System for Twisting and Cutting Paper into Packaging Cushioning Field of the Invention This invention relates in general to a system for twisting and cutting paper and more particularly to a system of folding, twisting and cutting paper into paper insulation packing or cushioning material or pet bedding or litter material.

Background of the Invention

When packing and shipping an item from one place to another, the item is typically placed in a container such as a box or envelope. Protective material is either added or is already part of the packing material so as to cushion or protect the item during shipping. One of the most common protective packing materials is made from plastic foam, namely polystyrene, which are typically shaped like a peanut. This material is convenient for packing as it flows easily into the container and fills any voids or spaces not occupied by the item. Although plastic foam peanuts have been used extensively throughout the packing industry, their impact on the environment has not gone unnoticed. Specifically commonly found plastic foam peanuts are not biodegradable and therefore directly impact the world's landfill site and contribute to pollution issues. Furthermore corporations are increasingly more aware of their corporate responsibility to the environment and as such are adopting "green" policies wherever possible. Safety problems also arise during manufacture because the peanuts are formed from a styrene monomer which is hazardous to workers if inhaled or ingested. The packing peanuts also accumulate static charges that cause them to stick to a product when the peanuts are closely packed about the product within a shipping carton. Finally polystyrene peanuts do not absorb the liquid so are not absorbent if there is a leak in the container, and often shrink considerably when exposed to liquid, losing their cushioning effect.

Expanded vermiculite is an alternative packaging material which is suitable for packaging glass containers filled with liquid because it is moisture absorbent. Vermiculite, however, includes fines which adhere to glass and plastic. The fines can contaminate solvents and damage electronic equipment when the fines remain on the products after being unpackaged. As such alternative forms of packaging or cushioning material with similar characteristics to traditional plastic foam peanuts are desirable. Paper is an excellent choice as an alternative as it is biodegradable, is a renewable resource and can be easily recycled in local recycling facilities. Although paper addresses the biodegradable aspect of the packing material, making the paper have the ability to pour or flow like plastic foam peanuts has proved more challenging.

Prior art packing or cushioning materials formed from paper have attempted to address the noted problems. For example recycled newspaper has been used to form a biodegradable, recyclable packaging material. These materials, formed from aqueous slurries of chopped newspapers, are molded into thin hollow walled shells or are extruded as pellets. Although these materials employ waste paper materials, they have several drawbacks. Such packaging materials do not have the cushioning properties and low density provided by expanded foam materials. The materials also require a significant amount of storage space before they are reused or transported for recycling. Packaging material has also been produced from paper forced through a die-forming process. Both processes however are complicated having exacting requirements and parameters.

A variety of methods and systems for producing a packing material or cushioning material are known in the art, and more particularly cushioning-producing methods embodying methods for converting a continuous web of sheet-like material such as paper into a generally continuous, resilient, pad-like cushioning product for use in packing and cushioning articles or products in shipping containers and the like.

Other systems have attempted to "crumple" or twist the paper into balls or peanuts so as to increase the paper's ability to flow. Such prior art mechanisms and methods are either too complex for the quality of packaging material produced, or they do not produce packing material which has suitable resiliency for giving good cushioning protection to articles disposed in shipping containers. Another example of an alternative method has been to crumple paper material manually with the packers crumpling the material and placing it into the containers as needed. The latter method is inefficient and time consuming but an option as these other methods generally either require too much storage space or are too expensive. In general all of these methods have been fraught with problems namely paper jams, issues with feeding or positioning the incoming paper into the system and effectively twisting or crunching the paper into the peanut like shape. Other challenges in developing a workable system included the ability to pull paper from the centre of the roll. Prior art devices and systems encountered difficulties from pulling the paper from the centre of the paper roll. Typically there were inconsistencies in the wind per foot ratio. More specifically the wind per foot ratio changes as the paper is pulled, namely after 3 inches of paper is removed from core, the wind to length ratio became 1 turn per foot of paper. By the end of the paper roll having a 36 inch diameter, the wind per foot ratio is down to 113 inches per rotation. The drop in the ratio dramatically affects the twist ratio and the tightness of the finished product or packaging cushioning. As such a system that could intake the paper with the varying twist rate and result in a consistent paper product ready to be fed into the machine for processing is needed.

Another challenge with prior art devices is the overall complexity and associated weight which precludes the device from being portable. Typical designs or systems are often very heavy and upwards of 140 lbs even without a feed system or stand. The reason for this excessive weight is due to the required robustness needed to handle the gyroscopic precession of the offset driver gears in relation to the rotational Y axis. Specifically, if the offset is not adjusted, its operation can produce destructive forces at 1700 RPMs resulting in the necessity for additional weight to keep the system stable.

Thus a paper twisting system which allows the paper to be easily fed into the system, which twists or crunches the paper effectively and shapes the paper into the required shape to allow the resulting packaging cushioning material to flow or pour into a container, is desirable.

Summary of the Invention

An object of one aspect of the present invention is to provide an improved system for twisting and cutting paper into packaging cushioning. In accordance with one aspect of the present invention there is provided a system for twisting and cutting paper into packaging cushioning including a feeder assembly having a series of rollers for intake, folding and creasing the paper, a forming assembly having a series of pulling wheels for twisting the paper and a cutting assembly having at least one blade for cutting the twisted paper into packaging cushioning. Conveniently, the series of rollers include a first set of rollers adapted to accept the paper and are positioned at offset angle to a central plane of the feeder assembly between 25 to 45°; a second set of rollers positioned vertically relative to the central plane of the feeder assembly and adapted to accept the paper and position the paper to form at least two vertical pleats; a third set of rollers positioned horizontally relative to the central plane of the feeder assembly and are height offset to one another providing creasing tension against the paper as it passes up and over the third set of rollers; a fourth set of rollers positioned vertically relative to the central plane of the feeder assembly and adapted to accept the paper and collapse the paper for engagement with a fifth set of rollers positioned horizontally relative the central plane of the feeder assembly that pinch the paper to a width of 1 to 0.5 inch.

In accordance with another aspect of the present invention, the forming assembly is positioned a twisting distance from the feeder assembly and may be defined as the distance the paper travels from the fifth set of rollers to the pulling wheels of the forming assembly. More preferably the speed of the pulling wheels may be adjustable and have a twist rate of the paper to length of paper is 1.5 twists per foot of paper.

In accordance with another aspect of the present invention, the forming assembly may further include feed wheels adapted to engage the pulling wheels at a 1 to 4.15 ratio. The feed wheels preferably rotate at a maximum of 481 RPMs and may have a diameter whereby the paper moves at a maximum speed of 477 feet per minute.

In accordance with another aspect of the present invention, the cutting assembly is positioned a maximum of 4 inches from the feed wheels and further includes pinch shears that engage the paper and advance the paper to the blade for cutting.

Advantages of the present invention are a lightweight portable system, a system capable of pulling paper such as a 14" wide x 350 lb roll of kraft paper, through the machine from the centre of a roll of paper, operates under a 15 amp/120 volt standard outlet and switchable voltage frequency drives for international compatibility, meets industrial sound requirements as well as safety standards, produces packaging cushioning at a certain rate, for example 4 cubic feet per minute.

Brief Description of the Drawings

A detailed description of the preferred embodiments is provided herein below by way of example only and with reference to the following drawings, in which: Figure 1 in a side view, illustrates a system for twisting and cutting paper into packaging cushioning in accordance with the preferred embodiment of the present invention;

Figure 2a in a top view, illustrates the system of Figure 1.

Figure 2b in a perspective view, illustrates the system of Figure 1. Figure 2c in a side view, illustrates the system of Figure 1.

Figure 2d in a front plane view, illustrates the feeder assembly of the system of Figure

1.

Figure 3 in a perspective view, illustrates the feeder assembly of the system of Figure

1. Figure 4 in a top perspective view, illustrates the forming assembly of the system of

Figure 1.

Figure 5 in a cross sectional view, illustrates the forming assembly of the system of Figure 1.

Figure 6 in a perspective view, illustrates the forming assembly of the system of Figure 1.

Figure 7a in a top view, illustrates the cutter assembly of the system of Figure 1. Figure 7b in a perspective view, illustrates the cutter assembly of the system of Figure

1.

Figure 7c in a front plan view, illustrates the cutter assembly of the system of Figure 1.

Figure 8a in a side view, illustrates the back plate of the cutter assembly of the system of Figure 1.

Figure 8b in a front view, illustrates the back plate of the cutter assembly of the system of Figure 1. Figure 8c in a perspective view, illustrates the back plate of the cutter assembly of the system of Figure 1. Figure 9a in a top view, illustrates the pressure plate of the cutter assembly of the system of Figure 1.

Figure 9b in a front view, illustrates the pressure plate of the cutter assembly of the system of Figure 1. Figure 9c in a perspective view, illustrates the pressure plate of the cutter assembly of the system of Figure 1.

In the drawings, preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.

Detailed Description of the Preferred Embodiment

Referring to Figures 1 to 9, there is illustrated in schematic views, a system for twisting and cutting paper 10 into packaging cushioning in accordance with a preferred embodiment of the present invention. The system for twisting and cutting paper 10 into packaging cushioning includes a feeder assembly 12 having a series of rollers 14 for intake, folding and creasing the paper. A forming assembly 16 may have a series of pulling wheels 18 for twisting the paper. A cutting assembly 20 may have at least one blade 22 or cutter back blade shear for cutting the twisted paper into packaging cushioning.

The series of rollers 14 may be further defined to include a first set of rollers 24 adapted to accept the paper and are positioned at offset angle to a central plane of the feeder assembly 12 between 25° to 45°. More specifically the first set of rollers 24 is offset by 39° to the central plane of the feeder assembly 12. The offset angle of the first set of rollers 24 is critical in that too shallow of an angle results in the paper snagging as the paper roll approaches its 18 inches offset pull point. Too great of an angle on the first set of rollers 24 however results in the rollers becoming ineffective and causes the paper to bunch towards the direction of the paper unwind.

The feeder assembly 14 prevents fluctuations in the paper input with the changing diameter of the roll of paper. The ability of the feeder assembly 12 to control input of the paper as it is removed from the varying diameters of the roll allows for a consistent packaging cushioning and superior twisting. A second set of rollers 26 may be positioned vertically relative to the central plane of the feeder assembly 12 and is adapted to accept the paper and position the paper to form at least two vertical pleats. More specifically the second set of vertical rollers 26 may form four pleats in the 13 ¾ inch wide kraft paper roll. The spacing between these rollers can vary and can therefore provide a varying result. For example as the spacing between the rollers becomes wider more pleats were formed. As the spacing between the rollers becomes narrower the opposite occurs, and less pleats are formed. The preferred operational distance between the vertical rollers was extremely critical with a total variance of width of less than ½" . A third set of rollers 28 may then be positioned horizontally relative to the central plane of the feeder assembly 12 and are height offset to one another providing creasing tension against the paper as it passes up and over the third set of rollers 18. The third set of rollers 28 preferably includes at least two rollers whereby one roller pushes up and the other roller pushes down so that the rollers are pushing against each other when the paper is in between them so as to form the crease.

The height offset of the individual rollers may be between 0.8 inches to 2.2 inches and preferably 0.7 inch. The variation of the height offset for the third set of rollers 28 which provides horizontal creasing may have a significant effect on the amount of energy required to pull the paper through the forming assembly. Specifically significant back pressure can occur when the packaging cushioning has a varying density. In general the desired density of the packaging cushioning is approximately 1.1 lbs per cubic foot. For example the placement of the third set of rollers 28 that provide the horizontal creasing affects the final packaging cushioning weight by approximately 1.8 lb per cubic foot to 0.7 lb per cubic foot. This variance was realized with an offset of only 0.7 of an inch.

A fourth set of rollers 30 may be positioned vertically relative to the central plane of the feeder assembly 12 and adapted to accept the paper and collapse the paper. The fourth set of rollers 30 may collapse the paper from 14 inches to 6 inches for engagement with a fifth set of rollers 32 positioned horizontally relative the central plane of the feeder assembly 12 that pinch the paper to a width of 1 to 0.5 inch. The fifth set of rollers 32 may be further defined as pinch horizontal rollers spaced approximately 0.875 inches apart. The forming assembly 16 may be further defined as being positioned a twisting distance from the feeder assembly 14. The twisting distance may be defined as the distance the paper travels from the fifth set of rollers 32 to the pulling wheels 18 of the forming assembly 16. Typically the distance is 24 ½ inches so as to form a consistent twist. Over this distance the paper is typically twisted to a rate of 4.15 twists per 12 inches. The positioning of the feeder assembly 14 to the forming assembly 16 creates a back tension on the paper feed into the forming assembly 16. An increase in the back tensions results on a tighter or denser packaging cushioning.

The level of twist, namely either a tighter or a looser twist, may be dependant on the density required by the packaging cushioning. The level of twist or twist rate may be controlled or determined by the speed of the paper pulling wheels 18. As such the series of pulling wheels 18 of the forming assembly may operate at different speeds. Specifically the increasing of the speed of the paper pulling wheels 18 results in less twist to the packaging cushioning and a decreased speed provides for more twists. The twist to length ratio also has a great impact on the resulting packaging cushioning namely the density and its ability to hold shape overtime. Typically, the tighter the twist on the packaging cushioning, the better ability it has to hold its shape over time. However a tighter twist results in a higher density namely it exceeds the desired parameters of 1.1 lb per cubic foot. To achieve this desired parameter, specific paper may be required to stay within the design parameters. The parameter of the 1.5 twist per foot is very critical in all brands and types of paper used.

The paper travels from the feeder assembly 14 through a funnel 34 to the forming assembly 16 where it is grabbed and twisted and then discharged through a first discharge chute 36 at a very high rate of speed. For example at 2000 RPM's the paper moves 479 inches per minute and pulling wheels 18 move at 481.92 RPMs providing 4.15 twists per 11.93 inches. The twist level of the paper is critical as it moves through the forming assembly 16. More specifically if the paper is twisted too loosely, the paper may begin to unfold resulting in unusable packaging cushioning.

The forming assembly 16 may be further defined as a pulling assembly 38. The pulling assembly 38 includes a front motor housing 40 have a main shaft 42 and shaft bearing. The main shaft 42 may be hollow and have a diameter of 1 to 1.5 inches and preferably 1.125 inches. The pulling assembly 38 further includes a first gear assembly 43 having a series of pulleys 44 and gears 45 adapted to engage the main shaft 42.

A second gear assembly 48 includes a shaft 50 and a pulley system 52 that connects the second gear assembly 48 to the main shaft 42 and is adapted to control the speed of a series of pulling wheels 18 relative to the rotation of the main shaft 42. The ability for the second gear assembly 48 to rotate at a speed that differs from the main shaft speed, allows the main shaft 42 to rotate at 4.15 turns to 1 turn of the pulling wheels 18. More specifically there is at least two second gear assemblies 48 positioned on either side of the main shaft 42.

The series of pulling wheels 18 and preferably two pulling wheels are connected to the hollow main shaft 42. More specifically the shaft 50 of the second gear assembly 48 is connected directly to pulling wheels 18 by a second shaft 60. The pulling wheels are set a distance of approximately 0.1 to 0.5 inches and preferably 0.3 inches apart from one another to form a gap. The pulling wheels 18 are positioned relative the hollow main shaft 42 by an inner and outer series of brackets 62. The inner and outer brackets 62 are positioned relative to the second gear assembly 48. The pulling wheels 18 rotate within the hollow main shaft 42 and allow the paper to engage the pulling wheels 18 at the gap when the paper enters the forming assembly 16. Too large of a gap between the pulling wheels 18 will not allow the paper to be grabbed by the pulling wheels as it will "slip". Too small of a gap will not allow the paper to consistently engage between the pulling wheels 18 and can cause a paper jam. The configuration of the forming assembly 16 of the present invention furthermore allows for an overall lighter system. As noted above traditional systems are excessively heavy due to the required robustness needed to handle the gyroscopic precession of the offset driver gears in relation to the rotational Y axis. Typically this offset was approx 3.14 inches off the Y axis which produced destructive forces at approximately 1700 RPMs. Specifically, the higher RPMs put excessive stress on the bearing and bolts of the system.

The instant invention eliminates the offset of these drive gears with a reduction in the offset rotational mass. Specifically this was accomplished by bringing the large paper pulling drive gears in line with the Y axis of rotation which resulted in neutral force about the Y axis. After the force was eliminated the forming assembly 16 was much lighter by using smaller bearings, thinner framework, smaller gears, and in some cases light weight timing belts. As a result the instant configuration weighs approximately 37 pounds and as such is portable. Furthermore the instant system for twisting and cutting paper may operate on a 15 amp/120 volt standard outlet. Traditional twisting and cutting systems have encountered high drag and offset forces that maximize the amount of the power available from a 15 amp/120 volt standard outlet. Typically the only way to lower the power required is to reduce the speed which has the net effect of producing less product per minute.

However the system for twisting and cutting paper into packaging cushioning of the instant invention is able to reduce the required power by reducing the gyroscopic precession forces and therefore able to maintain or speed up the rotation thereby producing more product per minute at approx 4 amps at 120 volts. Furthermore the instant system for twisting and cutting paper is significantly quieter than typical systems as traditional straight cut bevelled gears were replaced with very quiet gait polly chain belts. Typically the upper limit of speed on the main shaft of the forming assembly is 2000 RPMs. The ratio between the main shaft and the paper pulling wheels 18 is approximately 4.15 to 1 ratio whereby the pulling wheels 18 operate at 481 RPMs. The diameter of the pulling wheels is typically 3.795 inches, which gives the paper a theoretical speed of 5,731 inches per minute or 477 feet per minute through the forming assembly 16. Beyond this speed the paper is no longer effectively folded or twisted.

Adjusting the diameter of the pulling wheels 18 will affect the twist ratio. The larger the diameter of the pulling wheels the faster the speed of the paper being fed. The faster the wheels turn the less twist there is in the packaging cushioning. The pulling wheels typically rotate at a speed from 48 RPMs to 481 RPMs.

As the paper enters the forming assembly 16 it engages the paper pulling wheels 18 which then feed the paper through to the rotating hollow main shaft 42. During this process the paper is continually twisted and is then expelled from the first discharge chute 36 at a very high rate of speed. The paper exits the first discharge chute 36 towards the cutting assembly 20 positioned a short distance from the forming assembly 16.

As paper does not push well during processing and is easier to pull, the distance between the forming assembly 16 and cutting assembly 20 is critical to allow for only a pulling action. More specifically the distance from the forming assembly 16 to the cutting assembly 20 and specifically the pinching shears is no longer than 4 inches. A greater length than 4 inches results in paper jams. This length also represents the length of the final product. With respect to the cutting assembly 20, all pinch points were removed to improve safety and the cutting shear 22 is fully enclosed giving the end user no possible access to the blade while the machine is running. Traditional systems often have the cutting assemblies and specifically the blades spinning freely and easily accessible with no guards. The cutting assembly 20 may be further defined as a momentum cutter that may include an automatic sharpener. The sharpener may also include an in place oiling unit. A pressure plate 62 may be further included with the cutting assembly 20 so as to maintain pressure on the blades and reduce shear.

Finally the instant system for twisting and cutting paper may further include a second discharge chute system having a redirection stop that is positioned after the cutter assembly. The second discharge chute system may be positioned approximately six inches after the cutter assembly. As the packaging cushioning exits the cutter assembly it will encounter the second discharge chute system where it will encounter the redirection stop. Upon engaging with the redirection stop the packaging cushioning will stop its trajectory and gravity will force it to exit out of the second discharge chute.

The second discharge chute system prevents the packaging cushioning from losing its shape or blowing open as it exits the forming and cutting assembly at approximately 2000 RPMs or approximately 500 feet per minute. Furthermore the positioning of the second discharge chute relative to the cutting assembly results in additional safety to the entire system as it obstructs access to the cutting assembly and more specifically the cutting blade and cutter back blade shear. Finally the second discharge chute allows for the accurate positioning or placement of the packaging cushioning improves noise reduction of the cutting blade shearing the twist to length and reduces the amount of free dust created from the cutting process as it empties out of the bottom of the second discharge chute in a contained fashion with the packaging cushioning.

The system for twisting and cutting paper is able to produce packaging cushioning at a volume of 4 cubic feet per minute by way of example.

In operation the paper is removed from the centre of a roll of kraft paper namely, the paper is pulled from a 14" wide x 350 lb roll of kraft paper. As the paper exits the roll of kraft paper, it has a varying twist rate per foot ratio and a varying pull point. The varying pull point may be defined as the result of pulling paper out of the centre of the roll. Typically when a roll of paper is new, the paper leaves the roll from a point or position at its dead centre. As the roll of paper is consumed, the hole in the centre of the roll of paper becomes larger and the point of removal of the paper moves outwards.

Typically this central point is approximately ½" off centre. As the paper roll is consumed the pull point shifts outwards to a final offset of 18". Typically there is a varying twist rate from 1 twist per foot to 1 twist per 9.42 foot by the end of a 36" diameter roll.

Given the changing diameter of the pull point as the paper is consumed, the first set of rollers act as an input into the feeder system to address the offset and the pull point shifts.

As noted the first set of rollers is offset between 25 to 45 degrees from the central plane to reduce snagging as the paper roll approaches its 18" offset pull point. As the paper moves to the second set of rollers which are vertically oriented, four pleats are formed in the 13 ¾" wide paper roll.

After the pleats are formed the pleated paper then proceeds through to the third set of rollers oriented horizontally and have a height offset of 1.5 inches. The third set of rollers crease the pleated paper. Creasing the paper gives the packaging cushioning the ability to hold its shape after it has been formed. Typically the paper tends to unfold once it has been folded if it is not creased.

After the paper has cleared the third set of rollers, the paper moves to the forth set of rollers that are oriented vertically. The fourth set of rollers proceeds to collapse the paper to approximately 1.37" and prepare the paper for engagement by the fifth set of rollers. The fifth set of rollers further comprises at least two horizontal pinch rollers. The fifth set of rollers prevents the paper from twisting as it goes through the feeder system.

Both the fourth and fifth sets of rollers set the pleating and crease in the paper and prepare it for the twist process as it approaches the forming assembly. These rollers allow the paper to twist from this point forward into the forming assembly but do not allow it to twist before this point. There is no specific speed that the paper has to travel through the feeder assembly.

The paper now exits the feeder assembly and moves towards the forming assembly for further processing. Specifically after leaving the feeder assembly the paper enters a twisting space or breathing space defined as the distance between the feeder assembly and the forming assembly. Typically the distance is 24 ½ inches so as to form a consistent twist. Over this distance the paper is twisted to a rate of 4.15 twists per 12 inches.

Within the forming assembly, the paper enters the forming assembly via the funnel and engages the gap between the paper pulling wheels which grab the paper and creates a pinch point that allows the paper to be twisted as it flows through the hollow main shaft which is rotating. The rotation of the main shaft results in the paper twisting. This process results in the continued twisting of the paper, resulting in the paper being expelled from the discharge chute at a very high rate of speed. The paper is fed into a 1.15" diameter hole and that is where the twisting takes place. As the paper exits the first discharge chute, the paper moves towards the cutting assembly positioned a short distance from the forming assembly. Specifically the length from the forming assembly to the pinching shears of the cutting assembly is no greater than 4 inches. The pinching shears put a very tight crimp at the end of the discharging paper product and support the advancement of the packaging cushioning through the cutting assembly. The crimp is necessary to hold the paper shape at the high rate of speed 477 feet per minute otherwise the paper would blow open.

The paper then is cut by a blade into 4 inch long segments whereby a 12 foot cubic void may be filled within two minutes. The system for twisting and cutting paper 10 further includes a foot pedal that allows the operator to bypass the automatic mode of the system and control the process. When the foot pedal is depressed the system 10 is engaged and the paper is twisted and cut. As soon as the pressure is removed from the pedal the system 10 returns to standby.

Other variations and modifications of the invention are possible. All such modifications or variations are believed to be within the sphere and scope of the invention as defined by the claims appended hereto.