The present invention relates to an apparatus for forming void-fill packaging, particularly but not necessarily exclusively for paper- or cardboard-based void-fill packaging. A method of operating a void-fill packaging-forming apparatus, and a metering system for producing void-fill packaging are also provided.

Void-fill material, such as folded paper is well-known for insertion into parcels to help protect the contents from shock and damage, and can be inserted into spaces or voids which exist between the contents and the sides of the parcel.

In order to increase a volume of a paper- or cardboard-based void-fill material so as to be able to absorb shocks, the void-fill material must be folded into preferably random folds which are relatively resiliently crushable. This provides a cushioning effect within parcels.

In order to fill a parcel, void-fill packaging must be produced to size, and this is typically performed based on the judgment of the user. It is therefore relatively easy to overproduce void-fill packaging, and waste packaging is often then just discarded without use.

The present invention seeks to provide an improved apparatus for the production of void- filled packaging which limits the waste of void-fill material without reducing the ability to effective package goods in parcels. According to a first aspect of the invention, there is provided a void-fill paper-packaging apparatus comprising: a void-fill paper-packaging material guide path; a crushing mechanism on the void-fill paper-packaging material guide path through the apparatus, the crushing mechanism including at least one rotatable crusher element for crushing void-fill paper-packaging material introduced via an inlet of void-fill paper-packaging material guide path, the or each rotatable crusher element having a plurality of longitudinal crusher projections thereon; drive means for moving the void-fill paper packaging material along the void-fill paper-packaging material guide path; and a cutting mechanism comprising a cutter on the void-fill paper-packaging material guide path; the drive means being operable in first and second opposite directions, the crushing mechanism being coupled to the drive means so as to be only drivable in the first direction, and the cutting mechanism being coupled to the drive means so as to be only drivable in the second direction.

The linking of the crushing and cutting mechanisms, whilst separating their operation by the different directions of drive, allows for a simple means of producing void-fill paper packaging from a single point of control. This dramatically improves the speed with which large volumes of void-fill paper-packaging can be produced to order.

Preferably, the crushing mechanism may comprise first and second rotatable crushing elements which respectively include first and second roller bushings and which are respectively attached to first and second crusher-drive gears, which may be unidirectional needle roller bushings. Optionally, the crushing mechanism may be coupled to the drive means via a sprag clutch or other suitable one-way freewheel device.

In one embodiment, the drive means may comprise a motor having an output shaft which is drivable in either the first direction or the second direction, and a drive belt which is engagable with the crushing mechanism and cutting mechanism.

Preferably, the cutting mechanism may comprise a roller bushing which is attached to a cutter-drive gear, which may be a unidirectional needle roller bushing. Furthermore, the cutting mechanism may be coupled to the drive means via a sprag clutch.

The driving arrangement of the present apparatus beneficially allows for the separation of the crushing and cutting mechanisms. This is achieved using unidirectional shafts in the gearing of the various components, preventing the movement of the void-fill material whilst cutting occurs. Similarly, the cutter is isolated whilst the crushing process is active.

Preferably, there may be provided a material feed element which is positioned on the void-fill paper-packaging material guide path upstream of the crushing mechanism, the material feed element folding the void-fill paper-packaging material prior to insertion into the crushing mechanism.

The material feed element may advantageously manipulate the void-fill paper-packaging material prior to crushing so as to improve the volumetric increase of the void-fill paper packaging which is expelled from the apparatus.

The apparatus may further comprise a support frame to permit freestanding positioning of the apparatus. The provision of a support frame can advantageously allow for ready repositioning of the apparatus whilst also permitting portable usage of the apparatus. This improves the general utility of the apparatus.

Preferably, there is provided a controller associated with the drive means, the controller having a wireless communication means arranged to receive a wireless control signal, the controller automatically activating the drive means based on the wireless control signal. The wireless communication means may be an RFID communication means. Furthermore, the controller may include a void-fill paper-packaging measurement sensor, the controller automatically switching the drive means between the first and second directions when the void-fill paper-packaging measurement sensor determines that a predetermined length of void-fill paper-packaging has been processed as indicated by the wireless control signal.

The provision of such a control mechanism allows for precise metering of the void-fill paper-packaging which is produced by the apparatus, allowing a user to minimise wastage, and therefore minimise expenditure on the raw void-fill paper-packaging material, which can amount to the majority of the cost of packaging for a parcel.

In one embodiment, the drive means may include a manually-operable foot pedal.

The provision of a manual control mechanism allows for a user to accurately produce and cut bespoke void-fill packaging material to fit a particular parcel.

According to a second aspect of the invention, there is provided a method of operating a void-fill paper-packaging apparatus preferably in accordance with the first aspect of the invention, the method comprising the steps of: a] driving a drive means of the apparatus in a first direction to operate a crushing mechanism thereof, void-fill paper packaging material being drawn through the crushing mechanism as it is driven; and b] driving the drive means in a second direction which is opposite to the first direction to disengage the crushing mechanism and operate a cutting mechanism of the apparatus, to cut a void-fill paper-packaging produced by the apparatus.

The drive means may preferably include a controller which is automatically activatable via a wireless communication means arranged to receive a wireless control signal, the controller automatically performing both of steps a] and b]. According to a third aspect of the invention, there is provided a metering system for producing void-fill paper-packaging, the system comprising: a void-fill paper-packaging apparatus for forming void-fill paper-packaging, and at least one wireless communication element associated with void-fill packaging material to be processed by the void-fill paper-packaging apparatus; the void-fill paper-packaging apparatus having: a controller associated with drive means for moving the void-fill material through the apparatus, the controller having a wireless communication means arranged to receive a wireless control signal from the at least one wireless communication element, the controller automatically activating the drive means based on the wireless control signal.

The provision of a metering system which uses wireless communication elements to automatically control an amount of void-fill paper-packaging material which is utilised advantageously reduces the waste void-fill material used by such an apparatus.

The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a side representation of one embodiment of an apparatus for forming void-fill packaging in accordance with the first aspect of the invention;

Figure 2 shows a rear perspective representation of an upper portion of the apparatus shown in Figure 1, with a casing removed;

Figure 3 shows a front perspective representation of the upper portion of the apparatus shown in Figure 2;

Figure 4 shows an enlarged front perspective representation of a drive arrangement of apparatus as visible in Figure 2;

Figure 5 shows a side representation of the drive arrangement shown in Figure

4; and

Figure 6 shows a cross-section in a vertical plane containing line A-A through the apparatus shown in Figure 1.

Referring to Figure 1, there is illustrated a void-fill packaging apparatus, indicated globally at 10. In this embodiment, the apparatus 10 is designed specifically for forming crushed or folded paper or cardboard packaging, but could readily be adapted for other void-fill materials which are to be crushed or folded in a similar manner. For example plastics materials could be formed into void-fill packaging using this apparatus 10. However, the apparatus 10 can primarily be considered to be a void-fill paper-packaging apparatus 10.

The apparatus 10 comprises a support frame 12 which in use supports a main processing unit 14. A void-fill material support 16 may be provided at or adjacent to the support frame 12 which acts as a holding means for void-fill material to be processed by the processing unit 14. In the present embodiment, the void-fill material support 16 is provided as a reel holder for retaining a reel 18 of void-fill material to be unspooled during operation of the processing unit 14.

The support frame 12 is preferably provided so as to be three-dimensionally adjustable. A base frame 20 provides a stable platform for the support frame 12, and is preferably provided so as to be portable, here having a plurality of caster wheels 22. The base frame 20 is connected to an adjustable bracket 24 which is in turn connected to a, preferably telescopic, frame member 26. The frame member 26 may be rotatably adjusted in the bracket 24 to alter a yaw of the processing unit 14, which is positioned at an in use uppermost end of the frame member 26.

The processing unit 14 may be connected to the frame member 26 via a pivotable hinge 28 which allows for a pitch of the processing unit 14 relative to the support frame 12 to be adjusted.

The processing unit 14 is preferably provided having an external housing 30, which may be formed as a single piece of material which encases the processing components of the processing unit 14. The external housing 30 is removed for clarity in Figures 2 and 3.

A rear of the processing unit 14 can be seen in Figure 2, with an inner casing 32 of the processing unit 12 being visible. A material feed element 34 may be provided so as to extend in a direction of the void-fill paper-packaging material support 16 relative to the inner casing 32, that is, upstream on a void-fill material guide path of the apparatus 10, which is here formed as a trapezoidal or tapered platform 36 having a pair of side walls 38 upstanding therefrom. At a distalmost end of the material feed element 34 there is preferably provided a roller 40 which acts to ease void-fill material along the trapezoidal platform 36 towards a crushing mechanism 42 of the processing unit 14 in use. Void-fill material, such as void-fill paper-packaging material, fed along the trapezoidal platform 36 is folded or concertinaed roughly by the side walls 38 to be fed into the crushing mechanism 42 to be flattened in its folded state to increase a volume of the void-fill material once processed.

Figure 3 shows an output region of the processing unit 14. The drive arrangement 44 of the processing unit 14 can be more readily seen in Figure 3, and this will be discussed in detail below.

The output region includes a guide plate 46 along which processed void-fill packaging is ejected from the processing unit 14 from an opening 48 of the inner casing 32 in which the crushing mechanism 42 is housed. A cutter 50 may preferably be provided at or adjacent to the opening 48 cut the processed void-fill material to length once ejected.

Figures 4 and 5 show in more detail the drive arrangement 44 of the processing unit 14. A drive output 52 is provided, here illustrated as a toothed shaft extending from one side of the inner casing 32, and the drive output 52 is connected to a drive belt 54 to provide drive to the other components of the drive arrangement 44, such as a drive motor.

First and second crusher-drive gears 56, 58 are provided which are coupled to and provide the drive to first and second rotatable crushing elements 60, 62 of the crushing mechanism 42 via output shafts 64. The first crusher-drive gear 56 is a compound gear having first and second gear tooth sets. The second crusher-drive gear 58 is provided as a single gear which meshingly engages with the first gear tooth set of the first crusher- drive gear 56. The second gear tooth set of the first crusher-drive gear 56 is therefore used to engage with the drive belt 54. A cutter-drive gear 66 is also provided in engagement with the drive belt 54 at or adjacent to the output region of the processing unit 14.

The first and second crusher-drive gears 56, 58 are arranged to be driven when the drive output 52 provides motive power to the drive belt 54 in a first direction, with the cutter- drive gear 66 freewheeling in this direction. If the drive output 52 is reversed, with the drive belt 54 being driven in the opposite direction, that is, from clockwise to anti clockwise or vice versa.

The internal operation of the drive arrangement 44 can be seen in Figure 6. Each of the first and second crusher-drive gears 56, 58 is attached to the output shafts 64, which preferably are formed as first and second roller bushings. The rotatable crushing elements 60, 62 are then attached to the output shafts 64, with each rotatable crushing element 60, 62 here having a plurality of axially-extending or longitudinal projecting members 68 which assist with crushing of the void-fill paper-packaging material passed along a void-fill material guide path through the apparatus 10, though alternative crushing elements could of course be considered.

A plurality of guide members 70 may also be provided at or adjacent to the crushing mechanism 42 which assist with directing the void-fill paper-packaging material through the crushing mechanism 42 along the void-fill paper-packaging material guide path. Such guide members 70 may have rounded end portions to assist with progression of the void- fill paper-packaging material along the void-fill material guide path.

Each of the first and second roller bushings are preferably provided as unidirectional needle bushings which engage with their respective crusher-drive gears 56, 58 in the first direction, but disengage when driven in the second direction, thus freewheeling. This allows the void-fill paper-packaging material to be drawn along the void-fill paper packaging material guide path when the drive arrangement 44 is activated in the first direction, but no reverse force is applied when the direction of drive is reversed. As such, processed void-fill paper-packaging material cannot be unintentionally drawn back into the crushing mechanism 42 once produced.

The unidirectional needle bushings are preferably formed such that an outer run in the bushings are engaged with one or more springs. In the first direction of drive, the spring will urge the needle bearings into engagement with the respective runs of the bushings, forming a coupling between the rotation of the crusher-drive gears 56, 58 and the output shafts 64. However, when rotating in the second direction, the needle bearings will urge against the spring, decoupling the crusher-drive gears 56, 58 and the output shafts 64, and hence permitting the freewheeling condition.

A cutter mechanism 72 is provided in connection with the cutter 50, which is coupled to the drive means 44 via the cutter-drive gear 66. The cutter 50 is positioned so as to be downstream of the crushing mechanism 42 on the void-fill paper-packaging material guide path. In the present embodiment, the cutter-drive gear 66 is also connected to an output shaft 74 which is preferably formed as a roller bushing, and more preferably as a unidirectional needle bushing which is arranged so as to counter-rotate to the needle bushings of the crushing mechanism 42. As such, the cutter 50 is only actuated when the drive arrangement 44 is active in the second direction, and freewheels in the first direction.

The cutter mechanism 72 may be provided having a gear linkage 76 so as to couple to the cutter 50, with a high gear ratio to provide a powerful cutting action.

The drive arrangement 44 is preferably powered by an electric motor 78, which could be powered using a rechargeable power source, or could alternatively be mains electricity connected. The output of the electric motor 78 is coupled to the drive output 52 to provide motive force.

In use, the drive arrangement 44 can be activated in the first direction. The cutting mechanism 72 is not driven, as its output shaft 74 freewheels. The crushing mechanism 42 is, however, driven, which causes the first and second rotatable crushing elements 60, 62 to rotate. This rotation simultaneously draws and crushes void-fill paper packaging material into the void-fill material guide path.

As the void-fill material is drawn towards the crushing mechanism 42, it is folded or fluted by the material feed element 34, as the side walls 38 urge the void-fill paper-packaging material into itself. This folding or fluting is typically random, but the void-fill paper packaging material could feasibly be partially pre-folded in order to effect a desired folding arrangement.

The folded void-fill paper-packaging material is then crushed by the first and second output shafts 64, acting as rotatable crusher elements, to flatten the folds of the void-fill paper-packaging material against one another. The rotation of the first and second rotatable crushing elements 60, 62 urges the crushed and folded void-fill paper packaging material out of the opening 48 of the processing unit 14, ejecting a stream of void-fill paper-packaging, having an increased volume when compared with the pre- processed void-fill paper-packaging material.

When a desired length of void fill paper-packaging has been created, the direction of the drive arrangement 44 can be reversed. This disengages the crushing mechanism 42, as the first and second output shafts 64 are allowed to freewheel, whilst engaging the cutting mechanism 72. The cutter 50 is urged through the ejected and stationary void-fill packaging, cutting the void-fill packaging to a desired length. Typically, the apparatus 10 may include a manually-operable mechanism, such as a foot pedal, via which the drive means 44 can be operated in either the first or second direction, according to user preference.

However, it may also be possible to provide a controller associated with the drive arrangement 44, which has a wireless communication means arranged to receive a wireless control signal. The controller may then automatically activate the drive arrangement 44 based on the wireless control signal. The wireless communication means may preferably be an RFID communication means.

Furthermore, the controller may include a void-fill packaging measurement sensor. The controller may automatically switch the drive arrangement 44 between the first and second directions when the void-fill packaging measurement sensor determines that a predetermined length of void-fill paper-packaging has been processed as indicated by the wireless control signal. The void-fill paper-packaging measurement sensor is preferably formed as an inductive pick-up at or adjacent to the motor 78, which can convert the rotational output of the drive output 52 into a nominal linear distance of void- fill packaging produced.

This may be implemented by providing one or more RFID elements which can activate the controller. The RFID elements may be provided which indicate a certain length, for example, of void-fill paper-packaging to be output by the apparatus 10, and to what desired length that should be.

The controller and RFID elements may preferably be capable of bidirectional communication. This may allow the controller to void the RFID element once used, thereby providing a metering system for a void-fill packaging-forming apparatus 10.

This control mechanism may be generalised so as to provide a metering system for a wide variety of void-fill packaging apparatus, such as for those that produce plastics- based packaging, for example. Such a metering system for producing void-fill packaging may comprise a void-fill packaging apparatus for forming void-fill packaging, and at least one wireless communication element associated with void-fill packaging material to be processed by the void-fill packaging apparatus. Provided that the void-fill packaging apparatus has a controller associated with drive means for moving the void-fill material through the apparatus, and that the controller has a wireless communication means arranged to receive a wireless control signal from the at least one wireless communication element, then the controller can automatically activate the drive means based on the wireless control signal. This could obviously be used in conjunction with the above referenced driving arrangement in order to provide automated cutting of the void-fill packaging as well as for automated driving through the apparatus.

Whilst the embodiment of the apparatus hereto described includes a pair of rotatable crushing elements, it will be appreciated that it may be possible to provide only a single drivable roller which acts to crush the void-fill material against a hard surface.

It is therefore possible to provide an apparatus for producing void-fill packaging which has a driving arrangement which is bidirectional. The first direction allows for crushing of the void-fill material to form void-fill packaging, and the second direction stops the flow of void-fill material, cutting off the void-fill packaging produced. This reduces the amount of wastage of void-fill material due to inaccurate manual cutting of the packaging, whilst also improving the efficiency with which the packaging is produced.

The words ‘comprises/comprising’ and the words ‘having/including’ when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.