U.S. patent application number 09/785891 was filed with the patent office on 2001-07-19 for article packaging system.
Invention is credited to Craig, Frank, Straeter, Joseph G., Weder, Donald E..
Application Number | 20010008062 09/785891 |
Document ID | / |
Family ID | 27503656 |
Filed Date | 2001-07-19 |
United States Patent
Application |
20010008062 |
Kind Code |
A1 |
Craig, Frank ; et
al. |
July 19, 2001 |
Article packaging system
Abstract
The present invention is a modular system for packaging articles
for shipment. In particular, a potted plant is sorted according to
a grade, placed in a decorative cover, then automatically deposited
into a protective sleeve. The potted plant thus packaged is ready
for containment within a shipping carton. Various components of the
system may be adapted for various packaging needs and
circumstances.
Inventors: |
Craig, Frank; (Valley Park,
MO) ; Straeter, Joseph G.; (Highland, IL) ;
Weder, Donald E.; (Highland, IL) |
Correspondence
Address: |
Dunlap, Codding & Rogers, P.C.
Suite 420
9400 North Broadway
Oklahoma City
OK
73114
US
|
Family ID: |
27503656 |
Appl. No.: |
09/785891 |
Filed: |
February 16, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09785891 |
Feb 16, 2001 |
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09393041 |
Sep 8, 1999 |
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6189295 |
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09393041 |
Sep 8, 1999 |
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09005630 |
Jan 9, 1998 |
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6006500 |
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09005630 |
Jan 9, 1998 |
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08720961 |
Oct 10, 1996 |
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5706628 |
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08720961 |
Oct 10, 1996 |
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08462332 |
Jun 5, 1995 |
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5605029 |
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08462332 |
Jun 5, 1995 |
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08417477 |
Apr 5, 1995 |
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5586425 |
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08417477 |
Apr 5, 1995 |
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07954635 |
Sep 30, 1992 |
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Current U.S.
Class: |
53/397 ; 53/449;
53/459 |
Current CPC
Class: |
B65B 25/026
20130101 |
Class at
Publication: |
53/397 ; 53/449;
53/459 |
International
Class: |
B65B 025/02 |
Claims
What is claimed is:
1. A method of packaging an article comprising the steps of:
providing an article having an exterior surface; applying a cover
about the exterior surface of the article to form a covered
article; providing an automatic sleeving means for automatically
applying a sleeve to the covered article; conveying the article to
the automatic sleeving means; and automatically applying a sleeve
about the covered article to form a sleeved covered article.
2. The method of claim 1 wherein in the step of providing an
article, the article further comprises a potted plant.
3. The method of claim 1 comprising after the step of providing the
article the additional step of sorting the article into one of at
least two grades in accordance with a predetermined grading
criterion.
4. The method of claim 3 wherein the step of sorting the article
occurs before the step of applying the cover.
5. The method of claim 3 wherein the step of sorting the article
occurs after the step of applying the cover.
6. The method of claim 3 wherein the step of sorting the article
comprises using automatic sorting means to sort the article.
7. The method of claim 1 wherein the step of applying the cover
about the article is preceded by conveying the article via an
article conveying means to a cover applying station wherein the
cover is applied about the article.
8. The method of claim 1 wherein the cover is a preformed cover
having an interior surface, an exterior surface, and an interior
space adjacent and surrounded by the interior surface.
9. The method of claim 8 wherein in the step of applying the cover
to the article, the article is automatically deposited into the
interior space of the cover.
10. The method of claim 8 wherein in the step of applying the cover
to the article, the article is manually deposited into the interior
space of the cover.
11. The method of claim 8 wherein in the step of applying the
cover, the cover is a preformed cover provided by automatic cover
supplying means which retrieves the cover from a set of preformed
covers and places the coverin an article application position.
12. The method of claim 1 wherein the step of applying a cover is
preceded by the step of providing a cover which has been formed by
a mold type cover forming means, wherein after the cover is formed,
the cover is placed in an article application position for
application to the article.
13. The method of claim 1 wherein in the step of applying the cover
to the article, the cover is applied about the exterior surface of
the article by an appressing cover forming means which appresses a
sheet of material about the external surface of the article to form
the cover.
14. The method of claim 13 wherein the cover forming means
comprises a plurality of pivoting members which act together to
appress the sheet of material about the external surface of the
article.
15. The method of claim 14 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
article.
16. The method of claim 1 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
article.
17. The method of claim 1 wherein the step of conveying the article
further comprises conveying the article on automatic conveying
means.
18. The method of claim 17 wherein the automatic conveying means
further comprises a conveyor belt.
19. The method of claim 1 wherein the automatic sleeving means
comprises means for automatically opening the sleeve to provide an
open sleeve for receiving the covered article.
20. The method of claim 19 wherein the step of automatically
applying a sleeve further comprises automatically depositing the
covered article into the open sleeve.
21. The method of claim 20 wherein the covered article is
automatically deposited into the open sleeve by passing the covered
article through a guiding means.
22. The method of claim 1 wherein the step of automatically
applying a sleeve comprises wrapping a sheet of sleeving material
about the covered article to form a sleeved covered article.
23. The method of claim 1 comprising the additional step of sealing
an upper portion of the sleeve of the sleeved covered article.
24. The method of claim 23 wherein the step of sealing further
comprises using an automatic sealing device.
25. The method of claim 23 wherein the step of sealing further
comprises heat sealing.
26. The method of claim 23 wherein the step of sealing further
comprises sonic sealing.
27. The method of claim 23 wherein the step of sealing further
comprises vibratory sealing.
28. The method of claim 23 wherein the step of sealing further
comprises pressure-sensitive sealing.
29. The method of claim 1 further comprising the additional step of
providing a transfer means for engaging the sleeved covered article
for conveying the sleeved covered article to a boxing station.
30. The method of claim 29 wherein the transfer means further
comprises an automatic pushing means.
31. The method of claim 29 wherein the transfer means further
comprises an automatic gripping means.
32. A method of packaging a potted plant comprising the steps of:
providing a potted plant having an exterior surface; applying a
cover about the exterior surface of the potted plant to form a
covered potted plant; providing an automatic sleeving means for
automatically applying a sleeve to the covered potted plant;
conveying the potted plant to the automatic sleeving means; and
automatically applying a sleeve about the covered potted plant to
form a sleeved covered potted plant.
33. The method of claim 32 wherein in the step of providing a
potted plant, the potted plant further comprises a living potted
plant.
34. The method of claim 32 comprising after the step of providing
the potted plant the additional step of sorting the potted plant
into one of at least two grades in accordance with a predetermined
grading criterion.
35. The method of claim 34 wherein the step of sorting the potted
plant occurs before the step of applying the cover.
36. The method of claim 34 wherein the step of sorting the potted
plant occurs after the step of applying the cover.
37. The method of claim 34 wherein the step of sorting the potted
plant comprises using automatic sorting means to sort the potted
plant.
38. The method of claim 32 wherein the step of applying the cover
about the potted plant is preceded by conveying the potted plant
via a conveying means to a cover applying station wherein the cover
is applied about the potted plant.
39. The method of claim 32 wherein the cover is a preformed cover
having an interior surface, an exterior surface, and an interior
space adjacent and surrounded by the interior surface.
40. The method of claim 39 wherein in the step of applying the
cover to the potted plant,, the potted plant is automatically
deposited into the interior space of the cover.
41. The method of claim 39 wherein in the step of applying the
cover to the potted plant, the potted plant is manually deposited
into the interior space of the cover.
42. The method of claim 39 wherein in the step of applying the
cover, the cover is a preformed cover provided by automatic cover
supplying means which retrieves the cover from a set of preformed
covers and places the cover in an application position.
43. The method of claim 32 wherein the step of applying a cover is
preceded by the step of providing a cover which has been formed by
a mold type cover forming means, wherein after the cover is formed,
the cover is placed in an application position for application to
the potted plant.
44. The method of claim 32 wherein in the step of applying the
cover to the potted plant, the cover is applied about the exterior
surface of the potted plant by an appressing cover forming means
which appresses a sheet of material about the external surface of
the potted plant to form the cover.
45. The method of claim 44 wherein the cover forming means
comprises a plurality of pivoting members which act together to
appress the sheet of material about the external surface of the
potted plant.
46. The method of claim 45 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
potted plant.
47. The method of claim 32 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
potted plant.
48. The method of claim 32 wherein the step of conveying the potted
plant further comprises conveying the potted plant on automatic
conveying means.
49. The method of claim 48 wherein the automatic conveying means
further comprises a conveyor belt.
50. The method of claim 32 wherein the automatic sleeving means
comprises means for automatically opening the sleeve to provide an
open sleeve for receiving the covered potted plant.
51. The method of claim 50 wherein the step of automatically
applying a sleeve further comprises automatically depositing the
covered potted plant into the open sleeve.
52. The method of claim 51 wherein the covered potted plant is
automatically deposited into the open sleeve by passing the covered
potted plant through a guiding means.
53. The method of claim 32 wherein the step of automatically
applying a sleeve comprises wrapping a sheet of sleeving material
about the covered potted plant to form a sleeved covered potted
plant.
54. The method of claim 32 comprising the additional step of
sealing an upper portion of the sleeve of the sleeved covered
potted plant.
55. The method of claim 54 wherein the step of sealing further
comprises using an automatic sealing device.
56. The method of claim 54 wherein the step of sealing further
comprises heat sealing.
57. The method of claim 54 wherein the step of sealing further
comprises sonic sealing.
58. The method of claim 54 wherein the step of sealing further
comprises vibratory sealing.
59. The method of claim 55 wherein the step of sealing further
comprises pressure-sensitive sealing.
60. The method of claim 32 further comprising the additional step
of providing a transfer means for engaging the sleeved covered
plant and placing the sleeved covered plant into a carton.
61. The method of claim 60 wherein the transfer means further
comprises an automatic pushing means.
62. The method of claim 60 wherein the transfer means further
comprises an automatic gripping means.
63. A method of packaging a potted plant comprising the steps of:
providing a potted plant having an exterior surface; automatically
supplying a cover for application about the exterior of the potted
plant; applying the cover about the exterior surface of the potted
plant to form a covered potted plant; providing an automatic
sleeving means for automatically applying a sleeve to the covered
potted plant; conveying the potted plant to the automatic sleeving
means; and automatically applying a sleeve about the covered potted
plant to form a sleeved covered potted plant.
64. The method of claim 63 wherein in the step of providing a
potted plant, the potted plant further comprises a living potted
plant.
65. The method of claim 63 comprising after the step of providing
the potted plant the additional step of sorting the potted plant
into one of at least two grades in accordance with a predetermined
grading criterion.
66. The method of claim 65 wherein the step of sorting the potted
plant occurs before the step of applying the cover.
67. The method of claim 65 wherein the step of sorting the potted
plant occurs after the step of applying the cover.
68. The method of claim 65 wherein the step of sorting the potted
plant comprises using automatic sorting means to sort the potted
plant.
69. The method of claim 63 wherein the step of applying the cover
about the potted plant is preceded by conveying the potted plant
via a conveying means to a cover applying station wherein the cover
is applied about the potted plant.
70. The method of claim 63 wherein the cover is a preformed cover
having an interior surface, an exterior surface, and an interior
space adjacent and surrounded by the interior surface.
71. The method of claim 70 wherein in the step of applying the
cover to the potted plant, the potted plant is automatically
deposited into the interior space of the cover.
72. The method of claim 70 wherein in the step of applying the
cover to the potted plant, the potted plant is manually deposited
into the interior space of the cover.
73. The method of claim 70 wherein in the step of automatically
supplying the cover, the cover is a preformed cover provided by
automatic cover supplying means which automatically retrieves the
cover and places the cover in an application position.
74. The method of claim 73 wherein the step of supplying a cover is
preceded by the step of forming a cover by a mold type cover
forming means.
75. The method of claim 63 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
potted plant.
76. The method of claim 63 wherein the step of conveying the potted
plant further comprises conveying the potted plant on automatic
conveying means.
77. The method of claim 76 wherein the automatic conveying means
further comprises a conveyor belt.
78. The method of claim 63 wherein the automatic sleeving means
comprises means for automatically opening the sleeve to provide an
open sleeve for receiving the covered potted plant.
79. The method of claim 78 wherein the step of automatically
applying a sleeve further comprises automatically depositing the
covered potted plant into the open sleeve.
80. The method of claim 79 wherein the covered potted plant is
automatically deposited into the open sleeve by passing the covered
potted plant through a guiding means.
81. The method of claim 63 wherein the step of automatically
applying a sleeve comprises wrapping a sheet of sleeving material
about the covered potted plant to form a sleeved covered potted
plant.
82. The method of claim 63 comprising the additional step of
sealing an upper portion of the sleeve of the sleeved covered
potted plant.
83. The method of claim 82 wherein the step of sealing further
comprises using an automatic sealing device.
84. The method of claim 82 wherein the step of sealing further
comprises heat sealing.
85. The method of claim 82 wherein the step of sealing further
comprises sonic sealing.
86. The method of claim 82 wherein the step of sealing further
comprises vibratory sealing.
87. The method of claim 82 wherein the step of sealing further
comprises pressure-sensitive sealing.
88. The method of claim 63 further comprising the additional step
of providing a transfer means for engaging the sleeved covered
plant and placing the sleeved covered plant into a carton.
89. The method of claim 88 wherein the transfer means further
comprises an automatic pushing means.
90. The method of claim 88 wherein the transfer means further
comprises an automatic gripping means.
91. A method of packaging a potted plant comprising the steps of:
providing a potted plant having an exterior surface; providing
automatic covering means for automatically applying a cover to the
potted plant; automatically applying the cover about the exterior
surface of the potted plant to form a covered potted plant;
providing an automatic sleeving means for automatically applying a
sleeve to the covered potted plant; conveying the potted plant to
the automatic sleeving means; and automatically applying a sleeve
about the covered potted plant to form a sleeved covered potted
plant.
92. The method of claim 91 wherein in the step of providing a
potted plant, the potted plant further comprises a living potted
plant.
93. The method of claim 91 comprising after the step of providing
the potted plant the additional step of sorting the potted plant
into one of at least two grades in accordance with a predetermined
grading criterion.
94. The method of claim 93 wherein the step of sorting the potted
plant occurs before the step of applying the cover.
95. The method of claim 93 wherein the step of sorting the potted
plant occurs after the step of applying the cover.
96. The method of claim 93 wherein the step of sorting the potted
plant comprises using automatic sorting means to sort the potted
plant.
97. The method of claim 91 wherein the cover is a preformed cover
having an interior surface, an exterior surface, and an interior
space adjacent and surrounded by the interior surface.
98. The method of claim 91 wherein in the step of automatically
applying the cover to the potted plant, the cover is applied about
the exterior surface of the potted plant by a cover forming means
which appresses a sheet of material about the external surface of
the potted plant to form the cover.
99. The method of claim 91 wherein the automatic covering means
comprises an apparatus having a plurality of pivoting members which
act together to appress the sheet of material about the external
surface of the potted plant.
100. The method of claim 99 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
potted plant.
101. The method of claim 91 wherein the step of automatically
applying a cover further comprises bonding the cover to the
exterior surface of the potted plant.
102. The method of claim 91 wherein the step of conveying the
potted plant further comprises conveying the potted plant on
automatic conveying means.
103. The method of claim 102 wherein the automatic conveying means
further comprises a conveyor belt.
104. The method of claim 91 wherein the automatic sleeving means
comprises means for automatically opening the sleeve to provide an
open sleeve for receiving the covered potted plant.
105. The method of claim 104 wherein the step of automatically
applying a sleeve further comprises automatically depositing the
covered potted plant into the open sleeve.
106. The method of claim 105 wherein the covered potted plant is
automatically deposited into the open sleeve by passing the covered
potted plant through a guiding means.
107. The method of claim 91 wherein the step of automatically
applying a sleeve comprises wrapping a sheet of sleeving material
about the covered potted plant to form a sleeved covered potted
plant.
108. The method of claim 91 comprising the additional step of
sealing an upper portion of the sleeve of the sleeved covered
potted plant.
109. The method of claim 108 wherein the step of sealing further
comprises using an automatic sealing device.
110. The method of claim 108 wherein the step of sealing further
comprises heat sealing.
111. The method of claim 108 wherein the step of sealing further
comprises sonic sealing.
112. The method of claim 108 wherein the step of sealing further
comprises vibratory sealing.
113. The method of claim 108 wherein the step of sealing further
comprises pressure-sensitive sealing.
114. The method of claim 91 further comprising the additional step
of providing a transfer means for engaging the sleeved covered
plant and placing the sleeved covered plant into a carton.
115. The method of claim 114 wherein the transfer means further
comprises an automatic pushing means.
116. The method of claim 114 wherein the transfer means further
comprises an automatic gripping means.
117. A method of packaging a potted plant comprising the steps of:
providing a potted plant, the potted plant having an exterior
surface; sorting the potted plant into one of at least two grades
in accordance with a predetermined grading criterion to form a
sorted potted plant; applying a cover about the exterior surface of
the sorted potted plant to form a covered potted plant; providing
an automatic sleeving means for automatically applying a sleeve to
the covered potted plant; conveying the potted plant to the
automatic sleeving means; and automatically applying a sleeve about
the covered potted plant to form a sleeved covered potted
plant.
118. The method of claim 117 wherein in the step of providing a
potted plant, the potted plant further comprises a living potted
plant.
119. The method of claim 117 wherein the step of sorting the potted
plant occurs before the step of applying the cover.
120. The method of claim 117 wherein the step of sorting the potted
plant occurs after the step of applying the cover.
121. The method of claim 117 wherein the step of sorting the potted
plant comprises using automatic sorting means to sort the potted
plant.
122. The method of claim 117 wherein the step of sorting the potted
plant comprises manually sorting the potted plant.
123. The method of claim 117 wherein the step of applying the cover
about the potted plant is preceded by conveying the potted plant
via a conveying means to a cover applying station wherein the cover
is applied about the potted plant.
124. The method of claim 117 wherein the cover is a preformed cover
having an interior surface, an exterior surface, and an interior
space adjacent and surrounded by the interior surface.
125. The method of claim 124 wherein in the step of applying the
cover to the potted plant, the potted plant is automatically
deposited into the interior space of the cover.
126. The method of claim 124 wherein in the step of applying the
cover to the potted plant, the potted plant is manually deposited
into the interior space of the cover.
127. The method of claim 124 wherein in the step of applying the
cover, the cover is a preformed cover provided by automatic cover
supplying means which retrieves the cover from a set of preformed
covers and places the cover in an application position.
128. The method of claim 117 wherein the step of applying a cover
is preceded by the step of providing a cover which has been formed
by a mold type cover forming means, wherein after the cover is
formed, the cover is placed in an application position for
application to the potted plant.
129. The method of claim 117 wherein in the step of applying the
cover to the potted plant, the cover is applied about the exterior
surface of the potted plant by an appressing cover forming means
which appresses a sheet of material about the external surface of
the potted plant to form the cover.
130. The method of claim 129 wherein the cover forming means
comprises a plurality of pivoting members which act together to
appress the sheet of material about the external surface of the
potted plant.
131. The method of claim 130 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
potted plant.
132. The method of claim 117 wherein the step of applying a cover
further comprises bonding the cover to the exterior surface of the
potted plant.
133. The method of claim 117 wherein the step of conveying the
potted plant further comprises conveying the potted plant on
automatic conveying means.
134. The method of claim 133 wherein the automatic conveying means
further comprises a conveyor belt.
135. The method of claim 117 wherein the automatic sleeving means
comprises means for automatically opening the sleeve to provide an
open sleeve for receiving the covered potted plant.
136. The method of claim 135 wherein the step of automatically
applying a sleeve further comprises automatically depositing the
covered potted plant into the open sleeve.
137. The method of claim 136 wherein the covered potted plant is
automatically deposited into the open sleeve by passing the covered
potted plant through a guiding means.
138. The method of claim 117 wherein the step of automatically
applying a sleeve comprises wrapping a sheet of sleeving material
about the covered potted plant to form a sleeved covered potted
plant.
139. The method of claim 117 comprising the additional step of
sealing an upper portion of the sleeve of the sleeved covered
potted plant.
140. The method of claim 139 wherein the step of sealing further
comprises using an automatic sealing device.
141. The method of claim 139 wherein the step of sealing further
comprises heat sealing.
142. The method of claim 139 wherein the step of sealing further
comprises sonic sealing.
143. The method of claim 139 wherein the step of sealing further
comprises vibratory sealing.
144. The method of claim 139 wherein the step of sealing further
comprises pressure-sensitive sealing.
145. The method of claim 117 further comprising the additional step
of providing a transfer means for engaging the sleeved covered
plant and placing the sleeved covered plant into a carton.
146. The method of claim 145 wherein the transfer means further
comprises an automatic pushing means.
147. The method of claim 145 wherein the transfer means further
comprises an automatic gripping means.
148. A method of packaging a potted plant comprising the steps of:
providing a potted plant having an exterior surface; sorting the
potted plant into one of at least two grades in accordance with a
predetermined grading criterion; providing an automatic sleeving
means for automatically applying a sleeve to the sorted potted
plant; conveying the sorted potted plant to the automatic sleeving
means; and automatically applying a sleeve about the sorted potted
plant to form a sleeved potted plant.
149. The method of claim 148 wherein in the step of providing a
potted plant, the potted plant further comprises a living potted
plant.
150. The method of claim 148 wherein the step of sorting the potted
plant comprises using automatic sorting means to sort the potted
plant.
151. The method of claim 148 wherein the step of conveying the
potted plant further comprises conveying the potted plant on
automatic conveying means.
152. The method of claim 151 wherein the automatic conveying means
further comprises a conveyor belt.
153. The method of claim 148 wherein the automatic sleeving means
comprises means for automatically opening the sleeve to provide an
open sleeve for receiving the potted plant.
154. The method of claim 153 wherein the step of automatically
applying a sleeve further comprises automatically depositing the
potted plant into the open sleeve.
155. The method of claim 154 wherein the potted plant is
automatically deposited into the open sleeve by passing the potted
plant through a guiding means.
156. The method of claim 148 wherein the step of automatically
applying a sleeve comprises wrapping a sheet of sleeving material
about the potted plant to form a sleeved potted plant.
157. The method of claim 148 comprising the additional step of
sealing an upper portion of the sleeve of the sleeved potted
plant.
158. The method of claim 157 wherein the step of sealing further
comprises using an automatic sealing device.
159. The method of claim 157 wherein the step of sealing further
comprises heat sealing.
160. The method of claim 157 wherein the step of sealing further
comprises sonic sealing.
161. The method of claim 157 wherein the step of sealing further
comprises vibratory sealing.
162. The method of claim 157 wherein the step of sealing further
comprises pressure-sensitive sealing.
163. The method of claim 148 further comprising the additional step
of providing a transfer means for engaging the sleeved potted plant
and placing the sleeved potted plant into a carton.
164. The method of claim 163 wherein the transfer means further
comprises an automatic pushing means.
165. The method of claim 163 wherein the transfer means further
comprises an automatic gripping means.
166. A method of packaging a potted plant comprising the steps of:
providing an automatic sleeving means for automatically dispensing
and opening a sleeve; opening the sleeve automatically to form an
opened sleeve; providing a cover; depositing the decorative cover
into the opened sleeve to form a sleeved cover; providing a potted
plant having an exterior surface; conveying the potted plant to the
automatic sleeving means; and depositing the potted plant into the
sleeved cover thereby forming a sleeved covered potted plant.
167. The method of claim 166 comprising after the step of providing
the potted plant the additional step of sorting the potted plant
into one of at least two grades in accordance with a predetermined
grading criterion.
168. The method of claim 167 wherein the step of sorting the potted
plant comprises using automatic sorting means to sort the potted
plant.
169. The method of claim 166 wherein in the step of providing a
cover the cover has an interior surface, an exterior surface, and
an interior space adjacent and surrounded by the interior
surface.
170. The method of claim 166 wherein in the step of depositing the
cover in the opened sleeve, the cover is automatically deposited
into the opened sleeve.
171. The method of claim 166 wherein in the step of depositing the
cover in the opened sleeve, the cover is manually deposited into
the opened sleeve.
172. The method of claim 170 wherein in the step of providing the
cover, the cover is provided by automatic cover supplying means
which retrieves the cover from a set of preformed covers and places
the cover in the opened sleeve.
173. The method of claim 166 wherein the step of providing a cover
is preceded by the step of forming a cover using a mold type cover
forming means.
174. The method of claim 169 wherein a portion of the interior
surface of the cover has a bonding material applied thereto for
bonding to the exterior of the potted plant after the potted plant
has been deposited in the sleeved cover.
175. The method of claim 166 wherein the step of conveying the
potted plant further comprises conveying the potted plant on
automatic conveying means.
176. The method of claim 175 wherein the automatic conveying means
further comprises a conveyor belt.
177. The method of claim 166 wherein the step of depositing the
potted plant into the sleeved cover further comprises automatically
depositing the potted plant into the sleeved cover.
178. The method of claim 177 wherein the potted plant is
automatically deposited into the sleeved cover by passing the
potted plant through a guiding means.
179. The method of claim 166 comprising the additional step of
sealing an upper portion of the sleeve after the potted plant has
been deposited in the sleeved cover.
180. The method of claim 179 wherein the step of sealing further
comprises using an automatic sealing device.
181. The method of claim 179 wherein the step of sealing further
comprises heat sealing.
182. The method of claim 179 wherein the step of sealing further
comprises sonic sealing.
183. The method of claim 179 wherein the step of sealing further
comprises vibratory sealing.
184. The method of claim 179 wherein the step of sealing further
comprises pressure-sensitive sealing.
185. The method of claim 179 wherein the step of sealing further
comprises tying the upper portion of the sleeve.
186. The method of claim 166 further comprising the additional step
of providing a transfer means for engaging the sleeved covered
potted plant and placing the sleeved covered plant into a
carton.
187. The method of claim 186 wherein the transfer means further
comprises an automatic pushing means.
188. The method of claim 186 wherein the transfer means further
comprises an automatic gripping means.
189. An apparatus for applying a sleeve about a potted plant
comprising: sleeve support means for supporting a sleeve; sleeve
opening means for automatically opening the sleeve to form an
opened sleeve; guide means for automatically guiding a potted plant
to the opened sleeve whereby the potted plant is disposed within
the sleeve to form a sleeved potted plant; first conveyor means for
conveying the potted plant to the guide means; and second conveyor
means for receiving the sleeved potted plant and for conveying the
sleeved potted plant to another location for further
disposition.
190. The apparatus of claim 189 comprising sorting means for
sorting the potted plant into one of at least two grades in
accordance with a predetermined grading criterion before the potted
plant is conveyed to the guide means.
191. The apparatus of claim 190 wherein the sorting means further
comprises automatic sorting means.
192. The apparatus of claim 189 further comprising bonding means
for bonding the sleeve to an exterior surface of the potted
plant.
193. The apparatus of claim 189 wherein the first conveying means
comprises a first conveyor belt means.
194. The apparatus of claim 189 wherein the second conveying means
further comprises a second conveyor belt means.
195. The apparatus of claim 189 further comprising sealing means
for sealing a portion of the sleeve.
196. The apparatus of claim 195 wherein the sealing means further
comprises heat sealing means.
197. The apparatus of claim 195 wherein the sealing means further
comprises sonic sealing means.
198. The apparatus of claim 195 wherein the sealing means further
comprises vibratory sealing means.
199. The apparatus of claim 195 wherein the sealing means further
comprises pressure sensitive sealing means.
200. The apparatus of claim 195 wherein the sealing means further
comprises tying means.
201. The apparatus of claim 189 wherein the sleeve opening means
further comprises an inflation means for inflating the sleeve
thereby opening the sleeve in preparation for receiving the potted
plant.
202. The apparatus of claim 201 wherein the sleeve opening means
further comprises a suctioning means for exerting a vacuum against
a side of a sleeve thereby slightly opening the sleeve for further
inflation by the inflation means.
203. The apparatus of claim 189 further comprising disengaging
means for removing the sleeved potted plant from the sleeve support
means and for placing the sleeved potted plant onto the second
conveyor means.
204. The apparatus of claim 189 further comprising sensing means
for causing the sleeve opening means to open the sleeve in
preparation for depositing the potted plant therein.
205. The apparatus of claim 189 further comprising a transfer means
for engaging the sleeved potted plant on the second conveyor means
and placing the sleeved potted plant therefrom into a carton.
206. The apparatus of claim 205 wherein the transfer means further
comprises an automatic pushing means.
207. The apparatus of claim 205 wherein the transfer means further
comprises an automatic gripping means.
208. The apparatus of claim 205 further comprising automatic boxing
delivery means for delivering a carton into which sleeved potted
plants will be placed in preparation for shipping.
209. The apparatus of claim 189 wherein the potted plant has been
covered with a decorative cover prior to the disposing of the
potted plant into the opened sleeve.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a system for
packaging articles for shipment and, more particularly, but not by
way of limitation, to a system for automatically packaging potted
plants for shipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a schematic of an article packaging system which
is constructed in accordance with the present invention.
[0003] FIG. 2 is a plan view of part of the packaging system of
FIG. 1 showing an automated greenhouse.
[0004] FIG. 3 is a perspective view of a manual sorting station
which may be used in the article packaging system.
[0005] FIG. 4 is a plan view of an automatic sorting station which
may be used in the article packaging system.
[0006] FIG. 5 is an elevational view of a gate constructed in
accordance with the invention.
[0007] FIG. 6 is a plan view of one embodiment for a cover placing
station which may be used with the article packaging system.
[0008] FIG. 7 is an elevational view of the cover placing station
of FIG. 6.
[0009] FIG. 8 is an enlarged elevation of a cover placing sub-unit,
in position to retrieve a cover.
[0010] FIG. 9 is the cover placing sub-unit of FIG. 8 in position
for receiving an article.
[0011] FIG. 10 is the cover placing sub-unit of FIG. 8 shown
immediately after receiving an article.
[0012] FIG. 11 is an elevational view of another embodiment for the
cover placing sub-unit, constructed in accordance with the
invention.
[0013] FIG. 11A is a plan view of the cover placing sub-unit shown
in FIG. 11.
[0014] FIG. 12 is an elevational view of another embodiment for the
cover placing sub-unit, constructed in accordance with the
invention.
[0015] FIG. 12A is a plan view of the cover placing sub-unit shown
in FIG. 12.
[0016] FIG. 13 is a plan view of yet another embodiment for the
cover placing sub-unit, constructed in accordance with the
invention.
[0017] FIG. 14 is a view of a sleeve constructed in accordance with
the invention.
[0018] FIG. 15 is a perspective of part of a sleeving station
showing a sleeve before the sleeve is inflated.
[0019] FIG. 16 is a perspective of part of the sleeving station
showing an inflated sleeve.
[0020] FIG. 17 is an elevational view of the sleeving station with
parts removed for clarity.
[0021] FIG. 18 is a plan view of the sleeving station.
[0022] FIG. 19 is a perspective of the sleeving station and part of
the sealing station.
[0023] FIG. 20 is an elevational view showing a sealing and a
placing station constructed in accordance with the invention.
[0024] FIG. 21 is a plan view showing the sealing and placing
station of FIG. 19.
[0025] FIG. 22 is a schematic of another embodiment of an article
packaging system which is constructed in accordance with the
present invention.
[0026] FIG. 23 is a side view of the packaging system of FIG.
22.
[0027] FIG. 24A is an elevational view of a sleeving station which
may be used in an article packaging system.
[0028] FIG. 24B is a view of the sleeving station of FIG. 24A
indicating a sleeve positioned to receive a potted plant.
[0029] FIG. 24C is a view of the sleeving station of FIG. 24A after
a potted plant has been inserted into a sleeve.
[0030] FIG. 24D is a view of the sleeving station of FIG. 24A
showing a sleeved potted plant pushed onto a conveyor.
[0031] FIG. 25 is an elevational view of a sleeving station
modified to push sleeved potted plants directly into a box.
[0032] FIG. 26 is an elevational view of a sleeving station
modified to transfer a sleeved potted plant by lifting it into a
box.
[0033] FIG. 27A is a sleeving station modified to receive a pot
cover prior to receiving a potted plant.
[0034] FIG. 27B is the sleeving station of FIG. 27A prepared to
receive a potted plant.
[0035] FIG. 28A is an elevational view of a cover supplying device
which may be used in an article packaging system.
[0036] FIG. 28B is a plan view of the cover supplying device of
FIG. 28A.
[0037] FIG. 29A is an elevational view of another cover supplying
device which may be used in an article packaging system.
[0038] FIG. 29B is a plan view of the cover supplying device of
FIG. 29A.
[0039] FIG. 30A is an elevational view of another cover supplying
device which may be used in an article packaging system.
[0040] FIG. 30B is an elevational view of the device of FIG. 30A
after a cover has been picked up.
[0041] FIG. 30C is an elevational view of the device of FIG. 30A
wherein a sleeve is readied to receive a pot cover.
[0042] FIG. 30D is an elevational view of the device of FIG. 30A
wherein a pot cover has been inserted into a sleeve.
[0043] FIG. 31 is a plan schematic view of another article
packaging system.
[0044] FIG. 32 is a front elevational view of a mobile sleeving
station for use with an article packaging system such as that in
FIG. 31.
[0045] FIG. 33 is a plan view of a boxing system for use in an
article packaging system.
[0046] FIG. 34 is a plan view of a portion of another article
packaging system in which a cover is applied directly to the
article by a cover forming apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] The present invention, an article packaging system, is
described herein as being adapted to process potted plants.
However, a potted plant represents only one article which can be
processed with the present invention and the present invention
specifically contemplates various and numerous other types of
articles such as; vases, hats (including cowboy hats, fedoras,
caps, derbies, sombreros, fezzes and helmets), rose stem boxes,
flower pots, candy trays, baskets (such as Easter or decorative
baskets), corsage boxes, containers, and various other articles.
The term "article" as used herein is intended to encompass all of
the specific articles just mentioned and the term "article" also is
intended to be broad enough to encompass any other article which
may be decorated, sleeved, and then packed for shipping.
[0048] The term "potted plant" as used herein means a botanical
item and the pot, such as a flower pot, within which the botanical
item is contained. The potted plant has potting soil or any other
growth medium or filler, such as foam, known in the art to secure a
plant or other botanical item within a pot. One end of the
botanical item is secured in the pot and the other end exposed
through the opening in the flower pot. The potted plant has an
exterior surface comprising the outer surface of the pot, about
which a decorative cover may be placed or applied.
[0049] The term "botanical item" as used herein means a natural or
artificial herbaceous or woody plant, taken singly or in
combination. The term "botanical item" also means any portion or
portions of natural or artificial herbaceous or woody plants
including stems, leaves, flowers, blossoms, buds, blooms, cones, or
roots, taken singly or in combination, or in groupings of such
portions such as bouquet or floral grouping. The term "propagule"
as used herein means any structure capable of being propagated or
acting as an agent of reproduction including seeds, shoots, stems,
runners, tubers, plants, leaves, roots or spores. The term "growing
medium" used herein means any liquid, solid or gaseous material
used for plant growth or for the cultivation of propagules,
including organic and inorganic materials such as soil, humus,
perlite, vermiculite, sand, water, and including the nutrients,
fertilizers or hormones or combinations thereof required by the
plants or propagules for growth. The term "flower pot" means any
type of floral container used to hold a botanical item. Examples of
flower pots used in accordance with the present invention include
clay flower pots, plastic flower pots, and flower pots comprised of
other natural or synthetic materials.
[0050] The present invention particularly contemplates the
preparation of potted plants for shipment. More particularly a
potted plant may be covered with a formed sheet of decorative
material formed into a decorative cover having an interior surface,
exterior surface and an interior space adjacent and surrounded by
the interior surface such as that formed in a mold type article
forming system described in detail in U.S. Pat. No. 4,773,182
issued to Weder et al. on Sep. 27, 1988 and which is hereby
specifically incorporated herein by reference.
[0051] A decorative pattern, such as a color and/or an embossed
pattern, and/or other decorative surface ornamentation may be
applied to the upper surface and/or the lower surface of the sheet
of material comprising the decorative cover or portions thereof
including, but not limited to printed design, coatings, colors,
flocking or metallic finishes. The sheet of material comprising the
cover also may be opaque, translucent, or totally or partially
clear or tinted transparent material.
[0052] The sheet of material may be constructed of a single sheet
of material or a plurality of sheets. Any thickness of the sheet of
material may be utilized in accordance with the present invention
as long as the sheet of material may be wrapped about at least a
portion of a flower pot or deposited within a sleeve, as described
herein. The sheet of material may have a thickness of less than
about 1 mil to about 30 mils. Typically, the sheet of material has
a thickness in a range of less than about 0.2 mils to about 10
mils. In a preferred embodiment, the sheet of material is
constructed from one sheet of man-made organic polymer film having
a thickness in a range of from less than about 0.5 mils to about
2.5 mils.
[0053] The sheet of material is constructed from any suitable
material that is capable of being wrapped about a flower pot.
Preferably, the sheet of material comprises paper (untreated or
treated in any manner), cellophane, foil, synthetic organic polymer
film, fiber (woven or nonwoven or synthetic or natural), cloth
(woven or nonwoven or natural or synthetic), burlap, or any
combination thereof.
[0054] The term "synthetic organic polymer film" means a
synthetically made resin such as a polypropylene as opposed to
naturally occurring resins such as cellophane. A synthetic organic
polymer film is relatively strong and not as subject to tearing
(substantially non-tearable), as might be the case with paper or
foil. The synthetic organic polymer film is a substantially
linearly linked. Such films are synthetic polymers formed or
synthesized from monomers. Further, a relatively substantially
linearly linked processed organic polymer film is virtually
waterproof which may be desirable in many applications involving
wrapping botanical items or potted plants.
[0055] Additionally, a relatively thin film of substantially
linearly linked processed organic polymer does not substantially
deteriorate in sunlight. Processed organic polymer films having
carbon atoms both linearly linked and cross linked, and some cross
linked polymer films, also may be suitable for use in the present
invention provided such films are substantially flexible and can be
made in a sheet-like format for wrapping purposes consistent with
the present invention. For example, one such man-made organic
polymer film is a polypropylene film.
[0056] The sheet of material may vary in color. Further, the sheet
of material may consist of designs which are printed, etched,
and/or embossed; in addition, the sheet of material may have
various colorings, coatings, flocking and/or metallic finishes, or
be characterized totally or partially by pearlescent, translucent,
transparent, iridescent, or the like, characteristics. Each of the
above-named characteristics may occur alone or in combination.
Moreover, each surface of the sheet of material may vary in the
combination of such characteristics.
[0057] The sheet of material has a width extending generally
between the first side and the second side respectively,
sufficiently sized whereby the sheet of material can be wrapped
about and substantially surround and encompass a flower pot. The
sheet of material has a length extending generally between the
third side and the fourth side, respectively, sufficiently sized
whereby the sheet of material extends over a substantial portion of
the flower pot when the sheet of material has been applied about
the flower pot in accordance with the present invention shown and
described in detail herein.
[0058] The sheet of material may further comprise at least one
scent. Examples of scents utilized herein include (but are not
limited to) floral scents (flower blossoms, or any portion of a
plant), food scents (chocolate, sugar, fruits), herb or spice
scents (cinnamon), and the like. Additional examples of scents
include flowers (such as roses, daisies, lilacs), plants (such as
fruits, vegetables, grasses, trees), foods (for example, candies,
cookies, cake), food condiments (such as honey, sugar, salt),
herbs, spices, woods, roots, and the like, or any combination of
the foregoing. Such scents are known in the art and are
commercially available.
[0059] The scent may be disposed upon the sheet of material by
spraying the scent thereupon, painting the scent thereupon,
brushing the scent thereupon, lacquering the scent thereupon,
immersing the sheet of material to scent-containing gas, or any
combination thereof.
[0060] The scent may be contained within a lacquer, or other
liquid, before it is disposed upon the sheet of material. The scent
may also be contained within a dye, ink, and/or pigment (not
shown). Such dyes, inks, and pigments are known in the art, and are
commercially available, and may be disposed upon or incorporated in
the sheet of material by any method described herein or known in
the art.
[0061] The decorative cover may be bonded to the article or potted
plant by a bonding material. The term "bonding material" as used
herein means an adhesive, preferably a pressure sensitive adhesive,
or a cohesive. Where the bonding material is a cohesive, a similar
cohesive material must be placed on the adjacent surface for
bondingly contacting and bondingly engaging with the cohesive
material. The term "bonding material" also includes materials which
are heat sealable, sonic sealable and, vibratory sealable in these
instances, the adjacent portions of the material must be brought
into contact and then heat, sound waves or vibrations,
respectively, must be applied to effect the seal.
[0062] The term "bonding material" as used herein also means a heat
sealing lacquer which may be applied to the sheet of material and,
in this instance, heat also must be applied to effect the sealing.
The term "bonding material" as used herein means any type of
material or thing which can be used to effect the bonding or
connecting of the two adjacent portions of the material or sheet of
material to effect the connection or bonding described herein. The
term "bonding material" also includes ties, labels, bands, ribbons,
strings, tape, staples or combinations thereof.
[0063] The decorated article covered with a decorative cover may
then be placed in a sleeve to generally protect it during shipping.
For example, a potted plant may be sleeved to preserve water and
carbon dioxide for the plant, and to protect the plant during
shipping. The sleeve may be made from an impermeable material which
would retain all gases and liquids or from a semi-permeable
material, such as a material which would allow oxygen and carbon
dioxide to pass, but would inhibit the passage of water through the
material.
[0064] Sleeves are well known in the art of packaging potted
plants. As used herein, a sleeve is cylindrical, conical or
frusto-conical in shape and has an upper opening, which provides an
opening for the deposit of a potted plant, or other article,
therein. Sleeves may be comprised of any flexible material suitable
for covering a potted plant, including materials selected from a
group of materials, comprising paper, metal, foil cloth (natural or
synthetic), denim, burlap, or polymer film, or combinations
thereof. The term polymer film as used herein means any polymer
film, including for example, but not by way of limitation,
polypropylene film and cellophane. The material comprising the
sleeve may be opaque, translucent, or totally or partially
transparent and may be decorated with designs or tints.
[0065] The article, after having been placed in a sleeve, may then
be placed in a container for shipping. The container, such as a
box, carton or crate, may then be sealed and marked for easy
identification. The present invention provides an automated line
for preparing articles for shipping in the manner just described
thereby saving the seller considerable labor expense and reducing
the preparation time required for packaging articles.
[0066] In describing the preferred embodiment, a potted plant will
be used as an example of the article being processed. However, as
discussed above the invention may be used on various other
articles.
EMBODIMENTS OF FIGS. 1-21
[0067] Turning now to FIG. 1, an article packaging system
designated by the reference numeral 10 is shown which is
constructed in accordance with the present invention. The article
packaging system 10 is adapted to transport an article from a
storage location, place a decorative cover over or around the
article, place the covered article in a sleeve, and pack the
sleeved article in a carton for shipping.
[0068] A storage location such as a greenhouse, hereby designated
by the reference numeral 12, supplies potted plants 14 (FIG. 3) for
processing. The greenhouse 12 is frame covered with a material
which will allow the radiant energy from the sun to reach potted
plants 14 which are grown inside. Such structures are common in the
art. Within the greenhouse 12 are growing racks 16 adapted for
holding potted plants 14 while they are grown. The greenhouse 12
may be automated by installing conveyors, 18 and 20, adapted for
transporting the potted plants 14 into and out of the greenhouse
12. Conveyors 18 and 20 may also serve as additional growing racks.
Each conveyor, 18 or 20, should be reversible so it may serve to
bring potted plants 14 into the greenhouse 12 or supply potted
plants 14 from the greenhouse 12. Each conveyor 18 or 20 may be
similar in construction. The construction details of the conveyors
are not required herein as they are well known to persons of
ordinary skill in the art.
[0069] As indicated in FIG. 1, a conveyor 22 extends from the
greenhouse 12 to a sorting station 24. The sorting station 24 may
be a manual sorting station 26 (FIG. 3) or an automatic sorting
station 28 (FIG. 4). The manual sorting station 26 comprises a
table 30 which receives the potted plants 14 from the conveyor 22.
An operator (not shown) standing near table 30 may select a potted
plant 14, in accordance with a predetermined grading criterion such
as size and grade, and place it on a conveyor assembly 32 or a
conveyor assembly 34 with other potted plants (not shown) of a
similar grade. The potted plants 14 are sorted into one of at least
two grades. Conveyors 32 or 34 should begin near the manual sorting
station 26 and transport the potted plants 14 on to the next area
for further processing.
[0070] In an alternative embodiment (not shown), the manual
operator at station 26 may select potted plants 14 directly from
the conveyor 22 and grade and place them directly from the conveyor
22 to conveyors 32 and 34 thereby eliminating the need for table
30.
[0071] In the automatic sorting embodiment of FIG. 4, the automatic
sorting station 28 may be any one several apparatuses for sorting
the potted plants 14. One embodiment of an automatic sorting
station 28 is shown in FIG. 4 and comprises a first positioning
gate 36 and a second positioning gate 38, a light source assembly
40, a light sensor assembly 42 which is comprised of at least one
sensing device such as a photoelectric cell 43 and a support
backing 44, a light switch 45 and a gate 46 all located near the
discharge end of conveyor 22.
[0072] Referring now to FIGS. 4 and 5, the positioning gates 36 and
38 are similar in construction. Each positioning gate 36 or 38 has
an arm 48 (FIG. 5). The arm 48 is preferably made from a strip, of
stainless steel about four to eight inches tall and of sufficient
length to reach half way across conveyor 22. One end of the arm 48
is secured as by welding to a rod 50. The rod 50 extends up from
the arm 48 through bearing 52, and on to motor 54. A collar 56 is
secured to rod 50 above the bearing 52 by a set screw 58, thereby
holding the arm 48 up off the upper surface of the conveyor 22. The
bearing 52 is secured to a brace 60 which is mounted to the side of
conveyor 22.
[0073] The positioning gates 36 and 38 are secured to opposite
sides of the conveyor 22 and they work in conjunction to release
potted plants 14 at regular intervals. In addition to spacing the
potted plants 14 along the conveyor 22, the positioning gates 36
and 38 also position the potted plants 14 generally in the center
of conveyor 22. Therefore, all potted plants 14 are positioned
approximately the same distance from the light sensor assembly 42
as they pass in front of it.
[0074] With continued reference to FIG. 4, the light source
assembly 40 is comprised of a housing 62 having a slot 64 formed on
the side adjacent the conveyor 22. The housing 62 is secured on one
side of the conveyor 22 such that the slot 64 is on the side of the
housing 62 which faces the conveyor 22. At least one light source
66 such as a light bulb is secured within the housing 62 so that
light emitted by the-light source 66 passes through the slot 64 and
across the conveyor 22.
[0075] Directly across conveyor 22 from the light source assembly
40 is the light sensor assembly 42.
[0076] A light switch 45 is located in front of the light source
assembly 40 and turns on the light source 66 when a potted plant 14
is between the light source assembly 40 and the light sensor
assembly 42. Since the potted plant 14 is between the light source
assembly 40 and the light sensor assembly 42 when the light source
66 is turned on, the amount of light reaching the light sensor
assembly 42 depends the size and density of the foliage on the
plant 14. The taller and more dense the foliage, the less light
reaches light sensor assembly 42.
[0077] Gate 46 is located down stream from the light sensor
assembly 42 near the end of conveyor 22. The gate 46 is similar in
construction to positioning gate 36. The brace 60 of gate 46 is
positioned over the center of conveyor 22. The gate 46 is pivoted
to a first position 68 or second position 70 depending on the
amount of light hitting light sensor assembly 42. The action of
gate 46 is controlled by a control assembly (not shown) which
detects the degree of light detected by the photoelectric cell 43
and responds accordingly.
[0078] While the potted plant 14 is between the light source 66 and
the photoelectric cell 43, the plant may be rotated by a rotating
device (not shown). In this way light can be sensed and measured at
several points of rotation of the foliage of the potted plant 14,
thereby measuring an average amount of detected light which may
provide a more accurate grading system for the foliage of the
potted plants 14. Alternatively, instead of being rotated, several
light readings could be measured at several points along the
conveyor 80, for example, with the light readings taken at
different angles to the foliage, to derive an average of the
several readings.
[0079] Directly downstream from the gate 46 is a positioning bar
72. The positioning bar 72 is V shaped and is positioned so the
point of the V is directly down stream from brace 60 of gate 46. A
first end 74 and a second end 76 of the bar 72 extends off a side
of conveyor 22 and onto an adjacent conveyor. First end 74 extends
from conveyor 22 to conveyor 34. Second end 76 extends from
conveyor 22 to conveyor 32. Conveyors 32 and 34, first may lead to
similarly constructed processing lines and thus, only one such line
is described below.
[0080] In an alternative embodiment (not shown), the potted plants
14 can be graded on the basis of the difference between a known
tare weight of the pot and soil and the weight of potted plant. If
the tare weight of the pot and saturated soil contained therein is
known, this measurement can be subtracted from weight of a potted
plant having saturated soil. The difference in weight is an
approximate measure of the weight of the plant. This enables the
classification, or grading, of the potted plant 14 on the basis of
the criterion of weight, rather than of the basis of the amount of
light reaching a light sensor 42, which represents foliage
density.
[0081] Other automatic methods of grading the potted plants 14 are
to use other forms of electromagnetic radiation such as radar (not
shown) or an infra-red light sensing device (not shown) which
grades the plant by detecting the amount of heat the plant gives
off.
[0082] The embodiment of the article processing system described
herein envisions only a single sorting station 24 to grade the
potted plants 14. However, it will be appreciated by one of
ordinary skill in the art that additional sorting stations 24 could
be located downstream of either conveyor assemblies 32 or 34 to
provide additional grading of the potted plants 14.
[0083] Conveyor assembly 32 moves the potted plants 14 to a
covering station 82. The covering station 82 may be embodied in a
variety of different forms as described and shown below.
[0084] In one embodiment, the covering station 82 includes a first
gate 84 and a second gate 86, a turnstile 88 and a cover denesting
sub-unit 90. The gates 84 and 86 are secured to opposite sides of
the conveyor 32 and work in conjunction to release potted plants 14
at regular intervals. In addition to spacing the potted plants 14
along the conveyor 32 the gates 84 and 86 also position the potted
plants 14 in the center of conveyor 32. Therefore, all potted
plants 14 are positioned to be received by the turnstile 88.
[0085] The turnstile 88 and the cover denesting sub-unit 90 may be
mounted on a platform 92 with a plurality of locking casters 94
(FIG. 7), thus, they may be rolled to the side and replaced with a
section of conveyor (not shown) when covering the article is not a
required step.
[0086] The turnstile 88 has a conduit 98 with a first end 100 and a
second end 102. The first end 100 is secured to the platform 92.
The turnstile 88 has a turnstile axle 104 which has a first end 106
and a second end 108. The second end 102 of the conduit 98 is open
for accepting first end 106 of the turnstile axle 104. The diameter
of the first end 106 of the turnstile axle 104 is slightly smaller
than the diameter of the lumen in the conduit 98. This allows the
turnstile axle 104 to rotate freely within the conduit 98.
[0087] A drive assembly mount 110 is secured near the second end
102 of the conduit 98. Secured to the drive assembly mount 110 is a
drive assembly 112 with a rotatable shaft 114. Secured to the
rotatable shaft 114 is a first gear 116. A second gear 118 is
secured to the turnstile axle 104 between the first end 106 and the
second end 108 thereof, and in a position such that the first gear
116 and second gear 118 mesh.
[0088] Secured near the second end 108 of the turnstile axle 104
are four transfer assemblies 120A, 120B, 120C and 120D. Each
transfer assembly 120A-120D includes a carrying unit 121, a brace
122, and a cylinder 123. The brace 122 has a first end 124 and a
second end 125. Each carrying unit 121 comprises a first arm 126
and a second arm 128 (FIGS. 6-7).
[0089] The first end 124 of the brace 122 is secured to the
turnstile axle 104 and is adapted for supporting a cylinder 123.
The cylinder 123 is secured to the second end 125 of the brace
122.
[0090] Secured to the cylinder 123 are the first and second arms
126 and 128 of the carrying unit 121. The cylinder 123 is adapted
to reciprocatingly raise and lower the carrying unit 121.
[0091] Referring now to FIGS. 6-10, also secured to the platform 92
is an automatic cover supplying assembly, also referred to as the
cover denesting sub-unit 90. The cover denesting sub-unit 90
includes a cover dispenser housing 130 and a cover dispenser
support 132 (FIGS. 8-10) having a base 133. The cover dispenser
support 132 is adapted for supporting the cover dispenser housing
130 over the platform 92. The cover denesting sub-unit 90 also
includes a conveyor with a first parallel belt 134 and a second
parallel belt 136. The belts 134 and 136 are placed around rollers
138 and 140 (FIG. 7), and are spaced apart to provide a gap 142
lengthwise for enabling the placement of a retrieved cover into a
potted plant application position.
[0092] A conveyor 144 having a first end 146 and a second end 148
is abutted at its first end 146 to the end of belts 134 and 136 in
a position to receive a cover 158 or a covered potted plant from
belts 134 and 136.
[0093] A suction support arm 150 is generally L shaped and is
pivotally secured at a first end 151 near the base 133 of the cover
dispenser support 132. The suction support arm 150 has a free end
153.
[0094] A cylinder 152 extends between the platform 92 and the
suction support arm 150 and is slidingly secured to the suction
support arm 150 by a bracket 154. The cylinder 152 and bracket 154
are adapted for raising the suction support arm 150 so the suction
cup 156, which is connected to the free end 153 (FIG. 8) of the
suction support arm 150, is raised to a position for removing a
cover 158 (FIGS. 8-10) from the cover dispenser housing 130.
[0095] Secured to the platform 92 directly below the suction
support arm 150 is a vacuum valve 160 and a spring 162. A vacuum
line 164 extends from the suction cup 156 to the vacuum valve 160
and on to a vacuum source (not shown). Operational details of the
cover denesting subunit 90 are described below in the In Operation
section.
[0096] An alternate cover denesting sub-unit (automatic cover
supplying assembly) embodiment, herein designated by the reference
numeral 90A, is shown in FIG. 11. This embodiment uses an article
forming system 165, such as is disclosed in U.S. Pat. No.
4,773,182, the specification of which is hereby incorporated
specifically herein. The article forming system 165 places covers
on a suction cup 156A. The suction cup 156A is supported by a rod
166 which extends up between a first parallel belt 134A and a
second parallel belt 136A in a fashion similar to the suction
support arm 150 described above. This embodiment also includes a
vacuum valve 160A and a support spring 162A.
[0097] Another cover denesting sub-unit embodiment, herein
designated by the reference numeral 90B, is shown in FIGS. 12 and
12A. In this embodiment the article processing system 165 places a
cover (not shown) on a table 168, and a turnstile (not shown) then
places a potted plant (not shown) into the cover (not shown).
Alternatively, a potted plant may be placed manually within the
cover. A pusher assembly 170 comprised of a cylinder 171 and a
pushing arm 172 then pushes the covered potted plant (not shown)
onto the conveyor 144.
[0098] Another cover denesting sub-unit embodiment, herein
designated by the reference numeral 90C, is shown in FIG. 13.
Sub-unit 90C uses a first gate 174 and a second gate 176 to hold a
cover (not shown) stationary on the moving conveyor 144. Once the
potted plant (not shown) is in the cover (not shown), gates 174 and
176 open, allowing the covered potted plant (not shown) to proceed
down conveyor 144 for further processing.
[0099] At some point after the cover 158 has been denested and
positioned, a potted plant is placed into the interior space of the
cover 158 producing a covered potted plant 180. The potted plant
may be placed into the cover 158 manually or automatically. The
covered potted plant 180 is conveyed down conveyor 144 toward the
second end 148 where it is transferred to an automatic sleeving
station 184 for application of a sleeve about the covered potted
plant 180 to form a sleeved covered potted plant.
[0100] Referring now to FIGS. 1 and 17-19, the sleeving station 184
includes a guiding assembly comprising a first spring loaded guide
186 and a second spring loaded guide 188. The spring loaded guides
186 and 188 (FIG. 18) receive a covered potted plant 180 as it
moves from the second end 148 of conveyor 144. A brace 190 is
secured above the spring loaded guides 186 and 188 to keep the
potted plant 180 upright as it moves in direction 192 (FIG. 17)
through the spring loaded guides 186 and 188. Below the guides 186
and 188 are a first wicket 194 and a second wicket 196 for holding
a plurality of sleeves such as sleeve 198 (FIG. 16) and described
in detail below. Each wicket 194 and 196 has a first end 200 and a
second end 202 (FIG. 19). The first end 200 is secured to a brace
(not shown) and extends downwardly at an angle to a point 206
between the first end 200 and the second end 202. From the point
206 to the second end 202, the wickets 194 and 196 extend
horizontally or slightly downward.
[0101] As is shown in FIGS. 14-16, each sleeve 198 has a front side
208 having a height 210, and a back side 212 having a height 214.
The height 210 of the front side 208 of the sleeve 198 is less than
the height 214 of the back side 212 of the sleeve 198. Holes 216
and 218 are formed in the upper corners of the back side 212 of
each sleeve 198. Although sleeve 198 is shown in FIGS. 14-17 as
tubular, the shape of sleeve 198 may be any variety of shapes but
the preferred embodiment is frusto-conical. Additionally, in an
alternative embodiment, heights 210 and 214 may be the same and
holes 216 and 218 may extend through both sides 208 and 212.
[0102] Referring now in particular to FIGS. 15 and 16, the wickets
194 and 196 extend through the holes 216 and 218, respectively, to
support the sleeve 198. The wickets 194 and 196 are secured so the
sleeve 198 is pulled by gravity down the wickets 194 and 196 until
the backside 212 of the sleeve 198 comes into contact with an
automatic sleeve opening assembly comprising an inflator tube 220
(FIG. 16). Air exiting the inflator tube 220 opens and inflates the
sleeve 198.
[0103] In an alternative embodiment of the sleeve opening assembly,
suction cups (not shown) may be employed to pull open the side 208
of the sleeve 198 to allow the air blast from the inflator tube 220
and to more easily access and open the sleeve 198.
[0104] As the covered potted plant 180 reaches the end 148 of the
conveyor 144 and moves in direction 192 through the chute between
the guides 186 and 188 and the brace 190, it is deposited into an
open sleeve 198 (FIG. 19) to provide a sleeved potted plant 222
(also referred to in this instance as a sleeved covered potted
plant).
[0105] In an alternative embodiment (not shown), the covered potted
plant 180 may be formed into a sleeved covered potted plant 222 by
wrapping a sheet of sleeving material (not shown) about the covered
potted plant automatically.
[0106] Referring now to FIGS. 1 and 20, a gripping station 230,
also referred to as a transfer station, is positioned to remove a
sleeved potted plant 222 from the wickets 194 and 196. The gripping
station 230 comprises a turnstile 234 and a first gripping arm 236
and a second gripping arm 238. The turnstile 234 further comprises
a conduit 240 with a first end 242 and a second end 244. The first
end 242 is secured to a base 246. The second end 244 of the conduit
240 is open for accepting a first end (not shown) of a turnstile
axle 250. The turnstile axle 250 has a first end (placed inside the
conduit) and a second end 254. The diameter of the turnstile axle
250 is slightly smaller than the diameter of the opening in the
conduit 240. This allows the turnstile axle 250 to rotate freely
within the conduit 240.
[0107] A drive assembly bracket 256 is secured near the second end
244 of the conduit 240. Secured to the drive assembly bracket 256
is a drive assembly 258 such as a motor. The drive assembly 258 has
a rotatable shaft 260. Secured to the rotatable shaft 260 is a
first gear 262. A second gear 264 is secured to the turnstile axle
250 in a position such that the teeth on the first gear 262 mesh
with teeth of the second gear 264.
[0108] Secured to the second end 254 of the turnstile axle 250 are
support arms 266A, 266B, 266C and 266D. Each support arm 266A-266D
comprises a first gripping arm 236 and a second gripping arm 238.
Connected to each support arm 266A-266D is a cylinder 270 adapted
for closing the first gripping arm 236 and the second gripping arm
238 together against the upper end of the sleeve 198 of the sleeved
potted plant 222.
[0109] In an alternative embodiment, the first gripping arm 236
includes a heating element (not shown) adapted to seal the upper
position of the sleeve 198 of the sleeved potted plant 222 when the
upper end is compressed between the gripping arms 236 and 238
thereby forming a sealed sleeved potted plant 272. The sealing arms
236 and 238 grasp the sealed sleeved potted plant 272 thereby
freeing the sealed sleeved potted plant 272 from the guide wickets
194 and 196. From there, the support arm 266 carries the sealed
sleeved potted plant 272 to a placing station 274 (FIGS. 1, 20-21).
The upper portion of the sleeve 198 may alternately be sealed by
gripping arms 236 and 238 which comprise sonic elements, vibratory
elements or pressure-sensitive elements.
[0110] Positioned to receive a sleeved potted plant 222 or a sealed
sleeved potted plant 272 is a placing station 274 (FIGS. 20-21).
The placing station 274 comprises a lowering arm 276, and a first
pinching arm 278 and a second pinching arm 280, and a cylinder
282.
[0111] The lowering arm 276 is reciprocatingly secured to the
cylinder 282 such that the lowering arm 276 may be reciprocatingly
lowered and raised. The first pinching arm 278 is pivotally secured
opposite the pinching arm 280 of the lowering arm 276. The pinching
arms 278 and 280 first receive the article 272 or 222 at receiving
position 284 (FIG. 21). A small cylinder 288 is secured between the
lowering arm 276 and the pinching arm 278. The cylinder 288 is
adapted to allow the pinching arms 278 and 280 to grasp and release
the sealed sleeved pot 272 or the sleeved potted plant 222.
[0112] The cylinder 282 is suspended from a rail 290. The rail 290
has a first end 292 and a second end 294. Secured to the first end
292 is a motor 296 with rotatable shaft 298. Secured to the
rotatable shaft 298 is a sprocket 300. On the second end 294 of the
rail 290 is an idler sprocket 302. A continuous loop of chain 304
extends around the first sprocket 300 and the second sprocket 302.
The cylinder 282 is secured to the chain 304, thus,, by rotating
the shaft 298, the cylinder 282 is moved along the rail 290 to a
predetermined position for lowering the grasped sleeved potted
plant 222 or the sealed sleeved potted plant 272 into a box or
carton 306.
[0113] A carton placing conveyor 308 is adapted to move the carton
306 into position for receiving potted plants 222 or 272. Once the
carton 306 is full the conveyor 308 removes the carton 306 from the
packing area. Cartons, like carton 306, are supplied from carton
folding station 310 (FIG. 1). Many commercially available carton
folders are suitable, and therefore, need not be described herein.
Alternatively, cartons 306 may be supplied manually.
[0114] In Operation
[0115] Articles 14, which may be potted plants as shown, for
example in FIG. 3, are placed on conveyor 22, then are moved to a
sorting station 24 (FIG. 1). If the sorting station 24 is a manual
sorting station 26 such as shown in FIG. 3, an operator (not shown)
will select articles 14 to be packaged together, and place them on
a conveyor 32 or 34 which will carry them to the next station.
[0116] If the sorting station 24 is the automatic sorting station
28 such as shown in FIG. 4, the articles 14 will travel down
conveyor 22 until they come in contact with positioning gates 36
and 38. The positioning gates 36 and 38 will hold an article 14
until a predetermined distance 316 between it and the previous
article 14a has been achieved. Once the distance 316 between the
article 14 and the previous article 14a has been achieved,
positioning gates 36 and 38 will open allowing the article 14 to
proceed on to the light sensor 42.
[0117] Since the positioning gates 36 and 38 open simultaneously,
the article 14 will be centered on the conveyor 22, and thus, all
articles 14 will be the same distance from the light sensor
assembly 42 as they pass in front of it. As the article 14 passes
in front of the light sensor assembly 42 the article 14 comes into
contact with and moves a light switch 45. Movement of the light
switch 45 activates the light source 66 in the housing 62.
[0118] Light leaving the housing 62 through slot 64 will be
partially absorbed and partially reflected by the article 14. Thus,
the larger and more dense the article 14, the less light will reach
the photoelectric cell 43. In this way smaller or less dense
articles 14 may be distinguished from larger or denser articles 14.
If the article 14 is small the gate 46 will swing into the first
position 68 and if the article 14 is large the gate 46 will swing
into the second position 70 as determined by a control assembly
(not shown). As the article 14 comes into contact with gate 46 it
is directed to one side of the positioning bar 72. The positioning
bar 72 further directs the article 14 onto an adjacent conveyor
such as conveyor 32. Alternately, the article 14 may be sorted
after a decorative cover has been applied.
[0119] If the article 14 is to receive a decorative cover, which in
the case of a potted plant would be a flower pot cover, the
covering station 82 will be positioned at the end of conveyor 32.
The article covering station 82 is mounted on a platform 92 with
locking casters 94. Thus, if no covering is required the covering
station 82 may simply be rolled to the side and a section of
conveyor (not shown) may take its place. Assuming that covering is
desired, any of the several embodiments may be used with ease.
[0120] In the preferred operational embodiment, the article 14 will
first encounter the gates 84 and 86 (FIGS. 6-7). The gates 84 and
86 hold the article 14 until the turnstile 88 is in position to
accept the article 14, that is, when transfer assembly 120A is in
line with conveyor 32. As soon as the article 14 has entered the
arms 126 and 128, of the carrying unit 121, the carrying unit 121
is raised by cylinder 123 and the turnstile 88 begins to turn in a
counterclockwise direction 318 (FIG. 6).
[0121] When the transfer assembly 120A is in position 316 (FIG. 6)
the suction support arm 150 is raised by the cylinder 152 (see FIG.
8). By the time the transfer assembly 120A has reached position
318, arm 150 has been lowered by cylinder 152 suctionly bringing
with it a cover 158 from cover dispensing housing 130 (see FIG. 9).
When transfer assembly 120A reaches position 320 (FIG. 6) the
turnstile 88 momentarily stops over the cover 158 while the
cylinder 124 lowers the carrying unit 121 thereby lowering the
article 14 into the cover 158. The weight of the article 14 and
cover 158 depresses spring 162 thus lowering the covered article
180 onto conveyor belts 134 and 136 (see FIG. 10).
[0122] As spring 162 is depressed, the vacuum valve 160 is
deactivated thereby causing the suction cup 156 to release the
cover 158 and allowing the covered article 180 to rest upon the
conveyor belts 134 and 136. The conveyor belts 134 and 136 direct
the covered article 180 toward conveyor 182 (FIG. 7), and thus out
of the carrying unit 121. As the turnstile 88 resumes rotation, and
as transfer assembly 120A passes through position 322 (FIG. 6),
cylinder 124 retracts the carrying unit 121 thereby raising the
first arm 126 and the second arm 128 into position for receiving
the next article 14 from conveyor 32.
[0123] The covered article 180 is directed from belts 134 and 136
to conveyor 144 (FIG. 7), and continues to the sleeving station 184
(FIG. 17). As the article reaches the second end 148 of conveyor
144 it drops gravitationally through a pair of spring loaded guides
186 and 188 (FIG. 18). A brace 190 supports the upper side of the
covered article 180 as it drops from the conveyor 182 thereby
maintaining the vertical positioning of the covered article 180 as
it drops. The spring loaded guides, 186 and 188, guide the covered
article 180 into an opened sleeve 198 (FIG. 19).
[0124] As is shown in FIG. 16, a supply of sleeves 198 is supported
on wickets 194 and 196, and are gravitationally fed to the inflator
tube 220. The end of the inflator tube 220 comes into contact with
the back side 212 (FIG. 16) of the first sleeve 198 in the supply,
thus keeping the supply of sleeves 198 from sliding down the
wickets 194 and 196. Air exiting from the inflator tube 220
inflates the lower most sleeve 198 in preparation for receiving a
covered article 180. The added weight of the covered article 180
dropping from the conveyor 182 causes the opened sleeve 198 to sag
thus releasing it from the inflator tube 220 and enabling it to
slide down wickets 194 and 196 to the horizontal section of the
wickets 194 and 196 (FIG. 19). After the first sleeve 198 is
removed another sleeve 198 moves into position to be inflated. The
first sleeve 198 containing the covered article 180, now
constituting a sleeved covered article 222 is grasped by gripping
arms 236 and 238 (FIG. 19) of the gripping (transfer) station 230
(FIGS. 20 and 21).
[0125] The turnstile 234 then rotates, thus pulling the sleeve from
the wicket 194 and 196. In one embodiment, as the turnstile 234
continues to rotate, heating elements (not shown) in gripping arm
236 heat the gripped portions of the sleeve 198 sealing the front
and the back sides, 208 and 212, of the sleeve 198 of the sleeved
covered article 222 (FIG. 21) to form the sealed sleeved covered
article 272. In one version, the sleeve 198 is not sealed over the
sleeved covered article 222. As the turnstile 234 rotates 180
degrees to a position 284, the gripping arms 236 and 238, still
carrying the unsealed article 222 or the sealed article 272 (as the
case may be), move between the pinching arm 278 and the pinching
arm 280 of the placing station 274 (FIGS. 20-21).
[0126] Once the gripping arms 236 and 238 are between the pinching
arm 278 and pinching arm 280, the pinching arms 278 and 280 close
to pinch the sleeve of the sleeved covered article 222 or of the
sealed sleeved covered article 272 (as the case may be) and the
sealing arms 236 and 238 are opened slightly, thus the article 222
or 272 is now held by the pinching arms 278 and 280 of the placing
station 274. Immediately thereafter the cylinder 282 is pulled
along a rail 290 via motor 296 and chain 304 (FIGS. 20-21) from
position 284 to position 326 and the article 222 or 272 is lowered
into carton 306. The pinching arms 278 and 280 are then released
and the lifting arm 276 is raised and returned to position 284 to
accept the next article 222 or 272.
[0127] Each article 222 or 272 is received and placed in the carton
306. Placing of the article 222 or 272 in the carton 306 may be
manually or automatically controlled (control means not shown). The
conveyor 308 moves as necessary to allow placing of the articles
222 or 272 in the carton 306.
[0128] This cycle repeats until the carton 306 is full. At that
time conveyor 308 carries away the full carton 306 and replaces it
with a new container 306. The full carton 306 eventually reaches
the carton closing station 330 (FIG. 1) and then the carton
labeling station 332 (FIG. 1) where machines of construction well
known to those of ordinary skill in the art close and label the
carton 306. The carton 306 is then ready for shipment.
EMBODIMENTS OF FIGURES 22-34
[0129] Attention is now directed to the article packaging system
designated by the reference numeral 350 and represented in FIGS. 22
and 23. The packaging system 350 is a processing line for sorting
articles, for example in this case potted plants 352, according to
size, quality, or other criteria and then for processing and
packaging the processed plants. The system 350 would automatically
place a covered potted plant into a protective sleeve and would
then place the sleeved pot into a box or carton for shipping and
distribution.
[0130] In overview, the article packaging system 350 comprises a
service station 356 having a platform or table 358 serving to
support a set of unsorted potted plants 352. A sorting station 360
employs a sorter which inspects the potted plants 352 and sorts
them in accordance with predetermined criteria such as size,
quality or variety or any number of other criteria. The sorting
station 360 may be manually operated like the sorting station 26
described herein or it may operate automatically, for example, like
the automatic sorting station 28 described herein.
[0131] A cover supplying station 362 comprises an automatic cover
supplying assembly 364 for selecting a pot cover 366 and placing
the pot cover 366 in an application position for receiving a potted
plant 352 thereby forming a covered potted plant 368. The covered
potted plant 368 is then placed on a conveyor 370.
[0132] A sleeving station 372 constructed much the same as sleeving
station 184 described herein is downstream of the conveyor 370 and
comprises an apparatus for applying a protective sleeve 374 to the
covered potted plant 368 to form a sleeved covered potted plant
376. The sleeved covered potted plant 376 is placed onto a conveyor
378 for further processing. A gate station 380 is a gate 382 which
serves to divert the sleeved covered potted plants 376 to a
separate first lane 382 and a separate second lane 384 of the
conveyor 378 in preparation for being placed in a carton. A
gathering station 386 is a first gate 388 and a second gate 390 for
stopping and accumulating the sleeved plants 376 in preparation for
boxing. In an alternative embodiment either the gate station 380 or
the gathering station 386, or both stations 380 and 386, are
optional.
[0133] A carton feeding station 394 comprises a conveyor 396 for
conveying or feeding in direction 398 boxes or cartons 400 which
will receive the sleeved plants 376. A boxing station 404 pushes or
conveys, the sleeved plants 376 into an empty carton 400 for
shipping. A closing station 408, if present, serves to close and
secure by taping, gluing or stapling each full carton 402 in
preparation for shipping. The closing station 408 could be
automatic or could be manually operated. All stations from the
cover supplying station 362 to, the closing station 408, inclusive,
comprise a single processing stream of the packaging system 350.
The packaging system 350 may comprise a second processing stream
396 for processing other potted plants sorted at the second station
360.
EMBODIMENTS OF COVER SUPPLYING STATIONS
[0134] Turning now to FIGS. 28A-28B, the apparatus comprising the
cover supplying station 362 is described in more detail. The cover
supplying assembly 364 is an apparatus having a denesting arm 416
for denesting a pot cover 366 from a bin 418 and transferring the
pot cover 366 to a receiving position 420 for receiving a potted
plant 422. The denesting arm 416 has a grasping end 424 and a
pivoting end 426. The grasping end 424 has a shape adapted to fit
around the base 428 of a pot cover 366 resting in a bin 418 of pot
covers 366. The grasping end 424 grasps the base 428 of the pot
cover 366, in the preferred embodiment by a suctioning mechanism
430 and disengages the pot cover 366 from the bin 418 of pot covers
366. The arm 416, now carrying a pot cover 366, pivots in direction
432 to a position over a conveyor. The suction from the suctioning
mechanism 430 is removed, thereby releasing the pot cover 366 and
placing the pot cover 366 on the conveyor 370 in preparation for
receiving a potted plant 422. The conveyor 370 may be equipped with
guide walls 434 to guide the pot cover to a gate 436 to restrain
the pot cover in a stationary position. At this position, a pot is
disposed within the pot cover 366 to form a covered potted plant
368.
[0135] The gate 436 is opened. The covered potted plant 368 is
released therefrom and travels in direction 438 down the conveyor
370 to the next station. Meanwhile, the denesting arm 416 is
pivoted away in direction 440 and is returned to a position to
retrieve the next pot cover 366.
[0136] Another denesting embodiment of the cover supplying station
362, illustrated in FIGS. 29A-29B, comprises a cover supplying
assembly 364a having a denesting arm 416a for denesting from a bin
418 and transferring the pot cover 366 to a receiving position 420a
for receiving a potted plant 422. In this embodiment the grasping
end 424 of the arm 416a comprises a suction cup 424a which places a
suction on the outer bottom 442 of the base 428 of the pot cover
366. The denesting arm 416a pivots away from the bin 418, and the
pot cover 366 is removed from the bin 418 and carried to a conveyor
assembly 444.
[0137] The conveyor assembly 444 comprises a first parallel belt
446 and a second parallel belt 448 having a gap extending
lengthwise therebetween. The grasping end 424 with the suction cup
424a is disposed in the gap 450 between the parallel belts 446 and
448 of the conveyor assembly 444. As the bottom 442 of the pot
cover 366 approaches the conveyor assembly 444, the suction from
the suction cup 424a is released and, as the grasping arm 424
continues its downward motion, the pot cover 366 is rested gently
on the conveyor assembly 444 and is carried by the belts 446 and
448 in direction 452 through the guide walls 434 to a gate 436.
[0138] At gate 436, the pot cover 366 is held stationary while a
potted plant 422 is disposed manually or automatically, within the
pot cover 366, thereby providing a covered potted plant 368. The
denesting arm 416a is then available to retrieve another pot cover
366. The cover supplying assemblies 364 and 364a may be equipped
with sensors (not shown) to regulate and control the operation of
the denesting arms 416 and 416a and of the conveyor assemblies 370
sand 444 and gates 436.
EMBODIES OF SLEEVING STATIONS
[0139] Turning now to FIGS. 24A-D, the sleeving apparatus 460 of
the sleeving station 372 will be described. The sleeving apparatus
460 comprises a sleeve support assembly comprising a first wicket
462 and a second wicket 464 which bear a set of sleeves 466. The
sleeving apparatus 460 is the same as the sleeving station 484
described herein except for the modifications described herein.
Each wicket 462 and 464 extends horizontally for a distance, then
bends downward diagonally. The sleeving apparatus 460 further
comprises a suctioning tube 468 which applies a suction to a first
side 470 of a sleeve 466 for loosening and separating the first
side 470 from the second side 472 of the sleeve 466 to provide an
opening 474 at the upper end of the sleeve 466 (FIG. 24A).
[0140] Air is forced into the opening 474 of the sleeve 466 from an
inflator tube 476 and the sleeve 466 is thereby sufficiently
inflated to receive a potted plant. The inflator tube is retracted
in direction by an inflator cylinder or by another retracting
device (FIG. 24B). A covered potted plant 368 is then deposited
into the open sleeve 466. The covered potted plant 368 may be
automatically deposited to the sleeve 466 via a mechanism similar
to that described by FIGS. 17-18 above for the sleeving station 184
described previously. Alternatively, the covered potted plant 368
may be deposited into the sleeve 466 manually by an operator.
Alternatively, a potted plant 422 without a cover 366 may be
inserted into the sleeve 466, thereby bypassing the cover supplying
assembly 364.
[0141] The suction tube 468 is then retracted into the suction
cylinder 478. The resulting sleeved covered potted plant 480 will
then slide via gravity down the wickets 462 and 464 in direction
482 to a position 484 over the conveyor 378 (FIG. 24C). The sleeved
potted plant 480 may slide onto the conveyor 378 and, by the
friction of the conveyor 378 underneath the bottom 442 of the base
428 of the sleeved potted plant 480, be carried by the conveyor 378
away from the sleeving station 372.
[0142] Alternatively, the sleeving station apparatus 460 may be
equipped with a disengaging assembly comprising an extendable
pushing arm 486 to push the sleeved potted plant 480 in direction
485 off the wickets 462 and 464 onto the conveyor 378 (FIG. 24D).
The sleeved potted plant 480 is thereby conveyed upon the conveyor
378 downstream and is ultimately packed into a carton 400. The
extendable pushing arm 486 is then retracted by a pushing arm
cylinder 488 in preparation for the next sleeved potted plant 480.
Operation of the sleeving station 372 may be regulated by sensing
devices (not shown) opening the sleeve 466 in preparation for
depositing a potted plant therein and for maintaining an even and
regulated flow of sleeved potted plants 480 on the conveyor
378.
[0143] The components of the sleeving apparatus embodiments are
illustrated in FIGS. 15-19 and 24A-27B as isolated. However, it
will be appreciated and understood by one skilled in the art that
the components could be easily and completely attached and
assembled together to form a unified apparatus.
EMBODIMENTS OF THE BOXING STATIONS
[0144] Referring now to FIGS. 25-26, the sleeved potted plants 480
may be boxed at a boxing station 404 immediately after leaving the
sleeving station 372. In one embodiment, the boxing station 404
comprises a boxing assembly 500 and an extendable automatic pushing
arm 502 which, while pushing the sleeved potted plant 480 off the
wickets 462 and 464, proceeds to push the sleeved potted plant 480
in direction 504 into an open-sided box or carton 400 resting on an
adjacent conveying system 506 (FIG. 25). Once the carton 400 is
filled, the filled carton 402 is passed to the closing station 408
for closing and securing. The pushing arm 502 is retracted by a
retracting cylinder 508 in preparation for another sleeved potted
plant 480.
[0145] In another embodiment of the boxing station 404, a boxing
assembly 510 has a pivotable automatic gripping arm 512 having a
gripping end 514 (FIG. 26). The gripping end 514 of the gripping
arm 512 grips an upper portion 516 of the sleeved potted plant 480.
The gripping arm 512 is retractable by a cylinder 518 attached to a
pivoting brace 520. The brace 520 is pivoted in direction 522 to a
position over a carton 400a having an open upper side and the
gripping arm 512 lowers the sleeved potted plant 480 into the box
400a. The carton 400a can then be closed and secured for shipping.
Alternatively, rather than having the gripper arm 512 move the
sleeved potted plant 480 to a specific location in the box 400a,
the gripper arm 512 may only lift the sleeved potted plant 480 and,
the box 400a itself may be automatically moved beneath the lifted
potted plant 480 to be properly positioned to accept the package
lowered thereinto.
[0146] Another embodiment of a boxing assembly is designated by the
reference numeral 530 and is shown in FIG. 33. Sleeved potted
plants 480 are individually directed into an open-sided carton 400
with a pushing arm 532 in direction 534. Sensors (not shown) detect
the positions of the sleeved potted plants 480 already within the
carton 400 and regulate the action of the pushing arm 532. Once the
carton 400 is filled, the carton 400 is closed and secured and
moved in direction 536 on the conveyor 396 for shipping. An empty
open-sided carton 400 is delivered as a replacement, in one
embodiment by an automatic boxing delivery assembly. The extendable
pushing arm 532 is indicated in FIG. 33 as being driven by a
cylinder 538 but it is understood by one of ordinary skill in the
art that there are other mechanisms for causing the advancement and
retraction of the pushing arm 532.
PREINSERTION OF COVER INTO SLEEVE
[0147] Turning now to FIGS. 27A-B and 30A-D, instead of the potted
plant 422 being covered by a pot cover 366 prior to insertion into
the sleeve 466, the pot cover 366 may be preinserted into the
sleeve 466 prior to deposition of the potted plant 422 into the pot
cover 366. FIG. 27A indicates that the sleeve 466 is opened in a
manner identical to that described for sleeving apparatus 460 in
FIG. 24A. The pot cover 366 is then inserted in direction 550 into
the opening 474 of the sleeve 466. The suction tube 468 and
inflation tube 476 are retracted and the potted plant 422 is
deposited in direction 550 into cover/sleeve combination 552 in the
sesame manual or automatic manner as that described previously. The
sleeved covered potted plant 376 then is conveyed by the conveyor
378 to the boxing station 404.
[0148] The pot cover 366 may be placed manually into the sleeve
466, but in the preferred embodiment shown in FIGS. 30A-30D, a
cover supplying apparatus 364b has a retractable cover denesting
arm 554 having a suction end 556. The suction end 556 of the
denesting arm 554 retrieves a pot cover 366 from a bin 418b of pot
covers 366 (FIG. 30A). The denesting arm 554 is retracted by a
cylinder 558 to remove the pot cover 366 (FIG. 30B) from the bin
418a. The pot cover 366 is transferred to the sleeving station 372
(FIG. 30C) and is inserted into the previously opened sleeve 374
(FIG. 30D). Suction is removed from the suction end 556 therein
releasing the pot cover 366. The denesting arm 554 is retracted,
leaving the pot cover 366 within the sleeve 374 and in readiness
for insertion of a potted plant 422 therein using means described
herein.
EMBODIMENT OF FIGS. 31-32
[0149] Turning now to FIGS. 31 and 32, another embodiment of the
article packaging system is designated by the reference numeral
564. The article packaging system 564 has stations exactly as
described for article packaging system 350 as described in FIGS.
22-30 and 33 except that article packaging system 564 employs the
same cover supplying apparatus, the same sleeving apparatus and the
same boxing and closing devices for all categories of potted plants
sorted at the sorting station. The advantage of the articles
packaging system 564 over the article packaging system 350 is that
a single device performs each particular function such as sleeving
for all grades or categories. Since duplicate apparatuses are not
required for each function, the cost and the space required for the
overall system is reduced.
[0150] The article packaging system 564, as shown in FIG. 31, has a
platform or table 566 serving as a servicing station 568 supporting
a set of unsorted potted plants. A sorting station 570, employs a
sorter (not shown) of the same type a packaging system 350 which
inspects potted plants 572 and sorts them in accordance with
predetermined criteria such as size, quality, or variety or any of
a number of other criteria. The sorter directs each sorted potted
plant 572 to either a first parallel conveyor 574 or a second
parallel conveyor 576. Potted plants 572 of a particular category
are then accumulated on conveyor 574 by a restraining gate 578 or
on conveyor 576 by restraining gate 580 until a predetermined
number of the type of potted plant 572 is accumulated. When the
predetermined number of sorted potted plants 572 is accumulated,
the appropriate gate is opened.
[0151] The potted plants 572 are then conveyed to a covering
station 584 where a cover supplying apparatus 586 supplies a cover
588 and wherein the cover 588 is applied to the potted plant 572.
Each covered potted plant 590 in a particular category is then
conveyed to a sleeving station 592 where the covered potted plant
590 is deposited into a sleeve (not shown) in a manner exactly as
described herein for article packaging system 350 and its various
embodiments. Sleeved potted plants 594 thus produced are then
conveyed to a boxing station 596 such as the boxing station 404 or
its other embodiments described for system 350 where the sleeved
potted plants 594 are placed in cartons 400 which are then closed
and secured for shipment.
[0152] FIG. 32 shows a version of the article packaging system 564
having a first conveyor 600a, a second conveyor 600b and a third
conveyor 600c which lead to the single sleeving station 592. The
single sleeving station 592 has rollers 601 and can be rolled or
moved in direction 602 or direction 604 between the three conveyors
600a, 600b and 600c manually or automatically for the purpose of
supplying sleeves 606 to the potted plants 572 or covered potted
plants 590 conveyed thereupon. In this way a single sleeving
station 592 can supply sleeves 606 to more than one conveyor 600a,
600b or 600c and category of potted plant 572 to reduce the cost
and space required for the system 564.
[0153] Alternatively, rather than having a plurality of separate
conveyors such as conveyors 600a-600c conveying potted plants 572
to the sleeving station 592, a single conveyor having a plurality
of parallel lanes (not shown) could be used. Each parallel lane
would have a separately regulated gate (not shown) for allowing
accumulation and passage to the sleeving station 592 of a
predetermined number of potted plants 572 or covered potted plants
590.
[0154] The single sleeving station indicated in FIG. 32 is shown as
having separate conveyors 608a-608c for conveying the sleeved
potted plants 590 to the appropriate boxing station 596. Each
conveyor 608a-608c could direct the sleeved potted plants 594 to a
single conveyor (not shown) leading to a single boxing station.
Alternatively, each sleeved potted plant conveyor 608a-608c could
direct the sleeved potted plants 594 to a separate boxing station
596.
[0155] As described herein for article packaging system 350, the
article packaging system 564 could be modified in a number of ways.
For example, the pot cover 588 could be applied to the potted plant
572 prior to accumulation on conveyor 574 or 576 by gates 578 or
580, respectfully. Or, the pot cover 588 could be placed into the
open sleeve 606 prior to the introduction of the potted plant 572
into the sleeve 606, as indicated in the embodiment shown in FIGS.
27A-B.
EMBODIMENT OF FIG. 34
[0156] Referring now to FIG. 34, another embodiment of the article
packaging system referred to by the reference numeral 610 is
illustrated. The article packaging system 610 is constructed
exactly as described for article packaging systems 10, 350, or 564
or modifications thereof except that a decorative pot cover is
directly formed about the outer surface of a potted plant 612 using
an appressing cover forming apparatus such as a cover forming
apparatus 614 to form a covered potted plant 616 at a point prior
to application of a sleeve to the potted plant 612. The cover
forming apparatus 614 appresses a sheet of material (not shown)
about the external surface of the potted plant 612 to form a
covered potted plant 616 having a cover which may or may not be
bonded to the potted plants external surfaces as described
herein.
[0157] The cover forming apparatus 614 which could be used for
example is one described in the patent application filed in the
U.S. P.T.O. on Aug. 10, 1992 by Donald Weder, Joseph Straeter and
Frank Craig, entitled "Cover Forming Apparatus Having Pivoting
Forming Members", and not yet assigned a serial number, the
specification of which is hereby specifically incorporated herein.
This does not exclude the use of other types of cover forming
apparatuses adapted for forming a cover about the outer surface of
a potted plant to form the covered potted plant 616.
[0158] After the potted plant has been covered by the cover forming
apparatus 614, the covered potted plant 616 is transferred to a
conveyor 618 moving in direction 620 toward a sleeving station
exactly the same as other sleeving stations previously described
herein. The relocation of the covered potted plant 616 from the
cover forming apparatus 614 can be accomplished manually or
automatically such as by a transfer device 620 having an extendable
pushing arm 622 or by some other device adapted for moving the
covered potted plant 616 to a conveyor 618.
[0159] Changes may be made in the combinations, operations and
arrangements of the various parts and elements described herein
without departing from the spirit and scope of the invention as
defined in the following claims.
* * * * *