Apparatus and method for the production of a cushion product from a single- or multi-layer continuous paper strip

1. An apparatus for the production of a cushion product from a continuous paper strip, the apparatus comprising:

a feed unit configured for drawing the paper strip into the apparatus;

a cutting unit configured for cutting the cushion product from the paper strip, wherein the cutting unit comprises a rotation blade and a rotation cutting pad, the rotation cutting pad arranged opposing the rotation blade and configured to rotate adaptably to the rotation velocity of the rotation blade; and

a control electronics for an activation of the cutting unit according to a predetermined motion profile, the control electronics further comprising a sensor configured for capturing a rotation angle position of the feed unit, wherein the control electronics is configured to activate the feed unit continuously and to start the activation of the cutting unit for a discontinuous cutting operation during the capturing of the predetermined actual rotation angle position of the feed unit.

2. The apparatus according to claim 1 , wherein the control electronics is configured to determine a target feed rate for feeding the paper strip and to initialize the feed unit continuously according to the target feed rate, as well as to determine a target cushion length, and to adjust the cutting operation according to the target feed rate and the target cushion length, wherein the control electronics is configured to consider a feed diameter of the feed unit or a cutting diameter of a cutting unit.

3. The apparatus according to claim 2 , wherein the control electronics is configured to define the predetermined current rotation angle position for the cutting operation for the production of cushion products in accordance with the target cushion length on the basis of the target feed rate and the feed diameter, wherein the control electronics is configured to:

determine an incremental count threshold value, and in consideration of the feed diameter; and

induce an initialization of the cutting unit when the sensor is capturing the incremental count threshold value.

4. The apparatus according to claim 1 , wherein the sensor comprises a ferromagnetic incremental encoder and an electromagnetic incremental receiver, wherein the ferromagnetic incremental encoder has an incremental resolution between 20°-100° increments.

5. The apparatus according to claim 1 , wherein the control electronics is configured to coordinately trigger the feed unit and a cutting rate of the cutting unit and a circumferential velocity of a rotation blade is 1% to 10% larger than a circumferential velocity of the feed unit.

6. The apparatus according to claim 5 , wherein the cutting unit comprises a rotational blade and the control electronics comprises a second sensor assembly for capturing a rotation angle position of the rotation blade, wherein the sensor assembly comprising a second ferromagnetic incremental encoder and a second electromagnetic incremental receiver, wherein the second ferromagnetic incremental encoder has an incremental resolution between 10-100 increments.

7. The apparatus according to claim 6 , wherein the sensor assembly is configured to monitor a cutting rotation angle position or a hold point rotation angle position of the rotation blade, with one or two position encoders, wherein the control electronics is configured to initiate a braking procedure for the cutting unit during the monitoring of the cutting rotation angle position.

8. The apparatus according to claim 1 , wherein the predetermined motion profile comprises a velocity profile or a torque profile.

9. The apparatus according to claim 1 , wherein the paper strip is drawn from a supply roll or supply stack and formed to a three-dimensional fill material strand upstream in a feed direction of the cutting unit.

10. The apparatus according to claim 1 , wherein the central area is plastically deformed and the two hollow crumple spaces are formed by folding the edges towards the middle.

11. A method for the production of a cushion product from a continuous paper strip, the method comprising;

feeding the paper strip into the apparatus continuously by a feed unit with a constant feed rate;

cutting of the cushion product from the paper strip according to a predefined motion profile by a cutting unit being operated discontinuously, wherein the cutting unit comprises a rotation blade and a rotation cutting pad, the rotation cutting pad arranged opposing the rotation blade and configured to rotate adaptably to the rotation velocity of the rotation blade;

capturing a rotation angle position of the feed unit; and

inducing the discontinuous cutting when reaching a predetermined rotation angle position of the feed unit.

12. The method according to claim 11 , wherein the predetermined motion profile comprises:

an acceleration phase, in which a rotation blade of the cutting unit is accelerated to a nominal velocity;

an operation phase in which the rotation blade is moved constantly with nominal velocity, wherein the nominal velocity is 1% to 10% larger than the constant feed rate;

a cutting process, during which the cutting unit separating the cushion product from the paper strip, wherein the cutting rate of the rotation blade is 1% to 10% larger than the constant feed rate;

a braking phase, in which the velocity of the cutting unit is reduced; and

a hold phase, in which the rotation blade is held fixedly in an initial position.

13. The method according to claim 11 , wherein the predetermined motion profile comprises a velocity profile or a torque profile.

14. The method according to claim 11 , wherein the central area is plastically deformed and the two hollow crumple spaces are formed by folding the edges towards the middle.

15. The method according to claim 11 , further comprising:

determining a target feed rate for feeding the paper strip;

initializing the feed unit continuously according to the target feed rate;

determining a target cushion length; and to

adjusting the cutting operation according to the target feed rate and the target cushion length, wherein the adjusting considers a feed diameter of the feed unit or a cutting diameter of the cutting unit.

16. The method according to claim 15 , further comprising:

defining the predetermined current rotation angle position for the cutting operation for the production of cushion products in accordance with the target cushion length on the basis of the target feed rate and the feed diameter by:

determining an incremental count threshold value, and in consideration of the feed diameter; and

inducing an initialization of the cutting unit when the incremental count threshold value is captured by a sensor.

17. The method according to claim 16 , wherein the sensor comprises a ferromagnetic incremental encoder and an electromagnetic incremental receiver, wherein the ferromagnetic incremental encoder has an incremental resolution between 20°-100° increments.

18. The method according to claim 15 , further comprising:

coordinately trigger the feed unit and a cutting rate of the cutting unit and a circumferential velocity of the rotation blade is 1% to 10% larger than a circumferential velocity of the feed unit.

19. An apparatus for the production of a cushion product from a continuous paper strip, the apparatus comprising:

a feed unit configured for drawing the paper strip into the apparatus;

a cutting unit configured for cutting the cushion product from the paper strip; and

a control electronics for an activation of the cutting unit according to a predetermined motion profile, the control electronics further comprising a sensor configured for capturing a rotation angle position of the feed unit, wherein the control electronics is configured to activate the feed unit continuously and to start the activation of the cutting unit for a discontinuous cutting operation during the capturing of the predetermined actual rotation angle position of the feed unit, wherein the control electronics is configured to coordinately trigger the feed unit, and a cutting rate of the cutting unit and a circumferential velocity of a rotation blade is 1% to 10% larger than a circumferential velocity of the feed unit.

20. An apparatus for the production of a cushion product from a continuous paper strip, the apparatus comprising:

a feed unit configured for drawing the paper strip into the apparatus;

a cutting unit configured for cutting the cushion product from the paper strip; and

a control electronics for an activation of the cutting unit according to a predetermined motion profile, the control electronics further comprising a sensor configured for capturing a rotation angle position of the feed unit, wherein the sensor comprises a ferromagnetic incremental encoder and an electromagnetic incremental receiver, wherein the ferromagnetic incremental encoder has an incremental resolution between 20 and 100 increments/360°;

further wherein the control electronics is configured to activate the feed unit continuously and to start the activation of the cutting unit for a discontinuous cutting operation during the capturing of the predetermined actual rotation angle position of the feed unit.