US3555768A

US3555768A - Method and apparatus for handling and registering webs for forming packages

Info

Publication number: US3555768A
Application number: US708000A
Authority: US
Inventors: John M Miller
Original assignee: Continental Can Co Inc
Current assignee: Continental Can Co Inc
Priority date: 1968-02-26
Filing date: 1968-02-26
Publication date: 1971-01-19
Anticipated expiration: 1988-01-19

Abstract

METHODS AND APPARATUS FOR FORMING FILLED PACKAGES FROM A FIRST WEB HAVING FILL POCKETS THEREON AND A SECOND COVER WEB HAVING MARKINGS FOR REGISTRATION WITH THE POCKETS ARE DISCLOSED HEREIN. THE POCKETED AND MARKED WEBS ARE BROUGHT TOGETHER AND INTERMITTENTLY OR STEP-BYSTEP ADVANCED IN THE FORMATION OF PACKAGES AND TENSIONING OF THE MARKED COVER WEB IS EMPLOYED TO EFFECT REGISTRATION OF THE MARKINGS THEREON WITH THE POCKS OF THE FURTHER WEB. ABRUPT TENSION CHANGES IN THE MARKING BEARING COVER WEB, COMMONLY RESULTANT FROM THE STEP-BY-STEP ADVANCING OF SUCH WEB, ARE REDUCED BY FEEDING THE COVER WEB IN SYNCHRONISM WITH THE ADVANCING OF BOTH WEBS AND AT A POINT PRECEDING THE APPLICATION OF THE COVER WEB TO THE POCKETED WEB.

Description

Jan. 19, 1971 J. M. MILLER 3,555,765

METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES Filed Feb. 26, 1968 5 Sheets-Sheet 1 JOHN M. M\L.LER

ATTORNEYS Jan. 19, 1971 J. M. MILLER 3,555,?

METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES 5 Sheets-Sheet 2 F iled Feb. 26, 1968 INVENTOR JOHN M. MILLER Jan. 19, 1971 J. M. MILLER 3 METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES Filed Feb 26, 1968 5 Sheets-Sheet 3 INVENTOR JOHN M. MLLLER BY fla F y M g w/mu TTOR N EYS Jan. 19, 1971 J. M. MILLER 3,555,?

METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES Filed Feb. 26, 1968 5 Sheets-Sheet 4.

FIG.5

INVENT OR JOHN M.M\LLER ORNEYl J. M. MILLER Jan. 19, 1971 METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES 5 Sheets-Sheet 5 ,Filed Feb. 26, 1968 I I l l l II J 5 mg" 5% I @[bQ r mfi N wxfim 228: q 1. mm mud :6: 35 06% 33' hy em 5585 5581a INVENTOR JOHN M. M\L.LER

AMA??? @mmm United States Patent 3,555,768 METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES John M. Miller, Mount Vernon, Ohio, assignor to Continental Can Company, Inc., New York, N.Y., a corporation of New York Filed Feb. 26, 1968, Ser. No. 708,000 Int. Cl. B65b 7/16, 57/04; B31b 49/00 US. CI. 5339 21 Claims ABSTRACT OF THE DISCLOSURE Methods and apparatus for forming filled packages from a first web having fill pockets thereon and a second cover web having markings for registration with the pockets are disclosed herein. The pocketed and marked webs are brought together and intermittently or step-bystep advanced in the formation of packages and tensioning of the marked cover web is employed to effect registration of the markings thereon with the pocks of the further web. Abrupt tension changes in the marking bearing cover web, commonly resultant from the step-by-step advancing of such web, are reduced by feeding the cover web in synchronism with the advancing of both webs and at a point preceding the application of the cover web to the pocketed web.

The invention relates generally to package forming machines wherein first and second webs are brought together and joined to form a series of fill containing packages, and more particularly to machines of the type in which a marking bearing cover web and a pocket bearing further web are advanced intermittently or in step-by-step fashion and joined to form packages wherein the markings and the pockets are correctly registered.

In the past, package forming machines have been provided wherein first and second webs of heat scalable plastic material are provided on relatively large supply rolls to be joined together in the formation of fill containing packages. Commonly, fill pockets are provided in a first of the webs while fill identifying or advertising markings are provided on the other web which is joined with the pocket containing *web to form sealed fill containing packages, marked in accordance with consumer requirements. Inasmuch as it is often required that the markings or designs provided upon a cover web be exactly located or registered with the fill pockets of the further web, it has been necessary to provide arrangements whereby the location of cover web markings with respect to the location of the pockets provided in the web to which the cover is to be applied is carefully monitored and controlled for exact registration between the desired markings and the fill accommodating pockets.

Inasmuch as it is never possible to provide exactly equal spacing of the pockets provided in one of the webs and the markings provided upon the other of such webs such as to maintain constant registration of the markings and pockets without some drift during the employment of a package forming machine, it has been suggested that the markings provided upon the cover web be given a spacing somewhat less than the spacing of the pockets provided in the further web such that when the two webs are joined in a package forming process, the markings of the cover web will tend to advance slightly with respect to the pockets. In this type of suggested registration system, the tension applied to the cover web during the joining together of the cover web and the pocketed further web is controlled so as to stretch the marking bearing cover web whenever the markings thereon tend to advance beyond an acceptable limit of registration. In one such "ice suggested system, first and second tension levels are made available for application to the cover web whereby the first of such tension levels is not quite sufiicient to cause the spacing of the markings to equal the spacing of the pockets, while the second tension level is sufiicicnt to stretch the web to a point at which the spacing of the markings exceeds the spacing of the pockets. In this type of system, application of the cover web to the pocketed web while the cover is maintained at the lower level of tension provides a gradual creeping forward of the markings of the cover web with respect to the pockets of the further web, while the employment of the second, higher tension level is effective to cause the pockets of the pocket bearing web to move forward in position with respect to the markings. Constant surveillance of the relative positions of the markings and pockets is maintained, as through the use of a photo-electric sensor or electric eye employed to control the level of tension applied to the cover web.

Employment of systems of the aforementioned types and the pockets in packaging machines wherein both and the sprockets in packaging machines wherein both such webs are continuously fed from relatively large web supply rolls. However, numerous packaging machines employ intermittent or stcp-by-step feeding of the package forming webs wherein each of the webs is abruptly advanced during a portion of a package forming cycle and abruptly halted and maintained immobile during a further part of such cycle. As will be apparent, the abrupt pulling forward from a supply roll of a web which by its nature stretches under tension, causes abrupt inertial tension changes detrimental to the employment of tensioning of such a web for the aforementioned purposes. Thus, it becomes difficult to employ differential tensioning of a cover web to effect the correct registrations of markings provided thereon where such web is repeatedly pulled forward by the advancing mechanism of the package forming machine inasmuch as abruptly increased tension is exhibited by such cover web during the initial forward movement of the cover web in a particular cycle and further inasmuch as web relaxation is exhibited during the portion of the package forming cycle wherein the web is again brought to rest.

The abrupt pulling forward or jerking forward of the cover web as described hereinabovc further may result in a shearing or deformation of the web due to the suddenly increased tension thereon and such increased tension coupled with intermittent periods of relaxation commonly results in wrinkling of the cover web at its point of application to the remaining package forming web. Application of a braking force to the commonly employed web supply rolls such as to prevent the relaxation of the cover web is rendered difficult by the changes in inertia resultant from the reduction of web maintained on the supply rolls and attempts have been made to provide a displaceable idler roll or dancer roll intermediate the package forming machine and the web supply rolls so as to provide a small web inventory which is drawn off during each cycle and which is sufficient to prevent the abrupt tensioning of the cover web at the beginning of each cycle. However, the provision of dancer rolls in the web path increases the difficulty of applying tension to the cover web to effect proper web marking registration inasmuch as a relatively slack portion of web is provided in the web feed path.

In accordance with the foregoing, then, it is an object of this invention toprovide methods and apparatus capable of controlling the tensioning of a web in an intermittently driven or step-by-step driven package forming machine.

Similarly, it is an object of this invention to provide methods and apparatus for facilitating the registering of markings printed upon a first web with fill-accommodating portions of a second web wherein the first and second webs are joined together to form a filled package and wherein both such webs are intermittently advanced during package formation.

A further object of this invention is to provide package forming machines of the type employing a step-by-step or intermittent web advancing drive, cover web feed provisions driven in synchronism with the Web advancing drive to avoid abrupt tensional changes in the cover web in the area thereof intermediate the web advancing drive and the cover web feeding provisions.

Additionally, it is an object of this invention to provide cover web feeding provisions of the foregoing type wherein feeding of the cover web occurs prior to application of the cover web to the additional web and wherein such feeding is at substantially the same web feed speed as the web feed speed of the web advancing drive.

It is yet another object of this invention to provide cover web tensioning provisions in combination with cover web feedings provisions of the aforementioned types such as to control the tensioning applied to the cover web to effect registration of markings on the cover web with fill accommodating portions of the remaining web.

Still another object of this invention is to provide tensioning of a cover web through the employment of magnetic brake provisions in combination with tension controlling cover web feed provisions in a step-by-step web advancing package forming machine.

It is a further object of this invention to provide the tensioning of a cover web through the employment of first and second cover Web feed provisions and driving means coupled with the feed provisions for providing differences in the web feed speed of each such feed provisions so as to effect tensioning of the cover web intermediate the feed provisions and in combination with a step-by-step web advancing package forming machine.

Further still, it is an object of this invention to provide methods and apparatus for registering cover web markings with fill accommodation portions of a further web during the joining together of such webs in the formation of filled packages by the step-by-step advancing of both webs through the application of repeated abrupt forces thereto and by the application of a variable tension to the cover web sufficient to stretch the cover as required in the registration of the markings thereon with the fill accommodating portions of the additional web and by continually feeding the cover web in synchronism with the advancing thereof to effect a reduction in the abrupt tensioning in the cover web resultant from the step-by-step advancing thereof.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims, and the several views illustrated in the accompanying drawings.

In the drawings:

FIG. 1 is a fragmentary side elevational view of package making machine structure in accordance with this invention, and illustrates web advancing provisions, cover web supply provisions and a cover web feed mechanism driven in synchronism with the web advancing provisions.

FIG. 2 is an enlarged fragmentary side elevational view of a portion of the structure shown in FIG. 1, and illustrates in greater detail cover web tensioning provisions and cover web feed rolls forming part of the cover web feeding mechanism.

FIG. 3 is an enlarged fragmentary perspective view of a portion of the apparatus illustrated in FIG. 2 and shows in greater detail a cover web tensioning roll for applying a pretermined amount of tension to the cover web and a pair of cover web feed rolls for engaging the cover web preceding its joinder with a further web and for 4 feeding the cover web in synchronism with the advancing provisions of the package forming machine.

FIG. 4 is an enlarged fragmentary cross-sectional view of the several rolls of FIG. 3, and shows the relative positioning of the cover web tensioning and feeding provisions and the mounting of these provisions on the side thereof not illustrated in FIG. 3.

FIG. 5 is an enlarged fragmentary vertical cross-sectional view illustrating one form of a portion of the Web advancing provisions of the packaging machine.

FIG. 6 is a diagrammatic circuit illustration showing web tension control provisions suitable for controlling the tension applied to the cover by the web tensioning arrangements illustrated in FIGS. 1-4.

FIG. 7 is an enlarged fragmentary side elevational view of an alternate cover web tensioning arrangement, and shows first and second cover web feed rolls and a speed differential drive coupled to the first and second fees rolls for varying the tension applied to the cover we FIG. 8 is a diagrammatic circuit illustration of control provisions suitable for controlling the tension applied to the cover web through the use of the tensioning arrangement illustrated in FIG. 7.

Referring to the drawings in detail, there is illustrated generally at 10 in FIG. 1 a package forming machine of the type to which the invention may be applied and wherein a first web 11 is drawn into the machine for the forming of fill accommodating pockets therein. The web 11 is preferably thermoplastic in nature and is supplied from a suitably provided supply roll (not shown). A suitable pre-heating means 12 is provided proximate the web 11 adjacent its point of entry into the machine 10 to allow pocketing of the web 11 by a set of vertically reciprocable mold provisions 13 into which the web 11 is drawn for the formation of the pockets therein. A further set of vertically reciprocable mold provisions 14 are provided for holding the pockets recently formed in the mold 13 against deformation upon engagement of the mold 14 with such recently formed pockets. Filling of the pockets-of the web 11 may be effected manually or by suitable automatic filling provisions capable of employment in combination with the over-all package forming machine 10. A cover web 15 is entrained into engagement with the pocketed web 11 adjacent a cover web engaging roll 16. The cover web 15 is, of course, entrained into engagement with the pocketed web 11 for the covering of the pockets subsequently to the filling of the pockets with the desired commodity. Upon engagement of the cover web 15 with the pocketed web 11, heat-sealing of the two webs is effected through the utilization of vertically reciprocable heat sealers 17 and aligned web back-up provisions or plates 18.

In package forming machines of the type generally referred to by the numeral 10 in FIG. 1, web advancement is of an intermittent or step-by-step nature and the advancement of the pocketed web 11 in this fashion imparts step-by-step advancement or intermittent movement to the cover web 15 by reason of the sealed together engagement of the

webs

11 and 15.

Drive provisions for the machine 10 include a suitably selected drive motor 20 connected in driving engagement as at 21 with the input provisions 22 of a power transmission unit 23 coupled to a drive shaft 24. The drive shaft 24 provides an input to a suitably chosen stepper or indexing mechanism generally indicated at 25. The stepper mechanism 25 provides a step-by-step or intermittent motion output to the

webs

11 and 15 via an output shaft 26, and an output sprocket 27 engaging a first driven chain member 28 which is entrained about a driven sprocket 30 rotatably mounted by a shaft 31 journaled for rotation in a shaft mounting trunnion 32. An additional sprocket 33 is mounted upon the rotatable shaft 31 and is in driving engagement with a.- webconveying chain 34 which extends longitudinally along the machine and which is entrained at the other end thereof about a further suitably selected sprocket (not shown).

Transverse severing of the individually filled and covered package forming pockets is effected at and longitudinal severing of transversely spaced packages is effected through utilization of the cutting provisions indicated at 36. Thus, individual filled packages are delivered from the package forming machine 10 via a discharge chute 37 for the subsequent handling thereof.

Step-by-step advancement of the pocketed web 11 and the cover web 15 is effected, as best illustrated in FIG. 5 through the employment of suitable web engaging means. generally referred to by the numeral 40 carried by the intermittently driven web advancing chain 34. As illustrated in FIG. 5, the web engaging means 40 may include first and second

web clamping members

41 and 42 and means for biasing the clamping members into clamping engagement With the joined

webs

11 and 15, as for example, the spring bias means 43 in biasing engagement between the pivotally mounted clamping member 42 and the lower clamping member 41. Actuation of the pivotally mounted clamping member 42 into and out of clamping engagement with the joined webs may be effected through suitable cam actuating provisions (not shown) or alternate provisions suitable for effecting movement of the pivotally mounted member 42 into clamping engagement with the periphery if the joined webs and release of the joined webs for discharge from the package forming machine 10. As further illustrated in FIG. 5, the intermittently driven chain 34 may be guided in its movement relative to the path of conveyance of the

webs

11 and 15 through the provision of suitable guide roller means generally indicated by the numeral 44.

Returning to FIG. 1, the cover web 15 is supplied from a cover web supply roll 45 suitably journaled upon a roll stand 46 which, in turn, is supported upon a frame superstructure 47 afiixed to and above the framework of the machine 10. Overrunning of the web supply roll 45 is prevented by a supply roll brake means 48, illustrated more fully in FIG. 2.

The supply roll 45 is supported upon a shaft 50, journaled for rotation by the roll stand 46 and the shaft 50 has afiixed thereto a gear 51 in engagement with a further brake gear 52 which, in turn, is afiixed to a further shaft 53 which also is journaled for rotation by the roll stand 46. A braking disk 54 is affixed to the shaft 53 and a brake shoe 55 frictionally engages the periphery of the disk 54 to restrain movement of the supply roll 45 via the geared engagement of the

gears

51 and 52. The brake shoe 55 is biased into engagement with the periphery of the braking disk 54 by the interpositioning of a compression spring 56 intermediate the shoe 55 and a brake shoe mounting bracket 57. Adjustment of the force applied to the braking disk 54 via the brake shoe 55 is provided through the inclusion of manual adjustment means 58.

Tensioning of the cover web 15 is provided by the inclusion of a rubber sheathed main tension roll 60 mounted upon a shaft 61 journaled for rotation by a pair of side plates 62 of the frame super-structure 47.

The side plates 62 are provided with downwardly opening slots 63 which allow removal of the roll 60 upon detachment of a pair of shaft support bearing means 64. The shaft 61 is provided with a knob 65 allowing the manual movement of the tension roll 60.

An idler roll 66 is supported between the side plates 62 adjacent the tension roll 60 for movement with the web 15. A rubber sheathed presser roll 67 is located adjacent the main tension roll 60 opposite the idler roll 66 and the presser roll 67 has its ends trunnioned at 68 in the free lower ends of a suspension frame 70, said frame 70 including an intermediate connecting bar 71 and having free swinging support at 72 on the plates 62, as illustrated in FIGS. 2 and 3.

A cross bar 74 is fixedly supported between the plates 62 and extends parallel to the

rolls

60, 66 and 67 and threadedly receives anchor rods 75 having knurled manually operable adjuster nuts 76 thereon. The rods 75 are connected to the forward ends of tension springs 77, as shown in FIGS. 2 and 3, and the other ends of the springs 77 are connected at 78 to the bar 71 of the swingable frame 70. The springs 77 constantly urge the presser roll 67 against the main tensioning roll 60, and the degree of tensioning pressure may be readily adjusted by turning the knurled nuts 76. An idler roll 80 is mounted on the frame 24 forwardly of the tension rolls as best shown in FIGS. 2 and 3, and a further idler roll 81 is mounted on the plates 62 beneath the supply roll 45. It will be apparent from FIGS. 2, 3 and 4 that the cover web 9 passes down from the supply roll 45 under the guide or idler roll 81 and under the tensioning presser roll 67, upwardly over the main tensioning roll 60 and down under the idler roll 66, thus presenting a bight 79 of the web over the main tensioning roll 60 between the

aforementioned rolls

66 and 67 as clearly shown in FIG. 2. From the idler roll 66, the cover web 15 passes upwardly over the idler roll 55 and thence downwardly toward the location of application of the cover web 15 to the pocketed web 11.

A magnetic brake unit 82 is supported at 83 on the super-structure 47, as best shown in FIGS. 1 and 2, and the brake unit 82 includes a rotor shaft 84 having a sprocket 85 fixed thereon and chain coupled at 86 with a sprocket 87 fixedly connected to the main tensioning roll 60. The magnetic brake unit 82 applies controlled drag or braking action on the main tensioning roll 60 via the chain coupling 86 to resist drawing off of the cover web 15 from the supply roll 45 as the web 15, being heat-sealed to the pocketed Web 11, and the pocketed web are moved along.

The aforementioned magnetic brake unit may be a commercially available unit, as for example the units available from Vickers, Incorporated, Electronics Product Division of St. Louis, Mo. It is relatively well known that this type of brake has its projecting rotor shaft attached to an inner member enclosed by and rotating with an outer member, both members being independently supported by stator bearings and being separated from each other by a space or gap which remains constant. Said gap contains finely divided dry ferromagnetic particles. A stator coil is included and when said coil is not energized the magnetic particles within the gap have insignificant frictional or binding effect, but when the stator coil is energized, a magnetic film is produced in the gap and produces the bonding or braking action which is proportional to the applied energizing current. Controlling of the degree of energization will, of course, control the degree of braking action which will be applied to the tension roll 60 by the brake unit 82. It will be apparent that this braking action may also be modified somewhat by the adjustment of the tension springs 77, and also by the adjustable application of the brake shoe 55 against the braking disk 54, as best shown in FIG. 2, but this last-mentioned braking action serves principally to prevent overrunning of the roll 28 at the ends of the successively applied stepping movements of the pocketed web 11 with which the cover web 15 is moved along and drawn off the web supply roll 45.

The cover web- 15 has provided thereon a series of markings along the length thereof to be registered with the pockets formed in the pocketed web 11. Preferably, the markings provided upon the cover web 15 are printed short. 'That is, the markings to be registered with the pockets of the web 11 are spaced along the length of the cover web 15 at a spacing normally lesser than the spacing of the pockets along the length of the web 11. Tensioning of the cover web 15 by means of the magnetic brake unit 82 and the main tensioning roll 60 is employed to provide a stretching of the cover web 15 such that the markings applied thereto may be registered with the pockets at the point of application of the cover web to the pocketed web 11 adjacent the roll 16. Preferably, a first tension is insuflicient to increase the spacing of the level is applied to the web 15 which tension level markings provided upon the cover web for exact registration with the pockets formed in the web 11. Thus, application of the cover web 15 while the cover web is tensioned at the first tension level results in an advancement of the markings on the web 15 relative to the pockets of the web 11. Once the markings upon the cover web 15 have advanced a predetermined amount relative to the pockets, a second higher tension level is applied to the cover web 15 sufficient to stretch the cover such that the markings applied thereon are given a spacing greater than the spacing of the pockets with which such markings are to be registered. Accordingly, application of the cover web 15 under the second higher tension level results in an advancement of the pockets of the web 11 relative to the markings provided upon the cover web 15 until, again, the advancement of the pockets with respect to the markings reaches a predetermined maximum, at which time the first and lower tension level is again applied to the cover web 15.

Monitoring of the registration of cover web markings with respect to the pockets of the web 11 is provided, as will be more fully discussed hereinafter, through the employment of suitable sensing means, generally referred to by the numeral 90, which, as shown, may include a suitable light source and photo-electric cell combniation 91. 92 mounted upon the frame super-structure 47 intermediate the tensioning rolls 60, 66 and 67 and the point of application of the cover web 15 to the pocketed web 11 adjacent the idler roll 16.

The continual intermittent or stepping advancement of the cover web 15 as imparted thereto by the stepping mechanism results in an abrupt tensioning of the cover web 15 at the beginning of each cycle or stepping movement of the cover web and further results in a slackening of the cover web 15 each time the intermittently applied advancing force is terminated. Such abrupt increases and decreases in the tensioning of the cover web 15 will be readily appreciated from a realization that the web supply roll 45 exhibits a relatively large mass when a large quantity of cover web is maintained thereon and, accordingly, each time the cover web 15 is jerked forward the static inertia tending to maintain that web immobile must be overcome, while each time the cover web 15 is halted in its advance, the kinetic inertia of that web must again be overcome.

As will be apparent, the abrupt increases and decreases in the tensioning of the cover web present difficulties in the employment of tensioning of the cover web to provide correct registration of markings thereon with the further web 11. Additionally, distortion and/ or wrinkling of the cover web at its point of application to the pockets of the pocketed web must be avoided. A cover web feed means generally referred to by the numeral 93 is provided at a location preceding the application of the cover web 15 to the pocketed web 11. The cover web feed means 93 positively feeds the cover web 15 in synchronism with the advancing of the over-all package forming machine 10 and at essentially the same speed as that imparted to the cover web via the advancing step-by-step drive provisions of the machine 10. Thus, abrupt tensioning and slackening of the cover web 15 intermediate the cover web feed means 93 and the point of application of the cover web to the pocketed web is substantially reduced or elimnated inasmuch as the cover web 15 is positively fed into the package forming machine 10 as required during each cycle of that machine, thus allowing no abrupt speed differences in the cover web 15 intermediate the cover web feed means 93 and the location at which such cover web is applied in completing the individually formed packages. Similarly, the monitoring or sensing provisions 90 do not respond to undesirable abrupt tension level alterations but,

rather, the sensing or monitoring means respond only to the location of the markings upon the cover web 15 as determined by the tension at which the cover web 15 is fed into the area intermediate the cover web feed means 93 and the point of application of the cover web to the pocketed web.

As shown in FIGS. 1, 2 and 3, the cover web feed means 93 may include a pair of cover web feed rolls 92 and 93 supported upon the frame super-structure 47 intermediate the idler rolls 80 and 16. A first of the cover web feed rolls 92 is fixedly mounted upon a shaft 94 journaled for rotation, as by the bearing support means 95 mounted upon the super-structure support member 96. The feed roll 92 engages the cover web 15 and is rotatably driven to positively feed the web 15 by a sprocket 97 mounted upon the shaft 94, or similarly provided in positive driving relation with the feed roll 92. An elongate driving chain member 98 is entrained about the sprocket 97 and is driven in step-by-step or intermittent motion by the advancing apparatus of the package forming machine 10. As best shown in FIG. 1, the elongate chain 98 may be entrained about a further sprocket 100 fixedly mounted upon a shaft 101 which further fixedly supports a sprocket 102 in driven engagement with the web advancing chain 34.

The second of the cover web feed rolls 93 is freely rotatably journaled adjacent the driven feed roll 92 opposite the path of movement of the cover web 15 as by the shaft 103 supported in suitable movable mount means 104 located upon the support member 96. The freely rotatable feed roll 93 is biased toward the driven feed roll 92 to firmly engage the cover web 15 in the nip between the two rolls as through the provision of spring bias means 105. The

rolls

92 and 93 may be of suitably selected resilient or semi-resilient material or may be sheathed in rubber such that positive feed engagement with the cover web 15 is effected.

The light source 91 of the monitoring means 90 is supported upon the frame super-structure 47 to project a control means across the path of movement of a series of control marks 107, best shown in FIG. 2, provided in predetermined spaced arrangement upon the cover web 15 and in predetermined positional relation to the markings provided upon the cover web 15 which are to be registered with the pockets formed in the pocketed web 11.

The continuously driven shaft 24 which provides an input to the stepper mechanism 25 has afiixed thereto a pair of control cams 108 and 109 as best seen in 'FIG. 1. The cam 108 is disposed to control a normally open signal cut-out switch indicated at 111 in FIGS. 1 and 6 and the cam 109 is disposed to control a normally closed re-set switch indicated at 112.

Registration of the cover web markings with the pockets provided in the pocketed web will best be understood by reference to FIG. 6 wherein a pair of power supply lines L1 and L2 are shown in association with a mains supply switch or breaker MS.

The cover web monitoring provisions 90 including the light source 91 and the photo cell may include any of a number of suitably chosen commercially available scanner provisions, as for example, the commercially available #341 Dietz Scanner, in association with a suitably chosen control amplifier 113 such as, for example, the readily commercially available Dietz AD amplifier. Because the amplifier 113 is widely commercially available and relatively well known, no detailed reference will be made to the construction thereof, however, reference will be made to the amplifier actuated relay contacts 114, commonly employed in amplifier-photo-cell combinations of the type shown in FIG. 6.

A circuit relay CR is included across the supply lines L1, L2 in series with the amplifier controlled relay contacts 112 and the relay CR, when energized and deenergized, will respectively open and close the contacts CR1 and Electrical energizing sources T and T are provided in parallel across the lines L1, L2 and may comprise variable transformer means or variable voltage divider means T serving to supply an input for conditioning the magnetic brake 82 for applying the aforementioned desired predetermined definite low tension and stretch to the cover web 15, and T serving to supply an input at a value for conditioning the magnetic brake 82 for applying the aforementioned predetermined definite higher tension and stretch to the web 15. It is to be understood that the supply provisions T and T may be suitably selected from any of a number of well known provisions capable of providing predetermined voltage conditions as required by the magnetic brake unit 82 employed.

Closure of the circuit relay CR effects a closing of contacts CR to apply the first predetermined input from T to the magnetic brake 82 via a current limiting resistor 115 and a full wave rectifier arrangement 116. Similarly, closure of the contacts CR effect energization of the magnetic brake 82 at an input level provided by T A manual r-e-set switch 117 is shown in series with the normally closed cam actuated switch 112 for use in setting up and/or testing, or re-establishing normal operation of the web registering provisions.

Preferably, application of an input to the magnetic brake 82 from the input provisions T provides the aforementioned less than sufficient tensioning level in the cover web such that the markings upon the cover web are not stretched sufficiently to obtain an exact registration with the pockets in the pocketed web 11. Thus, when the brake 82 is energized from T a gradual creeping forward of the markings on the cover web with respect to the pockets of the pocketed web 11 is apparent. Similarly, upon application of a second input from T to the magnetic brake 82, tension upon the cover web 15 is increased and a gradual retreat of the markings on the cover web 15 with respect to the pockets of the web 11 is apparent.

Each control mark or spot 107 (FIG. 2) preferably cuts or blocks the beam of the sensor 90 during early motion of the web in a given feed cycle. The signal cutout cam 108 closes its associated switch 111 just as a properly registered given control mark 107 cuts or blocks the scanner beam. Closure of the switch 111 renders the scanner-amplifier combination ineffective, maintaining the relay CR unenergized wherein a low-level input from T is applied to the magnetic brake 82 to maintain the low tension level in the cover web 15. However, should the mark 107 out the scanner beam prior to the closure of the switch 111, disruption of the beam will effect closure of the contacts 114, thus energizing the relay CR to apply a second T input to the magnetic brake 82 via the nowclosed relay contacts CR As will be apparent, attention to the length of the dwell of the cam 108 which effects closure of the normally open switch 111 will determine the acceptable limits of the positioning of the cover web borne marks 107 during each machine cycle.

Upon termination of the stepping motion of the

webs

11 and 15, or after the mark 107 has safely passed the scanner beam, the cam 108 allows reopening of the switch 111 such that the switch 111 will be opened prior to the pulling forward of the

webs

11 and 15 during the next succeeding machine cycle.

The cam 109 effects closure of the switch 112 to provide opening of the amplifier relay contacts 114 to allow operation of the contacts 114 through the actuation of the normally open switch 111 and the photo-electric monitoring provisions 90 during the next succeeding machine cycle.

As before stated, the tension applied to the web 15 by the magnetic brake 82 when that brake is energized via T to apply a low tension to the web 15, should be sulficiently high that some stretching of the web 15 will occur. This lower tension may bring the cover web 15 close to registration such that the tensioning of the cover web 15 at the higher tension level need not be extreme. Preferably, each of the lower and higher tension levels should be applied to the cover web 15 for a number of successive machine cycles rather than having both the lower and higher tensions applied to the cover web 15 during each cycle or during each successive cycle.

Turning to FIG. 7, there is shown therein an alternate tensioning arrangement wherein provisions similar to those discussed hereinabove are given similar reference numerals. A cover web 15' is supplied from a cover web supply roll 45' to'the over-all package forming machine which may be of the type designated at numeral 10 in FIG. 1. The supply roll 45 is mounted upon a shaft 50" journaled for rotation upon a supply roll stand 46 which, in turn, is supported upon a frame super-structure 47' afiixed to the framework of the over-all machine as discussed hereinabove with respect to the frame super-structure 47.

Braking provisions, generally designated 48, are provided upon the roll stand 46' to reduce over-running of the supply roll 45 and the braking provisions 48' may be of the type discussed hereinabove with respect to FIG. 2 or may, as shown, include a pair of pivotally mounted shaft engaging brake members 120 and a threaded manually adjustable member 121 threadedly engaging the pivotal members 120 for adjusting the braking force applied to the shaft 50'.

The cover web 15 is entrained downwardly and about an idler roll 81' journaled for rotation by a pair of support plates 122, one of which is shown in FIG. 7, mounted upon the frame super-structure 47. A pair of feed rolls 123, 124 are mounted upon a pair of shaft .125, 126, journaled for rotation by the plates 122 and the feed rolls 123, 124 engage the cover web 15' in the nip therebetween and in feeding relation to the cover web. The web 15 passes from between the nip of the feed rolls 123, 124 about a further idler roll supported for rotation by the frame super-structure 47 and an additional pair of feed rolls 92, 93 engage the cover web in feeding relation preceding the application of the cover web to the pocketed web 1.1.

The feed rolls 92, 93' are similar in nature to the feed rolls 92, 93 discussed hereinabove, relieving abrupt tensional forces and slackening of the cover web 15 intermediate the feed rolls 92', 93' and the point of application of the cover web 15 to the pocketed web. The feed roll 92' is driven in synchronism with the web-advance mechanism of the over-all package forming machine through the provision of an elongate chain member 98', driven from the advancing provisions of the machine and entrained about a sprocket 97 affixed to the feed roll 92' for rotation therewith.

Once again, the feed rolls 124, 125 and 92', 93' may be of resilient or semi-resilient material or may be rubber sheathed to provide good feeding engagement with the cover web 15'. The feed roll 93 is shown biased into engagement with the cover web by a resilient member and the feed I011 124 may similarly be so biased.

Prior to the application of the cover web 15 to the pocketed web, the positional relationship of the markings provided upon the cover web 15' with respect to the pockets of the pocketed web is monitored'by a monitoring means 90', including a light source 91' and a photoelectric cell 92 positioned to scan across the path of movement of marks 107 provided upon the cover web 15'.

The feed roll 123 is driven from a sprocket 126, mounted upon the shaft 125 and in driven engagement with a drive chain 127. The drive chain 127 is entrained about a sprocket 128 fixed to an output shaft 130 of a speed differential drive unit 131. A first input to the speed differential unit 131 is provided by a shaft 132 having a sprocket 133 aflixed thereto. An input drive chain 134 engages the sprocket 133 to impart input drive rotation thereto and the chain 134 is entrained about a further sprocket (unnumbered) afiixed to the driven feed roll 92. Thus, the speed differential unit 131 receives an input synchronized with the advancing of the webs .11 and by the step-by-step advancing mechanism of the over-all package forming machine.

Speed differential units of the type shown in FIG. 7 are readily commercially available, as for example from Fairchild-Hiller Corporation, Industrial Products Branch, West Babylon, Long Island, NY. The speed differential unit 131 shown in FIG. 7 includes a suitably chosen commercially available differential gear box having, in addition to the input shaft 132 an output shaft 130*, a further input shaft 134 to which is coupled a suitably selected commercially available motor 135 for providing a second input to the gear box to determine the driven speed of the output shaft 130*. Application of an input to the shaft 132 via the input drive chain 34 and its associated sprockets provides an output at the shaft 130 to provide feeding of the cover web 15' via the chain 127 and the driven feed roll 123. As will be apparent to ones skilled in the art, the dimensions of the

sprockets

126 and 128 and the diameter of the feed roll 123 may be selected to provide a web feed speed from the feed roll 123 identical to the feed speed provided by the feed roll 92 and the feed roll 123 may be driven at a slightly lesser speed than the feed of the feed roll 92 by application of an input at 134 to impart the higher than normal level of tensioning to the cover web 15' in which case the web 15 will be stretched sufficiently to provide registration of the markings thereon with the pockets of the pocketed web in a fashion similar to that discussed hereinabove with respect to the utilization of first and second, lower and higher levels of cover web tensioning. Application of an input to the second input shaft 134 of the speed differential unit 131 in a reverse direction may also be provided by the motor 135 to increase the web feeding speed of the feed roll 123 to provide a relaxation of the tension level in the cover web 15' intermediate the feed rolls 123 and 92 such that the spac ing of markings is reduced from a predetermined maximum. It will, of course, be apparent to ones skilled in the art that the rnotor 135 may be coupled to the input shaft 134 to provide an increase in speed of the feed roll 123 such that the motor 135 would normally be energized when the lower tension level is to be applied to the cover web 15' and the motor 135 would be deenergized to result in a slowing of the feed rate applied to the feed roll 123 from the differential unit 131 when the second, higher tension level is desired.

FIG. 8 indicates generally the geared relation of the input and output shafts of a suitably selected differential gear box employable as the speed differential unit 131. An input applied to the shaft 132 is transmitted to the output shaft 130 inasmuch as the

shafts

132 and 130 are coupled together via the gearing provisions 136 diagrammatically illustrated in FIG. 8. An input applied to the second input shaft 134 from the motor 135 is applied to the output shaft 130 in addition to the rotation imparted thereto by the input shaft 132. Thus, the rotational output speed at shaft 130 will be increased or decreased by the application of a further input at the shaft 134, dependent upon the direction of rotational input at 134.

FIG. 8 further shows the utilization of control provisions, similar to those shown in FIG. 6 as discussed hereinabove, suitable for controlling the input applied to the secondary input shaft 134 of the speed differential unit 131. A pair of supply lines L1 and L2 are connected to suitably chosen supply provisions by a mains supply switch MS and a source T is connected across the lines L1, L2 to provide an input to the motor 135 via a pair of relay uontrolled contacts CR to impart rotation to the input shaft 134 upon a determination that an increased tension level is required of the cover web 15. The photocell light source combination of the scanner or monitoring means is essentially similar to those provisions as discussed in relation to FIG. 6 and the amplifier 113', amplifier relay contacts 114', circuit relay CR and the switches 111', 112' and 117 are also similar to the similarly referenced provisions of FIG. 6. The cam actuated switch 111' is cyclically driven from a cam of the type shown in FIG. 1 at 108 and interception of the light beam provided by the light source 91 by the registering mark 107 prior to the closure of the cam actuated switch 111' effects closure of the amplifier relay contacts 115' to energize the relay CR, whereupon the motor will be energized via the relay contacts CR Where as in FIG. 8, the secondary input to the differential unit 131 at 134 is unidirectional, the feed speed at

rolls

123 and 124 provided normally by application of a sole input at 132 may be equal to or less than the feed speed at rolls 92' and 93' depending upon the degree of relaxation of the web prior to its entrance between the first feed rolls.

Additionally, it will be apparent the motor 135 may be normally driven in a first direction to provide a first feed speed at

rolls

123 and 124 equal to or greater than the feed speed at rolls 92' and 93, in which case reversing of the motor may be employed to decrease the feed speed at

rolls

123 and 124.

The switch 117' is manually operable for use in setting up automatic registration control and the cam actuated switch 112 is driven from a cam of the nature of the cam 109 shown in FIG. 1 to re-set the amplifier relay contacts 115' preceding the beginning of each machine cycle.

Once again, the cover web 15 is, preferably, printed short and the feed roll 92' may be driven in synchronism with and at the same speed as the speed imparted to the joined web via the machine-included web advance mechanism. Tensioning of the cover web 15' is imparted to the Web in the portion of the web intermediate the feed means including the feed rolls 92' and 123. A feed speed imparted to the feed roll 123 which is equal to or slightly greater than the feed speed of the driven roll 92' will result in a moving forward of the web borne markings away from registration with the pockets in the associated pocketed web. As the cover web markings creep forward with respect to the associated pockets, a point will be reached wherein the cutting of the beam from the light source 91 by one of the marks 107' will effect energization of the motor 135 to decrease the speed of the feed roll 123 driven from the output of the differential gear box. Thus, a tensioning will be applied to the cover web 15' at a higher level, increasing the markings provided thereon to a spacing greater than the spacing of the associated pockets and the markings applied to the pockets will gradually tend toward perfect registration.

The methods of providing web registration and the structures and structural relationships employed in such methods as disclosed herein represent preferred forms of the invention, however, it will be readily apparent that variations may be made in the structures set forth without departure from the scope and spirit of the invention as defined by the appended claims.

I claim:

1. In a machine for forming filled packages from a filled pocket containing web having spaced pockets along the legnth thereof, web advance means for step-by-step advancing a first web having spaced pockets formed along the length thereof, means for applying to said web a cover web having thereon repeated marking patterns along the length thereof for registration with the pockets, the patterns being spaced apart less than the spacing apart of the pockets, means for applying tension to said cover web to increase the spacing of said patterns to a spacing greater than the spacing of the pockets, tension controlling feed means for engaging the cover web prior to the application thereof to the first web for stepby-step advancing the cover web in synchronism with the step-bystep advancing the cover web in synchronism with the step-by-step advancing of the first web to reduce abrupt tensioning of the cover web intermediate said feed means and the point of application thereof to said first web and drive means interconnecting said web advance means and said feed means for driving said feed means from and in synchronism with said advance means.

2. A machine according to claim 1 wherein said feed means comprises a pair of web feed rolls engaging the cover web in the nip therebetween at a location spaced from the point of application of the cover web to the first web, said rolls insulating the cover web at the point of application from abrupt inertial tension changes resulting from the step-by-step movement of the cover web.

3. A machine according to claim 1 wherein said drive means interconnecting said web advance and feed means comprises means for driving said feed means at substantially the same web-feed speed as the feed speed of said web advance means.

4. A machine according to claim 1 further comprising registration sensing control means responsive to the disposition of the patterns on the cover web with respect to the pockets of the first web for controlling said means for applying tension.

5. A machine according to claim 1 wherein said means for applying tension comprises second Web feed means for engaging said cover web at a location spaced from said tension controlling feed means, said drive means comprising speed differential drive means connected in driving relation to said tension controlling feed means and said second web feed tneans for providing differing web-feed speeds to both said tension controlling feed means and said second web feed means to increase and decrease the tension on the cover web.

6. A machine according to claim 5 wherein said speed differential drive means comprises input means, means interconnecting said input means, said web advance means and said tension control feed means, output means connected to said second web feed means for driving said second web feed means and means for varying the output speed of said output means.

7. A machine according to claim 6 further comprising registration sensing control means responsive to the disposition of the patterns on the cover web with respect to the pockets of the first Web for controlling said means for "varying the output speed of said output means of the speed differential drive means.

8. In a machine for forming filled packages from a firsit filled pocket containing web having spaced pockets along the length thereof and a cover web having thereon repeated markings to be registered with the pockets, web advancing means for step-by-step advancing said first and cover webs in a continual series of abrupt movement, means for applying said cover web to said first web, means for applying tension to said cover web to stretch said cover web to provide spacing of the repeated markings thereon at least as great as the spacing of the filled pockets of said web, tension controlling feed roll means for engaging said cover web in feeding relation at a location preceding the application of said cover web to said first web and drive means interconnecting said web advancing means and said feed roll means for driving said feed roll means in step-by-step synchronism with said web advancing means, said advancing means and feed roll means being spaced apart along the length of said cover web for driving said cover web at substantially equal feed speeds to reduce inertial tenison changes in the cover web portion extending between said advancing means and said feed roll means.

9. A machine according to claim 8 wherein said means for applying tension comprises electrically controlled magnetic brake means engaging said cover web preceding the engagement of said cover web with said feed roll means.

10. A machine according to claim 9 wherein said means for applying tension further comprises mark sensing means electrically connecting to said brake means for controlling said brake means in response to the relative disposition of the cover web markings with the filled pocket containing portions of the first web.

-11. In a machine for forming filled packages from a first filled pocket containing web having spaced pockets along the length thereof and a cover web having thereon repeated markings to be registered with the portions, web advance means for step-by-step advancing said first and cover webs in a continual series of abrupt movements, means for applying said cover web to said first web, means for applying tension to said cover Web to provide spacing of the repeated markings thereon at least as great as the spacing of the portions of said first web, tension controlling first feed roll means for engaging said cover web in feeding relation at a location preceding the application of said cover web to said first web, drive means interconnecting said web advance means and said first feed roll means for driving said feed roll means, said means for applying tension comprising second feed roll means for feeding said Web at a location spaced from said first feed roll means, and speed differential drive means interconnecting said first and second feed roll means for controlling differences in the feed speed of said first and second feed roll means to vary the tension in said cover web intermediate said first and second feed roll means.

12. A machine according to claim 11 wherein said speed differential drive means comprises an input shaft driven from said web advance means, an output shaft in driving connection with said second feed roll means and means for varying the output speed of said output shaft.

13. A machine according to claim 12 wherein said first feed roll means is driven from said Web advance means for feeding said cover web in synchronism and at the same speed at said web advance means, said means for varying the speed of the speed differential means output shaft comprising means for decreasing the feed speed of said second feed roll means to a feed speed lesser than the feed speed of said first feed-roll means to increase tension on said cover web intermediate said first and second feed roll means.

14. The machine according to claim 13 wherein said means for varying the output speed has electrically connected thereto mark sensing means for controlling the feed speed of said second feed roll means in response to the relative disposition of the cover web markings with the fill accommodating portions of said first web.

15. The method of registering cover Web markings with filled pockets of a further web during the joining together of the webs in a package producing process comprising the steps of advancing step-by-step the cover and further webs by the application of repeated abrupt forces thereto at a first location, joining the webs, applying variable tension to the cover web and to stretch the cover web and increase the spacing between the markings thereon, continually feeding the cover web in synchronism with the step of advancing and at a further location removed from the first location in a direction Opposite the direction of web advance and said step of feeding comprises imparting a web feed speed to the cover web at the further location substantially equal to the feed speed provided by said step of advancing stepby-step to reduce inertial tension changes in the web intermediate the first and second locations.

16. The method according to claim 15 wherein said step of feeding comprises providing a cover web feed roll, engaging the roll with the web at the further location and driving the roll step-by-step in synchronism with and at substantially the same feed speed as the step of advancing.

17. The method according to claim 16 wherein the 15 step of tensioning comprises applying a braking force to the cover web prior to the joining of the webs.

18. The method according to claim 17 further comprising the step of monitoring the position of the markings on the cover Web with respect to the positions of the pockets of the further web and altering the tensioning applied in said step of tensioning to effect registrations of the markings and the fill portions.

19. The method according to claim 15 comprising the additional step of feeding the cover web at a third location and varying the feed speed applied at the third location to provide variations in web tension intermediate the third and further locations.

20. The method according to claim 19 wherein the step of feeding the cover web at the further and third locations each comprise providing a feed roll, engaging the feed roll with the cover web at the further and third locations, said step of applying variable tension comprising driving the feed rolls at differing speeds to apply tension to the cover web intermediate the feed rolls.

21. The method according to claim 20 further comprising the step of monitoring the position of the markings on the cover web with respect to the positions of the fill portions of the further web and altering the feed speed of the feed roll at the third location to alter the tensioning applied in said step of tensioning to efiect registration of the markings and the pockets.

References Cited UNITED STATES PATENTS 3,411,767 11/1968 Moser 9335(PC0) Re. 25,736 3/1965 Willbrandt 5351 2,214,593 9/1940 Mustin (sheet 1) 535 1X 3,238,691 3/1966 Miller 533 3,267,639 8/1966 Ollier (sheet 1) 5351 3,276,183 10/1966 Carlisle 5351 3,294,301 12/1966 Richter 535 1X 3,405,501 10/ 1968 Edelberg 5364X 3,427,778 2/ 1969 McCluskey 533 3,453,799 7/1969 Cloud (last page) 535 1X WAYNE A. MORSE, JR., Primary Examiner US. Cl. X.R.