Method and apparatus for a product settler

Abstract

A method and apparatus for settling a product in a package made on a form, fill and seal machine. In one aspect the invention comprises the steps: providing a package material on a product conduit of a form, fill and seal machine; forming a first end seal on the package material to form a partially formed package; filling the partially formed package with product; and settling the product in the partially formed package while continuously conveying the package material along the product conduit. In a second aspect, the invention comprises a product settler comprising a first object positioned to cause an impact against a package material. The impact agitates the package material and settles a product from an unsettled height to a settled height while the package material is continuously conveyed.

What is claimed: 
     
         1 . A method for settling a product in a package made on a form, fill and seal machine, the method comprising the steps:
 a. providing a package material on a product conduit of a form, fill and seal machine;   c. forming a first end seal on the package material to form a partially formed package;   d. filling the partially formed package with the product; and   e. settling the product in the partially formed package while continuously conveying the package material along the product conduit.   
     
     
         2 . The method of  claim 1  further comprising the step:
 f. forming a second end seal on the partially formed package to form a package from the partially formed package. 
 
     
     
         3 . The method of  claim 1  further comprising the step:
 b. sealing the package material to form a longitudinal seal. 
 
     
     
         4 . The method of  claim 3 , wherein the first end seal is approximately perpendicular to the longitudinal seal. 
     
     
         5 . The method of  claim 1 , further comprising the step:
 directing a gas into the partially formed package.   
     
     
         6 . The method of  claim 5 , wherein the gas is directed into the partially formed package as a first jet of gas. 
     
     
         7 . The method of  claim 5 , wherein the gas pressurizes an interior of the partially formed package. 
     
     
         8 . The method of  claim 1 , wherein the settling step further comprises the steps:
 pressurizing an interior of the partially formed package to provide resistance; and   intermittently contacting the partially formed package to move the partially formed package, thereby moving the product.   
     
     
         9 . The method of  claim 1 , wherein the settling step further comprises the steps:
 rotating a paddle wheel comprising a paddle;   intermittently rotating the paddle into contact with the partially formed package, thereby moving the product while the product is inside the partially formed package.   
     
     
         10 . The method of  claim 9 , wherein an actuator rotates the paddle and stops the paddle in a desired position. 
     
     
         11 . The method of  claim 1  wherein the package material is a film. 
     
     
         12 . An improved continuous motion form, fill and seal machine, said machine comprising a product conduit, a conveyor, and seal jaws; wherein the conveyor is positioned to convey a package material that is wrapped around the product conduit; wherein the conveyor moves the package material along the product conduit; wherein the seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package; wherein the product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit; and wherein the product conduit is positioned above the seal jaws; wherein the improvement comprises:
 a product settler comprising a first object positioned to cause an impact against the package material;   wherein the impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit.   
     
     
         13 . The machine of  claim 12 , wherein the machine comprises a source of pressurized gas. 
     
     
         14 . The machine of  claim 13 , wherein the machine comprises a nozzle to direct the pressurized gas into the package material. 
     
     
         15 . The machine of  claim 12 , wherein the product settler comprises a controller to set a number of impacts per minute that the first object causes on the package material. 
     
     
         16 . The machine of  claim 12 , wherein the product settler comprises a positional sensor to determine a position of the first object. 
     
     
         17 . The machine of  claim 12 , wherein the impact occurs on one and only one face of the partially formed package. 
     
     
         18 . The machine of  claim 12 , wherein the first object directly contacts the package material to cause the impact. 
     
     
         19 . The machine of  claim 12 , wherein the impact against the package material occurs below the product conduit and above the unsettled height. 
     
     
         20 . The machine of  claim 12 , wherein the product settler comprises a motor with sufficiently low torque that if the motor turns off while the first object is in contact with the package material, as the package material is conveyed, the package material will push the first object out of a path of the package material. 
     
     
         21 . The machine of  claim 12 , wherein the product settler is modular. 
     
     
         22 . The machine of  claim 12 , wherein the product settler comprises a frame that spatially fixes the product settler in relation to a path of the package material. 
     
     
         23 . The machine of  claim 12 , wherein the product settler comprises a first adjustable mount to move the product settler in a first direction. 
     
     
         24 . The machine of  claim 12 , wherein the settler is positioned so that, as the first object moves into contact with the package material, the first object will first contact the package material at a first point that is a second distance below the product conduit. 
     
     
         25 . The machine of  claim 12 , wherein the product settler is positioned adjacent to the package material so that, as the first object moves into contact with the package material, the first object will contact the package material below the product conduit and above the unsettled height of the product. 
     
     
         26 . The machine of  claim 12 :
 wherein the seal jaws comprise a first seal jaw and a second seal jaw;   wherein the first seal jaw rotates around a first axis of rotation;   wherein the second seal jaw rotates around a second axis of rotation;   wherein the first seal jaw, the first axis of rotation, the second seal jaw and the second axis of rotation are positioned so that, as the first seal jaw and the second seal jaw rotate, the first seal jaw and the second seal jaw come together to form the first end seal.   
     
     
         27 . The machine of  claim 12 :
 wherein the seal jaws comprise a third seal jaw and a fourth seal jaw;   wherein the third seal jaw rotates around a first axis of rotation;   wherein the fourth seal jaw rotates around a second axis of rotation;   wherein the third seal jaw, the first axis of rotation, the fourth seal jaw and the second axis of rotation are positioned so that, as the third seal jaw and the fourth seal jaw rotate, the third seal and the fourth seal jaw come together to form a second end seal on the package material thereby forming a package.   
     
     
         28 . The machine of  claim 12 , wherein the package material is a film. 
     
     
         29 . The machine of  claim 12 , wherein the machine is a vertical form, fill and seal machine. 
     
     
         30 . The machine of  claim 12 :
 wherein the first object is a rotatable paddle wheel;   wherein the paddle wheel comprises a paddle; and   wherein the paddle is positioned so that, as the paddle wheel rotates, the paddle causes agitation of the package material and thereby settles the product.   
     
     
         31 . The machine of  claim 30 :
 wherein the package material comprises an impact face;   wherein the impact face is adjacent to the product settler;   wherein, when the impact face of the package material hangs under a force of gravity, the impact face defines a first position;   wherein the settler is positioned so that as the paddle wheel rotates, a first tip of the paddle will reach past the first position by a first distance; and   wherein the first distance reaches a maximum of about 2.5 inches while the paddle wheel rotates.   
     
     
         32 . The machine of  claim 30 , wherein the paddle wheel comprises a plurality of paddles.