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 a step selected from the group consisting of:
 b. sealing the package material to form a longitudinal seal; 
 f. forming a second end seal on the partially formed package to form a package from the partially formed package; and 
 a combination thereof. 
 
     
     
         3 . 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.   
     
     
         4 . 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.   
     
     
         5 . The method of  claim 4 , wherein an actuator rotates the paddle and stops the paddle in a desired position. 
     
     
         6 . The method of  claim 5 , wherein the method further comprises:
 using the actuator to change a rotational speed of the paddle at a first desired rate by changing a rotational speed of a component of the actuator, wherein the component of the actuator is linked to the paddle.   
     
     
         7 . The method of  claim 1 , wherein the settling step further comprises:
 using a product settler to provide the package material with an amplitude of vibration of 0.1 to 3 inches.   
     
     
         8 . The method of  claim 4 , wherein the paddle contacts the package once per rotation of the paddle. 
     
     
         9 . The method of  claim 4 , wherein the paddle does not bend by more than a specified bend tolerance during use, wherein the specified bend tolerance is an angle measured in a plane that is perpendicular to the axis of rotation of the paddle wheel, wherein the specified bend tolerance is no more than 30 degrees, and wherein the specified bend tolerance is measured on a leading surface of the paddle and from a proximal reference line to a distal reference line, wherein the proximal reference line is parallel to a proximal end of the paddle, and wherein the distal reference line is parallel to a distal end of the paddle. 
     
     
         10 . 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.   
     
     
         11 . The machine of  claim 10 , wherein the machine comprises a source of pressurized gas, and a conduit to direct the pressurized gas into the package material. 
     
     
         12 . The machine of  claim 10 , wherein the impact occurs on one and only one face of the partially formed package. 
     
     
         13 . The machine of  claim 10 , wherein the impact against the package material occurs below the product conduit and above the unsettled height. 
     
     
         14 . The machine of  claim 10 , wherein the product settler comprises a motor with sufficiently low torque so that if the motor is deactivated 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. 
     
     
         15 . The machine of  claim 10 :
 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.   
     
     
         16 . The machine of  claim 15 :
 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 product 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 0.25 to 3 inches while the paddle wheel rotates.   
     
     
         17 . The machine of  claim 15 , wherein the product settler comprises:
 a motor comprising a rotor;   wherein the motor causes the rotor to rotate; and   wherein an axis of rotation for the rotor and an axis of rotation for the paddle wheel are concentric.   
     
     
         18 . The machine of  claim 17 ,
 wherein, in use, the motor, the rotor, and the paddle wheel fit within a reference cylinder, wherein the reference cylinder has a reference cylinder radius of no more than 8 inches and a reference cylinder height of no more than 24 inches.   
     
     
         19 . The machine of  claim 17 , wherein the motor is a stepper motor. 
     
     
         20 . The machine of  claim 15 , wherein the paddle wheel comprises a plurality of paddles;
 wherein the plurality of paddles are spaced around a paddle wheel to provide a paddle spacing angle between each set of two adjacent paddles in the plurality of paddles;   wherein the paddle spacing angle differs from a common angle by no more than a specified tolerance;   wherein the common angle is defined to equal 360 degrees divided by the number of paddles in the plurality of paddles; and   wherein the specified tolerance has a magnitude of no more than 45 degrees.   
     
     
         21 . The machine of  claim 15 , wherein the paddle comprises at least one aperture; and
 wherein the at least one aperture is configured so that the at least one aperture has a total aperture surface area equal to at least 30% of the surface area of a leading surface of the paddle.   
     
     
         22 . The machine of  claim 10 , wherein the first object does not bend by more than a specified bend tolerance during use;
 wherein the specified bend tolerance is no more than 30 degrees;   wherein the specified bend tolerance is measured from a proximal reference line to a distal reference line and measured in a plane perpendicular to the axis of rotation of the paddle wheel;   wherein the proximal reference line is parallel to a proximal end of the first object; and   wherein the distal reference line is parallel to a distal end of the first object.   
     
     
         23 . The machine of  claim 10 , wherein the first object is made from a material selected from the group consisting of metal, alloy, steel, polymer, plastic, resin, rubber and wood. 
     
     
         24 . The machine of  claim 15 , wherein the length of the paddle, as measured radially outward from an axis of rotation of the paddle wheel to a distal end of the paddle: (i) is long enough to enable to the paddle to reach the package material and past the package material by at least 0.5 inches, or (ii) is at least 0.5 inches.