Packing machine and method

Abstract

In an insulation blanket-packaging machine and method for continuously packaging insulation blanket in the form of batts there is a continuous: infeed of batts into a loading station; movement of batts from the loading station into a transfer station that also functions as a batt-stacking station; formation of a batt stack in the transfer station; compression of a batt stack in a compression station; envelopment of a compressed batt stack within sheet material in a packaging station to form a package; and removal of a package from the machine. The machine can also be used to package insulation blanket in roll form.

1. An insulation blanket-packaging machine, comprising:
 an insulation blanket loading station for successively receiving insulation blankets; the insulation blankets each having a length and a width that define major surfaces of the insulation blanket and a thickness; the insulation blankets each being compressible;  
 an insulation blanket transfer station for successively receiving insulation blankets from the insulation blanket loading station and vertically transferring the insulation blankets from the insulation blanket loading station to an insulation blanket compression station;  
 vertical insulation blanket moving means for successively elevating groupings of one or more insulation blankets at a time in a generally vertical direction from the insulation blanket loading station up through the insulation blanket transfer station into the insulation blanket compression station while simultaneously permitting insulation blankets to be fed into the loading station;  
 the insulation blanket compression station comprising upper and lower compression conveyors for successively receiving there between the groupings of one or more insulation blankets moved from the insulation blanket loading station through the insulation blanket transfer station into the insulation blanket compression station by the vertical insulation blanket moving means; the upper and lower compression conveyors being movable relative to each other for successively compressing each grouping of one or more insulation blankets located intermediate the upper and lower compression conveyors to successively form groupings of one or more compressed insulation blankets; the upper and lower compression conveyors being operable to successively move each grouping of one or more compressed insulation blankets from the insulation blanket compression station into an insulation blanket packaging station; and  
 the insulation blanket packaging station comprising means for successively enveloping each grouping of one or more compressed insulation blankets fed from the insulation blanket compression station into the insulation blanket packaging station within sheet material to successively form packages of each grouping of one or more compressed insulation blankets fed from the insulation blanket compression station into the insulation blanket packaging station.  
 
     
     
       2. The insulation blanket-packaging machine according to  claim 1 , wherein:
 the insulation blanket loading station is for receiving insulation blankets in the form of unfolded or single-fold insulation batts;  
 the insulation blanket transfer station and the vertical insulation blanket moving means are for moving each grouping of one or more unfolded or single-fold insulation batts from the insulation blanket loading station into the insulation blanket compression station with the major surfaces of the one or more unfolded or single-fold batts in each grouping oriented to lie in planes parallel to planes of compressing surfaces of the compression conveyors of the compression station;  
 the compressing conveyors are for compressing the one or more unfolded or single-fold batts in each grouping in a direction perpendicular to the thicknesses of the one or more unfolded or single-fold batts in each grouping to form each grouping of one or more unfolded or single-fold insulation batts into a grouping of one or more compressed unfolded or single-fold insulation batts; and  
 the vertical insulation blanket moving means comprising reciprocating insulation blanket supporting and elevating means that reciprocates from a retracted position to an extended position in the insulation blanket loading station for successively engaging and elevating groupings of one or more insulation blankets from the insulation blanket loading station through the insulation blanket transfer station into the insulation blanket compression station and back to the retracted position while in the insulation blanket compression station with the reciprocating insulation blanket supporting and elevating means being retracted as the lower compression conveyor of the insulation blanket compression station advances to successively transfer the groupings of one or more insulation blankets from the reciprocating insulation blanket support and elevating means to the lower compression conveyor of the insulation blanket compression station for the successive compression of the groupings of one or more insulation blankets in the compression station.  
 
     
     
       3. The insulation blanket-packaging machine according to  claim 1 , wherein:
 the insulation blanket loading station is for receiving insulation blankets in groupings of one or more spiral wound rolls of insulation blanket having a generally round shape;  
 the insulation blanket transfer station and the vertical insulation blanket moving means are for moving each grouping of one or more spiral wound rolls of insulation blanket from the insulation blanket loading station into the insulation blanket compression station with central axes of the one or more spiral wound rolls of insulation blanket in each grouping being oriented to lie in planes parallel to planes of compressing surfaces of the compression conveyors of the compression station;  
 the compressing conveyors are for compressing the one or more spiral wound rolls of insulation blanket in each grouping in a direction perpendicular to the central axes of the one or more spiral wound rolls of insulation blanket in each grouping to form each grouping of one or more spiral wound rolls of insulation blanket into a grouping of one or more compressed spiral wound rolls of insulation blanket having a generally flat oval shape; and  
 the vertical insulation blanket moving means comprising reciprocating insulation blanket supporting and elevating means that reciprocates from a retracted position to an extended position in the insulation blanket loading station for successively engaging and elevating groupings of one or more insulation blankets from the insulation blanket loading station through the insulation blanket transfer station into the insulation blanket compression station and back to the retracted position while in the insulation blanket compression station with the reciprocating insulation blanket supporting and elevating means being retracted as the lower compression conveyor of the insulation blanket compression station advances to successively transfer the groupings of one or more insulation blankets from the reciprocating insulation blanket support and elevating means to the lower compression conveyor of the insulation blanket compression station for the successive compression of the groupings of one or more insulation blankets in the compression station.  
 
     
     
       4. An insulation blanket-packaging machine, comprising:
 a batt loading station for receiving batts; the batts each having a length and a width that define major surfaces of the batt and a thickness; the batts each being compressible in a direction generally perpendicular to the thickness of the batt;  
 a transfer and batt-stacking station for receiving batts from the batt loading station;  
 vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station;  
 means in the transfer and batt-stacking station for successively forming batt stacks of vertically stacked batts from batts successively moved into the transfer and batt-stacking station from the batt loading station;  
 a batt stack compression station for successively receiving batt stacks from the transfer and batt-stacking station; and  
 vertical batt stack moving means for successively moving batt stacks in a generally vertical direction from the transfer and batt-stacking station into the batt compression station;  
 the vertical batt moving means successively moving batts from the batt loading station into the transfer and batt-stacking station until a first selected number of batts, that is one less than a second selected number of batts to be formed into the batt stack in the transfer and batt-stacking station, has been moved into the transfer and batt-stacking station; the vertical batt moving means being deactivated once the first selected number of batts has been moved into the transfer and batt-stacking station; the vertical batt stacking moving means being activated to move a single batt from the batt loading station into the transfer and batt-stacking station to complete the formation of the batt stack in the transfer and batt-stacking and move the batt stack thus formed from the transfer and batt-stacking station into the batt compression station when the vertical batt moving means is deactivated; and the vertical batt moving means being reactivated to again successively move batts from the batt loading station into the transfer and batt-stacking station once the vertical batt moving means has moved the single batt into the transfer and batt-stacking station from the batt loading station to complete the formation of the batt stack in the transfer and batt-stacking station;  
 the batt compression station comprising upper and lower compression conveyors for successively receiving there between batt stacks fed from the transfer and batt-stacking station into the batt compression station; the upper and lower compression conveyors being movable relative to each other for successively compressing batt stacks located intermediate the upper and lower compression conveyors in a direction perpendicular to the thicknesses of the batts in the batt stacks to successively form compressed batt stacks; the upper and lower compression conveyors being operable to successively move the compressed batt stack from the batt compression station into a batt packaging station; and  
 the batt packaging station comprising means for successively enveloping compressed batt stacks successively fed from the batt compression station into the batt packaging station within sheet material to successively form packages of the compressed batt stacks fed from the batt compression station into the batt packaging station.  
 
     
     
       5. The insulation blanket-packaging machine according to  claim 4 , including:
 means for successively feeding batts into the batt loading station; and  
 means for successively removing packages from the batt packaging station.  
 
     
     
       6. The insulation blanket-packaging machine according to  claim 4 , wherein:
 the vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station elevates the batts;  
 the vertical batt stack moving means for moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station elevates the batt stacks; and  
 the compression conveyors are operative to move the compressed batt stacks in a generally horizontal direction into the batt packaging station.  
 
     
     
       7. The insulation blanket-packaging machine according to  claim 4 , wherein:
 the vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station is a reciprocating launch frame that reciprocates between a retracted position for permitting batts to be successively fed into the batt loading station and an extended position for successively feeding the batts from the batt loading station into a batt-stacking chamber of the transfer and batt-stacking station.  
 
     
     
       8. The insulation blanket-packaging machine according to  claim 4 , wherein:
 the vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station is a reciprocating launch frame that reciprocates between a retracted position for permitting batts to be successively fed into the batt loading station and an extended position for successively elevating and feeding the batts from the batt loading station into a batt-stacking chamber of the transfer and batt-stacking station; and  
 the batt-stacking chamber of the transfer and batt-stacking station includes means for retaining the batts successively fed into the batt-stacking chamber of the transfer batt-stacking station stacked and elevated above the batt loading station until the vertical batt stack moving means for vertically moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station moves the successively formed batt stacks into the batt compression station.  
 
     
     
       9. The insulation blanket-packaging machine according to  claim 4 , wherein:
 the vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station is a reciprocating launch frame that reciprocates between a retracted position for permitting batts to be successively fed into the batt loading station and an extended position for successively elevating and feeding the batts from the batt loading station into a batt-stacking chamber of the transfer and batt-stacking station; and  
 the batt-stacking chamber of the transfer and batt-stacking station includes means for retaining the batts successively fed into the batt-stacking chamber of the transfer and batt-stacking station stacked and elevated above the batt loading station until the vertical batt stack moving means for vertically moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station moves the successively formed batt stacks into the batt compression station; and  
 the vertical batt stack moving means for vertically moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station comprises reciprocating batt stack supporting and elevating means that reciprocates from a retracted position for permitting the batts to be successively fed from the batt loading station into the batt-stacking chamber of the transfer and batt-stacking station by the vertical batt moving means during the formation of each batt stack in the transfer and batt-stacking station to an extended position for moving the single batt from the batt loading station into the transfer and batt-stacking station to complete the formation of each batt stack in the transfer and batt-stacking station and for supporting the batt stack thus formed while the batt stack is elevated within the batt-stacking chamber from the transfer and batt-stacking station into the batt compression station and back to the retracted position while in the batt compression station with the reciprocating batt stack supporting and elevating means being retracted as the lower compression conveyor of the batt compression station advances to transfer the batt stack from the reciprocating batt stack support and elevating means to the lower compression conveyor for compression in a compression chamber of the batt compression station.  
 
     
     
       10. An insulation blanket-packaging machine, comprising:
 a batt loading station for receiving batts; the batts each having a length and a width that define major surfaces of the batt and a thickness; the batts each being compressible in a direction generally perpendicular to the thickness of the batt;  
 a transfer and batt-stacking station for receiving batts from the batt loading station;  
 vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station; the vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station being a reciprocating launch frame that reciprocates between a retracted position for permitting the batts to be successively fed into the batt loading station and an extended position for successively elevating and feeding the batts from the batt loading station into a batt-stacking chamber of the transfer and batt-stacking station;  
 a batt stack compression station for successively receiving batt stacks from the transfer and batt-stacking station;  
 vertical batt stack moving means for successively moving batt stacks in a generally vertical direction from the transfer and batt-stacking station into the batt compression station;  
 the batt-stacking chamber of the transfer and batt-stacking station comprising means for successively forming batt stacks of vertically stacked batts from batts successively moved into the transfer and batt-stacking station from the batt loading station that includes means for retaining the batts successively fed into the batt-stacking chamber of the transfer and batt-stacking station stacked and elevated above the batt loading station until the vertical batt stack moving means for vertically moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station moves the successively formed batt stacks into the batt compression station;  
 the batt compression station comprising upper and lower compression conveyors for successively receiving there between batt stacks fed from the transfer and batt-stacking station into the batt compression station; the upper and lower compression conveyors being movable relative to each other for successively compressing batt stacks located intermediate the upper and lower compression conveyors in a direction perpendicular to the thicknesses of the batts in the batt stacks to successively form compressed batt stacks; the upper and lower compression conveyors being operable to successively move the compressed batt stacks from the batt compression station into a batt packaging station;  
 the vertical batt stack moving means for vertically moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station comprises reciprocating batt stack supporting and elevated means that reciprocates from a retracted position for permitting the batts to be successively fed from the batt loading station into the batt-stacking chamber of the transfer and batt-stacking station by the vertical batt moving means during the formation of each batt stack in the transfer and batt-stacking station to an extended position for moving the single batt from the batt loading station into the transfer and batt-stacking station to complete the formation of each batt stack in the transfer and batt-stacking station and for supporting the batt stack thus formed while the batt stack is elevated within the batt-stacking chamber from the transfer and batt-stacking station into the batt compression station and back to the retracted position while in the batt compression station with the reciprocating batt stack supporting and elevating means being retracted as the lower compression conveyor of the batt compression station advances to transfer the batt stack from the reciprocating batt stack support and elevating means to the lower compression conveyor for compression in a compression chamber of the batt compression station; and  
 the batt packaging station comprising means for successively enveloping compressed batt stacks successively fed from the batt compression station into the batt packaging station within sheet material to successively form packages of the compressed batt stacks fed from the batt compression station into the batt packaging station; the means for successively enveloping compressed batt stacks comprising a means for feeding a first sheet of packaging material over the compressed batt stacks successively fed from the batt compression station into the batt packaging station; a means for feeding a second sheet of packaging material beneath the compressed batt stacks successively fed from the batt compression station into the batt packaging station; and means for sealing lateral edges of the sheets of packaging material together, for transversely sealing portions of the sheets of packaging material together intermediate the successive compressed batt stacks fed from the batt compression station, and for transversely serving the sheets of packaging material intermediate the successive compressed batt stacks fed from the batt compression station to successively encapsulate the compressed batt stacks to form the packages.  
 
     
     
       11. The insulation blanket-packaging machine according to  claim 10 , wherein:
 the batt packaging station includes means for successively depositing banners intermediate one the sheets of packaging material and the compressed batt stacks successively fed from the batt compression station; and the packaging material is sufficiently clear to view the banner through the packaging material.  
 
     
     
       12. The insulation blanket-packaging machine according to  claim 10 , wherein:
 the means for retaining the batts successively fed into the batt-stacking chamber of the transfer and batt-stacking station stacked and elevated above the loading station until the means for vertically moving the successively formed batt stacks from the transfer and batt-stacking station into the batt compression station, moves the successively formed batt stacks into the batt compression station, comprises a series of opposed retaining mechanisms adjacent a bottom end of the batt-stacking chamber that each include a pivotally mounted support element that pivots between an extended position where an upper surface of the support element projects out into the batt-stacking chamber to engage an underside of and support a batt within the batt-stacking chamber and a retracted position where a batt can be fed into the batt-stacking chamber by the launch frame of the batt loading station; the support element being moved to the retracted position by a batt being fed into the batt-stacking chamber from the batt loading station by the launch frame of the batt loading station; and the retaining mechanism including means for urging the support element into the extended position after a batt is moved past the upper surface of the support element to place the support element in the extended batt supporting position.  
 
     
     
       13. An insulation blanket-packaging machine, comprising:
 a batt loading station for receiving batts: the batts each having a length and a width that define major surfaces of the batt and a thickness; the batts each being compressible in a direction generally perpendicular to the thickness of the batt;  
 a transfer and batt-stacking station for receiving batts from the batt loading station;  
 vertical batt moving means for successively moving batts in a generally vertical direction from the batt loading station into the transfer and batt-stacking station;  
 means in the transfer and batt-stacking station for successively forming batt stacks of vertically stacked batts from batts successively moved into the transfer and batt-stacking station from the batt loading station;  
 a batt stack compression station for successively receiving batt stacks from the transfer and batt-stacking station;  
 vertical batt stack moving means for successively moving batt stacks in a generally vertical direction from the transfer and batt-stacking station into the batt compression station;  
 the batt compression station comprising upper and lower compression conveyors for successively receiving there between batt stacks fed from the transfer and batt-stacking station into the batt compression station; the upper and lower compression conveyors being movable relative to each other for successively compressing batt stacks located intermediate the upper and lower compression conveyors in a direction perpendicular to the thicknesses of the batts in the batt stacks to successively form compressed batt stacks; the upper and lower compression conveyors being operable to successively move the compressed batt stacks from the batt compression station into a batt packaging station; and  
 the batt packaging station comprising means for successively enveloping compressed batt stacks successively fed from the batt compression station into the batt packaging station within sheet material to successively form packages of the compressed batt stacks fed from the batt compression station into the batt packaging station; the means for successively enveloping compressed batt stacks comprising a means for feeding a first sheet of packaging material over the compressed batt stacks successively fed from the batt compression station into the batt packaging station; a means for feeding a second sheet of packaging material beneath the compressed batt stacks successively fed from the batt compression station into the batt packaging station; and means for sealing lateral edges of the sheets of packaging material together, for transversely sealing portions of the sheets of packaging material together intermediate the successive compressed batt stacks fed from the batt compression station, and for transversely severing the sheets of packaging material intermediate the successive compressed batt stacks fed from the batt compression station to successively encapsulate the compressed batt stacks to form the packages.  
 
     
     
       14. The insulation blanket-packaging machine according to  claim 13 , wherein:
 the packaging station includes means for successively depositing banners intermediate one the sheets of packaging material and the compressed batt stacks successively fed from the batt compression station; and the packaging material is sufficiently clear to view the banner through the packaging material.  
 
     
     
       15. An insulation blanket- packaging machine, comprising:      an insulation blanket loading station for receiving compressible insulation blankets;        an insulation blanket elevator for successively elevating groupings of one or more insulation blankets at a time in a generally vertical direction from the insulation blanket loading station into an insulation blanket compression station while simultaneously permitting insulation blankets to be fed into the loading station;        the insulation blanket compression station comprising upper and lower compression devices for successively receiving there between the groupings of one or more insulation blankets moved from the insulation blanket loading station into the insulation blanket compression station by the insulation blanket elevator; the upper and lower compression being movable relative to each other for compressing each grouping of one or more insulation blankets located intermediate the upper and lower compression devices to form groupings of one or more compressed insulation blankets;        a transport mechanism operable to move each grouping of one or more compressed insulation blankets from the insulation blanket compression station into an insulation blanket packaging station; and        the insulation blanket packaging station comprising a package forming unit that encloses each grouping of one or more compressed insulation blankets fed from the insulation blanket compression station into the insulation blanket packaging station within sheet material to successively form packages of each grouping of one or more compressed insulation blankets.      
     
     
       16. The insulation blanket- packaging machine of    claim 15   , wherein said compression devices comprise upper and lower conveyors that are movable relative to one another, and which also form said transport mechanism.    
     
     
       17. The insulation blanket- packaging machine of    claim 15   , wherein said upper and lower conveyors form said transport mechanism.    
     
     
       18. The insulation blanket- packaging machine of    claim 15   , wherein said elevator is located within a transfer station in which a predetermined number of said insulation blankets are successively stacked upon one another to form one of said groupings, prior to being elevated to said compression station.    
     
     
       19. An insulation blanket- packaging machine, comprising:      a batt loading station for receiving batts;        a transfer and batt - stacking station for receiving batts from the batt loading station;        a batt stack compression station for successively receiving batt stacks from the transfer and batt - stacking station;        a batt stacker and elevator for successively forming stacks of vertically stacked batts by successively moving batts from the batt loading station into the transfer and batt - stacking station until a first selected number of batts, that is one less than a second selected number of batts to be formed into the batt stack in the transfer and batt - stacking station, has been moved into the transfer and batt - stacking station from the batt loading station, said batt stacker being deactivated once the first selected number of batts has been moved into the transfer and batt - stacking station, and said elevator being activated to move a single batt from the batt loading station into the transfer and batt - stacking station to complete the formation of the batt stack in the transfer and batt - stacking station and elevate the batt stack thus formed from the transfer and batt - stacking station into the batt compression station; and the batt stacker being reactivated to again successively move batts from the batt loading station into the transfer and batt - stacking station once the elevator has moved the single batt into the transfer and batt - stacking station from the batt loading station to complete the formation of the batt stack in the transfer and batt - stacking station;        said batt compression station comprising upper and lower compression devices for successively receiving therebetween batt stacks fed from the transfer and batt - stacking station into the batt compression station; said upper and lower compression devices being movable relative to each other for successively compressing batt stacks located intermediate the upper and lower compression devices in a direction perpendicular to the thicknesses of the batts in the batt stacks to successively form compressed batt stacks; and        a batt packaging station that packages compressed batt stacks successively fed from the batt compression station to form packages of the compressed batt stacks fed from the batt compression station into the batt packaging station.      
     
     
       20. The insulation blanket- packaging machine of    claim 19   , wherein said compression devices comprise upper and lower conveyors that are movable relative to one another.    
     
     
       21. The insulation blanket- packaging machine of    claim 19   , wherein said batt stacker comprises a reciprocating launch frame that reciprocates between a retracted position for permitting the batts to be successively fed into the batt loading station and an extended position for successively elevating and feeding the batts from the batt loading station into a batt - stacking chamber of the transfer and batt - stacking station.