EP3284588B1 - Device and method for manufacturing filler material - Google Patents

Description

The present invention relates to a device and a method for producing filling material. Such devices and methods have long been known from the prior art. Such filling material is placed in boxes, for example, to protect goods to be shipped or to fill empty spaces so that goods to be packaged cannot be moved too much within a larger box. Such devices are known from the prior art. These usually have guide curves with mechanisms coupled to one another, with a feed mechanism being provided that advances a paper strip, as well as a stamping mechanism that on the one hand cuts the paper into strips and on the other hand presses such cut strips through matrices. These devices known from the applicant's internal prior art have proven themselves, but have the disadvantage that, particularly at higher throughput rates, the coupling and the provision of the guide curves have a speed-limiting effect.

The WO 2011/025614 A1 describes a method and a device for producing packaging padding. The US 5,257,492 describes a method and a device for producing packaging material from a band-like material with a conveyor device and a cutting device, wherein paper strips are deformed by rotating rollers.

The EP 2 719 528 A1 describes a device for producing a cushioning product from paper with an output channel which conveys separated paper sections to an output opening, this channel being designed in such a way that a user cannot reach a cutting device through it. The US 2009/0082187 A1 describes a device for producing packaging material in which material is compressed in one direction and then connected to a carrier.

The present invention is therefore based on the object of providing a method and a device which allow a higher throughput. These objects are achieved according to the invention by the subject matter of the independent patent claims. Advantageous embodiments and further developments are the subject matter of the subclaims.

The invention is directed to a device for producing filling material according to claim 1.

Advantageously, these are drives that can be controlled independently of one another. By providing different drives, it is possible to dispense with a mechanical coupling between the transport and pressing processes. This enables more precise control and the throughput rates can also be increased considerably. In detail, different drives allow for significantly better coordination than the guide curves known in the state of the art or generally in the case of a mechanical coupling.

Advantageously, at least one of the two drives is an electric motor and in particular a servo motor. Preferably, there is no mechanical coupling between the first transport device and the pressing device. Preferably, however, the corresponding drives are controlled in coordination with one another.

In a further advantageous embodiment, the pressing device has a pressing body which presses the strips through the matrices in order to produce the filling material. This filling material is curved material scraps, for example curved paper scraps or the like. The material to be conveyed is advantageously a paper or cardboard material. However, it could also be a plastic material or generally a recyclable material. In a further advantageous embodiment, the matrices have a cross-shaped cross-section. This can in particular be a cross with curved arms. Such a matrix produces the corresponding filling material in a particularly advantageous manner.

In a further advantageous embodiment, the pressing device moves a pressing ram substantially perpendicular to the conveying direction of the material.

The device advantageously has at least two stamps, which are preferably coupled to one another or which preferably press different strips through the matrices synchronously. The device advantageously has at least four and advantageously at least six such stamps. These stamps can be arranged next to one another in groups of two stamps each, for example, and can also preferably be attached to a common stamp carrier, which presses these stamps against the material in order to produce the filling material.

In a further advantageous embodiment, the device has an insertion opening and in particular an insertion slot, with which the direction of movement of the filling material, more precisely the paper material strip, is also aligned. This insertion slot is preferably arranged in front of the first transport device. Furthermore, it would also be possible for lateral guide elements to be connected to this insertion slot, which prevent the paper material from deviating or drifting laterally from its transport direction. It is possible for such lateral guide elements to be adjustable, for example in order to be able to switch the device to different widths of the material strip.

In a further advantageous embodiment, the device also has a guide device for guiding the stamps and/or for guiding the stamp movement.

Advantageously, a movement of the first cutting device is coupled with a movement of the stamp or pressing device. This makes it possible that when the pressing device is placed on the transported paper material, the latter is first cut and then the individual strips are pressed through the dies.

In a further advantageous embodiment, a cutting element and/or several cutting elements are arranged between individual pressing devices.

In a further advantageous embodiment, the device has a second conveyor device which is arranged along the conveying direction after the first conveyor device and which is also suitable and intended to transport the elongated material along the predetermined conveying direction. Preferably, the second conveying direction also has its own drive. This own drive can be controlled independently of the above-mentioned first drive. It is therefore also possible for these two drives to convey the material at different times or periods. The device therefore preferably has at least three drives and in particular three independent drives.

In a further advantageous embodiment, a buffer area is arranged between the first conveyor device and the second conveyor device, which can accommodate different amounts of the elongated material strip. This buffer area can, for example, be a simple empty section through which the material runs, whereby more or less of the material can be accommodated in this area.

The material strip is advantageously deflected in this buffer area. Preferably, the material strip can move freely in this buffer area. Preferably, the material in this area is therefore not contacted by transport or guide elements such as rails, rollers or the like. Preferably, the material strip is deflected at least once in this area. Preferably, the material strip is deflected at least once in this area by at least 40°, preferably at least 60°, preferably at least 100° and particularly preferably at least 140°. Preferably, the material strip is deflected at least twice in this area. Preferably, the material strip is also deflected at least 40°, preferably at least 60°, preferably at least 100° and particularly preferably at least 140° during the second deflection. Preferably, the material strip is conveyed at least in sections in a horizontal direction. Preferably, the material strip is therefore conveyed in a serpentine manner in said buffer area. However, it would also be possible for buffering elements such as so-called dancer rollers to be arranged in the buffer area.

This procedure makes it possible for the two conveyor systems to run independently of each other. For example, when only the first conveyor system is in operation, the buffer is emptied, whereas when the first conveyor system is in operation, it is only filled up.

In a further advantageous embodiment, at least one conveyor device is suitable and intended to convey the material strip in a timed manner. Both conveyor devices are advantageously suitable and intended to convey the material strip in a timed manner. In this way, the overall production process can be accelerated, since a pressing process can be carried out during downtimes, for example.

In a further advantageous embodiment, the device has a plurality of cutting elements arranged one behind the other along the conveying direction, each of which is suitable and intended to cut the material in the direction deviating from the conveying direction.

As mentioned above, this is preferably a direction that is perpendicular to the conveying direction. This procedure, particularly in conjunction with cyclical operation, allows a large number of strips to be cut at a time and then pressed through the die using the stamping device. For example, four, six or eight pieces of filling material can be produced in a single pressing process.

The device advantageously has a receiving container for receiving the filling material. This receiving container can directly receive the filling bodies pressed through the die.

In a further advantageous embodiment, the device has at least one control device for controlling the drives of the first conveyor device and the pressing device, wherein these drives are controlled in such a way that the strips of tape are pressed through the matrices while the strips of tape are not conveyed in the conveying direction. This means that the tape is conveyed to a position, then at a standstill is cut, and in the next step the bodies or the filling material are pressed out of the strip.

In a further advantageous embodiment, the device has a second cutting device which cuts the material strip in a direction that deviates from the conveying direction by no more than 30°. This cutting device advantageously cuts the material strip exactly in the conveying device or at an angle that deviates from the conveying direction by no more than 10°, preferably no more than 5°. In a further advantageous embodiment, the cutting device is a movable cutting blade, for example a rotatable cutting blade. This can, for example, be arranged centrally in the area of a width of the material strip and cut it into two parallel strips that extend in the conveying direction. The second cutting device is preferably arranged in front of the first cutting device. This means that in terms of the process, the material strip is preferably first cut in its direction of extension and then transversely to it. In a further preferred embodiment, the second cutting device also has a drive device, such as in particular but not exclusively an electric motor.

Preferably, however, the drive of the pressing device is coupled to the drive of the first cutting device.

In a further advantageous embodiment, at least one conveyor device has a conveyor roller which conveys the material strip in the conveying direction. For example, the first conveyor device can have two conveyor rollers which work together and push the strip through between them.

In a further advantageous embodiment, the second conveyor device also has a conveyor roller. In this case, a counter plane can also be arranged, along which the material strip is conveyed by this conveyor roller. For example, the material strip can slide with respect to a counter plane and be pushed along this counter plane by the corresponding second conveyor roller. This counter plane can also have rollers by means of which the material is conveyed. These rollers can be passive.

In addition, the device can have lateral guide elements which ensure a substantially straight-line transport or a transport in which the paper strip cannot deviate laterally from its transport path. These lateral guide devices can be designed as lateral rails, for example. In this way, it is ensured that the material strips cannot be moved laterally at least in a direction perpendicular to the material strip and in particular also in a direction running horizontally.

Advantageously, the second cutting device is arranged in the said conveying plane.

In a further advantageous embodiment, at least one conveyor device has two rollers, i.e. one roller and one counter roller. These can be spaced apart from one another, in particular for introducing the material strip. In this way, the material strip can first be threaded through and then the rollers can start operating, i.e. enable the material strip to be conveyed.

In a further advantageous embodiment, the device has a carrier on which at least the first conveyor device and the second conveyor device are arranged. For example, a carrier plate can be provided on which both the drives for the conveyor rollers and the drives for the pressing device are arranged.

In a further advantageous embodiment, the pressing device has a worm motor or a motor which is geared down to achieve the pressing movement.

In a further advantageous embodiment, the device has a transmitting device which is suitable and intended to transmit data characteristic of the device. This can be data which is characteristic of an operation of the device, for example. The transmitting device is preferably suitable and intended to transmit this data wirelessly.

Preferably, the data are selected from a group of data which are characteristic of an operating time of the device, which are characteristic of a material processed by the device, which are characteristic of an ageing and/or wear state of the device and/or components of the device, which are characteristic of fault conditions of the machine and the like.

In addition, data can also be transmitted using the transmitter, which indicates, for example, the exchange of machine parts and/or wearing parts. For example, information can be output that the user has replaced a certain wearing part, such as a die. The corresponding times of such a change can also be transmitted. This gives the manufacturer the opportunity to monitor whether components are being replaced properly.

In this way, the machine manufacturer can react very quickly to any errors that occur. The machine manufacturer can also quickly identify possible sources of errors.

This transmitting device is preferably in communication with a control device of the device. This can output the corresponding data to the transmitting device. The transmitting device can preferably be a GSM module. In addition, however, data transmission via secure connections such as VPN lines would also be possible. In addition, it would also generally be possible for the data to be transmitted via the Internet. In a further preferred embodiment, the device also has sensor devices which are suitable and/or intended to detect machine states. This can be, for example, temperatures, torques or the like. Such data can also be output by means of the transmitting device.

In a further preferred embodiment, the device has a storage device which records data characteristic of the operation of the device (such as the data mentioned above). In this way, long-term monitoring of the device is possible. The data stored by this storage device can also be transmitted by the transmitting device.

In a further preferred embodiment, a control device is designed in such a way that it only enables the device to operate if the transmission of data via the transmission device is also possible. If, for any reason, the transmission of data by the transmitting device is or will be interrupted, the control device can stop the device from operating and/or prevent the machine from starting.

It is also possible that if the transmission is interrupted by the transmitting device, a warning is first issued to a machine operator and only after a certain time does the device stop operating. The transmitting device preferably has a transmitting element such as a transmitting antenna. It would be possible for the device to be interrupted when the transmitting antenna is removed, for example. For example, mechanical interruption elements can be provided, such as switches that switch the device off when the transmitting antenna is removed. Detection means could also be provided that detect the lack of data communication and switch the device off accordingly.

It is possible for the transmitting device to transmit data continuously, but it would also be possible for data to be transmitted in a timed manner or at certain defined intervals. For example, a protocol with data could be transmitted at regular intervals.

In a further advantageous embodiment, the device also has a receiving device which is suitable and intended for receiving signals and/or data. In this case, control data can be transmitted to the device, for example a software update can be transmitted. The receiving device is also advantageously suitable and intended for receiving data wirelessly.

The present invention is further directed to a method for producing filling material and in particular for producing filling material from paper or cardboard or similar recyclable materials according to claim 11.

Advantageously, the pressing device and the conveyor device are driven at different times. Preferably, the material strips are pressed by the dies while the material belt is at a standstill in the conveying direction.

Advantageously, the material strip is buffered in at least one section of the device, i.e. a different amount of material strip is accommodated.

In a further preferred method, the material strip is conveyed by two successive conveyor devices, wherein these two conveyor devices are operated independently of one another and preferably convey the material strip at least temporarily at different times.

In another preferred method, the material strip is conveyed in a cyclic manner.

Advantageously, the material strip is also cut in a further cutting direction, which runs in particular in the extension direction of the material strip.

Preferably, the material strip is cut with cuts that are at least temporarily perpendicular to each other.

Fig. 1

eine Gesamtdarstellung einer erfindungsgemäßen Vorrichtung 1;

Fig. 2

eine Darstellung eines Schneid- und Presswerkes für die in Figur 1 gezeigte Vorrichtung;

Fig. 3

eine weitere detailliertere Darstellung der in Figur 2 gezeigten Vorrichtung;

Fig. 4

eine Draufsicht entlang der Linie D-D aus Figur 2;

Fig. 5

eine Darstellung entlang der Linie C-C aus Figur 3;

Fig. 6

eine Darstellung der Schneideinrichtung; und

Fig. 7

eine Darstellung der Rückseite der erfindungsgemäßen Vorrichtung.

Further advantages and embodiments can be seen from the attached drawings:
In it show:

Fig. 1

an overall view of a device 1 according to the invention;

Fig. 2

a representation of a cutting and pressing plant for the Figure 1 device shown;

Fig. 3

a further detailed presentation of the Figure 2 device shown;

Fig. 4

a plan view along the line DD Figure 2 ;

Fig. 5

a representation along the line CC from Figure 3 ;

Fig. 6

a representation of the cutting device; and

Fig. 7

a representation of the back of the device according to the invention.

Figure 1 shows a representation of a device 1 according to the invention for producing filling material. A carrier roll 25 is provided on which a paper material 20 is stored and from which the paper material 20 is unrolled. The paper material is preferably strip-shaped. The reference number 2 designates a first transport device which serves to transport the paper strip 20 in the direction X. This transport device has two transport rollers 32 and 34, of which, however, preferably only one roller is driven. A corresponding drive device, such as an electric motor, is not shown. These rollers 32 and 34 can be tensioned towards one another by means of a pretensioning device (not shown) in order to be able to guide the paper material safely. It would also be possible for these two rollers to be temporarily spaced apart from one another in order to be able to thread a material strip, for example.

The reference number 4 designates a second transport device which, as explained below, is also suitable and intended for transporting the paper tape in the direction X. This second transport device 4 has a driven transport roller 42 and a counter roller 44. Preferably, one of these two rollers is again driven by a drive (not shown). The reference number 46 designates a support surface on which the paper tape 20 can rest and which it can be moved.

The reference number 6 designates in its entirety a cutting device which serves to cut the material strip. This cutting device has three cutting elements 62, 64 and 66.

The reference number 12 designates in its entirety a pressing device which is suitable and intended for pressing individual strips of material through matrices. This pressing device has a drive 24. This drive has a drive wheel 52 which drives a rack 54 and moves it downwards in the direction Y to achieve pressing.

Figure 2 shows a detailed view of the Figure 1 shown device. The three matrices 82, 84 and 86 through which the material strips are pressed can also be seen here. In addition, a second cutting device 18 is shown, which cuts the paper material in the transport direction X, in this case into two strips that are essentially parallel to one another. These strips are then cut in the transverse direction by the cutting device 6 and then pressed through the matrices. In this way, six filling bodies can be produced by one pressing process.

The reference symbol PB designates a buffer area of the material belt. This is located here between the first and the second conveyor. It can be seen that in this area the material is essentially conveyed in a serpentine manner. If, for example, the second conveyor 4 is stationary and the second conveyor 2 continues to move, the buffer area PB is also filled up further. Conversely, this buffer area is emptied when the first transport device 2 is stationary and only the second transport device 4 is moving.

The reference number 70 designates a carrier on which three pressing rods 72, 74 and 76 are arranged. These serve - as mentioned above - to press the paper material, which has already been cut in the longitudinal and transverse directions, through the individual matrices 82, 84 and 86.

Figure 3 shows a further detailed representation of a device according to the invention. Here, the individual cutting elements 62, 64 and 66 are also shown, which cut the material in a direction perpendicular to the plane of the figure. The reference numerals 68 identify guide elements or counter-cutting elements, which serve to guide the cutting elements. The reference numeral 65 indicates pre-tensioning devices with which the guide elements 68 are pre-tensioned, here in the Figure 3 to the right - i.e. in the direction of the respective cutting element.

Figure 4 shows a view along the line DD in Figure 2 Here you can see the three matrices 82, 84 and 86, each of which has cross-shaped openings (for reasons of clarity only the openings 82a and 82b shown). The roller 44 can also be seen, which interacts with the Figure 3 shown roller 42 serves to convey the paper strip as well as the counter-pressure roller 16, which serves with the cutting roller 18 to cut the paper strip in the transport direction X. The counter-pressure roller 16 has a slot 16a into which the cutting edge of the cutting roller 18 can penetrate.

Figure 5 shows a view along the line CC from Figure 3 . Here, a cutting element 62 is again shown, as well as the guide element 68, which also serves as a counter-cutting element. To carry out the cutting process, the cutting element 62 is fed downwards in the Y direction. More precisely, this is a pivoting movement of the cutting elements, which also has a component in this Y direction. The dies 82 can also be seen again. The reference number 24 designates a drive motor, which drives a gear 52 via a reduction gear, and this in turn drives the rack 54. A pressing body is arranged on this rack, which presses the paper strips through the die. In addition, the drive motor also drives the cutting element 62 via a drive rod 56. This creates a mechanical coupling between the movement of the pressing bodies and the movement of the cutting elements. However, it is also conceivable that these movements are adjustable relative to one another, i.e. it can be set when the cutting process is finished before the pressing process begins.

Figure 6 shows a detailed representation of the cutting device 6. The individual cutting elements 62, 64 and 66 are shown again, as well as two counter-cutting bars 68 and also the pre-tensioning means or springs 65, which push the respective counter-cutting bars 68 in the direction of the cutting elements 62, 64 and 66 assigned to them. The reference number 60 designates a carrier on which the cutting elements 62, 64 and 66 are arranged together. It can be seen that the cutting elements 62, 64 and 66 do not move exactly in the direction Y, but are pivoted about a rotation axis D. In this way, the cut is not carried out at all points at the same time, but runs in the said transverse direction Z from the inside to the outside.

Figure 7 shows a rear view of the device according to the invention. The reference number 50 refers to a control device which controls the individual drives of the device 1. This control device is located on the rear of the carrier 30, ie on the opposite side to the actual device. Preferably, this control device controls all drives which are responsible for the transport and the pressing process.

The reference number 100 designates a control device for controlling the device 1. This control device can control the individual drives, such as the drives of the transport devices. The reference number 18 designates a transmitting device that is suitable for wirelessly outputting data and/or signals. This transmitting device 14 can also be in communication with the control device and receive data from it.

The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided that they are new individually or in combination compared to the prior art. It is also pointed out that the individual figures also describe features that can be advantageous in themselves. The person skilled in the art will immediately recognize that a particular feature described in a figure can also be advantageous without adopting further features from this figure. The person skilled in the art will also recognize that advantages can also arise from a combination of several features shown in individual or different figures.

list of reference symbols

D

axis of rotation

PB

buffer area

X

Direction

Y

Direction

Z

transverse direction

1

device

2

first transport device/conveyor device

4

second transport device/conveyor device

6

cutting device

12

pressing device

14

transmitter

16

counterpressure roller

16a

slot in counterpressure roller

18

cutting device/cutting roller

20

paper material/paper tape/material tape/elongated material

24

drive/drive motor

25

carrier role

26

conveyor roller

30

carrier

32

transport roller

34

transport roller

42

transport roller

44

counter-role

46

support surface

50

control device

52

drive wheel/gear

54

rack

56

drive rods

62

cutting element

64

cutting element

65

pre-tensioning devices

66

cutting element

68

guide element/counter-cutting bar

70

carrier

72

press rod

74

press rod

76

press rod

82

die

84

die

86

die

100

control device

Claims (11)

1. Apparatus for producing filling material, having a first conveying device (2) which is suitable and intended for conveying an elongate material strip (20) along a predetermined conveying direction (X), and having a first cutting device (6) which is suitable and intended for cutting the material strip (20) into strips in a direction which deviates from the conveying direction (X), and having a pressing device (12) which presses these strips through dies (82, 84, 86) in order to produce the filling material from these strips,
   wherein different drives (24) are provided at least for the pressing device (12) and the conveying device (2) and the dies have a cross-shaped cross-section and the pressing device moves a pressing punch substantially perpendicular to the conveying direction of the material.
2. Apparatus (1) according to claim 1,
   characterized in that
   the apparatus (1) has a second conveying device (4) which is arranged along the conveying direction (X) after the first conveying device (2) and which is also suitable and intended for transporting the elongated material (20) along the predetermined conveying direction.
3. Apparatus (1) according to claim 2,
   characterized in that
   a buffer area (PB) is arranged between the first conveying device (2) and the second conveying device (4), which can accommodate different quantities of the elongated material belt (20).
4. Apparatus (1) according to at least one of the preceding claims,
   characterized in that
   at least one conveying device (2, 4) is suitable and intended for conveying the material belt (20) in a clocked manner.
5. Apparatus (1) according to at least one of the preceding claims,
   characterized in that
   the apparatus (1) has a plurality of cutting elements (62, 64, 66) arranged one behind the other along the conveying direction (X), which cutting elements are each suitable and intended for cutting the material belt in the direction (Y) deviating from the conveying direction (X).
6. Apparatus (1) according to at least one of the preceding claims,
   characterized in that
   the apparatus has at least one control device (50) for controlling the drives of the first conveying device (2) and the pressing device (12), which controls these drives in such a way that the tape strips are pressed through the dies (82, 84, 86) while the tape strips are not conveyed in the conveying direction (X).
7. Apparatus (1) according to at least one of the preceding claims,
   characterized in that
   the apparatus (1) has a second cutting device (18) which cuts the material belt (20) in a direction which does not deviate by more than 30° from the conveying direction (X).
8. Apparatus (1) according to at least one of the preceding claims,
   characterized in that
   at least one conveying device (2, 4) has a conveyor roller (32, 42) which conveys the material belt (20) in the conveying direction (X).
9. Apparatus (1) according to at least one of the preceding claims,
   characterized in that
   the apparatus (1) has a carrier (30) on which at least the first conveying device (2) and the pressing device (12) are arranged.
10. Apparatus (1) according to at least one of the preceding claims,
    characterized in that
    the apparatus has a transmitting device which is suitable and intended for transmitting data characteristic of the apparatus and/or an operation of the apparatus (1).
11. Method for producing filling material, wherein a material belt (20) is transported by a first conveying device (2) in a conveying direction (X) and strips of material are cut off from the material belt by a first cutting device along a first cutting direction (Y) which deviates from the conveying direction (X) and these strips of material are pressed through dies (82, 84, 86) in order to produce the filling material, wherein the conveying device (2) and the pressing device are driven by different drives (24) and the dies have a cross-shaped cross-section and the pressing device moves a pressing punch substantially perpendicular to the conveying direction of the material.

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