Technical Field

[0001] The technical field of this invention related to the production device of product with plastic film.

Background Art

[0002] Patent No. 6217689, registered with the USPTO under the name Apparatus and method for manufacturing packing material. In this invention it is disclosed:

[0003] An apparatus for manufacturing packing material from a web material includes a folding member that folds the web material into a folded web, a longitudinal sealing assembly for sealing the longitudinal ends of the folded web material forming a continuous tube, and a lateral sealing assembly including a pair of lateral sealing rollers that effect staged lateral sealing of the continuous tube of the web material. Pressurized air is outlet after the longitudinal seal is formed and prior to forming the lateral seal.

[0004] With this arrangement, air-filled pockets suitable for packing material can be readily formed for immediate use. The arrangement is compact in size and capable of producing packing material on-demand and at a sufficient rate to satisfy immediate packing material needs.

[0005] This invention does not describe product packing in machines. It is not specified that whether the output of the machine can be packaged in a box or not? And whether it is possible to connect the end and the beginning of each bag to each other or not? On the other hand, it is not clear whether it can be easier to remove the bag from the box by stacking part of the bags?

Technical Problem

[0006] Traditionally, freezer bags have been manufactured with plastic film in an unhygienic manner and humans take part directly in its production line. In process of its conventional production and consumption, as the whole product is not conserved in the final package, it is unhygienic and practically the quality of the product deteriorates. Traditional machines for manufacturing this product are characterized by high energy consumption efficiency and are not cost-effective.

[0007] At the same time, all types of freezer bags, gloves or any other product that are made with plastic film as disposable, once packed in a box, like a tissue, while picking one, the next one comes out a little to make it hygienic and easier to pick up.

[0008] Otherwise, probably, a large number of bags (for instance, disposable gloves) are accidentally removed from the box, which this process is unhygienic and difficult to do. Another solution is to attach from a few very small sections, the end of one bag to the beginning of the next one. But, in this method, when picking up a bag, the attachment may not be cut properly and more bags may come out from the box. Hence, the produced bags need to be packed and folded in such a way that without connecting, by removing one bag, another bag will come out of the box in half.

[0009] Another issue with plastic film-based freezer bags machines is the slow production while heat treatment. In existing machines, the movement of plastic film to thermal operations for sealing or cutting is stopped, which in turn, causes a slowdown in production.

Solution to Problem

[0010] The present invention develops a new method for freezer bag heat sealing and perforation and folding operations in two lines for different uses. The main feature of this machine is that it can produce plastic in each of its lines at a rate of 120 to 300 cm per minute, which allows folding like a tissue. In this method, the final product will be folded in such a way that part of the produced part is folded while folding the next piece.

[0011 ] The user when using the bags produced by this machine can pull out any piece that is not attached to the next one as the same as a tissue. The piece coming out of the box also brings out the beginning of the next piece. For example, in case disposable gloves are produced with this machine when the glove is pulled out of the box, the beginning of the next glove will also come out of the box. This makes using gloves easier, faster, and more hygienic.

[0012] The machine speed for different products is as follows: a. - Freezer bag 200 cm per second in each separate line which has two lines and 400 meters per second according to the microns of the product, the final weight is 55 kg per hour. b. - Garbage bag 250 cm per second in two separate lines, the total of which is 500 meters per second, and according to the microns of the product, the final weight is 120 kg per hour. c. - Disposable tablecloth 300 cm per second in two separate lines, the total of which is 600 cm / s, which according to the micron of the final product is 240 kg I h d. - Shopping bags 120 cm per second in two separate lines, the total of which is 240 m / s, and according to the microns of the product, the final weight is 80 kg / h

[0013] The plastic film heat sealing operation system in this machine is such that the two thermal jaws are rotary, and in this system, the polyethylene film does not stop and the sealing operation is performed on the film while moving. The strength of this method is that the sealing speed is about 5 times faster than the old conventional systems and it is characterized by a higher sealing quality.

Advantageous Effects of Invention

[0014] • Obviating needs for manpower and manual operations while manufacturing for hygienic purposes

[0015] • Elimination of manpower to improve production efficiency

[0016] • Resolving the defects of previous machines and speeding up the current production rate

[0017] • Improving quality - health - energy consumption efficiency by 80%

[0018] • Increasing the machines manufacturing rate due to the optimization of design and technology [0019] • The best and highest production method

[0020] • Enhancing consumer satisfaction of the final product

Brief Description of Drawings

[0021] Fig 1 : General schematic of the Device

[0022] Fig 2: Independent Type unwind Device Material (PLASTIC)

[0023] Fig 3: Pushing robber roller

[0024] Fig 4: MAIN SEALING KNIFE EQUIPMENT

[0025] Fig 5: Punching equipment

[0026] Fig 6: Overlap robber roller equipment

[0027] Fig 7: Folding Cylinder with vacuum

Description of Embodiments

[0028] Independent type unwind device (1 ) is the first part of the machine that is responsible for unwinding the plastic bolt and supplying the required plastic during the sealing, punching, and perforating process of the machine. This section has an Unwinder Electromotor (101) which is used to unwind the plastic bolt when starting the device. Air Shaft (102) is applied to hold the plastic bolt in the right place for the plastic bolt unwinder electromotor.

[0029] The pushing roller equipment (103) suitable for the plastic bolt is used to properly guide the unwinder plastic film in the appropriate direction to guide it to the sealing operation and subsequent processes of the machine. A tension roller (104) is used to pull the raw materials in a suitable amount and proportion to the speed of the device. The next part is Tension Control Equipment (105), which includes an analog sensor. This sensor is embedded to determine the proper speed of the engine and a Stop sensor is considered to stop the device in case of rupture and cut in the plastic film.

[0030] The operation box panel (electronic box) is the electronic part of the device, which supplies the required electricity and commands all electronic parts, and controls the thermostat and electromotors of the device during operation. [0031 ] Programmable logic controller-PLC is a programmable logic controller that is the main part of device automation as an industrial computer. This section aims to receive the device information by the sensors and plan the activity of the device and send it by electromagnetic relays to all electrical parts of the device. All activities are analyzed by a programmer within the CPU.

[0032] Servomotor drive control is the software driver of the control and monitoring section in the function of electric motors and servomotors.

[0033] Temperature control is responsible for monitoring and planning the thermal temperature control of temperature control thermostats in the thermal sealing part of the device. Vacuum control is the part of controlling and monitoring the activity of the vacuum of the device, which works in the part of folding the final product. Task of Power supply ac-pc is supplying and converting 220V input power to 24V AC and DC voltages required by various electronic parts of the device.

[0034] The next part of the device is the pushing robber roller (3), whose task is to pull the plastic film in proportion to the set speed of the device and feed the film of the machine to the parts of thermal sealing, punch and perforation. Up Robber Roller (301 ) is a rubber roller that is moved by a metal roller under it and is responsible for pulling the material and feeding the film to the sealing, punching and perforating part.

[0035] The Down Metal Roller (302) is driven by a timing belt and servo motor. It is responsible for stretching and feeding the plastic film to the sealing, punching, and perforation parts. Servo Motor is also responsible for providing speed and sizing for the rollers and stretching the film in proportion tO sealing, punching, and perforating parts.

[0036] The next part is the main sealing knife equipment (4), which is responsible for heat sealing the end of plastic bags. In this section, two sealing knives are used, which are moved by Polyamide Sprocket. Up sealing knife (401 ) and down sealing knife (402) which consists of two heat blades (403) made of steel that can be sealed with a thickness of 1 mm on plastic film.

[0037] While sealing knife operation, the two heat blades face each other and perform the sealing operation while moving the plastic film. Teflon tape is attached to the heat blades so that the plastic does not come into direct contact with the steel and the heat sealing process is applied correctly and hygienically.

[0038] The heat required for sealing is provided by the heating element. The whole part of the thermal sealing and the application of the thermal sealing are controlled at intervals and at appropriate times with the program of the machine by the servo motor. Given that the sealing operation is performed by the thermal blades of the rotating sealing knife, there is no interruption in the system and the production speed is not reduced.

[0039] The next part of the device is the punching equipment (5), which is responsible for punching on the plastic film according to the sample designed on the punching blade, in predetermined sizes and models. This part has a servo motor whose task is to move the punch template and determine the punching time on the plastic film.

[0040] Liner bushing (501 ) is embedded to accurately guide the template in the up- down to accurately come on the plastic film.

[0041] A hard chrome shaft (502) is used to hold the liner bushing and the whole template in the right direction (up-down) of the template when punching on the plastic film.

[0042] The cutting blade template (503) is a template on which a cutting blade or punch is held. There are screws (504) on the four sides of this template that allow mm regulation on the punch cutting blade holder.

[0043] The next part is overlap rubber roller equipment (6), whose task is to separate the connection point and stack the edges of the plastic film on each other.

[0044] This part is characterized by metal and rubber rollers by the vacuum system. Up Rubber-Vacuum roller (601 ) is a rubber roller with a v-shaped groove (602) along the surface of the roller. The function of the V-shaped groove is to bend the plastic to fold it. In fact, this groove forces the plastic to bend and fold in the middle of the groove.

[0045] The suction process is used to uptake plastic into the groove. Two valves (603) are located at the beginning and end of the roller or cylinder. These vents are the inlet and outlet of air that vacuums the plastic into the V-shaped groove at specified times. The air is vacuumed through the holes (604) on the surface of the roller and the plastic adheres to the surface of the roller. After the process of bending or folding the plastic again, the valves are closed and the vacuum operation is completed. The same process is repeated in the next period.

[0046] In this part, there is also a metal-vacuum roller (605). The reason that one of the rollers is metal and one is rubber is to prevent static electricity and disrupt the absorption and disposal of plastic film. It also has a v-shaped groove. In this piece, vacuum outlet valves are embedded to overlap or stack the edges of the plastic film after the process of cutting the point to point connection.

[0047] In this part the servo motor allows the rollers to perform the process of cutting the two point to point connection and stacking the edges of the film in the form of overlap. In this part, the vacuum inlet and outlet valves (606) are embedded into rollers equipped with a switch.

[0048] The last part of the device is a folding cylinder with a vacuum (7). There are also grooved cylinders in this section. The vacuum inlet and outlet are also embedded for the final folding process of the product for final packaging.

[0049] The left cylinder (701 ) is characterized by vacuum inlet and outlet holes to fold the final product to the right (702) with vacuum inlet and outlet holes to fold the final product to the left. The cylinders have an inlet (703) and an outlet (704) of vacuum air. There are also vacuum inlet and outlet valves (705) along with switches along this part.

[0050] This part also has a servo motor whose task is to rotate the cylinders at a speed commensurate with the folding process (folding the final product) and finally the packaging part of the final plastic product (706) is embedded to place the final product in boxes and package.

Industrial Applicability

[0051] The invention is applied in factories manufacturing products from plastic film. Products that can be manufactured with this device are plastic bags, garbage bags, disposable tablecloth, freezer bags, and disposable gloves and so on.