Systems for dispensing pillows for product packaging

1 . A device for dispensing pillows for product packaging, each of the cushioning pillows comprising a first portion, and second portions each having a thickness less than a thickness of the first portion, the second portions of adjacent pillows adjoining each other to form a continuous web of the pillows, the web defining peaks coinciding with locations of maximum thickness of the first portions, and valleys located between the peaks, the device comprising:

a transfer unit including:

a rotatable hub, and

a pushing member connected to the hub; wherein:

the pushing member is configured to engage the web of pillows so that the pushing member draws the web of pillows into the transfer unit, and moves the web of pillows through the transfer unit toward of an exit opening of the transfer unit; and

the pushing member is angled away from a direction of rotation of the pushing member and extends from the hub in a direction away from the direction of rotation of the pushing member.

2 . The device of claim 1 , wherein the pushing member includes a vane.

3 . The device of claim 1 , wherein the transfer unit further includes a plurality of pushing members.

4 . The device of claim 3 , wherein a spacing between tips of adjacent pushing members is about equal to a length of the pillows.

5 . The device of claim 1 , wherein

the pushing member extends in a direction tangential to an outer surface of the hub.

6 . The device of claim 1 , wherein the transfer unit further comprises a guide configured to guide the web of pillows along a path.

7 . The device of claim 6 , wherein:

a forward side of the pushing member is configured to contact and advance the pillows;

the forward side of the pushing member is angled in relation to an adjacent portion of the guide by a first angle;

a rearward side of the pushing member is angled in relation to the adjacent portion of the guide by a second angle supplemental to the first angle; and

the first angle is less than the second angle.

8 . The device of claim 6 , wherein the guide comprises:

a curvilinear portion configured to guide the web of pillows along a curvilinear path; and

a vertical portion adjoining the curvilinear portion and configured to guide the web of pillows to the exit opening.

9 . The device of claim 6 , wherein the guide interferes with the pushing member as the pushing member moves past the guide.

10 . The device of claim 9 , wherein the pushing member is configured to flex in response to the interference between the pushing member and guide.

11 . The device of claim 10 , wherein the pushing member and the guide are configured so that the second portions of the pillows are entrained between a tip of the pushing member and the guide as the pushing member moves past the guide.

12 . The device of claim 6 , wherein:

the guide is a second guide;

the dispensing unit further comprises a first guide;

the first and second guides are configured to guide the web of pillows toward the pushing member;

the first and second guides are spaced apart from each other by a spacing that ensures proper engagement of the web of pillows within the transfer unit; and

the second guide is configured as a ramp that lifts the web of pillows as the second guide guides the web of pillows along the path.

13 . The device of claim 1 , wherein:

the pushing member is configured to advance the web of pillows in a first direction; and

the dispensing unit further comprises an anti-reverse feature configured to inhibit movement of the web of pillows in a second direction opposite the first direction.

14 . The device of claim 13 , wherein the anti-reverse feature comprises a brush.

15 . The device of claim 1 , wherein the dispensing unit further comprises a wiper configured to contact the pillows and separate the pillows from the pushing member as the pushing member and the pillows rotate past the wiper.

16 . The device of claim 15 , wherein the wiper comprises a brush.

17 . The device of claim 1 , further comprising a holding bin, wherein the pushing member is configured to engage the web of pillows as the pushing member rotates so that the pushing member draws the web of pillows into the transfer unit from the holding bin.

18 . The device of claim 17 , wherein the transfer unit is configured to be mounted on, and removed from the holding bin as a modular unit.

19 . A device for dispensing pillows for product packaging, each of the cushioning pillows comprising a first portion, and second portions each having a thickness less than a thickness of the first portion, the second portions of adjacent pillows adjoining each other to form a continuous web of the pillows, the web defining peaks coinciding with locations of maximum thickness of the first portions, and valleys located between the peaks, the device comprising:

a separation unit configured to receive the web of packaging items, the separation unit comprising:

an anvil configured to support a cover and a cutting device of the separation unit,

the cover, the cover mounted on the anvil and configured to move in relation to the anvil between a first position and second position of the cover,

a press movable between a first position and a second position of the press, the press configured to move the cover from the first to the second position of the cover, and to push the webbing into the cutting device, when the press moves from the first to the second position of the press, the press also configured to at least partially enclose the cutting device when the cover is in the second position of the cover; and

the cutting device, the cutting device mounted on the anvil and configured to sever the second portions of the pillows upon contact with the second portions, wherein:

the cover at least partially encloses the cutting device when the cover is in the first position of the cover.

20 . The device of claim 19 , wherein the cutting device includes a cutting wire.

21 . The device of claim 19 , further comprising a control element connected to the cover and configured to rotate in relation to the cover between a first and second position of the control element; wherein:

the control element is configured to engage the anvil when the control element is in the first position of the control element; and

the engagement of the control element and the anvil prevents the cover from moving from the first to the second position of the cover.

22 . The device of claim 21 , wherein the control element includes a locking arm comprising a latch configured to engage the anvil when the control element is in the first position of the control element.

23 . The device of claim 22 , wherein:

the press comprises a roller;

the locking arm has a slot formed therein and configured to receive the roller;

the roller translates within the slot as the press moves from the first to the second position of the press; and

the slot is configured so that the translation of roller within the slot causes the control element to rotate in relation between the first and second positions of the control element.

24 . The device of claim 23 , wherein:

the slot includes a first portion that extends in a first direction, and a second portion that extends in a second direction different than the first direction; and

the slot is further configured so that translation of the roller within the second portion of the slot urges the control element from the first to the second position of the control element.

25 . The device of claim 24 , wherein the cover does not enclose the cutting device when the cover is in the second position of the cover.

26 . The device of claim 25 , wherein the cover defines a channel configured to receive the cutting device when the cover is in the first position of the cover.

27 . The device of claim 26 , wherein:

the press includes a body, and a U-shaped member mounted on the body and facing the cutting device and the cover; and

the U-shaped member is configured to contact an end of the cover at locations above and below the channel as the press moves from the first to the second position of the press.

28 . The device of claim 27 , wherein the U-shaped member is configured to pull and stretch the second portions of the pillows between prongs of the U-shaped member as the press moves from the first position to the second position of the press.

29 . The device of claim 28 , wherein the U-shaped member is further configured to at least partially enclose the cutting device when the cover is in the second position of the cover.

30 . The device of claim 28 , wherein the U-shaped member and the cover are further configured to contact and pinch the second portions of the pillows at locations above and below the channel.

31 . The device of claim 19 , wherein the separation unit further includes an actuator configured to move the press between the first and second positions of the press.

32 . The device of claim 31 , further comprising a transfer unit including a pushing member, and a motor configured to, during operation, move the pushing member, wherein:

the pushing member is configured to engage the web of pillows so that the pushing member draws the web of pillows into the transfer unit and moves the web of pillows along a path within the transfer unit and out of an exit opening of the transfer unit;

the press and the cover define an opening configured to receive the web of pillows when the press is in the first position of the press; and

the opening defined by the press and the cover is located directly below the exit opening of the transfer unit.

33 . The device of claim 32 , wherein:

the device further includes a control unit communicatively coupled to the motor; and

the control unit and the motor are configured to position the pushing member in a plurality of predetermined angular positions at which one of the second portions of the pillows aligns with the press and the cutting device.

34 . The device of claim 33 , wherein:

the transfer unit further includes a hub, a plurality of the pushing members mounted on the hub, a plurality of magnets mounted on the hub, and a sensor;

the sensor and the magnets are configured so that the sensor aligns with respective ones of the magnets when the pushing members are positioned in the predetermined angular positions;

the sensor is configured to generate an output indicating when the sensor is aligned with any of the magnets; and

the control unit and the motor are further configured to position the pushing members so that one of the magnets aligns with the sensor.

35 . The device of claim 34 , wherein the control unit and the motor are configured to reverse a direction of rotation of the hub upon, or after the cutting device severs the webbing of the web of pre-inflated pillows.

36 . The device of claim 35 , wherein the control unit and the motor are further configured to reverse a direction of rotation of the hub upon, or after the cutting device severs the webbing of the web of packaging articles so that contact between a leading edge of the web of packaging articles and the cutting device is minimized.

37 . A device for dispensing pillows for product packaging, each of the cushioning pillows comprising a first portion, and second portions each having a thickness less than a thickness of the first portion, the second portions of adjacent pillows adjoining each other to form a continuous web of the pillows, the web defining peaks coinciding with locations of maximum thickness of the first portions, and valleys located between the peaks, the device comprising:

a holding bin defining an internal volume configured to receive the web of pillows;

a duct defining a channel configured to receive the web of pillows and guide the web of pillows to the internal volume of the holding bin in a first direction;

an air circulating device in fluid communication with the channel and configured to, during operation, direct air into the channel at a pressure and flow-rate sufficient to move the web of pillows through the channel in the first direction; and

an anti-reverse feature mounted within the channel and configured to inhibit movement of the web of pillows in a second direction opposite the first direction.

38 . The device of claim 37 , further comprising a transfer unit comprising a pushing member, the pushing member configured to engage the web of pillows so that the pushing member draws the web of pillows into the transfer unit from the holding bin and advances the web of pillows within the transfer unit and toward an exit of the transfer unit.

39 . The device of claim 37 , wherein:

the duct is mounted on an external surface of the holding bin; and

the duct and the external surface of the holding bin define the channel.

40 . The device of claim 39 , wherein the anti-reverse feature includes a tab.

41 . The device of claim 37 , wherein the internal volume of the holding bin has a width about equal to a maximum width of the pillows.

42 . The device of claim 37 , wherein:

the holding bin includes a first and a second sidewall spaced apart by a distance defining a width of the internal volume of the holding bin; and

the pillows within the holding bin are constrained from substantial movement in a widthwise direction of the pillows by the first and second sidewalls.

43 . The device of claim 37 , wherein the channel has a width about equal to a maximum width of the pillows.

44 . The device of claim 37 , wherein the channel has a substantially vertical orientation.

45 . The device of claim 37 , wherein the channel has cross-sectional dimensions about equal to a thickness and a maximum width of the pillows.

46 . The device of claim 37 , wherein the air circulating device is one of a fan and a blower.

47 . The device of claim 37 , wherein the bin is configured so that the web of pillows falls toward a bottom of the holding bin and folds upon itself after entering the holding bin.

48 . The device of claim 47 , wherein the bin is further configured so that the web of pillows folds in a random pattern after entering the holding bin.

49 . The device of claim 37 , further comprising an inflation and sealing machine positioned relative to the holding bin so that the web of pillows exits the inflation and sealing machine at a point lower than a bottom of the holding bin, the inflating and sealing machine configured to form the web of inflatable pillows and to feed the web into the holding bin.

50 . The device of claim 37 , further comprising a conveyor positioned below a bottom of the holding bin.