Technical Field

The invention relates to the production of bellow bags made of polypropylene (PP) or woven or nonwoven technical fabrics suitable for ultrasonic welding (combining) and other different fabrics.

In particular, the invention relates to an automated production machine and method for producing 3-dimensional bags as self-bellows by means of ultrasonic welded combining, which enables a high reduction of wastes in sacks or bags.

State of the Art

Plastic carrying bags and sacks, nylon bags in other words, have been used in many different sectors for many years and are consumed in very high quantities. In the production of plastic bags with a life time of 12-15 minutes per day, petroleum-derived polyethylene material is used and this material is a major threat to the environment and human health. The time required for degradation of them in nature is 400 to 1000 years at sea, 800 to 1000 years on land. During this degradation, all the harmful materials contained in it pass into the soil and water. During the disposal of plastic bags, many harmful gases are released and this situation causes harm to the environment as well as the use of bags. In addition, transparent ones of these bags absorb the heat by causing greenhouse effect and cause forest fires. Under the influence of light, plastic bags turn into more toxic small petro-polymers. This causes many generations to be negatively affected.

In addition to all these, plastic bags left to nature cause the animals to try to consume them thinking as food and cause their death due to disruption of the digestive systems and cause the ecological balance to be disrupted. It is also known that especially black plastic bags are obtained from garbage and thus are more harmful. Black bags are offered to consumers by separating materials such as buckets, pet bottles and medical waste from the garbage and staining them to black to hide their defects.

Because of the widespread use of plastic bags and their harm to human and environment are known, bags and sacks made of recyclable materials and textile fabrics that protect the environment and support sustainable production are now used. Recycling can mainly be explained by bringinging the recyclable wastes out of use to production as raw materials by various methods. By providing recycling, raw material needs can be reduced, harm to nature and human health is prevented and consumption can be balanced. In addition, the use of recyclable materials as raw materials contributes to the limited consumption of consumable energy resources by saving energy. The recycling process is also of great importance for the prevention of environmental pollution.

The use of products such as bags and sacks made of fabric is becoming increasingly common. Garment stitched products are widely used in the production of sacks and bags made of fabric and the production of this type of products is mostly achieved by manual processes. In this direction, the pieces are cut from the fabric from which the bag will be manufactured according to the desired bag size in the dimensions determined by the molds and these pieces are sewn manually in the garment sewing machines. Then, the handles are also adapted to the bag by hand sewing or by machine with garment sewing. Therefore, a production performed in this way creates a waste of time, increases production costs and can affect the quality standard according to the skill of the person performing the garment sewing process.

In order to provide production without wastage and to realize faster production by reducing production costs, the automated manufacturing system mentioned in the application No 2016/14354 can be mentioned. This manufacturing system basically refers to a manufacturing system in which fabrics are combined by ultrasonic welding technique. Similarly, in order to improve the production without waste, there is an application No 2016/12701 is present in the current technique. The present application relates to a bag- bottom combining machine with ultrasonic welding system, which is basically aimed at combining the base of the bags with separate base and enables a faster production process and a reduction in waste compared to the garment process. These present applications are mainly used for the manufacture of bags using 2 or more processes, but do not include embodiments suitable for the manufacture of bags in a single process. As a result, due to the above-mentioned negativities and the inadequacy of the existing solutions on the issue, a development in the relevant technical field was required.

Brief Description of the Invention

The present invention relates to an ultrasonic welded manufacturing machine and method for obtaining a bellows form carrying bag of polypropylene (PP) or of woven or nonwoven technical fabrics suitable for ultrasonic welding (combining), meeting the above-mentioned requirements, eliminating all disadvantages and introducing some additional advantages.

The primary object of the invention is to provide an automation-dependent bellows bag manufacturing machine and method, which provides a high reduction of wastes in the manufacture of bags or sacks of woven or nonwoven technical or non-technical fabrics suitable for polypropylene (PP) or ultrasonic welding (combining).

It is an object of the present invention to provide a manufacturing machine and method which reduces the production time and costs of the bellow bag and sack manufacturing processes and reduces labor costs.

Another object of the invention is to provide a production machine and method which enables non-standard production to be prevented to produce standard quality products.

It is a similar object of the invention to provide a production machine and method that provides for improved process stability.

In order to fulfill the above-described purposes, the present invention comprises of steps wherein an input unit in which a roll of fabric for the production of a bellow bag or sack of woven or nonwoven technical fabrics suitable for ultrasonic welding (combining) or polypropylene (PP), edge folding unit which allows the two sides of the fabric to be folded and ultrasonic welded in the continuation of the input unit, the handle folding station in which the carrying handles adjusted to the desired size in the bag following the edge folding unit are ultrasonic welded, the first sensing photocell and the first puller driver mechanism determining the place where the handle is to be attached, a pleating unit which enables the folding points to become apparent, the folding station for the overlapping of the two sides of the fabric, the height adjustment station where the length ultrasonic welding point of the bag is adjusted, length welding station which provides ultrasonic welding of one side of the two bags, respectively, the second puller drive mechanism which drives the ultrasonic welded bags to the cutting unit, the cutting station, the transfer conveyor, the shaped bag coming out of the cutting unit and the handles fitted with the handles, so as to provide a desired three-dimensional structure, a bellowing station in which the side bellows and the bottom bellows are opened according to the bag size, triangular cutting and sticking station that cuts the triangular paddles formed in the lower two corners of the box-shaped bag with bellows, and a bellows folding station which allows the bag with the bellows to be folded inwards from the side and bottom bellows surfaces, an ironing and stacking station to which the bags are delivered to maintain the form of the resulting bag and to reduce the volume during the stacking step.

The structural and characteristic features and all advantages of the invention will become more apparent from the following figures and the detailed description made with reference to these figures, and therefore the evaluation should be made considering these figures and detailed description.

Figures to Help Understand the Invention

Figure 1 is a general schematic view of the production system according to the invention.

Figure 2 is a detailed view of the production system according to the invention.

Figure 3 is another detailed view of the production system according to the invention.

The drawings do not necessarily have to be scaled and details which are not necessary to understand the present invention may be omitted. Over and above this, elements which are at least substantially identical or at least with substantially identical functions are designated by the same number.

Description of References

10 Production System

1 1 Input Unit

1 1 1 Roll Loading Station

1 12 Brake Mechanism

12 Edge Folding Station 13 Handle Fitting Station

14 First Puller Drive Mechanism

141 First Sensor

142 First Carrier Mechanism

15 Forming Unit

151 Pleating Unit

152 Folding Station

153 Second Sensor

154 Second Carrier Mechanism

16 Length Combining Station

161 Length Adjuster Unit

17 Second Puller Drive Mechanism

18 Length Cutting Unit

19 T ransfer Conveyor

20 Bellowing Station

21 Cutting and Sticking Station

22 Bellow Folding Station

23 Ironing and Stacking Station

Detailed Description of the Invention

In this detailed description, the ultrasonic welded bellow fabric bag production system (10) and method of the present invention are explained only for a better understanding of the subject and with no limiting effect.

Referring to Fig. 1 , the automation production system (10), which is schematically illustrated comprises of basically an input unit (1 1 ), an edge folding station (12) provided down of said input unit (1 1 ), a handle preparation and fitting station (13) provided behind said edge folding station (12) and the first puller driving mechanism (14) located in the continuation of said handle preparation and fitting station (13) provided with a forming unit (15) and a continuation of said shaping unit (15) after the first puller driving mechanism

(14), a length combining station (16), respectively, in the continuation of said forming unit

(15), a second puller drive mechanism (17), a length cutting unit (18), a transfer conveyor (19), a bellowing station (20), a cutting station (21 ), a bellow folding station (22), and one ironing and stacking station (23). Input unit (1 1 ) according to the invention comprises a roll loading station (1 1 ) and a brake mechanism (1 12) provided in the continuation of said roll loading station (1 1 ). The First Puller Drive Mechanism (14) comprises a first carrier photocell (141 ) and a first carrier mechanism (142) provided in the continuation of said first sensor photocell (141 ). The forming unit comprises a pleating unit (151 ), a folding station (152), a second sensing photocell (153) and a second carrier mechanism (154). A length adjuster unit (161 ) is also provided within said length combining station (16).

In the production system according to the invention, the production of the bag or sack is initiated by placing the fabric forming the bag in roll in the loading unit (1 1 1 ) in the input unit (1 1 ). The fabric contained in the fabric roll may preferably be a woven or non-woven technical fabric suitable for polypropylene (PP) or ultrasonic welding (combining), or preferably any fabric suitable for ultrasonic welding. The fabric loaded in the roll loading station (1 1 1 ) is then directed to the edge folding station (12) by means of the brake mechanisms (1 12). The brake mechanisms (1 12) adjust the tension of the fabric to ensure that it is always fed at the same tension before entering the ultrasonic welding combining process. At the edge folding station (12), the edges of the fabric to be fitted with handles are folded and joined by ultrasonic welding. The purpose of this is to ensure that the edges to be handled are secured. After the edge folding operation, it is provided to attach a handle on the folded edge. Handle fitting is performed by ultrasonic welding at the handle fitting station (13). Handles can be fitted in desired lengths. Attachment of the handles is carried out when the fabric forming the bag is in the open state.

After the handles are adapted to the folded edges, the fabric comes to the first puller drive mechanism (14). Here, the first sensor (141 ) is provided to position the place where the handles desired to be obtained are to be fitted. A photocell is preferably used as the first sensor (141 ).

The fabric which comes to the forming unit (15) is folded and the handles of which are fitted to the folded edges are first taken to the pleating unit (151 ) and folding traces are provided from the bag in accordance with the desired model (bellows etc.). Then, at the folding station (152), the two sides of the bag forming the mouth part are folded so as to overlap or to the brim. In the folding process at the folding station (152), the second sensor (153) is utilized to bring the fabrics to the brim. A photocell is preferably used as the second sensor (153). Following the completion of the folding process, the bag is guided to the length combining station (16) by the rollers in the second carrier mechanism (154).

In the length combining station (16), first of all, the position of the side ultrasonic welding of the bag is set in the length adjuster unit (161 ). Then, ultrasonic welding is performed. The bag, whose side combining is also completed, proceeds to the length cutting unit (18) by means of the rollers in the second puller drive mechanism (17), where the cutting process of the bag is performed. Acquired bag is transferred to the transfer conveyor (19). The transfer conveyor (19) ensures that the bag exiting the second puller drive mechanism (17) is centered on said bellowing station (20). For this purpose, the transfer conveyor (19) is preferably servo-motor controlled.

There are holder tips and opener sleeves at bellowing station (20). The holder tips allow the bag to be opened from the mouth and hold the bag from the combining the bag in order to maintain the position of the bag during the bellowing process. Opener sleeves enter into the bag from the mouth of the bag. Opener sleeves are preferably positioned automatically with servo motor drive according to the size of the bag to be made. When entering into the bag, the opener arms in the closed position are opened with a scissor angle at the width of the bellows desired to be formed at the bottom of the bag. In this way, the bag comes into the shape of a box and the triangular paddles form on the base. The paddles formed at the bottom of the bag are brought to the position of the moving ultrasonic welding unit in the cutting and sticking station (21 ) while the opener sleeves are still in the open position, they are welded by ultrasonic method, ultrasonic or mechanically cut. The bag of which the paddles are cut comes to the bellow folding station (22). Here, the bag with the bellows formed is folded into the interior of the bag by guides moving inwardly from the side and bottom bellow surfaces. Following the completion of the bellow folding process, the bags are directed to the ironing and stacking station (23) to maintain the form of the bag and to reduce its volume during the stacking step. At the ironing and stacking station (23), the bags are preferably passed between the printing and heat applying rollers.

The production system (10) used in the production of bellow bags or sacks with ultrasonic welding combining is operated and controlled by an automation system. Thus, the bag within the compass of the production system (10), can be obtained without leaving the production line (10) and as a result of mass production. In addition to this, wastes occur duringcut of sack or bag material or handle installation with manual garment processes are prevented. In addition, all of the processes are provided within the automation system, so that possible time losses can be avoided, production costs are reduced and standardization of all products is provided.