“On demand”apparatus and method for producing air-cushioning product
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-031/12
출원번호
US-0669684
(1984-11-09)
발명자
/ 주소
Caputo Garry L. (464 Riverside Ave. Rutherford NJ 07070)
인용정보
피인용 횟수 :
58인용 특허 :
1
초록▼
There is depicted and claimed “on demand”apparatus and method for producing air-cushioning material for end-user manufacture. There are two arrangements and both provide economy of apparatus, space, labor and materials. Two thermoplastic film strips are carried from roll storage means to this air-cu
There is depicted and claimed “on demand”apparatus and method for producing air-cushioning material for end-user manufacture. There are two arrangements and both provide economy of apparatus, space, labor and materials. Two thermoplastic film strips are carried from roll storage means to this air-cushioning forming means whereat the webs of film are locally heat-sealed together. A first film is fed to a heated roll whereat this film is heated sufficiently to be thermoformed on a cooled roll with cavities formed therein. These cavities are manifold-connected to a source of vacuum which draws the heated film into the formed cavities. The second strip of film is fed to another heated roll having a resilient covering material with thermoconductive metal powder as a substantial component, thus providing sufficient thermoconductivity and resilience to heat-seal or weld this second film to those areas around the cavities formed in the first film. This resilient surface or cover surface on the heated roll is sufficient to accommodate imperfections on interstice portions of the forming roll to effect full welding of those portions of film between formed cells. A cooled roll is provided to set the seal and/or welds of the strip of air-cushioning product. The product may then be stored in roll form or cut to short lengths for immediate use.
대표청구항▼
A method for producing air-cushioning material for end users\consumption in their own facilities, said material being from two rolls of thermoplastic material such as polyethylene or the like which may be combined with other plastic materials to provide air passage-inhibiting properties, said method
A method for producing air-cushioning material for end users\consumption in their own facilities, said material being from two rolls of thermoplastic material such as polyethylene or the like which may be combined with other plastic materials to provide air passage-inhibiting properties, said method providing means for a start and stop of the apparatus by the operator and without alteration of the produced product by said starting and stopping of the apparatus for an “on demand”manufacture and supplying of air-cushioning material to said facility, said method including the steps of: (a) providing a first roll of thin, thermoplastic film having thermoforming properties when heat-softened; (b) carrying said roll on a supported shaft and as a continuous strip of film and replacing said roll on said shaft when replenishing the film on the first roll is desired or required; (c) rotating and driving a first heat-conductive roller to and carrying on said roller the strip of first film around which the wrap extent is at least one hundred fify degrees of arc; (d) electrically heating said first film on said first heat-conducting roll to a temperature between two hundred and two hundred sixty degrees F. and with a thermostatic control of said first heat-conductive roller whereby and whereon the first film is heat-softened to a thermoforming condition; (e) rotating a cooled, driven forming roller adjacent to and spacing said forming roller from the first heat-conducting roller so that non-contact is maintained with said first heat-conducting roller and providing between said first roller and said forming roller an S-path of heat-softened first film, said forming roller having its outer peripheral surface with a controlled temperature and formed with a multiplicity of shaped cavities, and providing each cavity at its inner extent a small conductor leading to a conductor connected to a source of vacuum; (f) carrying valve means in association with a conductor to said source of vacuum, and providing with this valve means a mask, of a determined extent or sector therewith, and opening of about one-half of the small conductors from the shaped cavities to a source of vacuum so that the heat-softened first film when coming in contiguous contact with those cavities connected to said source of vacuum is drawn by vacuum into these shaped cavities forming shaped cell forms, this forming roller cooling the now-formed first film while rotatably and tightly carrying this first film by vacuum on said driven forming roller; (g) providing a second roll of thin, thermoplastic film as a lidding cover for the air-cushioning material; (h) driving a thermoconductive pressure roller and heating said roller to a selected temperature by electrical energy and providing on this roll a resilient, thermoconductive cover or outer layer on said pressure roller, said cover having sufficient resiliency and thermal conductivity so that with a wrap of less than ninety degrees of arc, said second lidding film is heated to a welding condition, and with the second film in a wrap condition on said pressure roller, said heat is sufficient that the peripheral temperature of the roller brings the second film to a temperature of at least two hundred seventy degrees F. and while the first thermoformed and heated film is brought in way of this second heated, lidding film, pressing these films together into a welded condition, the cover on this pressure roller sufficiently resilient so that with a minimum of applied pressure the second heated film is pressed to and into the first thermoformed film so that at the peripheral interstices between shaped cavities and at the outer surface of the forming roller the welding is achieved, the peripheral speed of the driven pressure roller and the forming roller substantially in coincidence, the welding of the two plies of film material providing in the thermoformed air-cushioning material a multiplicity of air-encased cells, and moving the pressure roll toward and away from the forming roll and adjustably applying such pressure and maintaining said pressure to accommodate the type and thickness of the films being welded; (i) thermostatically controlling the electrical heating of said drive thermoconductive pressure roll to maintain the temperature in said lidding material provided by this second film where and when the wrap of film is on said roll; (j) cooling a chill roll and positioning said roll so as to receive the welded strip of material and engaging said welded air-cushioning strip on the outer surface of said material, this cooling sufficient to bring the welded air-cushioning material to a temperature that is at or near room temperature, and (k) carrying said cooled air-cushioning material to accumulation means such as a storage roll or a packing table.
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