Cushion forming machine

Abstract

The invention relates to a cushion forming machine (10) having a forming device (22) by means of which a flat web-shaped tubular starting material (16) is expanded into a three-dimensional tubular cushion product (20), wherein the forming device (22) has a floating elongated core (24) onto which the tubular starting material (16) is drawn. According to the invention, the core (24) has at least one longitudinal portion (28) with a plurality of contact surfaces (34) which extend, overall, in the longitudinal direction and are spaced apart from one another as viewed in the circumferential direction.

Description

[0001] Applicant:

[0002] Storopack Hans Reichenecker GmbH

[0003] Untere Rietstraße 30

[0004] 72555 Metzingen

[0005] General Power of Attorney: 514560 . 2

[0006] 35020912WO 17.09.2025

[0007] KNA / MAY

[0008] Title: Upholstery forming machine

[0009] Description

[0010] The invention relates to a cushion forming machine according to the preamble of claim 1.

[0011] DE 102 42 998 A of fenbart describes a cushion forming machine for the production of elastic, tubular cushioning products. These can be used to fill empty spaces in shipping containers and thus protect the items contained within. For this purpose, the cushion forming machine has a forming unit. This unit draws a tubular, web-shaped, and flat starting material onto a floating, elongated core, thereby expanding it into the tubular cushioning product.

[0012] The tubular cushioning product is widened by the

[0013] Forming device still crumpled in the longitudinal direction.

[0014] The present invention aims to create a cushion forming machine with relatively small dimensions and low energy consumption, which also operates reliably.

[0015] This problem is solved by a cushion forming machine with the features of claim 1. Advantageous embodiments are specified in the dependent claims.

[0016] In the upholstery forming machine according to the invention, the total contact area between the core and the upholstery product is significantly reduced. This reduces friction between the core and the upholstery product. Consequently, smaller motors can be used to convey the raw material or the upholstery product, allowing the upholstery forming machine to have smaller dimensions and consume less power during operation. Furthermore, the risk of the upholstery product becoming jammed at an outlet area of ​​the upholstery forming machine is reduced.

[0017] Specifically, this is achieved by a cushion forming machine for producing elastic cushioning material, which can be used, for example, to at least partially fill empty space in a shipping carton. This prevents items in the shipping carton from being damaged during transport. The cushion forming machine according to the invention has a forming device by which a flat, web-shaped, and tubular starting material is expanded into a three-dimensional, tubular cushioning product. The flat, web-shaped, and tubular starting material can, for example, be a flattened paper tube, which is either wound onto a roll or provided as a zigzag-folded stack of paper.

[0018] The forming device has a floating, elongated core onto which the tube-like starting material is drawn. The core can, in a certain sense, have the shape of an elongated rugby ball. "Floating" means that the core is not rigidly connected, at least within the forming device, to a supporting structure, for example, but is held freely movable within certain limits, with a certain degree of play, particularly radial play, and a continuous gap in the circumferential direction.

[0019] According to the invention, the core has at least one longitudinal section which comprises a plurality of contact surfaces for the cushioning product, extending in the longitudinal direction or in the direction of movement of the starting material and the cushioning product. These contact surfaces are contacted at least temporarily and in certain areas by the tubular cushioning product or an immediate precursor (intermediate product). They serve to guide the cushioning product or precursor in a typically straight line during its movement towards an outlet area of ​​the forming device. The contact surfaces are spaced apart from one another in the circumferential direction, so that a gap exists between adjacent contact surfaces in the circumferential direction. In the area of ​​this gap, the tubular cushioning product or precursor is thus typically at a distance from the core and therefore does not touch it.The free space can be formed, for example, by the kernel extending radially inwards from an ideal circular shape.

[0020] In a further development, it is stipulated that the contact surfaces are arranged essentially uniformly in the circumferential direction. This prevents unwanted deformation of the tubular cushion product on its way to the outlet area of ​​the forming device. However, it is also conceivable that the contact surfaces are not arranged uniformly in the circumferential direction, but that, for example, in the normal operating position of the cushion forming machine, more contact surfaces are arranged in an upper area of ​​the core than in a lower area.

[0021] In a further development, it is provided that the core, viewed circumferentially, has at least 3, preferably 4-8, and more preferably 4 contact surfaces. This offers advantages in manufacturing technology.

[0022] In a further development, it is provided that at least one contact surface is arranged at a radially outer end of a core section, which, viewed in the axial direction of the core, has an approximately triangular cross-section. The contact surface is thus arranged on the radially outward projecting "tip" of the triangle. This also has manufacturing advantages and ensures high stability of the longitudinal section with the contact surfaces.

[0023] It is understood that the width of the contact surfaces can be very small, and may even be almost or completely linear. Therefore, in a further development, it is provided that the width of a contact surface is approximately a maximum of 5%, preferably approximately 1%, of the imaginary total circumference of the core in that longitudinal section of the core in which the contact surfaces are arranged. In other words, the core is designed in this longitudinal section such that, viewed in the circumferential direction of the core, the radially outer total contact surface of the core, with which it at least temporarily touches or can touch the applied starting material, occupies an angular segment that is considerably less than 360°. The contact surface is thus very narrow and, compared to its width, very long. Typically, the length-to-width ratio of a contact surface can be in the range of 20–50.This resulted in particularly low friction during the movement of the upholstery product along the core.

[0024] In a further development, it is provided that at least one of the contact surfaces, viewed longitudinally, comprises at least two partial contact surfaces, wherein an upstream partial contact surface has a greater distance from a central axis of the core than a downstream partial contact surface (the terms "upstream" and "downstream" here and subsequently always refer to the typical direction of movement of the starting material or the cushioning product from the inlet area to the outlet area of ​​the forming device). This upstream partial contact surface is typically arranged in that area of ​​the core which is involved in the forming of the cushioning product, for example, in its compression or crumpling in the longitudinal direction. The forming process is facilitated and improved by the measure according to the invention.

[0025] In a further development of this design, it is stipulated that the upstream partial contact surface is resilient in the radial direction. This is particularly advantageous when the resilient partial contact surface serves to guide a cushioning product that is crumpled in its longitudinal direction.

[0026] In a further development of this design, a motor-driven conveying wheel is arranged radially outwards opposite an upstream partial contact surface, preferably having a plurality of conveying sections projecting radially outwards. This improves the reliability of conveying and crumpling.

[0027] In a further development, the core is provided with an upstream longitudinal section and a downstream longitudinal section, with the upstream longitudinal section comprising an upstream sub-longitudinal section and a downstream sub-longitudinal section, with the upstream sub-longitudinal section being conical overall, the downstream sub-longitudinal section being cylindrical overall, and the downstream sub-longitudinal section having the majority of contact surfaces. With this core design, the tubular cushioning product can be formed from the tubular starting material in a particularly energy-efficient and reliable manner.

[0028] In one aspect of the invention, the following is proposed:

[0029] Cushion forming machine, with a forming device by which a flat, web-shaped, tubular starting material is expanded into a three-dimensional tubular cushion product, wherein the forming device has a floating elongated core onto which the tubular starting material is drawn, characterized in that the core has at least one longitudinal section which has a plurality of contact surfaces extending in the longitudinal direction and spaced apart from each other in the circumferential direction.

[0030] One embodiment of the invention is explained below with reference to the drawing. The drawing shows:

[0031] Figure 1 shows a perspective view of an upholstery forming machine from a slanted front / top angle;

[0032] Figure 2 is a perspective view of the upholstery forming machine from Figure 1 from a rear / top angle;

[0033] Figure 3 is a perspective view of a core of the cushion forming machine from Figure 1 from a front / top angle; Figure 4 is a perspective cutaway view similar to Figure 1;

[0034] Figure 5 is a perspective view similar to Figure 3, but showing a downstream longitudinal section of the core of Figure 3; and

[0035] Figure 6 shows a front view of the downstream longitudinal section of Figure 5.

[0036] For the sake of clarity, not all reference symbols are included in all figures.

[0037] A cushion forming machine is represented in the figures by the reference symbol 10. It comprises a housing 12 and an inlet area 14 for a flat, web-shaped, and tube-like starting material 16, for example, a flattened paper tube. For example, the housing 12 can include an internal support structure made of metal (not visible here) and an outer shell made of plastic. The flat, web-shaped, and tube-like starting material 16 is indicated only by an arrow.

[0038] The cushion forming machine 10 also includes an outlet area 18 for a three-dimensional tubular cushion product 20. The three-dimensional tubular cushion product 20 is produced from the flat, web-shaped, and tubular starting material 16 in a forming unit 22, which is functionally arranged between the inlet area 14 and the outlet area 18. The three-dimensional tubular cushion product 20 is indicated here by a dashed circle and by arrows.

[0039] The forming device 22 comprises a floating elongated core 24 (Figure 3) with a longitudinal axis 25. The core 24 comprises an upstream longitudinal section 26 and a downstream longitudinal section 28, viewed in the direction of movement (from the inlet region 14 to the outlet region 18) of the starting material 16 and the cushioning product 20. The upstream longitudinal section 26 in turn has an upstream partial longitudinal section 30 and a downstream partial longitudinal section 32. The upstream partial longitudinal section 30 is conical overall. The downstream partial longitudinal section 32 is cylindrical overall.

[0040] The downstream longitudinal section 28 has a plurality of contact surfaces 34 extending longitudinally, i.e., parallel to the longitudinal axis 25. During operation of the cushion forming machine 10, these contact surfaces can be made contact by the tubular cushion product 20, thus guiding the tubular cushion product 20 towards the outlet area 18. The contact surfaces 34 are spaced apart from one another in the circumferential direction of the core 24, as indicated by double arrows 36 in Figure 5. Furthermore, the contact surfaces 34 are arranged in a substantially uniform distribution in the circumferential direction. In this example, the core has four contact surfaces 34 in the circumferential direction. However, a different number of contact surfaces is also conceivable, for example, at least three, preferably four to eight.As can be seen from the figures, all contact surfaces 34 are arranged, by way of example, at a radially outer end of a core section 37, which, viewed in the axial direction of the core, has an approximately triangular cross-section. The contact surface 34 is thus located at each radially projecting tip of the core section 37 having the triangular cross-section. A free space 39 is therefore present between the contact surfaces 34 and the core sections 37.

[0041] The contact surfaces 34 are elongated in one direction parallel to the longitudinal axis 25, but very narrow, indeed almost linear, in one direction transverse to the longitudinal axis 25 or in the circumferential direction (width). Preferably, the width of a contact surface 34 is approximately a maximum of 5%, preferably approximately one percent, of the imaginary total circumferential extent of the core 24 in the longitudinal section 28 in which the contact surfaces 34 are arranged.

[0042] As can be seen particularly from Figure 5, all contact surfaces 34 shown here, viewed longitudinally, have two partial contact surfaces 34a and 34b. A partial contact surface 34a located upstream in the direction of movement of the cushioning product 20 has a greater distance D1 from the longitudinal or central axis 25 of the core 24 than the downstream partial contact surface 34b (distance D2). The upstream partial contact surface 34a is formed by a spring clip and is therefore resilient in the radial direction.

[0043] As can be seen from Figure 4, core 24 of the

[0044] Forming device 22 with three drive stages 38, 40 and 42 arranged sequentially in the direction of movement of the starting material 16 or the cushioning product 20. Each drive stage 38, 40 and 42 in turn comprises four driven rollers 44, 46 and 48. The four rollers 44, 46 and 48 of a drive stage 38, 40 and 42 are arranged evenly distributed in the circumferential direction of the core 24. In Figure 4, the respective upper and lower rollers 44, 46 and 48 are visible.

[0045] Core 24 also has four rollers 50 and four rollers 52, which, however, are not driven. The rollers 50 are arranged in the area of ​​the rollers 44 and just upstream of them, whereas the rollers 52 are arranged in the area of ​​the rollers 46 and just downstream of them. The driven rollers 48 have a plurality of radially outward projecting conveying sections 54. They are arranged radially outward opposite a respective upstream partial contact surface 34a.

[0046] As mentioned at the outset, the core 24 is mounted in a "floating" manner. This means that the core 24 is not connected to a support structure of the cushion forming machine 10 via a rigid or flexible connecting element, but rather that a continuous gap exists between the core 24 and the elements of the forming device 22 surrounding it radially outwards, both circumferentially and longitudinally, through which the tubular cushion product 20 can pass. In the axial direction, the position of the core 24 is approximately determined by the fact that an outer diameter of the core 24 in the area of ​​the rollers 50 and 52 is larger than an inner width between opposing rollers 44 and 46. The rollers 50 are elastically actuated against the rollers 44, and the rollers 52 are elastically actuated against the rollers 46. The conveying sections 54 of the rollers 48 cooperate with the associated spring contact surface 34a .

[0047] The cushion forming machine 10 operates as follows: the flat, web-shaped, and tube-like starting material 16 is fed to the inlet area 14 via inlet-side guide rollers 56, where it is drawn onto the conical upstream longitudinal section 26 of the core 24 and thereby expanded into a tube shape. The starting material 16 is conveyed by means of the driven rollers 44 and 46.

[0048] The rollers 48 rotate at a lower speed than the rollers 44 and 46. This causes the tubular starting material 16, which is wound onto the core 24 with radial play, to be compressed longitudinally and thus crumpled. The crumpled, tubular cushion product 20 is guided downstream from the drive stage 42 via the downstream longitudinal section 28 of the core 24 to the outlet area 18.

[0049] The crumpled, tubular cushioning product 20 contacts the core 24 in the downstream longitudinal section 28 only in the area of ​​the narrow contact surfaces 34b. In the area of ​​the rollers 48, the crumpled, tubular cushioning product 20 contacts the core 24 in the downstream longitudinal section 28 only in the area of ​​the narrow, resilient contact surfaces 34a. The friction between the crumpled, tubular cushioning product 20 and the core 24 is thus minimized in the downstream longitudinal section 28 during the movement of the tubular cushioning product 20.

[0050] To produce a discreet upholstery product 20 of a desired length, the starting material 16 has regular

[0051] Perforation lines are located at intervals (viewed in its longitudinal direction). If a desired length of a cushioning product 20 is to be separated from the rest, the rollers 44 of the drive stage 38 are briefly stopped, while the rollers 46 of the drive stage 40 continue to operate when a perforation line is located between the two drive stages 38 and 40. This separates the length of a cushioning product 20 conveyed by the rollers 46 of the drive stage 40 along the perforation line from the residual material held by the stationary rollers 44 of the drive stage 38.

Claims

Patent claims 1. Cushion forming machine (10) with a forming device (22) by which a flat, web-shaped, tubular starting material (16) is expanded into a three-dimensional tubular cushion product (20), wherein the forming device (22) has a floating elongated core (24) onto which the tubular starting material (16) is drawn, wherein the core (24) has at least one longitudinal section (28) having a plurality of contact surfaces (34) extending in the longitudinal direction and spaced apart from one another in the circumferential direction, characterized in that the core (24) has an upstream longitudinal section (26) and a downstream longitudinal section (28), that the upstream longitudinal section (26) has an upstream partial longitudinal section (30) and a downstream partial longitudinal section (32), that the upstream Partial longitudinal section (30) is conically shaped overall,the downstream longitudinal section (32) is cylindrical overall, and the downstream longitudinal section (28) has the majority of contact surfaces (34).

2. Cushion forming machine (10) according to claim 1, characterized in that the contact surfaces (34) are arranged in a substantially uniform distribution in the circumferential direction.

3. Upholstery forming machine (10) according to at least one of the preceding claims, characterized in that the core (24) has at least 3, preferably 4-8, more preferably 4 contact surfaces (34) viewed in the circumferential direction.

4. Cushion forming machine (10) according to at least one of the preceding claims, characterized in that at least one contact surface (34) is arranged at a radially outer end of a core section (37) which, viewed in the axial direction of the core (24), has an approximately triangular cross-section.

5. Cushion forming machine (10) according to at least one of the preceding claims, wherein a width of a contact surface (34) is approximately a maximum of 5%, preferably approximately 1%, of the imagined total circumferential extent of the core (24) in that longitudinal section (28) of the core (24) in which the contact surfaces are arranged.

6. Cushion forming machine (10) according to at least one of the preceding claims, characterized in that at least one of the contact surfaces (34) comprises at least two partial contact surfaces (34 a, 34 b) viewed in the longitudinal direction, wherein an upstream partial contact surface (34 a) has a greater distance (Dl) from a central axis (25) of the core (24) than a downstream partial contact surface (34 b) .

7. Cushion forming machine (10) according to claim 6, wherein the upstream partial contact surface (34 a) is resilient in the radial direction.

8. Cushion forming machine (10) according to at least one of claims 6 or 7, characterized in that radially outwards opposite an upstream A motor-driven conveyor wheel (48) is arranged on the partial contact surface (34 a), which preferably has a has a majority of conveying sections (54) projecting radially outwards.

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