Packaging machine with independently controllable movers

Abstract

A packaging machine is provided for producing single and multiple compartment film wrapped pouches. Multiple linear motors allow aspects of the forming, filling, cutting and discharging to run at different speeds. The pouches are formed, filled and discharged from platens that are secured to movers that proceed through the packaging process by following magnetic fields created by independently controlled linear motors. Overall, cycle time is decreased as a result of speeding up parts of the process, including the platen return process, possible because there is no mechanical connection and not a single conveyor moving the platens while the other parts of the process may be simultaneously slowed down or even temporarily stopped. Changeover of platens, to accommodate different products, such as single compartment pouch to multiple compartment pouches, is also simplified because platens are simply connected to the movers and are thus easily removed and replaced.

What is claimed: 
     
         1 . A packaging machine for making film wrapped pouches, comprising:
 multiple stages for making film wrapped pouches on platens;   a track through the multiple stages;   movers carrying the platens through the multiple stages around the track; and, the movers move independently about the track through each of the multiple stages.   
     
     
         2 . The packaging machine as set forth in  claim 1 , wherein the movers are processed in a first stage with a first speed and acceleration characteristic and in a second stage at a second speed and acceleration characteristic, the first and second speed and acceleration characteristics being independently controlled. 
     
     
         3 . The packaging machine as set forth in  claim 2 , wherein the movers are driven through the multiple stages by multiple mechanically independent linear motors. 
     
     
         4 . The packaging machine as set forth in  claim 3 , wherein the movers are provided with magnets affixed thereto and propelled through the multiple stages by magnetic fields provided by the linear motors. 
     
     
         5 . The packaging machine as set forth in  claim 4 , wherein there is no mechanical contact between the magnets and the linear motors. 
     
     
         6 . The packaging machine as set forth in  claim 5 , wherein the movers are accelerated and decelerated through the multiple stages independently in each of the multiple stages. 
     
     
         7 . The packaging machine as set forth in  claim 6 , wherein the movers are simultaneously propelled at one speed in a first relatively slow stage of processing and propelled at a second speed in a relatively fast stage of processing. 
     
     
         8 . The packaging machine as set forth in  claim 1 , further comprising a vacuum plenum, a vacuum belt engages an opening of the platen with the vacuum plenum to provide a vacuum force to molds in the platens. 
     
     
         9 . The packaging machine as set forth in  claim 1 , wherein the multiple stages comprise a fill stage and wherein the pouch is propelled slowly through the fill stage relative to other the multiple stages. 
     
     
         10 . The packaging machine as set forth in  claim 1 , wherein the movers are mechanically independent. 
     
     
         11 . The packaging machine as set forth in  claim 10 , wherein the multiple movers are propelled by following magnetic fields created by a series of linear motors, the multiple movers having magnets that follow the magnetic fields. 
     
     
         12 . The packaging machine as set forth in  claim 11 , wherein the platens having molds therein for pouch formation. 
     
     
         13 . The packaging machine as set forth in  claim 12 , wherein the platens are removably secured to the movers and the platens are replaceable with other platens. 
     
     
         14 . The packaging machine as set forth in  claim 1 , comprising at least one fill station transferring a product into the mold. 
     
     
         15 . The packaging machine as set forth in  claim 15 , wherein another fill station is added or removed without modifying other stations. 
     
     
         16 . The packaging machine as set forth in  claim 1 , further comprising a moving filling system, wherein the moving filling system comprises a filling housing that moves generally perpendicularly to a movement of the platens while filling molds of the platens with a chemical. 
     
     
         17 . The packaging machine as set forth in  claim 16 , wherein the filling housing includes an array of filling spouts that deposits the chemical into the molds. 
     
     
         18 . The packaging machine as set forth in  claim 17 , wherein the filling spouts are spaced along a cross member, the cross member positioned above the platens, and the cross member having a length to pass over a width of the platens. 
     
     
         19 . The packaging machine as set forth in  claim 16 , wherein the moving filling system further comprises a drive shaft that rotates forward and reverse in order to drive the filling housing. 
     
     
         20 . The packaging machine as set forth in  claim 16 , wherein the filling housing is positioned below a powder spout of the packaging machine, wherein the powder spout remains stationary. 
     
     
         21 . The packaging machine as set forth in  claim 16 , wherein the chemical is a powder detergent. 
     
     
         22 . The packaging machine as set forth in  claim 1 , further comprising a moving filling system, wherein the moving filling system comprises a cross-member that crosses over a top of the platens and positions an array of filling nozzles over the platens to deposit a chemical into molds of the platens. 
     
     
         23 . The packaging machine as set forth in  claim 22 , wherein the moving filling system moves the filling nozzles in a same direction as the molds. 
     
     
         24 . The packaging machine as set forth in  claim 22 , wherein the moving filling system moves the filling nozzles in a same direction as the molds while depositing chemical into the molds. 
     
     
         25 . The packaging machine as set forth in  claim 22 , wherein the cross member is in a moving engagement with a front track of the packaging machine, a front member fixedly engages with and supports the cross member, the front member movingly engages to the front track, a rear member fixedly engages with the cross member, and the rear member movingly engages with a drive shaft. 
     
     
         26 . The packaging machine as set forth in  claim 22 , wherein the moving filling system moves the filling nozzles in same direction as the platens and at a faster rate than the platens while filling the molds with the chemical. 
     
     
         27 . The packaging machine as set forth in  claim 22 , wherein the chemical is a liquid detergent. 
     
     
         28 . The packaging machine as set forth in  claim 1 , further comprising a vacuum system, wherein the moving vacuum system comprises a vacuum manifold with vacuum nozzles positioned over the platens. 
     
     
         29 . The packaging machine as set forth in  claim 28 , wherein the vacuum manifold crosses over a top of the platens, and the vacuum nozzles descend vertically from the vacuum manifold. 
     
     
         30 . The packaging machine as set forth in  claim 29 , wherein the vacuum nozzles are positioned to clean only one depression in a mold of the platen. 
     
     
         31 . The packaging machine as set forth in  claim 28 , wherein the vacuum system is positioned between a powder fill head and a liquid fill head, wherein the platen moves under the powder fill head, then under the vacuum nozzle, and then under the liquid fill head. 
     
     
         32 . A packaging machine for film wrapped pouches, comprising:
 a track passing through a base film application stage, a filling stage, a lid film application stage;   independent movers engaged to the track, the independent movers carrying platens to the base film application stage, the filling stage, and the lid film application stage;   the independent movers provided with magnets affixed thereto wherein the movers are driven through the stages by magnetic fields of the linear motors; and,   the platens comprising molds for forming film wrapped pouches.   
     
     
         33 . The packaging machine as set forth in  claim 32 , wherein each mover carries a single platen. 
     
     
         34 . The packaging machine as set forth in  claim 32 , wherein the linear motors drive the movers at varying velocities around the track. 
     
     
         35 . A packaging machine for film wrapped pouches, comprising:
 multiple stages for making the film wrapped pouches on platens;   movers carrying the platens through the multiple stages;   a base film application and draw down stage wherein the base film is drawn down into molds of the platens by applying a vacuum to the molds; and,   the movers carry the platens over a vacuum plenum, and the vacuum plenum provides the vacuum to the molds.   
     
     
         36 . The packaging machine as set forth in  claim 35 , wherein a vacuum connection is formed between the vacuum plenum and the molds by a vacuum belt. 
     
     
         37 . The packaging machine as set forth in  claim 35 , wherein the vacuum plenum is in communication with the molds through platen port holes aligned with belt port holes of a vacuum belt, wherein the belt port holes align with an opening of the vacuum plenum. 
     
     
         38 . The packaging machine as set forth in  claim 37 , wherein a central controller synchronizes the platen port holes with the belt port holes. 
     
     
         39 . A method of manufacturing film wrapped pouches, comprising:
 providing platens with molds affixed to movers;   engaging the movers to a track, wherein the movers move independently around the track;   applying a base layer of film to the molds of the platens at a base layer stage;   applying a vacuum to pull the base film down into the molds of the platens;   filling the molds with a chemical;   bonding the lid film to the base film;   cutting the lid film and the base film;   removing the pouches from the molds of the platens; and, moving the platens back to the base layer stage at an accelerated speed.   
     
     
         40 . The method of manufacturing film wrapped pouches according to  claim 39 , further comprising positioning an array of filling nozzles over the platens, and depositing the chemical into the molds of the platens while moving the array of filling nozzles along with the platens. 
     
     
         41 . The method of manufacturing film wrapped pouches according to  claim 39 , further comprising positioning a moving filling system over the platens, and moving a filling housing generally perpendicularly to the movement of the platens while filling the molds of the platens with a chemical. 
     
     
         42 . A method of manufacturing film wrapped pouches, comprising:
 providing platens with molds;   applying a base layer of film to the molds of the platens;   applying a vacuum to pull the base film down into the molds of the platens;   filling a first side of the mold with a first chemical;   vacuuming a second side of the mold to clean the second side of the mold of any of the first chemical;   filling a second side of the mold with a second chemical;   bonding the lid film to the base film;   cutting the lid film and the base film; and,   removing the pouches from the molds of the platens.