippers 105, and the transverse member 22, which had pulled the front wall 57 of the envelope 52 away from the rear wall 59 with the grippers 105 disposed in their gripping positions. The grippers 105 are rotated between their open and gripping positions by a camming mechanism described in detail below. The grippers 105 can be rotated by electric, pneumatic, hydraulic, or other types of actuators in alternative embodiments.18175705203Docket No. 194313.18202

[0126] At this point in the cycle, the envelope 52 to be loaded is located within an envelopereceiving space 21. The envelope-receiving space 21 is defined between a pressure plate 23 of the transverse member 22 and a sealing bar 24 of the sealing mechanism 20 when the pressure plate 23 is spaced apart from the sealing bar 24. Alternatively, a single envelope 52, i.e., an envelope not part of a web 50, can be positioned in the envelope-receiving space 21 for loading and sealing as discussed below.

[0127] After the operator has placed the item 103 in the envelope pocket 55, the operator can commence the sealing cycle by pressing or otherwise activating an input device in the form of a pushbutton 89. In alternative embodiments, a foot pedal, touchscreen, or other type of input device can be used in lieu of, or in addition to the pushbutton 89. The bagging machine 18 includes two pushbuttons 89, as shown in FIG 1. The bagging machine 18 is configured so that the sealing cycle commences when one of the pushbuttons 89 is activated. Alternatively, the bagging machine 18 can be configured so that the sealing cycle will not commence until both pushbuttons 89 are activated on a simultaneous basis. Requiring both pushbuttons 89 to be activated simultaneously is a safety measure that helps ensure that both hands of the operator are positioned outside the envelope-receiving space 21 prior to commencing the sealing cycle.

[0128] The pushbutton 89, activation, sends a signal to a controller 87 of the bagging machine 18. In response, the controller 87 activates a low-force actuator 28 of the bagging machine 18. The low-force actuator 28 moves the transverse member 22 and the grippers 105 (which continue to grasp the front wall 57 in their gripping position) in a rearward direction, toward the rear wall 59 of the envelope 52.

[0129] The rearward movement of the transverse member 22 eventually causes the pressure plate 23 to push the front wall 57 of the envelope 52 into the rear wall 59 so that the closuresealing element 54 becomes sandwiched between the front wall 57 and the rear wall 59, with the sealing bar 24 contacting the outward-facing surface of the rear wall 59 and resisting movement of the rear wall 59 in the rearward direction. As the pressure plate 23 approached the sealing bar 24 in the rearward direction, the grippers 105 rotated from the gripping position to the open position, which caused the grippers 105 to move out of the pocket opening 53 and out of contact with the front wall 57. Also, the controller 87 activated a high-force actuator 30 as the pressure plate 23 approached the sealing bar 24, which caused the high-force actuator 30 to exert a higher force on the transverse member 22 in the rearward direction than the low-force actuator 28. In 19175705203Docket No. 194313.18202 alternative embodiments, the transverse member 22 can be actuated by a single actuator in lieu of the low-force actuator 28 and the high-force actuator 30 and / or can be actuated by a substantially constant actuation force instead of a low force and a high force.

[0130] The bagging machine 18 is equipped with a foam pad 91 that is mounted on and moves with the transverse member 22 to compress or squeeze the envelope 52 and thereby drive air out of the envelope pocket 55 as the transverse member, including the attached the pressure plate 23, moves rearward to close the envelope opening 53 in preparation for the sealing process. Alternative embodiments of the bagging machine 18 can be equipped without the foam pad 91.

[0131] The sealing mechanism 20 also includes a heating element 26 associated with the sealing bar 24. The heating element 26 is configured to heat the closure-sealing element 54 through the rear wall 59 of the envelope 52 as the rear wall 59 is pushed into the sealing bar 24 by the pressure plate 23. The combination of heat and pressure applied by the pressure plate 23, the sealing bar 24, and the heating element 26 activate the closure-sealing element 54 to form the closure seal 61 between the front wall 57 and the rear wall 59. In alternative embodiments of the bagging machine 18 that are configured to process webs 50 that do not incorporate a heat- activatable closure-sealing element 54, the bagging machine 18 can be configured without the heating element 26.

[0132] Alternative embodiments of the bagging machine can be equipped with seal flatteners as disclosed in U.S. Application No. 18 / 920,740 referred to above, to smooth the closure-sealing element 54 prior to sealing.

[0133] After a predetermined dwell time sufficient to allow formation of the closure seal 61, the controller 87 activates a web advancement mechanism 86 of the bagging machine 18. The web advancement mechanism 86 pulls the web 50 in the upstream direction while the pressure plate 23 and the sealing bar 24 continue to grip the web 50, causing the perforations 56 between the newly-sealed envelope 52 and the adjacent envelope 52 to break, thereby separating the envelope 52 from the web 50.

[0134] In alternative embodiments, the envelope 52 can be separated from the remainder of the web 50 using other techniques, such as one or more cutting edges configured to form a laceration along the region of weakness, the focused application of heat applied along the region of weakness, a heated wire, etc. In other alternative embodiments, the envelope 52 can be20175705203Docket No. 194313.18202 separated from the remainder of the web 50 on a manual basis. FIG. 4 depicts the separated envelope 52 with the item 103 sealed therein.

[0135] Once the perforations 56 have been broken, the controller 87 deactivates the web advancement mechanism 86 and the high-force actuator 30, and activates the low-force actuator 28 to cause the transverse member 22 (including the pressure plate 23) and the grippers 105 (still in their open position) to move in the forward direction, away from the sealing bar 24. The forward movement of the pressure plate 23 allows the envelope 52 to drop from the sealing mechanism 20. The controller 87 then activates the web advancement mechanism 86 to cause the web 50 to advance in the downstream direction until the closure-sealing element 54 of the next envelope 52 on the web 50 aligns with the pressure plate 23, the sealing bar 24, and the heating element 26.

[0136] Once the web 50 has advanced, the controller 87 activates the low-force actuator 28 to move the transverse member 22 (including the pressure plate 23) and the attached grippers 105 (still in their open position) in the rearward direction, toward the newly positioned envelope 52.

[0137] The suction cup 120 mounted on the transverse member 22 contacts the front wall 57 as the transverse member 22 approaches the envelope 52. The suction cup 120 is in fluid communication with a vacuum source 77. At this point, the controller 87 activates the low-force actuator 28 to begin moving the transverse member 22 (including the pressure plate 23) and the grippers 105 in the forward direction, away from the sealing bar 24, causing the front wall 57 to be drawn away from the rear wall 59 by the suction cup 120. Alternative embodiments of the bagging machine 18 can include an air blower configured to direct air onto the front wall 57 to aid in pre-forming the opening 53.

[0138] As the transverse member 22 and the grippers 105 continue to be drawn in the forward direction, the grippers 105 are rotated to their gripping position at which the grippers 105 contact the inwardly-facing upper edge portion of the front wall 57 of the envelope 52. Further movement of the pressure plate 23 in the forward direction causes the front wall 57 to be drawn further away from the rear wall 59 by the grippers 105 and the suction cup 120, defining the envelope pocket 55 and the envelope opening 53. Once the pressure plate 23 reaches its open, or forward-most position, the controller 87 deactivates the low-force actuator 28. At this point, the sealing cycle has been completed and the newly-advanced envelope 52 is ready to be loaded and sealed during the next sealing cycle as discussed above.21175705203Docket No. 194313.18202

[0139] The bagging machine 18 can include a web separator in the form of perforation breakers 94, described in detail below, that tear the perforations 56 located at and near the side edges of the web 50 as the pressure plate 23 is moved toward its sealing position immediately before the front wall 57 is drawn rearward to define the envelope pocket 55 and the envelope opening 53. (The bagging machine 18 as depicted in FIG. 1 does not include perforation breakers 94 or any other type of web separator.) The torn perforations 56 allow the side (outward) portions of the rear wall 59 of the envelope 52 to move in the forward direction as the opening 53 is being formed, which can help to prevent the inter-wall seals 131 along the sides of the envelope 52 from being subject to excessive stress. The noted movement of the outward portions of the rear wall 59 also can help to increase the overall size of the opening 53. Alternative embodiments of the bagging machine 18 can be configured with a web separator having a configuration other than the perforation breakers 94. Other alternative embodiments can be configured without any web separator.

[0140] The bagging machine 18 includes a label maker 65 communicatively coupled to the controller 87 and configured to print a label 79, such as an address label, and to place the label 79 on an outer surface of the envelope 52. Alternative embodiments of the bagging machine 18 can be configured without the label maker 65.

[0141] The bagging machine 18 can include an expansion device 63, shown diagrammatically in FIG. 18. The expansion device 63 is configured to apply expanding conditions to the web 50 or the envelope 52 to expand an expansion material incorporated into the web 50 (when the web 50 is so configured). The expanding conditions can include an expansion temperature that causes the expandable material to expand from an expandable configuration to an expanded configuration. The expansion material, when in the expanded configuration, can add padding or insulation to the envelope 52. Alternative embodiments of the bagging machine 18 can be configured without the expansion device 63.

[0142] A more detailed description of various components of the bagging machine 18 follows.

[0143] The web advancement mechanism 86 is shown in part in FIG. 8, and is configured to advance the web 50 in the downstream direction. As noted above, the web advancement mechanism 86 also can pull the web 50 in the upstream direction to break the perforations 56 after the envelope 52 has been sealed. The web advancement mechanism 86 includes frames 93, nip rollers 82, a motor 47 that is communicatively coupled to the controller 87, an input drive 84, 22175705203Docket No. 194313.18202 and a transmission 95. The nip rollers 82 are rotatably mounted along parallel axes to the frames 93, and are oriented transverse to the path of the web 50. The frames 93 further position the nip rollers 82 such that the web 50 can pass between the nip rollers 82.

[0144] The input drive 84 includes a drive belt 97 and a drive pulley 99. The transmission 95 includes a geartrain with gears 101 configured to cause each nip roller 82 to rotate in opposite directions. When the motor 47 is activated by the controller 87, power is transmitted to the input drive 84 through the drive belt 97 and to the drive pulley 99 to drive one of the nip rollers 82 in rotation. The transmission 95 causes both nip rollers 82 to rotate in opposite directions. The cooperative rotating motion of the nip rollers 82 causes the web 50 to be advanced in the downstream direction. The controller 87 also can activate the motor 47 in reverse. When the motor 47 is activated in reverse, the forgoing process proceeds similarly, with the cooperative rotating motion of the nip rollers 82 causing the web 50 to move in the upstream direction.

[0145] Alternative embodiments of the bagging machine 18 can be configured with other types of drive mechanisms to rotate the nip rollers 82. For example, the each nip roller 82 can be directly driven by a respective motor 47 in alternative embodiments. Additionally or alternatively, the input drive 84 and the transmission 95 can be combined. In other alternative embodiments, one of the nip rollers 82 can be driven in rotation with the other nip roller 82 can freewheel in response to the driven nip roller 82. In other alternative embodiments, the web advancement mechanism 86 can be configured with wheels, paddles, teeth, or other suitable devices in lieu of the nip rollers 82.

[0146] The controller 87 can include a central processing unit (CPU), a system bus, a memory connected to and accessible by other portions of controller through the system bus, a system interface, and hardware entities connected to system bus. The controller 87 can be connected to the input device, e.g., the pushbutton 89, and to one or more output devices via a wired (serial or Wired LAN) or wireless connection (e.g., a Bluetooth® connection or WiFi connection). The output devices can include, for example, a touchscreen display 85 shown in FIG. 1, one or more speakers, one or more alarms and / or warning lights, etc. (the display 85 also can act as a user interface that facilitates user inputs to the bagging machine 18). The system interface is configured to facilitate wired or wireless communications to and from external devices, e.g., network nodes such as access points, etc.23175705203Docket No. 194313.18202

[0147] At least some of the hardware entities of the controller 87 perform actions involving access to and use of memory, which can be a random access memory (RAM), a disk driver, a compact disc read only memory (CD-ROM), or remote “cloud” based processing. The hardware entities can include a disk drive unit that includes a computer-readable storage medium on which is stored one or more sets of instructions, e.g., software code, configured to implement one or more of the methodologies, procedures, or functions described herein. The instructions also can reside, completely or at least partially, within the memory and / or within the CPU during execution thereof by the controller 87. The memory and the CPU also can constitute machine- readable media. The term “machine-readable media,” as used herein, refers to a single medium or multiple media (e.g., a centralized or distributed database, and / or associated caches and servers) that store the one or more sets of the instructions. The term “machine-readable media,” as used herein, also refers to any medium that is capable of storing, encoding or carrying a set of the instructions for execution by the controller 87 and that cause the controller to perform any one or more of the methodologies of the present disclosure.

[0148] The above details of the controller 87 are presented for illustrative purposes only. The controller 87 can have other configurations in alternative embodiments.

[0149] As discussed above, the sealing mechanism 20 heats and applies pressure to the closure-sealing element 54 after the item 103 to be packaged has been loaded into the envelope pocket 55, to form the closure seal 61 that seals the opening 53 of the envelope 52. Referring to FIGS. 5 and 9, the sealing mechanism 20 includes the transverse member 22, which includes the pressure plate 23. The transverse member 22 also includes a friction material 35 fixed to the pressure plate 23. The sealing mechanism 20 further includes the sealing bar 24, and the heating element 26 fixed to the sealing bar 24. In alternative embodiments, the heating element 26 can be fixed to the pressure plate 23, and the friction material 35 can be fixed to the sealing bar 24. Other alternative embodiments can be configured without the friction material 35.

[0150] In alternative embodiments, the sealing bar 24 can include a receptacle configured to receive the heating element 26. The receptable is positioned within the sealing bar 24, parallel to a heating surface of the sealing bar 24. The receptacle positions the heating element 26 at a distance from a heating surface of the sealing bar 24. The distance from the heating surface can be adjusted to vary heat transfer characteristics. For example, locating the receptacle close to the heating surface positions the heating element 26 close to the heating surface, which can cause 24175705203Docket No. 194313.18202 heat to be transferred to the heating surface more quickly than if the receptable were positioned at a further distance from the heating surface. The heating element can be configured as a cartridge that fits within the receptable. In some embodiments, more than one receptable and heating element 26 can be provided. Additionally, or alternatively, the receptable and heating element 26 can be oriented non-parallel to the heating surface. In other alternative embodiments, the pressure plate 23 can include the receptacle configured to receive the heating element 26, the details of which are similar to those discussed above in relation to the sealing bar 24. In some embodiments, the heating surface of the sealing bar 24 can include a low friction material or coating, such as a TEFLON hard coating.

[0151] The pressure plate 23 can translate between the open position referred to above, an intermediate position, and a closed or sealing position. The direction in which pressure plate 23 translates when moving toward its open position is referred to herein as the forward direction, and is denoted by the arrow 42 in FIG. 5. The direction in which pressure plate 23 translates when moving toward its sealing position is referred to herein as the rearward direction.

[0152] The envelope-receiving space 21 is defined between the sealing bar 24 and the pressure plate 23 when the pressure plate 23 is spaced from the sealing bar 24, e.g., when pressure plate 23 is in its open position. FIG. 8 depicts the pressure plate 23 in a maximal open position. In this position, the pressure plate 23 is spaced from the sealing bar 24 the greatest possible distance as limited by the physical structure of the sealing mechanism 20. The maximal open position of the pressure plate 23 defines the maximum size of the envelope-receiving space 21.

[0153] The open position of the pressure plate 23 can be adjusted to be smaller than the maximal open position to suit different sizes of the web 50. The open position can be adjusted, for example, by programming limits into the controller 87, or through the use of mechanical stops. In some embodiments, the maximal open position is the same as the open position.

[0154] FIG. 1 depicts the pressure plate 23 in an open position at which the pressure plate 23 is spaced from the sealing bar 24 by a distance sufficient to allow the web 50 to be advanced through the envelope-receiving space 21, and to allow the item 103 to be loaded into the envelope 52 via the envelope opening 53. FIG. 5 shows the pressure plate 23 in the intermediate position. FIG. 13 shows the pressure plate 23 in the sealing position, at which the pressure plate 23 is pressing the web 50 against the sealing bar 24.25175705203Docket No. 194313.18202

[0155] The web 50 can be advanced between the pressure plate 23 and the sealing bar 24 when the pressure plate 23 has advanced away from the sealing position, so that the closure-sealing element 54 on the envelope 52 located at the downstream end of the web 50 aligns with the pressure plate 23 and the sealing bar 24. As discussed above, the pressure plate 23 is configured to exert pressure on the closure-sealing element 54 when the pressure plate 23 moves to its sealing position. The combination of heat and pressure exerted on the closure-sealing element 54 by the heating element 26, the pressure plate 23, and the sealing bar 24 forms the closure seal 61 that seals the opening 53 of the envelope 52.

[0156] Referring to FIG. 5, the sealing mechanism 20 also includes biasing members in the form of springs 25; guide pins 27; and guide blocks 29. The guide blocks 29 are fixed to a frame 41 of the bagging machine 18. A first end of each guide pin 27 is fixed to the sealing bar 24. Each guide pin 27 extends through a corresponding one of the guide blocks 29 by way of a bore or passage formed in the guide block 29. The sealing bar 24 and the attached heating element 26 thus are suspended from the guide blocks 29 by way of the guide pins 27, and can undergo a limited amount of linear movement in relation to the guide blocks 29 and the frame 41. Each guide pin 27 is restrained from moving out of its corresponding passage in the forward direction by a restraint, such as a washer or other suitable device, secured to a second end of the guide pin 27.

[0157] Each spring 25 is positioned around a corresponding one of the guide pins 27, between the corresponding guide block 29 and the sealing bar 24. The springs 25 thus bias the sealing bar 24 and attached heating element 26 toward the forward direction. As the pressure plate 23 approaches its intermediate position, the pressure plate 23 begins to push the sealing bar 24 in the rearward direction, which in turn causes the springs 25 to deflect and the guide pins 27 to move through their corresponding guide blocks 29. The springs 25 reach their maximum deflection as the pressure plate 23 reaches its sealing position. The springs 25 thus exert a force on the sealing bar 24 in the forward direction, thereby helping to establish a sealing pressure between the sealing bar 24 and the pressure plate 23.

[0158] In alternative embodiments, the sealing bar 24 can be mounted in a manner that does not facilitate relative movement between the sealing bar 24 and the frame 41.

[0159] Referring again to FIG. 5, the bagging machine 18 further comprises an actuator mechanism 19, or pressure-plate drive, configured to move the pressure plate 23 between its 26175705203Docket No. 194313.18202 open, intermediate, and sealing positions. The actuator mechanism 19 includes a pressure-plate linkage 32, and a drive mechanism that includes the low-force actuator 28 and the high-force actuator 30. As discussed below, the low-force actuator 28 is configured to move the pressure plate 23 between its open and intermediate positions, and the high-force actuator 30 is configured to move the pressure plate 23 between its intermediate and sealing positions, via the pressure-plate linkage 32.

[0160] Also, the low-force actuator 28 and the high-force actuator 30 are configured to apply different degrees of force to the pressure plate 23. Specifically, the low-force actuator 28 is configured to drive the pressure-plate linkage 32 between the open and intermediate positions via a first force. The high-force actuator 30, which is disengaged from the pressure-plate linkage 32 at the open position of the pressure plate 23 and is engaged with the pressure-plate linkage 32 between the intermediate and sealing positions of the pressure plate 23, is configured to drive the pressure-plate linkage 32 to move the pressure plate 23 from the intermediate position to the sealing position via a second force that is greater than the first force. For example, the second force can be substantially greater, e.g. several times larger, than the first force.

[0161] Referring to FIG. 5, the transverse member 22 (including the pressure plate 23) is carried by the pressure-plate linkage 32. The pressure-plate linkage 32 includes two connecting members in the form of, for example, rods 34. The pressure-plate linkage 32 also includes two bushings 40; two tracks 36; two sliding carriages 38; two mounts 43; and two rack gears 60.

[0162] Each rack gear 60 is fixed to a corresponding one of the sliding carriages 38. The tracks 36 are fixed to the frame 41 of the bagging machine 18, proximate opposite sides of the bagging machine 18 as can be seen in FIG. 5. Each sliding carriage 38 is configured to engage a corresponding one of the tracks 36, and to translate linearly on the track 36 in the forward and rearward directions.

[0163] The mounts 43 are fixed to the frame 41, on opposite sides of the transverse member 22 as shown in FIG. 5. Each bushing 40 is mounted on a corresponding one of the mounts 43.

[0164] A rearward end of each rod 34 is secured to a corresponding one of the sliding carriages 38. Each rod 34 extends through a corresponding one of the bushings 40, and a forward end of each rod 34 is connected to a corresponding end portion of the pressure plate 23. The rods 34 thus translate reciprocally with the sliding carriages 38, with the bushings 40 supporting and27175705203Docket No. 194313.18202 guiding the forward ends of the rods 34. The reciprocal movement of the rods 34 causes a corresponding movement of the pressure plate 23 between its open and sealing positions.

[0165] The low-force actuator 28 includes a transverse driveshaft 46, three mounts 39, and an actuator member in the form of the motor 62. The mounts 39 are fixed to the frame 41, with one centrally located and two positioned on opposite sides of the driveshaft 46 as shown in FIG. 5. The motor 62 is connected to the transverse driveshaft 46, and is configured to rotate the transverse driveshaft 46 in both the clockwise and counterclockwise directions. The motor 62 can be, for example, an electric motor. Other types of actuator members can be used in lieu of the motor 62 in alternative embodiments. For example, the actuator member can be configured as a rotary drive, a hydraulic or pneumatic piston actuator, etc. The motor 62 is communicatively coupled the controller 87.

[0166] The low-force actuator 28 also includes two pinion gears 48. The pinion gears 48 are fixed to opposite ends of the transverse driveshaft 46, so that the pinion gears 48 rotate with the transverse driveshaft 46. Each pinion gear 48 engages a corresponding one of the rack gears 60, so that the rotational movement of the transverse driveshaft 46 and the pinion gears 48 causes the rack gears 60, and the attached rods 34 to move linearly in the above-noted manner upon activation of the motor 62, which in turn causes the pressure plate 23 to move between its open and intermediate positions.

[0167] The transverse driveshaft 46, mounts 39, pinion gears 48, rack gears 60, sliding carriages 38, rods 34, and bushings 40 constitute a low-torque transmission. The low-torque transmission is connected to and actuated by the actuator member, in this example the motor 62, to drive the pressure-plate linkage 32 between the open and intermediate positions. Other types of transmissions comprising components that differ from those of the low-torque transmission can be used in alternative embodiments. For example, alternative embodiments of the low- torque transmission can include a gear train, pulleys, cables, belts, hydraulic or pneumatic piston actuators, etc.

[0168] The high-force actuator 30 includes an actuator member in the form of the motor 64; a transverse driveshaft 70; three mounts 49, two spiral cams 68; and two cam followers 66. The mounts 49 are fixed to the frame 41, with one centrally located and two positioned on opposite sides of the driveshaft 70 as shown in FIG. 5. The motor 64 is connected to the transverse driveshaft 70, and is configured to rotate the transverse driveshaft 70 in both the clockwise and 28175705203Docket No. 194313.18202 counterclockwise directions. The motor 64 can be, for example, an electric motor. Other types of actuator members can be used in lieu of the motor 64 in alternative embodiments. For example, the actuator member can be configured as a rotary drive, a hydraulic or pneumatic piston actuator, etc.

[0169] The spiral cams 68 are fixed to opposite ends of the transverse driveshaft 70, so that the spiral cams 68 rotate with the transverse driveshaft 70. As shown in FIGS. 6 and 7, each spiral cam 68 is affixed to the transverse driveshaft 70 with an indexing key 76, to index the spiral cam 68 to the transverse driveshaft 70 and to prevent or minimize relative rotation between the spiral cam 68 and the transverse driveshaft 70. The spiral cams 68 each have a recess 71 formed therein. The recess 71 is defined, in part, by first and second camming surfaces 72, 73 and an end surface 74 of the spiral cam 68. The first and second camming surfaces 72, 73 each have a spiral configuration, as can be seen in FIGS. 5 and 6.

[0170] The cam followers 66 each include a body 67, and a cylindrical projection 69 that extends from the body 67, as shown in FIGS. 6 and 7. Referring to FIG. 5, the body 67 of each cam follower 66 is fixed to a corresponding one of the sliding carriages 38 of the pressure-plate linkage 32, and the projection 69 is configured to engage a corresponding one of the spiral cams 68 on a selective basis. In particular, the projection 69 is configured to enter the recess 71 of the spiral cam 68 by way of an entry 78 to the recess, and to contact the first and second camming surfaces 72, 73 of the spiral cam 68 as discussed below. The high-force actuator 30 is decoupled from the pressure-plate linkage 32 when the cam followers 66 are disengaged from the spiral cams 68. The high-force actuator 30 thus cannot actuate the pressure-plate linkage 32 and the attached pressure plate 23 under such a condition.

[0171] Referring to FIG. 6, the projections 69 of the cam followers 66 become disposed in the recesses 71 of the spiral cams 68 when the pressure plate 23 reaches its intermediate position. In some applications, the motor 62 of the low-force actuator 28 can be configured as a stepper motor, to provide the requisite precision in the movement of cam followers 66 needed to position the projections 69 within the spiral cams 68.

[0172] The transverse driveshaft 70, spiral cams 68, and cam followers 66 constitute a high- torque transmission. The high-torque transmission is connected to and actuated by the actuator member, in this example the motor 64, to cause the pressure-plate linkage 32 to drive the pressure plate 23 between the intermediate and sealing positions. Other types of transmissions 29175705203Docket No. 194313.18202 comprising components that differ from those of the high-torque transmission shown can be used in alternative embodiments. For example, alternative embodiments of the high-torque transmission can include a gear train, pulleys, cables, belts, hydraulic or pneumatic piston actuators, etc.

[0173] The high-force actuator 30 acts as a torque-multiplying transmission that converts a relatively large angular movement of the transverse driveshaft 70 and the spiral cams 68 to a small linear movement of the cam followers 66, the sliding carriages 38, the rods 34, and the sealing bar 24.

[0174] As noted above, the projections 69 of the cam followers 66 enter the recesses 71 of their corresponding spiral cams 68 by way of the entries 78 as the sealing bar 24 reaches its intermediate position. Each cam follower 66 is configured so that its projection 69 contacts the first camming surface 72 of the corresponding spiral cam 68 as the pressure plate 23 reaches its intermediate position.

[0175] At this point, i.e., as the pressure plate 23 reaches its intermediate position, the motor is activated. The motor 64 imparts a clockwise rotation (from the perspective of FIG. 5) to the spiral cams 68 by way of the transverse driveshaft 70).

[0176] As can be seen in FIG. 7, due to the spiral configuration of the first and second camming surfaces 72, 73, the respective radii of the first and second camming surfaces 72, 73 decrease along the length of the recess 71 as the recess 71 extends away from the entry 78. The clockwise rotation of the spiral cams 68 thus causes the projections 69 of the cam followers 66 to be drawn along the second camming surface 73, with the decreasing radius of the second camming surfaces 73 causing the second camming surfaces 73 to exert a progressively increasing force on the corresponding projections 69, in the forward direction. This force is transmitted to the sealing bar 24 by way of the respective bodies 67 of the cam followers 66, the sliding carriages 38, and the rods 34, and causes further movement of the pressure plate 23 in the forward direction. The force also results in further compression of the springs 25. The pressure plate 23 thus exerts a progressively increasing force on the closure-sealing element 54 located on the portion of the web 50 positioned between the pressure plate 23 and the sealing bar 24. The motor 62 of the low-force actuator 28, which remains deactivated at this point, is free to rotate so as not to interfere with the transmission of the linear force to the pressure plate 23.30175705203Docket No. 194313.18202

[0177] The motor 64 of the high-force actuator 30 continues to rotate the spiral cams 68 until the projections 69 reach the ends of their corresponding recesses 71, i.e., until the projections 69 reach the end surfaces 74 of their corresponding recesses 71. The linear distance that the pressure-plate linkage 32 travels as the spiral cams 68 rotate through their range of angular displacement is relatively small. The spiral cams 68, however, impart an elevated mechanical advantage over this distance, progressively increasing the pressure exerted by the pressure plate 23 on the sealing bar 24, and on the closure-sealing element 54 located on the portion of the web 50 positioned between the pressure plate 23 and the sealing bar 24. This elevated pressure can increase the strength of the closure seal 61 formed from the closure-sealing element 54, and / or can reduce the dwell time and / or the temperature needed to form the closure seal 61.

[0178] As shown in FIG. 5, the high-force actuator 30 is positioned in a rearward position relative to low-force actuator 28. In alternative embodiments, the high-force actuator 30 can be positioned in a forward position relative to the low force actuator 28. For example, referring to FIG. 5, the relative positions of the low-force actuator 28 and high-force actuator 30 on the frame 41 can be exchanged, thereby positioning the high-force actuator 30 in the forward position relative to the low -force actuator 28. The cam followers 66 can be relocated from the rear edge of the carriage 38 to the front edge of the carriage 38. The remaining details of this alternative arrangement of the sealing mechanism 20 are substantially identical to those discussed above in relation to FIGS. 5-7.

[0179] FIG. 8 depicts an alternative embodiment of the sealing mechanism 20 in the form of the sealing mechanism 300. The above-noted descriptions of the sealing mechanism 20 apply equally to the respective sealing mechanism 300 unless otherwise noted. Components of the sealing mechanism 300 that are identical or substantially identical to those of the sealing mechanism 20 are identified using the same reference numbers.

[0180] The sealing mechanism 300 includes the transverse member 22 (including the pressure plate 23) and is carried by the pressure-plate linkage 32. The pressure-plate linkage 32 includes two connecting members in the form of, for example, rods 334. The rods 334 are substantially identical to the rods 34 with the exception that the rods 334 each have an integral rack gear 360.

[0181] The pressure-plate linkage 32 includes two bushings 40; two tracks 36; two sliding carriages 38; and two mounts 43. A rearward end of each rod 334 is secured to a corresponding one of the sliding carriages 38. Each rod 334 extends through a corresponding one of the 31175705203Docket No. 194313.18202 bushings 40, and a forward end of each rod 334 is connected to a corresponding end portion of the pressure plate 23. The rods 334 thus translate reciprocally with the sliding carriages 38, with the bushings 40 supporting and guiding the forward ends of the rods 334. The reciprocal movement of the rods 334 causes a corresponding movement of the pressure plate 23 between its open and sealing positions.

[0182] The low-force actuator 28 includes a transverse driveshaft 46, and an actuator member in the form of the motor 62. The motor 62 is connected to the transverse driveshaft 46, and is configured to rotate the transverse driveshaft 46 in both the clockwise and counterclockwise directions. The motor 62 can be, for example, an electric motor. Other types of actuator members can be used in lieu of the motor 62 in alternative embodiments. For example, the actuator member can be configured as a rotary drive, a hydraulic or pneumatic piston actuator, etc. The motor 62 is communicatively coupled the controller 87.

[0183] The low-force actuator 28 also includes two pinion gears 48. The pinion gears 48 are fixed to opposite ends of the transverse driveshaft 46, so that the pinion gears 48 rotate with the transverse driveshaft 46. Each pinion gear 48 engages a corresponding one of the integral rack gears 360 of the rod 334, so that the rotational movement of the transverse driveshaft 46 and the pinion gears 48 causes the rack gears 360, integral to the rods 334, to move linearly in the abovenoted manner upon activation of the motor 62, which in turn causes the pressure plate 23 to move between its open and intermediate positions.

[0184] In alternative embodiments, the low-force actuator 28 can include motors 62 and pinion gears 48 that engage the each of rack gears 360 directly. One of the motors 62 and one of the pinion gears 48 can be provided and positioned at each of the rack gears 360. The controller 87 can be configured to coordinate and synchronize operation of the motors 62 to extend and retract the rods 334.

[0185] Referring to FIG. 8, the sealing mechanism 300 also includes a sealing guard 331 mounted on the sealing bar 24. The sealing guard 331 is configured to translate in relation to the sealing bar 24 and the heating element 26 between an extended position shown in FIG. 8, and a retracted position (not shown). The sealing guard 331 partially encloses and covers the heating element 26 and the heated surface of the sealing bar 24 when the sealing guard 331 is in the first position, to help prevent the operator or other individuals from inadvertently contacting the heating element 26 or the heated surface of the sealing bar 24. The sealing guard 331 is biased 32175705203Docket No. 194313.18202 toward its extended position by biasing members in the form of springs (not shown) or other suitable devices.

[0186] The sealing guard 331 has a sealing guard slot 333 configured to provide access to the web 50, the heating element 26, and the heated surface of the sealing bar 24. The sealing guard 331 is configured to move from its extended position to its retracted position as the pressure plate 23 pushes the sealing guard 431 in the rearward direction as the pressure plate 23 approaches its intermediate position. The retraction of the sealing guard 331 permits the pressure plate 23 to contact the sealing area of the web 50, which is exposed by way of the sealing guard slot 333, and to push the sealing area into contact with the heating element 26 and the heated surface of the sealing bar 24. The springs of the sealing guard 331 are weaker than the springs 25 of the sealing bar 24, so that the sealing guard 331 begins retracting upon coming into contact with the advancing pressure plate 23.

[0187] Other aspects of the sealing mechanism 300 and its operation are similar to those discussed above in relation to the sealing mechanism 20.

[0188] FIGS. 1 and 15 depict an alternative embodiment of the sealing mechanism 20 in the form of the sealing mechanism 250. The above-noted descriptions of the sealing mechanism 20 apply equally to the respective sealing mechanism 250 unless otherwise noted. Components of the sealing mechanism 250 that are identical or substantially identical to those of the sealing mechanism 20 are identified using the same reference numbers.

[0189] The sealing mechanism 250 includes a transverse member 222 that includes the pressure plate 23, and is carried by the pressure-plate linkage 32. The pressure-plate linkage 32 includes two connecting members 234. The transverse member 222 is substantially identical to the transverse member 22 except that the transverse member 222 includes two slots 228 that are configured to slidably mount accessories. In alternative embodiments, the transverse member 222 can include less, or more than two slots 228.

[0190] The connecting members 234 are substantially identical to the rods 34 except the connecting members 234 have a flat surface 235. The flat surface 235 can be used to removably mount components. In some embodiments, the flat surface 235 can include a wear material and / or coating. The wear material can be removably mounted to the flat surface 235.Additionally, or in the alternative, the wear material can be sacrificial and can be configured to33175705203Docket No. 194313.18202 be replaced when depleted. Tn some embodiments, the wear material and / or coating can be configured to reduce friction.

[0191] Other aspects of the sealing mechanism 250 and its operation are similar to those discussed above in relation to the sealing mechanism 20.

[0192] Once the pressure plate 23 has exerted maximal pressure on the sealing bar 24 and the web 50 for the predetermined dwell time, the loaded and sealed downstream envelope 52 can be separated from the web 50 in the manner described in detail below. More specifically, the controller 87 can cause the web advancement mechanism 86 to activate to rotate the nip rollers 82 in a direction opposite the direction needed to advance the web 50 in the downstream direction. The reverse rotation of the nip rollers 82 results in an upstream force being exerted on the web 50 upstream of the perforations 56 between the downstream envelope 52 and the adjacent envelope 52. This force, in combination with the restraint of the downstream envelope 52 by the sealing bar 24 and the pressure plate 23, which continue to grasp downstream envelope 52, cause the unbroken ties along the region of weakness, i.e., the line of perforations 56, to break, thereby separating the envelope 52 from the web 50.

[0193] In alternative embodiments, the loaded and sealed envelope 52 can be separated from the remainder of the web 50 using other techniques, such as one or more cutting edges configured to form a laceration along the region of weakness, the focused application of heat applied along the region of weakness, a heated wire, etc.

[0194] After the loaded and sealed envelope 52 has been separated from the web 50, the pressure plate 23 can be returned to the intermediate position. In particular, the motor 64 of the high-force actuator 30 can be activated to rotate the spiral cams 68 in a counterclockwise direction, from the perspective of FIG. 5. The counterclockwise rotation of the spiral cams 68 causes the projections 69 of the cam followers 66 to be drawn along the first camming surface 72 of the spiral cams 68. The increase in the radius of the first camming surface 72 as the projections 69 move within their corresponding recesses 71 and toward the entry 78 of each recess 71 causes the first camming surface 72 to urge the cam followers 66 in the rearward direction, until the projections 69 reach the entries 78, returning to the position depicted by FIG. 6.

[0195] At this point, the pressure plate 23 has returned to its intermediate position, the motor 64 of the high-force actuator 30 is deactivated, and the projections 69 are able to exit their 34175705203Docket No. 194313.18202 corresponding recesses by way of the corresponding entry 78, and the loaded and sealed envelope 52 has been released so that the envelope 52 can drop onto a conveyer, or into a bin or other holding device (not shown).

[0196] The motor 62 of the low-force actuator 28 is then activated, and rotates the transverse driveshaft 46 and the attached pinion gears 48 to cause the sliding carriages 38 and the rods 34 to move in the forward direction, which in turn causes the pressure plate 23 to move in the forward direction. The pressure plate 23 is first moved forward to a partially-open position at which the pressure plate 23 is spaced from the sealing bar 24 by a distance sufficient to allow the web 50 to be advanced through the envelope-receiving space 21. After the web 50 has advanced, the motor 62 of the low-force actuator 28 is again activated, and rotates the transverse driveshaft 46 and the attached pinion gears 48 to cause the sliding carriages 38 and the rods 34 to move in the rearward direction, which in turn causes the pressure plate 23 to move in the rearward direction, toward the sealing bar 24. As discussed in detail below, when the pressure plate 23 is in this position, the perforation breakers 94 separate a portion of the perforations 56 at and near the side edges of the web 50.

[0197] The motor 62 of the low-force actuator 28 is again activated and rotates the transverse driveshaft 46 and the attached pinion gears 48 to cause the sliding carriages 38 and the rods 34 to move in the forward direction, which in turn causes the pressure plate 23 to move in the forward direction, away from the sealing bar 24. As described in detail below, the suction cup 150 and the grippers 105 cooperate urge the front wall 57 of the envelope 52 slightly away from the rear wall 59 so that the grippers 105 can engage the front wall 57 and form the opening 53 as the pressure plate 23 is moved to the open position by the motor 62. The motor 62 is then deactivated after the pressure plate 23 reaches the open position, thus ending the sealing cycle.

[0198] The pressure-plate linkage 32, the low-force actuator 28, and the high-force actuator 30 can have configurations other than those discussed above. For example, the pressure-plate linkage 32, the low-force actuator 28, and the high-force actuator 30 can incorporate kinematic alternatives such as multi-member linkages, rotary drives, hydraulic or pneumatic piston actuators, etc.

[0199] The use of the low-force actuator 28 in conjunction with the high-force actuator 30 can enhance operator safety. In particular, the spacing between the opposing surfaces of the pressure plate 23 and the sealing bar 24 is minimal, e.g., about Vi-inch or less, when the pressure plate 23 35175705203Docket No. 194313.18202 is in its intermediate position, thereby preventing the operator from inserting a finger or hand between the pressure plate 23 and the sealing bar 24 when the pressure plate 23 is located at or between its intermediate and sealing positions. Also, the low-force actuator 28 can be configured so that the force generated by the low-force actuator 28 is relatively low and is insufficient to result in injury if the operator’s finger or hand is pressed between the pressure plate 23 and the sealing bar 24 while the pressure plate 23 is being actuated exclusively by the low-force actuator 28. Under such circumstances, the pressure plate 23 will stop advancing until the user’s finger or hand is removed from between the pressure plate 23 and the sealing bar 24.

[0200] In addition, the high-force actuator 30 remains physically disengaged from the pressure-plate linkage 32 until the pressure plate 23 reaches the intermediate position, and therefore is incapable of exerting any force on the pressure plate 23 as the pressure plate 23 moves between the open and intermediate positions. Thus, by the point in the sealing cycle at which the higher, potentially injurious force is exerted on the pressure plate 23 by the high-force actuator 30, the potential for the operator’s fingers or hand to be positioned between the pressure plate 23 and the sealing bar 24 is extremely low or non-existent.

[0201] Referring to FIGS. 8, 9 and 10, the perforation breakers 94 are fixed to the pressure plate 23 of the transverse member 22, proximate the opposite ends thereof. As discussed above, the perforation breakers 94 tear the perforations 56 located at and near the side edges of the web 50 before the opening 53 in the envelope 52 is formed. The tom perforations 56 allow the side (outward) portions of the rear wall 59 of the envelope 52 to move in the forward direction as the envelope as the opening 53 is being formed, which can help to prevent the inter-wall seals 131 along the sides of the envelope 52 from being subject to excessive stress. The noted movement of the rear wall 59 also can help to increase the overall size of the opening 53.

[0202] Referring to FIG. 9, each perforation breaker 94 includes a holding element 98 and a breaking element 96 both contained in a common housing 100. The housing 100 is fixed to the pressure plate 23, as shown in FIG. 8.

[0203] The holding element 98 and breaking element 96 are biased by separate biasing elements in the form of springs (not shown) that contract and expand independently of each other. The springs bias the holding element 98 and breaking element 96 in the forward direction. The spring associated with the holding element 98 is weaker, i.e., less stiff, than the spring associated with the breaking element 96.36175705203Docket No. 194313.18202

[0204] The bagging machine 18 further includes a breaker plate 88 with a breaker cavity 90 defined therein, as shown in FIG. 8. The breaker plate 88 is mounted below the web advancement mechanism 86 and above the sealing bar 24, such that the line of weakness between the two envelopes 52 on the downstream end of the web 50 is positioned adjacent the breaker cavity 90 upon advancement of the web 50 by the web advancement mechanism 86.

[0205] As the pressure plate 23 travels rearward to the intermediate position in preparation for forming the opening 53 in the envelope 52 to be loaded, a holding surface 104 of the holding element 98 (visible in FIG. 9) contacts the web 50 directly above the line of weakness, i.e., the perforations 56. The holding surface 104, which is biased toward the breaker plate 88 by the spring associated with the holding element 98, thereby restrains the portion of the web 50 entrained between the holding surface 104 and the breaker plate 88, as can be seen in FIG. 10.

[0206] In addition, a breaking surface 102 of the breaking element 96 (visible in FIG. 9) contacts the portion of the web 50 that is positioned adjacent the breaker cavity 90 of the breaker plate 88. The force exerted on the web 50 by the breaking surface 102, which is biased toward the web 50 by the spring associated with the breaking element 96, in combination with the restraint of the web 50 by the holding element 98, cause the perforations 56 proximate the breaking element 96 to tear. Because the perforation breakers 94 are located proximate the ends of the pressure plate 23, the perforations 56 located at and near the side edges of the web 50 are torn. As noted above, the tom perforations 56 allow the side or outward portions of the rear wall 59 of the envelope 52 to move in the forward direction when drawn in that direction by the front wall 57 of the envelope 52 as the opening 53 is being formed, which can help to prevent the inter-wall seals 131 along the sides of the envelope 52 from being subject to excessive stress. The rearward movement of the rear wall 59 also can help to increase the overall size of the opening 53.

[0207] The amount of holding force exerted by the holding element 98 on the web 50 can be set through the selection of a biasing spring having an appropriate level of stiffness. The amount of force exerted by the breaking element 96 on the web 50 likewise can be set through the selection of a biasing spring having an appropriate level of stiffness.

[0208] Referring to FIGS. 8 and 11-13, the bagging machine 18 further includes a gripper drive 92. The gripper drive 92 and the grippers 105 facilitate the formation of the opening 53 in the envelopes 52 so that the item 103 to be packaged can be placed in the envelope pocket 55.37175705203Docket No. 194313.18202The gripper drive 92 and the grippers 105 also facilitate closing of the opening 53 after the item 103 has been placed in the envelope pocket 55, so that the envelope 52 can be sealed.

[0209] The gripper drive 92 is fixed to the transverse member 22. The gripper drive 92 mechanically actuates the grippers 105 as the pressure plate 23 moves from the open position to the intermediate position, to cause the grippers 105 to move between the gripping position shown in FIGS. 8 and 11, and the open position shown in FIGS. 12 and 13. As noted above, the grippers 105, when in the gripping position, are configured to grip an inwardly-facing upper edge portion of the front wall 57 of the envelope 52 to be loaded, i.e., the envelope 52 located, in part, within the envelope-receiving space 21. The bagging machine 18 is depicted with two of the grippers 105. The bagging machine 18 can include more, or less than two of the grippers 105 in alternative embodiments.

[0210] Referring to FIG. 9, each gripper 105 includes a gripper jaw 106. The gripper jaw 106 is the portion of the gripper 105 that contacts the inwardly-facing upper edge portion of the front wall 57 of the envelope 52 along a gripper contact distance denoted by the arrow 116 in FIG. 9, when the gripper 105 is in the gripping position.

[0211] Referring to FIGS. 8 and 11, the gripper drive 92 includes a rotatable gripper driveshaft 112. The gripper driveshaft 112 is positioned on supports 114. As shown in FIGS. 8 and 9, the supports 114 are fixed to the pressure plate 23 of the transverse member 22 and permit the gripper driveshaft 112 to rotate in relation to the pressure plate 23.

[0212] Referring to FIG. 9, the grippers 105 are positioned on, and engage the gripper driveshaft 112 so that the grippers 105 rotate with the gripper driveshaft 112. In particular, the gripper drive 92 includes gripper couplings 122 that are positioned on, and rotate with the gripper driveshaft 112. Each gripper coupler 122 couples a corresponding one of the grippers 105 to the gripper driveshaft 112, so that the grippers 105 rotate with the gripper driveshaft 112. The mechanical interface 126 between each gripper coupler 122 and the gripper driveshaft 112 has a hexagonal profile, to help minimize or prevent relative rotation between the gripper couplings 122 and the gripper driveshaft 112. In alternative embodiments, the mechanical interface 126 between each gripper coupler 122 and the gripper driveshaft 112 can have other types of non-circular profiles that help minimize or prevent relative rotation between the gripper couplings 122 and the gripper driveshaft 112.38175705203Docket No. 194313.18202

[0213] Each gripper 105 is positioned with respect to a longitudinal axis of the gripper driveshaft 112 by a gripper mount 115, visible in FIG. 9. Each gripper mount 115 is slidably mounted on the transverse member 22. The gripper 105 is captive within the gripper mount 115. Moving the gripper mount 115 along the gripper driveshaft 112 also moves the gripper 105. Movement of the grippers 105 is useful during set-up and maintenance operations of the bagging machine 18 and / or when configuring the bagging machine 18 for differently-sized envelopes 52. In use, each gripper mount 115 is locked to secure the gripper 105 in a fixed location along the gripper driveshaft 112 . In alternative embodiments, the gripper mount 115 can be fixed to the transverse member 22.

[0214] Referring again to FIGS. 8 and 11, the gripper drive 92 is configured as a closed-track cam mechanism that rotates the gripper driveshaft 112, causing the gripper driveshaft 112 to rotate the grippers 105 between their open and gripping positions as the pressure plate 23 moves between its intermediate and open positions.

[0215] The gripper drive 92 includes a gripper actuator 130 and a drive body 132, shown in FIG. 10. The drive body 132 is fixed to the pressure plate 23 of the transverse member 22. The gripper actuator 130 is coupled to the drive body 132 so that the gripper actuator 130 can undergo a limited amount of linear movement in relation to the drive body 132, in the forward and rearward directions. The gripper actuator 130 is biased in the forward direction by a spring (not shown). Referring to FIG. 12, as the pressure plate 23 moves in the rearward direction and approaches its intermediate position, the gripper actuator 130 engages a contact surface 110 of a stationary drive contact 108 fixed to the frame 41 of the bagging machine 18, visible in FIG. 8. As the pressure plate 23 continues to move toward the sealing bar 24 in the rearward direction, the gripper actuator 130 is restrained from further forward movement by the contact surface 110, while the drive body 132 continues to move in the forward direction. The gripper drive 92 rotates the gripper driveshaft 112 and the attached grippers 105 in response to the movement of the pressure plate 23 in relation to the gripper actuator 130. Referring again to FIG. 11, the gripper drive 92 further includes a closed-track 134 formed in the gripper actuator 130, a cylindrical follower 136, and a drive cam 142. The closed-track 134 has a first surface 138 and a second surface 140, and defines a passage 135 having a curvilinear shape. The cylindrical follower 136 is positioned, and can translate within the passage 135. The cylindrical follower39175705203Docket No. 194313.18202136 is fixed to the drive cam 142. The drive cam 142 is fixed to an end of the gripper driveshaft 112.

[0216] FIG. 11 depicts the cylindrical follower 136 in a first position at a first end of the passage 135. As the pressure plate 23 approaches the intermediate position while moving in the rearward direction and the drive body 132 and the pressure plate 23 translate in relation to the now stationary gripper actuator 130 as discussed above, the relative movement between cylindrical follower 136 (which is connected indirectly to the pressure plate 23) and the gripper actuator 130 causes the cylindrical follower 136 to move away from its first position within the passage 135.

[0217] Continued movement of the pressure plate 23 toward the intermediate position causes the cylindrical follower 136 to translate further within the passage 135. Due to the curvilinear shape of the passage 135, the forced movement of the cylindrical follower 136 over the second surface 140 of the stationary closed-track 134 causes the cylindrical follower 136 to move along a curvilinear path matching the shape of the second surface 140.

[0218] The curvilinear movement of the cylindrical follower 136 causes the drive cam 142 and the attached gripper driveshaft 112 to rotate in a clockwise direction, as depicted in FIGS. 12 and 13. The rotation of the gripper driveshaft 112 imparts a corresponding rotation to the grippers 105, causing the grippers 105 to move from the gripping position and toward the open position.

[0219] As depicted in FIG. 12, the cylindrical follower 136 travels within the passage 135 and reaches a second end of the passage 135 as the pressure plate 23 nears its intermediate position. As can be seen in FIG. 13, when the pressure plate 23 is in the sealing position, the cylindrical follower 136 has reached the end of its travel within the passage 135 after having changed direction and moved away from the second end of the passage 135 as the pressure plate 23 moved from near the intermediate position to the sealing position, with clockwise rotation of the gripper driveshaft 112 having continued until the pressure plate 23 reached the sealing position. The cylindrical follower 136 thus reversed direction within the passage 135 while the clockwise rotation of the gripper driveshaft continued. By the point at which the pressure plate 23 reached the sealing position, the movement of the cylindrical follower 136 along the length of the second surface 140 had caused the gripper driveshaft 112 to rotate sufficiently to position the grippers 105 in their open position.40175705203Docket No. 194313.18202

[0220] Referring again to FIG. 8, the suction cup 120 is fixed to the transverse member 22 and is configured to contact the web 50 as the pressure plate 23 reaches its intermediate position. The suction cup 120 draws the front wall 57 of the envelope 52 slightly away from the rear wall 59 so that the grippers 105 can be inserted between the front wall 57 and the rear wall 59 so as to engage the front wall 57. Alternative embodiments of the bagging machine 18 can include more than one suction cup 120. Other alternative embodiments can be configured without any suction cups 120.

[0221] Once the pressure plate 23 reaches its intermediate position (with the grippers 105 now in their opening position), the actuator mechanism 19 can begin moving the pressure plate 23 in the forward direction, toward its open position, to form the opening 53 of the envelope 52 to be loaded. As discussed above, at another point in the sealing cycle, the pressure plate 23 is moved rearward from the intermediate position to its sealing position, with the grippers 105 remaining in their open position, to facilitate sealing of the envelope 52.

[0222] As the pressure plate 23 is drawn forward from its intermediate position, the drive body 132 of the gripper drive 92 moves in the rearward direction in relation to the gripper actuator 130, which is still being held against the contact surface 110 due to the spring bias acting on the gripper actuator 130.

[0223] As depicted in FIGS. 8 and 12, the gripper drive 92 includes a detent mechanism configured to further hold the gripper actuator 130 against the contact surface 110 of the stationary drive contact 108. The detent mechanism includes a hook 139 associated with the gripper actuator 130, and a catch 141 associated with the stationary guide contact 108. A receiving surface 110 of the hook 139 is configured to engage the catch 141 when the gripper actuator 130 contacts the contact surface 110 of the stationary drive contact 108. When the catch 141 is engaged with the hook 139, a detent force develops to keep the gripper actuator 130 stationary. As the pressure plate 23 moves forward, the drive body 132 moves away from the stationary guide contact 108. The hook 139 and the catch 141 keep the gripper actuator 130 stationary until the limited amount of linear movement in relation to the drive body 132 is reached. Forces associated with the pressure plate 23 being driven forward overcome the detent force and disengage the hook 139 from the catch 141. The gripper actuator 130 is then free to move with the pressure plate 23 away from the stationary guide contact 108. Keeping the gripper actuator 130 stationary and in contact with the contact surface 110 of the stationary guide contact 41175705203Docket No. 194313.18202108 promotes proper operation of the gripper drive 92 and the grippers 105. In alternative embodiments, other suitable mechanisms can be used to maintain contact between the gripper actuator 130 and the stationary guide contact 108. For example, magnets, catching mechanisms, and / or high friction materials can be used. In other alternative embodiments, the gripper actuator 130 can be biased on springs strong enough to maintain contact.

[0224] Also, as the pressure plate 23 is drawn forward from its intermediate position, the cylindrical follower 136 begins moving away from the second end of the passage 135 due to the relative movement between the cylindrical follower 136 and the gripper actuator 130. The resulting movement of the cylindrical follower 136 along the first surface 138 of the gripper actuator 130 causes the drive cam 142 and the attached gripper driveshaft 112 to rotate in a counterclockwise direction, from the perspective of FIGS. 12-13. The rotation of the gripper driveshaft 112 imparts a corresponding rotation to the grippers 105, causing the grippers 105 to move from the open position and toward the gripping position.

[0225] Also, the suction cup 120 pulls the front wall 57 of the envelope 52 away from the rear wall 59 to begin forming opening 53 of the envelope 52 as the pressure plate 23 begins to move forward from the intermediate position. The gripper jaws 106 of the grippers 105 subsequently enter the pre-formed opening as the continued movement of the pressure plate 23 in the forward direction causes the cylindrical follower 136 to continue to travel along the first surface 138 of the gripper actuator 130, causing further counterclockwise rotation of the grippers 105. The grippers 105 subsequently reach their gripping position as the cylindrical follower 136 reaches the first end of the passage 135 in the gripper actuator 130. At this point, the gripper jaws 106 of the grippers 105 are contacting the inwardly-facing upper edge portion of the front wall 57 of the envelope 52 along the gripper contact distance 116, as discussed above and depicted in FIG. 9. Also, the bias on the gripper actuator 130 has caused the gripper actuator 130 to return to its undeflected position in relation to the drive body 132.

[0226] Continued rearward movement of the pressure plate 23 with the grippers 105 and the suction cup 120 engaging the front wall 57 of the envelope 52 causes the front wall 57 to be drawn further from the rear wall 59 until the pressure plate 23 reaches its open position, at which point the envelope opening 53 has been fully formed.

[0227] Referring to FIG. 14, the gripper drive 92 is configured to allow the grippers 105 to disengage, or break-away, from the gripper driveshaft 112 when the gripper jaws 106 encounter 42175705203Docket No. 194313.18202 an obstruction. In particular, each gripper 105 is secured to its associated gripper coupler 122 by a coupling in the form of a magnetic coupling that includes two magnets 128. One of the magnets 128 is fixed to an underside of the gripper coupler 122, at a break-away interface 146 between the gripper coupler 122 and the gripper jaw 106. The other magnet 128 is fixed to the top of the gripper jaw 106. The magnets 128 are positioned such that the north and south magnetic poles of the first of the magnets 128 face the respective south and north poles of the other magnet 128. The resulting magnetic attraction between the magnets 128 retains the gripper 105 in rotational coupling with the gripper coupler 122 at the break-away interface 146. In the absence of a magnetic attractive force sufficient to maintain the magnetic coupling, the gripper 105, including its gripper jaw 106, can rotate in relation to the associated gripper coupler 122, along a smooth coupling-jaw interface 124 between the gripper 105 and the gripper coupler 122. When the gripper 105 has broken away, i.e., rotationally disengaged, from the gripper coupler 122 in this manner, torque is not transmitted from the gripper driveshaft 112 and to the gripper 105 through the break-away interface 146. Therefore, no gripping force is applied by the corresponding gripper jaw 106 over the gripper contact distance 116.

[0228] During normal operation, the gripper driveshaft 112, the gripper coupler 122, and the gripper jaw 106 rotate in unison, with the attractive magnetic force between the magnets 128 being sufficient to rotationally coupled the gripper 105 to the gripper coupler 122 at the breakaway interface 146. If the gripper jaw 106 or another portion of the gripper 105 is subject to an excessive force that opposes its rotation, such as a force due to an obstruction encountered by the gripper jaw 106 as the gripper 105 moves from its open to its gripping position, the magnetic attraction between the magnets 128 at the break-away interface 146 will be overcome and the gripper 105 will rotationally disengage from the gripper coupler 122, i.e., the gripper 105 will begin to slide in relation to the gripper coupler 122 at the break-away interface 146. The breakaway force needed to decouple the gripper 105 from its gripper coupler 122 can be set through the selection of magnets 128 with the appropriate degree of magnetic attraction. The gripper 105 also can be rotationally decoupled from the gripper coupler 122 on a manual basis, by grasping and rotating a tab 118 provided on the top of the gripper 105.

[0229] In alternative embodiments, the grippers 105 can be secured to their associated gripper couplers 122 by a coupling other than a magnetic coupling, such as a spring-loaded coupling.43175705203Docket No. 194313.18202

[0230] FIGS. 15-17 depict an alternative embodiment of the gripper drive 92 in the form of a gripper drive 200, and an alternative embodiment of the grippers 105 in the form of grippers 202. The above-noted descriptions of the gripper drive 92 and the grippers 105 apply equally to the respective gripper drive 200 and grippers 202 unless otherwise noted. Components of the gripper drive 200 that are identical or substantially identical to those of the gripper drive 92 are identified using the same reference numbers. Components of the grippers 202 that are identical or substantially identical to those of the grippers 105 likewise are identified using the same reference numbers.

[0231] The grippers 202 are substantially similar to the grippers 105, with the exception that the tab 118 used to rotate the grippers 202 on a manual basis extends from the forward-facing side, rather than the top of the gripper 202 (as referenced to the gripper 202 in its gripping position). Furthermore, as depicted in FIG. 16, the grippers 202 also include a limiter 201 that limits the range of motion of the gripper jaw 106 when the gripper 202 is decoupled. A stop 205 is included on the gripper 202. Said stop 205 is configured to contact the gripper coupler 122 at a stopping surface 207 when the gripper 202 is decoupled and slides in relation to the gripper coupler 122 at the break-away interface 146. When the stop 205 encounters the stopping surface 207, a rotation angle of the gripper 202 relative to the gripper coupling 122 is limited. In some embodiments the rotation angle is limited to 15 degrees or less. In alternative embodiments, the rotation angle is limited to 30 degrees or less. In other alternative embodiments, the rotation angle is limited to 90 degrees or less. In still other embodiments the rotation angle limit is adjustable.

[0232] The gripper drive 200, like the gripper drive 92, is configured as a closed-track cam mechanism that rotates the gripper driveshaft 112, causing the gripper driveshaft 112 to rotate the grippers 202 between their open and gripping positions as the pressure plate 23 moves between its intermediate and open positions.

[0233] The gripper drive 200 includes a gripper actuator 204. The gripper actuator 204 is fixed to the frame 41 of the bagging machine 18. The gripper drive 200 rotates the gripper driveshaft 112 and the attached gripper 202 in response to the movement of the pressure plate 23 in relation to the gripper actuator 204.

[0234] Referring to FIG. 15, the gripper drive 200 further includes a closed track 206 formed in the gripper actuator 204, a cylindrical follower 208, and a drive cam 210. The closed track 44175705203Docket No. 194313.18202206 has a first surface 212 and a second surface 214, and defines a passage 216 having an elongated linear portion 218 and a curvilinear portion 220 that adjoins the linear portion 218. The cylindrical follower 208 is positioned within the passage 216, and can translate within the passage 216. The cylindrical follower 208 is mounted on a shaft 209 that is fixed to a first end of the drive cam 210 so that the cylindrical follower 208 is coupled to, and can rotate in relation to the drive cam 210. A second end of the drive cam 210 is fixed to an end of the gripper driveshaft 112.

[0235] The actuator 204 is positioned so that the cylindrical follower 208 is located at the forward end of the linear portion 218 of the passage 216 when the pressure plate 23 is in its open position, as shown in FIG 15. At this point, the grippers 202 are retained in their gripping position due to the relative positioning of the gripper actuator 204, the cylindrical follower 208, the cam follower 208, and the gripper driveshaft 112.

[0236] The cylindrical follower 208 travels rearward within the linear portion 218 of the passage 216 as the pressure plate 23 initially moves rearward, toward its intermediate position. Because the gripper drive 200 is fixed to the non-moving frame 41, the cam follower 208, which is coupled to the pressure plate 23 via the shaft 209, the drive cam 210, and the gripper driveshaft 112, and the supports 114, moves with the pressure plate 23. The first and second surfaces 212, 214 of the closed track 206 constrain the cylindrical follower 208 from movement in the vertical direction while the cam follower 208 is located within the linear portion 218 of the passage 216. The angular positions of the drive cam 210, the gripper driveshaft 112, and the grippers 202 thus remain constant and the grippers 202 remain in their gripping position as the pressure plate 23 moves toward its intermediate position with the cam follower 208 located within the linear portion 218 of the passage 216.

[0237] Referring to FIG 16, as the pressure plate 23 approaches the intermediate position, the cylindrical follower 208 begins to enter the curvilinear portion 220 of the passage 216. Due to the curvilinear shape of the curvilinear portion 220 of the passage 216 (and the curvilinear shape of the portion of the second surface 214 that borders the curvilinear portion 220), the cam follower 208 is forced upward by the second surface 214 of the closed track 206 as the pressure plate 23 continues to move rearward. The curvilinear movement of the cylindrical follower 208 imparts clockwise rotation to the drive cam 210 and the attached gripper driveshaft 112 (from the45175705203Docket No. 194313.18202 perspective of FIG. 15), which in turn rotates the grippers 202 from their gripping position and toward the open position.

[0238] The cylindrical follower 208 reaches the end of its travel within the passage 216, i.e., the cylindrical follower 208 reaches the upper end of the curvilinear portion 220 of the passage 216, as the pressure plate 23 reaches the sealing position, as depicted in FIG. 16. At this point, the movement of the cylindrical follower 136 along the curvilinear portion of the second surface 214 of the closed track 206 has caused the drive cam 210 and the gripper driveshaft 112 to rotate sufficiently to position the grippers 105 in their open position.

[0239] When the pressure plate 23 begins to move forward to return to its open position, the cam follower 208 is drawn against the curvilinear portion of the first surface 212 of the closed track 206 as the cam follower 208 moves within the curvilinear portion 220 of the passage 216. Due to the curvilinear shape of the curvilinear portion 220 of the passage 216 (and the curvilinear shape of the portion of the first surface 212 that borders the curvilinear portion 220), the cam follower 208 is forced downward by the first surface 212 as the pressure plate 23 continues to move forward. The curvilinear movement of the cylindrical follower 208 imparts counterclockwise rotation to the drive cam 210 and the attached gripper driveshaft 112 (from the perspective of FIG. 16), which in turn rotates the grippers 202 from their open position and toward the gripping position. At the approximate point the cam follower 208 enters the linear portion 218 of the passage 216, the grippers 202 reach their gripping position. The grippers 202 will remain in the gripping position as the pressure plate 23 returns to its open position, due the restraint of the cam follower 208 from vertical movement exerted by the first surface 212 and the second surface 214 of the closed track 206 within the linear portion 218 of the passage 216.

[0240] As can be seen in FIG 17, each gripper 202 is mounted on a respective carriage 224 along with a suction cup 120. The carriages 224 are mounted on the pressure plate 23, and are secured to the pressure plate 23 by clamps 226 that extend through a slot 228 (visible in FIG. 16) in the pressure plate 23. The slot 228 extends along the length of the pressure plate 23, and permits the clamps 226 to be secured to the pressure plate 23 at various positions along the length of the pressure plate 23, so that the transverse positions of the grippers 202 and the suction cups 120 in relation of the path of the web 50 can be varied.

[0241] Respective sensors 232, visible in FIG. 16, are mounted on each of the carriages 224. The sensors 232 are optical sensors that each include an integrated transmitter and receiver. The 46175705203Docket No. 194313.18202 sensor 232 can be other types of sensors in alternative embodiments. The sensors 232 are communicatively coupled to the controller 87. Each sensor 232 is configured to detect the presence of the front wall 57 when the front wall 57 is being held between the gripper 202 associated with the sensor 232 and the pressure plate 23, and to generate an output indicating the presence of the front wall 57. Each gripper 202 has a through hole 238 formed therein. As shown in FIG. 16 the through holes 238 permit sensing beams 236 of the sensors 232 to pass through the grippers 202 when the grippers 202 are in their gripping position and the front wall 57 is not present between the gripper 202 and the pressure plate 23.

[0242] Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.175705203

Claims

Docket No. 194313.18202What is claimed is:

1. A bagging machine, comprising: a sealing mechanism that includes: a pressure plate, and a sealing bar opposing the pressure plate by an envelope-receiving space; and a pressure-plate linkage associated with the pressure plate to move the pressure plate between: an open position at a distance from the sealing bar that allows loading of an envelope that is received in the envelope-receiving space, an intermediate position spaced nearer to the sealing bar than at the open position, and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of the envelope; and an actuator mechanism that includes: a low-force actuator configured to drive the pressure-plate linkage to move the pressure plate between the open and intermediate positions via a first force, and a high-force actuator that is disengaged from the pressure-plate linkage at the open position of the pressure plate, and that is engaged with the pressure-plate linkage between the intermediate and sealing positions of the pressure plate to drive the pressure-plate linkage to move the pressure plate from the intermediate position to the sealing position via a second force that is greater than the first force.

2. The bagging machine of claim 1, wherein the high-force actuator is incapable of applying force to the pressure plate when the high-force actuator is disengaged from the pressure-plate linkage.

3. The bagging machine of claim 2, wherein the high-force actuator is disengaged from the pressure-plate linkage between the intermediate and open positions of the pressure plate.48175705203Docket No. 194313.182024. The bagging machine of claim 3, wherein the pressure-plate linkage is engaged with the pressure-plate linkage only between the intermediate and sealing positions of the pressure plate.

5. The bagging machine of claim 1, wherein the pressure plate is spaced from the sealing bar by about % inch or less when the pressure plate is in the intermediate position.

6. The bagging machine of claim 1, wherein the second force is at least two times greater than the first force.

7. The bagging machine of claim 1, wherein the second force is at least five times greater than the first force.

8. The bagging machine of claim 1, wherein the high-force actuator includes a spiral cam configured to provide an elevated mechanical advantage to drive the pressure-plate linkage compared to the low-force actuator.

9. The bagging machine of claim 1, wherein: the high-force actuator includes a cam, and an actuator member coupled to the cam and configured to rotate the cam; the cam includes a curvilinear first camming surface coupled to the pressure-plate linkage when the pressure plate moves from the intermediate position to the sealing position; and the first camming surface is configured to exert the second force on the pressure-plate linkage.

10. The bagging machine of claim 9, wherein the first camming surface is configured so that the second force increases as the pressure plate moves from the intermediate position to the sealing position.

11. The bagging machine of claim 10, wherein a radius of curvature of the first camming surface decreases along a length of the camming surface.49175705203Docket No. 194313.1820212. The bagging machine of claim 11 , wherein: the cam is configured to rotate between: a first angular position at which the pressure plate is located in the intermediate position and a first end portion of the camming surface is coupled the pressure plate linkage; and a second angular position at which the pressure plate is located in the sealing position and a second end portion of the camming surface is coupled the pressure plate linkage; and the radius of curvature of the first camming surface at the second end portion of the camming surface is less than the radius of curvature of the first camming surface at the first end portion of the camming surface.

13. The bagging machine of claim 9, wherein the pressure-plate linkage is configured to disengage from the cam as the pressure plate moves from the intermediate position and toward the open position.

14. The bagging machine of claim 9, wherein: the cam includes a curvilinear second camming surface coupled to the pressure-plate linkage when the pressure plate moves from the sealing position to the intermediate position; the second camming surface is configured to exert a third force on the pressure-plate linkage; and the third force drives the pressure-plate linkage to move the pressure plate from the sealing position to the intermediate position.

15. The bagging machine of claim 14, wherein the first and second camming surfaces partially define a recess configured to receive a portion of the pressure-plate linkage when the pressure plate moves between the intermediate and open positions.

16. The bagging machine of claim 15, wherein the low-force actuator is configured to remain deactivated, and engaged with the pressure-plate linkage as the pressure plate moves between the intermediate and sealing positions.50175705203Docket No. 194313.1820217. The bagging machine of claim 1 , wherein: the closure seal is formed from a heat-sealable material; the sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar; and the heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

18. The bagging machine of claim 17, further comprising a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

19. A bagging machine, comprising: a sealing mechanism that includes: a sealing bar, and a pressure plate movable with respect to the sealing bar between: an open position at a distance from the sealing bar that allows loading of an envelope that is received in an envelope-receiving space, and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of a first envelope; a gripper mounted to the pressure plate and configured to move from an open position to a gripping position to grip an upper edge of a front wall of the first envelope sufficiently to pull the envelope open; a gripper drive drivingly engaged with the gripper to drive the gripper to the gripping position; and a coupling between the gripper drive and the gripper that is configured to disengage the gripper from the gripper drive in response to a predetermined force resisting movement of the gripper to the gripping position, causing the gripper to release the front wall.51175705203Docket No. 194313.1820220. The bagging machine of claim 19, wherein the coupling is configured couple the gripper to the gripper drive as the pressure plate is moved to the open position of the pressure plate and the envelope is loaded in the envelope-receiving space.

21. The bagging machine of claim 19, wherein: the gripper is configured to rotate between the open and gripping positions of the gripper; the gripper drive includes a rotatable gripper drive shaft; and the coupling is configured to releasably couple the gripper to the gripper drive shaft in rotation.

22. The bagging machine of claim 21, wherein: the gripper drive further includes a gripper coupler mounted on the gripper drive shaft and configured to rotate with the gripper drive shaft; and the coupling is configured to releasably couple the gripper to the gripper coupler in rotation via the gripper coupler.

23. The bagging machine of claim 22, wherein the coupling is configured to rotationally decouple the gripper from the gripper coupler upon the predetermined force resisting movement of the gripper to the gripping position.

24. The bagging machine of claim 22, wherein the gripper is configured to slide in relation to the gripper coupler in response to the predetermined force resisting movement of the gripper to the gripping position.

25. The bagging machine of claim 22, wherein: the gripper is configured to rotationally decouple from the gripper coupler; and a rotation angle of the gripper relative to the gripper coupler is limited by a stop.

26. The bagging machine of claim 25, wherein the rotation angle is limited to 15 degrees or less.52175705203Docket No. 194313.1820227. The bagging machine of claim 23, wherein the coupling is a magnetic coupling including a first magnet mounted on the gripper, and a second magnet mounted on the gripper coupler.

28. The bagging machine of claim 27, wherein a magnetic attraction between the first and second magnets is sufficiently high to allow the gripper drive to drive the gripper to the gripping position and sufficiently low to allow the gripper to disengage from the gripper drive in response to the predetermined force resisting movement of the gripper to the gripping position.

29. The bagging machine of claim 28, wherein the magnetic attraction between the first and second magnets is sufficiently high to couple the gripper drive to the gripper as the pressure plate is moved to the open position of the pressure plate and the envelope is loaded within the envelope-receiving space with the gripper gripping the upper edge of the front wall of the envelope.

30. The bagging machine of claim 27, wherein; the gripper has a backing surface located within a magnetic field of the first magnet; the gripper coupler has a backing surface located within a magnetic field of the second magnet; and the backing surface of the gripper is driven into contact with the backing surface of the gripper coupler by magnetic attraction between the first and second magnets.

31. The bagging machine of claim 27, wherein the first magnet is driven toward the second magnet as the gripper is driven to the gripping position.

32. The bagging machine of claim 22, wherein: an outer surface of the gripper drive shaft has a polygonal shape; and the gripper coupler has an inner surface configured to engage the outer surface of the gripper drive shaft.

33. The bagging machine of claim 32, wherein a shape the inner surface of the gripper matches the polygonal shape of the outer surface of the gripper drive shaft.53175705203Docket No. 194313.1820234. The bagging machine of claim 32, wherein the outer surface of the gripper drive shaft has a hexagonal shape.

35. The bagging machine of claim 19, wherein the gripper is further configured to move from the open to the gripping position of the gripper to grip the upper edge of the front wall of the envelope sufficiently to pull the envelope open as the pressure plate moves toward the open position of the pressure plate.

36. The bagging machine of claim 19, wherein the gripper includes a tab configured to facilitate manual application of a force to the gripper sufficient to disengage the gripper from the gripper drive.

37. The bagging machine of claim 19, wherein: the closure seal is formed from a heat-sealable material; the sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar; and the heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

38. The bagging machine of claim 37, further comprising a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

39. A bagging machine, comprising: a sealing mechanism that includes: a sealing bar, and a pressure plate movable with respect to the sealing bar between:54175705203Docket No. 194313.18202 an open position at a distance from the sealing bar that allows loading of an envelope that is received in an envelope-receiving space, and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of a first envelope; a gripper mounted to the pressure plate and configured to move from an open position to a gripping position to grip an upper edge of a front wall of the first envelope sufficiently to pull the envelope open; and a gripper drive configured to move the gripper between the open and gripping positions of the gripper and actuated by the movement of the pressure plate with respect to the sealing bar.

40. The bagging machine of claim 39, wherein the gripper drive is configured to move the gripper between the open and gripping positions of the gripper based on a position of the pressure plate with respect to the sealing bar.

41. The bagging machine of claim 39, wherein: the gripper drive includes a drive cam, a follower, a gripper actuator, and a rotatable gripper drive shaft; the gripper is mounted to the gripper drive shaft and is configured to rotate with the gripper drive shaft between the open and gripping positions of the gripper; the gripper actuator engages the follower and is configured to displace the follower in response to the movement of the pressure plate with respect to the sealing bar; and the follower is coupled to the drive cam and the gripper driveshaft is fixed to the drive cam so that the displacement of the follower causes the drive cam to rotate the gripper drive shaft.

42. The bagging machine of claim 41, wherein: the gripper actuator includes a closed track defining a passage configured to receive the follower; and at least a portion of the closed track is curved so that relative movement between the follower and the gripper actuator displaces the follower in a direction other than a direction of travel of the pressure plate between the open and sealing positions of the pressure plate.55175705203Docket No. 194313.1820243. The bagging machine of claim 42, wherein the direction other than a direction of travel of the pressure plate between the open and sealing positions of the pressure plate is a direction orthogonal to the direction of travel of the pressure plate between the open and sealing positions of the pressure plate.

44. The bagging machine of claim 42, wherein the gripper actuator is stationary in relation to the pressure plate as the pressure plate moves between the open and sealing positions of the pressure plate.

45. The bagging machine of claim 44, wherein: the passage has a linear portion and a curvilinear portion; and the follower is displaced in the direction other than a direction of travel of the pressure plate between the open and sealing positions of the pressure plate when the follower moves within the curvilinear portion of the passage.

46. The bagging machine of claim 42, wherein: the gripper drive further includes a drive body coupled to the pressure plate so that the drive body moves with the pressure plate; the gripper actuator is coupled to the drive body and is configured to move linearly in relation to the drive body; and the drive body is configured to displace the gripper actuator in relation to the follower as the pressure plate approaches the sealing position of the pressure plate.

47. The bagging machine of claim 39, wherein the gripper is further configured to move from the open position to the gripping position of the gripper to grip the upper edge of the front wall of the envelope sufficiently to pull the envelope open as the pressure plate moves toward the open position of the pressure plate.

48. The bagging machine of claim 39, wherein: the closure seal is formed from a heat-sealable material;56175705203Docket No. 194313.18202 the sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar; and the heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

49. The bagging machine of claim 48, further comprising a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

50. A bagging machine, comprising: a sealing bar; a pressure plate movable with respect to the sealing bar between: an open position at a distance from the sealing bar that allows loading of a first envelope that is received in an envelope-receiving space, and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of the first envelope; and a biasing member configured to bias the sealing bar toward the pressure plate.

51. The bagging machine of claim 50, wherein the biasing member is configured to establish a sealing pressure on the closure by the pressure plate and the sealing bar when the pressure plate is pushed against the sealing bar.

52. The bagging machine of claim 51, wherein: the bagging machine further includes: a guide block fixed to a frame of the bagging machine, and a guide pin fixed to the sealing bar and extending through the guide block; the guide pin engages the sealing bar so that the sealing bar is suspended from the guide pin; and57175705203Docket No. 194313.18202 the biasing member is positioned between the guide block and the sealing bar so that the biasing member biases the sealing bar away from the guide block.

53. The bagging machine of claim 52, wherein the biasing member includes a spring.

54. The bagging machine of claim 53, wherein the spring is positioned around the guide pin.

55. The bagging machine of claim 52, further including a restraint fixed to the guide pin and configured to restrain the guide pin from exiting the guide block.

56. The bagging machine of claim 52, wherein the sealing bar is configured to move on the guide pin in relation to the frame.

57. The bagging machine of claim 50, wherein: the closure seal is formed from a heat-sealable material; the sealing bar further includes a heating element associated with the pressure plate and / or the sealing bar; and the heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

58. The bagging machine of claim 57, further comprising a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.

59. The bagging machine of claim 58, wherein: the sealing guard includes a biasing member configured to bias the heating element toward the extended position; and58175705203Docket No. 194313.18202 the bias of the biasing member configured to bias the heating element toward the extended position is less than the bias of the biasing member configured to bias the sealing bar toward the pressure plate.

60. A bagging machine configured for use with a web of interconnected envelopes, the bagging machine comprising: a sealing mechanism that includes: a sealing bar, and a pressure plate movable with respect to the sealing bar between: an open position at a distance from the sealing bar that allows loading of a first envelope that is received in an envelope-receiving space, and a sealing position in which the pressure plate is pressed against the sealing bar to form a closure seal of the envelope; and a web separator configured to separate a portion of the first envelope from a portion of an adjacent second envelope on the web as the sealing bar moves toward the sealing position.

61. The bagging machine of claim 60, wherein the web separator is coupled the pressure plate so that the web separator moves with the pressure plate.

62. The bagging machine of claim 60, wherein the web separator is configured to separate the portion of the first envelope from the portion of the second envelope prior to formation of the closure seal.

63. The bagging machine of claim 60, wherein: the portion of the first envelope is adjacent a side of the first envelope; and the portion of the second envelope is adjacent a side of the second envelope.

64. The bagging machine of claim 60, wherein the web separator includes a perforation breaker configured to break one or more perforations located on the web between the first envelope and the second envelope as the sealing bar moves toward the sealing position to separate the portion of the first envelope from the portion of the second envelope.59175705203Docket No. 194313.1820265. The bagging machine of claim 64, wherein: the perforation breaker includes a breaking element and a holding member; the breaking element is configured to break the one or more perforations as the sealing bar moves toward the sealing position; and the holding member is configured to hold a portion of the second envelope in place as the breaking element breaks the one or more perforations.

66. The bagging machine of claim 65, wherein the holding member is configured to hold a portion of the second envelope in place as the breaking element breaks the one or more perforations.

67. The bagging machine of claim 66, wherein the breaking element is configured move in relation to the holding member as the breaking element breaks the one or more perforations.

68. The bagging machine of claim 65, wherein: the web separator further includes a breaker plate defining a breaker cavity therein; and the breaker cavity is configured to receive a portion of the breaking element as the breaking element breaks the one or more perforations.

69. The bagging machine of claim 68, wherein the breaker plate is mounted above the sealing bar.

70. The bagging machine of claim 65, wherein the perforation breaker further includes a spring associated with the holding member and biasing the holding member toward the sealing bar.

71. The bagging machine of claim 70, wherein: the perforation breaker further includes a spring associated with the breaking element and biasing the breaking element toward the sealing bar; and60175705203Docket No. 194313.18202 the spring associated with the breaking element is stiffer than the spring associated with the holding member.

72. The bagging machine of claim 66, wherein: the breaking element includes a forward surface, and an upper surface adjoining the forward surface; the forward surface is oriented at an acute angle in relation to the upper surface; the forward surface and the upper surface define a forward edge of the breaking element; and the forward edge of the breaking element is configured to break the one or more perforations as the sealing bar moves toward the sealing position.

73. The bagging machine of claim 60, wherein: the closure seal is formed from a heat-sealable material; the sealing mechanism further includes a heating element associated with the pressure plate and / or the sealing bar; and the heating element is configured to heat the heat-sealable material when the pressure plate is in the sealing position.

74. The bagging machine of claim 73, further comprising a sealing guard configured to translate in relation to the heating element between an extended position at which the sealing guard at least partially encloses and covers the heating element, and a retracted position at which the sealing guard allows the heating element to contact the envelope when the pressure plate is in the sealing position.61175705203

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