U.S. patent application number 09/742632 was filed with the patent office on 2001-10-18 for stacked article packaging method.
Invention is credited to Lashyro, Jeffrey A., Vulgamore, Gary J., Ziegler, Kelly W..
Application Number | 20010029723 09/742632 |
Document ID | / |
Family ID | 21891990 |
Filed Date | 2001-10-18 |
United States Patent
Application |
20010029723 |
Kind Code |
A1 |
Ziegler, Kelly W. ; et
al. |
October 18, 2001 |
Stacked article packaging method
Abstract
A method for continuously forming stacked article groups,
comprising the steps of supplying at least two streams of articles,
each at a predetermined vertically distinct level; forming and
longitudinally transporting a stream of first article groups having
at least one article, at a first level; placing a support base on a
top surface of each first article group; and forming a second
article group, having at least one article, at a second level on
top of the support base of each longitudinally moving first article
group, whereby stacked article groups are formed. The stacked
article groups are subsequently processed for packaging.
Inventors: |
Ziegler, Kelly W.; (Crosby,
MN) ; Lashyro, Jeffrey A.; (Crosby, MN) ;
Vulgamore, Gary J.; (Marietta, GA) |
Correspondence
Address: |
SKINNER & ASSOCIATES
619 SECOND STREET
SUITE 201
HUDSON
WI
54016
US
|
Family ID: |
21891990 |
Appl. No.: |
09/742632 |
Filed: |
December 20, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09742632 |
Dec 20, 2000 |
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09338093 |
Jun 23, 1999 |
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09338093 |
Jun 23, 1999 |
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08944634 |
Oct 6, 1997 |
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08944634 |
Oct 6, 1997 |
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08541739 |
Oct 10, 1995 |
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5692361 |
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08541739 |
Oct 10, 1995 |
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08343790 |
Nov 22, 1994 |
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08343790 |
Nov 22, 1994 |
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08037017 |
Mar 25, 1993 |
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Current U.S.
Class: |
53/445 ; 53/157;
53/447; 53/531 |
Current CPC
Class: |
B65B 61/207 20130101;
B65B 35/50 20130101; B65B 5/106 20130101 |
Class at
Publication: |
53/445 ; 53/531;
53/447; 53/157 |
International
Class: |
B65B 035/50; B65B
061/20 |
Claims
What is claimed is:
1. A method for forming stacked article groups, comprising the
steps of: (a) supplying at least two streams of articles, each at a
predetermined ertically distinct level; (b) forming and
longitudinally transporting a stream of first article groups having
at least one article, at a first level; (c) placing a support base
on a top surface of each the first article group; and (d) forming a
second article group, having at least one article, at a second
level on top of said support base of each said longitudinally
moving first article group, whereby stacked article groups are
formed.
2. A continuous method for forming stacked article groups having
upper and lower sub-groups of at least one article, comprising the
steps of: (a) inputting a stream of articles at a first location
along a longitudinally oriented axis and at a first vertical level
to form a stream of longitudinally moving lower article sub-groups;
(b) placing a divider structure on each said lower article
sub-group; and (c) inputting a stream of articles at a second
location along said axis and at a second vertical level to form the
upper article sub-group on the top surface of each said divider
structure whereby longitudinally moving stacked article groups are
formed.
3. The method of claim 1, wherein two article streams are supplied,
a first said article stream being supplied at a first longitudinal
position, and a second article stream being supplied at a second,
distinct longitudinal position, said first article group being
formed at said first position, said second article group being
formed at said second position, and said support base being placed
at a position between said first and said second positions.
4. The method of claim 3, wherein said second article group is
slidingly moved across said support base to form said stacked
article group.
5. The method of claim 3, wherein said second article group is
deposited onto said support base to form said stacked article
group.
6. The method of claim 3, wherein said support base has a thin,
substantially flat, rectilinear configuration with a surface area
substantially coextensive with that of the top surface of said
first article group.
7. The method of claim 6, wherein said support base further has a
flap member disposed along one base edge and defined by a
scoreline, said flap member being foldable over one edge of the top
surface of said first article group.
8. The method of claim 6, wherein said support base is constructed
of paperboard.
9. The method of claim 4, further comprising the step stabilizing
said support base on its operative top position on said first
article group.
10. The method of claim 1, wherein said infeed articles are further
segregated into at least two rectilinear article lanes.
11. The method of claim 10, wherein said article lanes intersect
said longitudinal stream at a predetermined angle and wherein said
first and second article groups are formed by being raked from said
article lanes.
12. The method of claim 1, further comprising the step of placing
said stacked article groups in cartons.
13. The method of claim 12, wherein said cartons are provided in a
longitudinally oriented stream, synchronized with said stacked
article groups, and further have open ends facing said stacked
article groups.
14. The method of claim 13, wherein said stacked article groups are
placed into cartons by laterally loading them into open sides of
the cartons.
15. The method of claim 14, wherein the carton is constructed of
paperboard and includes an outer structure with top, bottom, front
and rear sides, and open ends bounded by end flaps, and wherein the
articles are beverage cans.
16. A continuous method for forming stacked article groups,
comprising the steps of: (a) supplying at least one stream of
articles at a first predetermined location and a first vertical
level along a longitudinally oriented axis; (b) forming and
longitudinally transporting a stream of lower article sub-groups at
said first location; (c) depositing a divider structure at a second
predetermined location along said axis, downstream from said first
location; (d) supplying at least one stream of articles at a third
location downstream from said second location, and at a second
vertical level higher than said first vertical level; (e) forming,
at said third location, an upper article group on each said divider
structure of each said lower article sub-group, whereby stacked
article groups are formed; and (f) transporting said stacked
article groups along said longitudinal axis.
17. A method of continuously loading cartons with stacked article
groups having upper and lower sub-groups of at least one article,
comprising the steps of: (a) supplying an input stream of articles
at a first location; (b) selecting articles at said first location
to form a lower article sub-group; (c) transporting the lower
article sub-group longitudinally to a second location; (d)
depositing a base structure on said lower article sub-group prior
to its arrival at said second location; (e) supplying an input
stream of articles at said second location; (f) selecting articles
at said second location to form an upper article sub-group on top
of the lower article sub-group, which is slidably moved across said
base structure, to thereby form a stacked article group; (g)
longitudinally transporting said stacked article group; (h)
supplying and longitudinally transporting a carton in spacial
synchronization with the stacked article group; and (i) laterally
transferring the stacked article group into the longitudinally
transported carton.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS, IF ANY
[0001] This application is a continuation of application Ser. No.
09/338,093, filed Jun. 23, 1999, pending; which is a continuation
of application Ser. No. 08/944,634, filed Oct. 6, 1997; which is a
continuation of application Ser. No. 08/541,739, filed Oct. 10,
1995; which is a continuation of application Ser. No. 08/343,790,
filed Nov. 24, 1994; which is a continuation of application Ser.
No. 08/037,017, filed Mar. 25, 1993, which are hereby incorporated
by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates, generally, to packaging
methods and apparatus. More particularly, this invention relates to
a continuous method of forming stacked or multiple layer article
groups. The packaging method of the present invention is useable to
package different types, styles and sizes of articles, in a wide
range of stacked article group patterns, and into a variety of
packaging media, into cartons in a fast and reliable manner.
[0004] 2. Background Information
[0005] In the past, various machines and processes have been
proposed and utilized to package selected article groups into
packages. Each prior art machine and process, however, accomplishes
the packaging of the article groups in a distinct manner and
utilizes particular machinery. Moreover, prior art cartoners have
limited adjustability, limited output capability, and have been
difficult to construct and maintain due to their respective
designs. And finally, no method or apparatus, insofar as is known
provides continuous motion packaging of stacked or layered product
groups.
[0006] Prior art packaging assemblies include U.S. Pat. No.
4,802,324 to applicants' assignee for a Vertical Cartoning Assembly
and Method which discloses the placement and assembly of cartons
over preselected article groups being moved on a conveyor. U.S.
Pat. No. 5,036,644, also to applicants' assignee, discloses a
Packaging Sleever Assembly which transfers flat packaging sleeves
directly onto preselected article groups and subsequently wraps and
closes the cartons. Various end loading packaging machines have
also been proposed in the art. For example, U.S. Pat. No. 3,778,959
to Langen et al. discloses an end loader which utilizes a plurality
of transversely extending spaced apart fences or flights mounted on
a conveyor to rake or capture a predetermined number of containers
from infeed container slips. U.S. Pat. No. 4,237,673 to Calvert et
al. discloses a machine also for loading container sleeves through
their open ends. U.S. Pat. No. 4,936,077 to Langen et al. discloses
a carton loading machine which utilizes pusher mechanisms with
spring loaded pusher heads to stagger adjacent product group rows
during transfer into the carton.
[0007] In view of the limitations and shortcomings of prior art
methods and apparatus, it is an object of this invention to provide
a method of continuously and reliably forming stacked product
groups at high speed. Another object of this invention is to
provide a packaging method which is useable with a variety of
package types, articles and stacked article group types and sizes.
A particular object of the invention is to provide a method which
forms stacked or multiple layer article groups via a base member
disposed between a lower article sub-group and an upper article
sub-group.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides a method for continuously
forming stacked article groups, comprising the steps of: supplying
at least two streams of articles, each at a predetermined
vertically distinct level; forming and longitudinally transporting
a stream of first article groups having at least one article, at a
first level; placing a support base on a top surface of each the
first article group; forming a second article group, having at
least one article, at a second level at or above the support base
of each longitudinally moving first article group, whereby stacked
article groups are formed. The support base is preferably
constructed of paperboard and has a thin, substantially flat,
rectilinear configuration with a surface area substantially
coextensive with that of the top surface of the first article
group. The support base may have a flap member disposed along one
base edge and defined by a scoreline, the flap member being
foldable over one edge of the top surface of the first article
group.
[0009] In a preferred embodiment, the invention provides a
continuous cartoning method for loading stacked article groups into
packages or cartons of a type having an outer structure and an
inner divider structure, comprising the steps of: supplying at
least one stream of articles at a first predetermined location and
a first vertical level along a longitudinally oriented axis;
forming and longitudinally transporting a stream of lower article
sub-groups at the first location; depositing the inner divider
structure at a second predetermined location along the axis,
downstream from the first location; supplying at least one stream
of articles at a third location downstream from the second
location, and at a second vertical level higher than the first
vertical level; slidably forming, at the third location, an upper
article group on each the divider structure of each the lower
article sub-group, whereby stacked article groups are formed;
transporting the stacked article groups along the longitudinal
axis; providing a longitudinal stream of cartons, with open ends
facing and synchronized with the stacked article groups, adjacent
to and parallel with the article groups; and laterally moving the
stacked article groups into the synchronized cartons.
[0010] These and other benefits of this invention will become clear
from the following description by reference to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0011] FIG. 1 is a side view of the packaging or cartoning assembly
of the present invention.
[0012] FIG. 2 is a top plan view of the cartoner assembly.
[0013] FIG. 3 is a perspective view of a carton assembled by the
cartoner assembly.
[0014] FIG. 4 is a crossectional view of the carton taken along
line 4-4 of FIG. 3.
[0015] FIG. 5 is a detailed side view of the cartoner assembly.
[0016] FIG. 6 is a detailed top plan view of the cartoner
assembly.
[0017] FIG. 7 is a top plan view of a portion of the cartoner
assembly.
[0018] FIG. 8 is a side view of selected portions of the article
group selection and transport mechanism.
[0019] FIG. 9 is a top view of a portion of the carton supply and
transport mechanism.
[0020] FIG. 10 is a side view of a portion of the carton supply and
transport mechanism.
[0021] FIG. 11 is a top view of the discharge end of the carton
supply and transport mechanism.
[0022] FIG. 12 is a side view of the discharge end of the carton
supply and transport mechanism.
[0023] FIG. 13 is a side view of the infeed guides of the article
supply mechanisms.
[0024] FIG. 14 is a side view of the carton support assembly of the
carton supply and transport mechanism.
[0025] FIG. 15 is a top view of the carton support assembly of FIG.
14.
[0026] FIG. 16 is a left end view of the carton support assembly of
FIG. 14.
[0027] FIG. 17 is a right end view of the carton support assembly
of FIG. 14.
[0028] FIG. 18 is a top view of the crossloading mechanism.
[0029] FIG. 19 is a crossectional view of the cartoner apparatus
taken approximately along line 19-19 of FIG. 5.
[0030] FIG. 20 is a crossectional view of the cartoner apparatus
taken approximately along line 20-20 of FIG. 5.
[0031] FIG. 21 is a crossectional view of the cartoner apparatus
showing details of the article group selection and transport
mechanism.
[0032] FIG. 22 is a crossectional view of the cartoner apparatus
taken along line 22-22 of FIG. 7.
[0033] FIG. 23 is a crossectional view of the cartoner apparatus
taken approximately along line 23-23 of FIG. 5.
[0034] FIG. 24 is a crossectional view of the cartoner apparatus
taken approximately along line 24-24 of FIG. 5.
[0035] FIG. 25 is a crossectional view of the cartoner apparatus
taken approximately along line 25-25 of FIG. 5.
[0036] FIG. 26 is a top view of a loader arm assembly.
[0037] FIG. 27 is a combined side and end view of a pushing
face.
[0038] FIG. 28 is an end view of the loader arm assembly taken
along line 28-28 of FIG. 26.
[0039] FIG. 29 is an end view of a loader arm guide.
[0040] FIG. 30 is a crossectional view of a loader arm assembly
operatively extended across the article group selection and
transport mechanism.
[0041] FIG. 31 is a detailed side view of the flight bar structures
of the article group selection and transport mechanism.
[0042] FIG. 32 is a top view of the loading zone of an alternative
embodiment of the present invention.
[0043] FIG. 33 is a side view of the embodiment shown in FIG.
32.
DETAILED DESCRIPTION
[0044] The methods and apparatus of the present invention are for
forming stacked article groups in a continuous, high speed process.
As shown in the drawings, the method of this invention is
implemented via a continuous motion, high-speed packaging apparatus
10. The apparatus 10 is adjustable to provide reliable, continuous
and high speed packaging of articles or products of varying types,
sizes and quantities into packages of varying types and sizes. For
example, the apparatus 10 is useable to load standard twelve ounce
beverage cans into 24(12/12), 30(15/15) and 36(18/18) pack stacked
combinations. Moreover, the process of loading beverage containers
into paperboard cartons, for example, is accomplished quickly and
reliably, under typical industry tolerances for both container and
carton construction. The resultant filled cartons output by the
apparatus 10 are of high quality and consistency, having maximized
squareness and tautness for improved storage qualities and
transportability. Although the embodiments disclosed load stacked
article groups into paperboard cartons, its within the purview of
this invention to process the stacked article groups in a variety
of ways subsequent their formation, including side loading, shrink
wrapping, banding or having paperboard or other material formed
around them.
[0045] Referring to FIGS. 1 and 2, the continuous motion cartoner
assembly 10 generally comprises a carton supply and transport
mechanism or stream 11, an article group selection and transport
mechanism or stream 12, a pair of article supply mechanisms or
streams 13 and 14, a divider placement mechanism 15, and an article
group transfer or cross loading mechanism 16. These mechanisms are
shown to be supported by a unitary frame structure 17, although if
aligned properly, separate support structures may be utilized
consistent with the teachings of this invention.
[0046] The carton supply mechanism 11 is shown to be disposed
proximate an input end 18 of the assembly 10. Carton sleeves or
blanks 25 are subsequently transported in a linear fashion to an
output end 21 of the apparatus 10. The article supply mechanisms 13
and 14 are also shown to be disposed at the input end 20 of the
apparatus 10. A first portion of each article supply mechanism 13
and 14 is disposed spacially parallel to the article group
selection and transport mechanism 12, and a second portion merges,
at a predetermined angle, with the article group selection
transport mechanism 12 to supply streams of product or articles 20
to two separate positions along the article group selection and
transport mechanism 12. These merging mechanisms 12-14 are further
constructed and arranged to meter individual articles 20, via a
fixed flight bar arrangement, into predetermined stacked article
groups 21 and 22 on the mechanism 12.
[0047] The stacking function of the device 10 is accomplished by
forming a first group 21 at a low level, placing a separator or
divider sheet 24 on the lower group 21 via the divider sheet
placement mechanism 15, and then simultaneously forming a second
group 22 downstream at a higher level and allowing the upper group
22 to slide across the divider sheet 24 by the action of the flight
bars of the article group selecting mechanism 12. In an alternative
embodiment, the second group is formed on an upper dead plate and
dropped or otherwise deposited onto the divider sheet.
[0048] The article group selection and transport mechanism 12 is
disposed adjacent and parallel to the carton supply and transport
mechanism 11 and extends downstream, in a linear orientation.
Merged or combined article groups 23 are transported downstream
thereon in a spaced and metered fashion, each group 23 being
aligned with a carton 25 traveling on the carton supply and
transport mechanism 11. The crossloading mechanism 16 is disposed
adjacent to and parallel with the second portion of the article
group selection and transport mechanism 12, extending and traveling
longitudinally with respect to the apparatus 10. The crossloading
mechanism 16 has a plurality of loading arms which extend
transversely or perpendicularly with respect to the transport
mechanisms 11, 13 and 14, to move product groups 23 on the article
group selection transport mechanism 12 into aligned cartons 25
traveling on the carton transport mechanism 11, thereby loading the
cartons 25 with product groups 23. Preferably, each of the
aforementioned mechanisms 11-14 and 16 has a conveyor type
structure with an endless chain or belt configured about rotatable
drive and idler end means and moving longitudinally with respect to
the input (upstream) and output (downstream) ends 18 and 19 of the
apparatus 10. The movement of each mechanism is further
synchronized with one another, for example by a common drive and/or
gearing means.
[0049] Referring to FIGS. 3 and 4, the method of this invention is
useable to construct carriers or cartons 26 containing cans 20 or
other articles which are disposed on top of one another or stacked.
The paperboard carrier blank or sleeve 26 is comprised of leading
and trailing side panels 40 and 41 foldably connected to top panel
42 and to a bottom panel 43. End panels 44 connect the top, bottom
and side panels 40-43. As shown, the carrier 26 contains a bottom
layer or sub-group 21 of articles, shown for purpose of
illustration as beverage cans 20, and an upper layer or sub-group
22 of cans in stacked relationship. The lower ends of the upper
cans 22 are supported on a thin, paperboard divider sheet 24 (also
referred to as a base or support sheet) with the bottom cans 21
resting on the bottom panel 43. An extension tab located on the
medial edge of the sheet 24, and which folds down via a perforation
or scoreline is preferably provided to help stabilize the divider
sheet 24. The extension tab provides a means for holding the sheet
24 stable while the upper layer of cans 22 are pushed onto the
separator sheet 24. Once the cans 23 have been all properly
positioned the sheet 24 is held in place by guides on the apparatus
10. The top panel 42 is disposed closely adjacent, and preferably
is in contact with, the top chimes 43 of the upper level 22 of cans
to provide for a tight fit between the cans 20 and the carrier 25.
Although the apparatus 10 shown in the drawings is utilized in a
beverage can cartoning operation with paperboard carrier sleeves,
modifications consistent with the teachings of this invention may
be made to package various other stacked containers or articles in
various carrier configurations or to package the article groups via
shrink wrapping, banding or the like.
[0050] Referring also to FIGS. 5, 6, 20 and 22, the carton supply
and transport mechanism 11 is preferably a rotary type carton
placer 49, such as that disclosed in U.S. Pat. No. 4,530,686 owned
by Applicants' assignee. The carton erecting apparatus 49 is
supported above the input end of the carton transport mechanism 11
by a vertically adjustable frame structure 50, and basically
transfers flat carton blanks or sleeves 25 from a power magazine 51
to the conveyance surface of the mechanism 11, simultaneously
opening the blank 25 so that it assumes a four-sided configuration
with opposing open ends bounded by at least one flap 44 each.
Importantly, the partially erected carton 25 is placed in a
transverse or lateral orientation so that its ends are open to the
sides of the carton transport mechanism 11 for loading
purposes.
[0051] The carton transport conveyor 52 receives cartons or other
carriers 25 from the carton supply placer 49 and transports them
linearly downstream with respect to the overall apparatus 10. The
downstream transport of cartons 25 is synchronized with the article
group selection and transport mechanism 12 and with the
crossloading mechanism 16, as described further below, to
effectuate carton 25 loading. Importantly, the carton transport
conveyor 52 is adjustable to accommodate cartons 25 of varying
types and sizes. Referring also to FIGS. 9, 10 and 22-25 in
particular, the carton transport conveyor 52 basically comprises a
plurality of flight lugs 56 which are connected to a pair of flight
chains 181 and 182, the flight chains 181 and 182 being connected
to and revolving about drive and idler ends 53 and 54. Although a
pair of lugs 56 is shown, the number of lugs 56 per carton 25 may
be varied for alternative carton configurations. The lugs 56 are
shown to serve a dual purpose in that they are disposed anterior
with respect to a particular carton 25 for control and
stabilization purposes, while the pair 56 which is disposed
posterior to the carton urges the carton 25 forward on the conveyor
mechanism 52. The lugs 56 are preferably constructed of nylon or a
similar material. The lugs 56 are attached to the flight chains 181
and 182 via lug bases. The flight chains 181 and 182 are supported
at the top or forward run of the conveyor 52 by chain guides 183.
The chain guides 183 are connected to the main frame 17 via guide
supports 184. An elongated, longitudinally extending return guide
185 is disposed along the bottom run of the conveyor 52 and mates
with a notch in each lug 56 to stabilize their return during high
speed operation. Additionally, a longitudinally oriented slide rail
(not shown) may be disposed between the flight chains 181 and 182,
level with the horizontal plane of the chain guides 183, and with a
low-friction top surface to support the bottom of each carton 25 on
the conveyor 52. The width-wise or transverse spacing between lugs
56 on the parallel, side-by-side chains is preferably variable via
a transverse lug adjustment mechanism. Although a single pair of
flight lugs 56 is shown, an alternative structure may be
constructed with phase adjustable leading and trailing flight lugs,
as is known in the art. This phase adjustment is desirable to
permit the apparatus 10 to be used with various carton
configurations to allow for adjustment of carton spacing between,
for example, 6 and 12 inch, on center arrangements to convert the
apparatus 10 from 6 to 36 pack processing.
[0052] Referring to FIGS. 5, 10 and 14-17, the apparatus preferably
includes a carton stabilization structure 28 which supports the
tops of the relatively tall, bi-level cartons 25 traveling on the
carton supply and transport mechanism 11, particularly during the
loading phase of operation. The carton stabilization structure 28
basically comprises a pair of overhead rails 191 and 192 connected
to vertical and horizontal support members 193 and 194 which are
linked via adjustment mechanism 195 supported by posts 196. A
carton sleeve set up guide assembly 197 is also preferably disposed
anterior to the carton stabilizer 28 and immediately downstream of
the point of initial placement of the sleeve on the conveyor 52 by
placer 49.
[0053] Referring to FIGS. 5, 6 and 13, the first or low article
supply mechanism 13 provides a plurality of input individual
articles 20 to the apparatus 10 at a first predetermined level or
height and at a predetermined point on the article group selection
and transport mechanism 12. The mechanism 13 is shown to comprise a
conveyor 60 disposed about a drive sprocket/shaft assembly 61 and
an idler sprocket/shaft assembly 62. The conveyor 60 preferably
consists of a unitary, belt. Articles 20 transported on the top,
forward run of the conveyor 60 are separated into a plurality of
single file paths by lane separators 63. Each lane separator 63 is
shown to be an upstanding plate of a height sufficient to guide the
flow of one or more containers 20 on the conveyor 60, and which is
suspended above the conveyor 60. The lane separators 63 form
product conveyance lanes which angle towards the article group
selection and conveyance mechanism 12. An approach angle of
approximately 20-25 degrees with respect to the longitudinal axis
of the mechanism 12 has been found to provide optimal product group
selection results. The conveyor 60 is disposed parallel with and
immediately proximate to the article group selection and transport
conveyor 12 to allow for article movement thereinbetween. A low
friction, dead plate having angled lane grooves which correspond
with the lane separators 63 is preferably interposed at the
interface between the conveyor 60 and the transport mechanism 12.
Each lane separator 63 has a terminal portion 64 of a predetermined
length, such that it extends into the path of the article group
selection and transport mechanism 12 a distance approximately equal
to one-third the width of the mechanism 12 conveyance path. Each
terminal portion 64 is constructed such that it allows
longitudinally transported flight structures 74 (described further
below) of the article group selection and transport mechanism 12 to
pass through the angled conveyance lanes. As the flight bars 74
mesh with and pass through the lane separator end portions 64, they
engage articles 20 disposed in lanes and rake them onto the
longitudinal conveyance path of the mechanism 12 and between
adjacent flight bars 74.
[0054] The combination of forces exerted by the flight bars 74,
lane ends 64, and conveyors 60 and 12 serve to select and meter
individual articles 20 into predetermined article groups 21 which
are fully merged onto the article group selection and transport
mechanism 12. The size, orientation and dimensions of the resultant
product groups 21 is dependent upon the number of infeed lanes,
product dimensions, and the configuration and spacing of the flight
bars 74. For example, in the instant embodiment, six (6) lanes of
product are active, and the flight bars 74 are spaced such that the
resultant product group 21 is selected of eighteen (18) articles in
three rows of six cans each. Lanes may be blocked off by closure
means 67 to alter the group 21 size and/or orientation. The lane
separators 63 and the flight bars 74 are adjustable to provide full
variability of product group parameters.
[0055] The low article supply mechanism 13 is shown to terminate at
its infeed end 18 for mating with a complementary external
apparatus, for example an additional infeed conveyor or conveyors.
Alternatively, such infeed conveyor may be integrated with the
apparatus 10. Further, although this embodiment utilizes conveyance
lanes which are initially oriented parallel with the remaining
elements of the apparatus 10 and subsequently angle towards the
article group selection transport mechanism 12, it is possible to
provide an infeed conveyor that is entirely angled as such.
[0056] The article group selection and transport mechanism 12
selects article groups 21 and 22 from the first or low article
supply mechanism 13 as set forth above and from the second or high
article supply mechanism 19 discussed below, and transports them
linearly downstream with respect to the overall apparatus 10. The
downstream transport of article groups 21 and 22 is synchronized
with the carton supply and transport mechanism 11 and with the
crossloading mechanism 16, as described further below, to
effectuate carton 25 loading. Referring also to FIGS. 7, 21 and 22,
the article group selection and transport mechanism 12 generally
comprises a conveyor 73, a plurality of flight bar assemblies 74
fixed to and longitudinally transported on the conveyor 73, and a
plurality of slide plates 75, which are disposed on the conveyor 73
between the spaced flight bars 74.
[0057] The conveyor 73 runs at a predetermined speed and includes a
drive procket/shaft assembly 76 and an idler sprocket/shaft
assembly 77, a pair of parallel endless conveyor chains 78 which
are connected to and revolve about the sprocket/shaft assemblies 76
and 77, forming a longitudinally extending forward or top run 79
and a return or bottom run 80. Idler assembly 77 is disposed ust
anterior to the area where the first or low article supply
mechanism 13 merges with the article group selection and transport
mechanism 12, and marks the beginning of the conveyor 73. The drive
sprocket/shaft assembly 76 is disposed adjacent the end of the
crossloading mechanism 16 and marks the end of the conveyor 73. The
conveyor chains 78 are each supported by top and bottom
longitudinally extending chain guides 81, which in turn are
connected to the main frame 17 via upstanding conveyor supports
82.
[0058] Referring also to FIG. 31, the flight bar assemblies 74 are
each shown to include a top rail member 83 and a bottom rail member
84 which are connected to one another by vertical spacers 85. The
top and bottom members 83 and 84 are shown disposed parallel to one
another and spacially separated by the spacers 85. Each top and
bottom member 83 and 84 further has an angled front end 150 and an
elongated, rectilinear body 151 terminating in a flat back end. The
front end 150 slants or angles inwardly from its leading edge to
its trailing edge to enable the flight bars 74 to select individual
articles 20 disposed in the article infeed lanes and to separate
them from the closely spaced nearest upstream article 20.
[0059] As is best shown in FIG. 7, a pair of fixed slide plates 152
and 153 are connected to each flight bar 74 assembly. Both the
flight bars 74 and the slide plates 152 and 153 are connected to
the flight chains 78 via connection brackets 86. The slide plates
152 and 153 are thin, flat structures with a low friction top
surface which support the lower article groups 21 and further
permit sliding movement thereon. Additionally, slotted slide plates
154 are disposed between adjacent flight bar assemblies 74, each
plate 154 including a laterally oriented slot 155.
[0060] The height of the flight bar 74 (i.e., the separation
distance between the top and bottom members 83 and 84) is a
function of the container and container group size and
configuration. For example, taller cans (12 oz.) require greater
flight bar 74 height than a short can (10 oz.), for proper
selection and transport. The width of the top and bottom members 83
and 84 is a function of the desired dimensions of the product
groups 21 and 22 formed. It is within the purview of this invention
that the flight bar 74 height and width be fully adjustable to
accommodate various container and group parameters.
[0061] As is best shown in FIGS. 7, 8 and 21, a group stabilization
structure 161 including a pair of longitudinally oriented upper and
lower guide rails 162 and 163, and lateral adjustment structures
163 is disposed on the outer or lateral side of the article group
selection and transport mechanism 12. The lower guide rail 162
extends from the upstream end of the mechanism 12 to a point
anterior to a point on the mechanism 12 at which the upper group 22
is formed. The upper guide rail 162 extends throughout the region
on the article group selection and transport mechanism 12 at which
the upper group 22 is formed. The upper and lower rails 162 and 163
are disposed at predetermined vertical levels, between the upper
and lower members 83 and 84 of the flight bars 74, to contact the
base and upper article sub-groups 21 and 22 respectively. The
lateral extension distance of the rails 162 and 163 is adjustable
by means of the lateral adjustment structures 164 for varying
article group 23 sizes.
[0062] Referring to FIGS. 5 and 19, the divider placement mechanism
15 deposits a divider sheet 24 on the top surface of lower or base
article group 21 formed and traveling on the article group
selection and transport mechanism 12.
[0063] The divider placement mechanism 15 is shown to be disposed
above the article group selection and transport mechanism 12 at a
predetermined point downstream from where the base article group 21
is first fully formed. The divider placement mechanism 15
preferably comprises a rotary placer mechanism 92 of the type
manufactured and sold by Applicants' assignee and having a pair of
apex positions with vacuum control members 94. A power magazine 93
is shown operatively connected to the placer 92 to provide a
continuous supply of divider sheets 24 thereto. Although a
rotary-type placer is preferred for divider sheet placement, other
placement means may be substituted to practice the basic method of
this invention.
[0064] Referring again to FIGS. 7, 8 and 21, a divider hold down
assembly 168 including a pair of medial and lateral rails 169 and
170 and adjustment structures 171 is disposed above a segment of
the article group selection and transport mechanism 12, extending
downstream from a point immediately posterior to the point of
placement of the divider sheet 24 by the placer 92. The medial rail
169 has a anterior segment which includes a top member 169 with an
upturned forward lip 174 and a side member 173 with a plow
configuration, and a rail shaped posterior segment 175. This
configuration is designed to engage and fold down the medial flap
on the divider sheet 24, formed by a perforation or scoreline, and
to hold the flap down over the medial edge of the lower article
sub-group 21 to stabilize the position of the divider sheet 24
during downstream transport and lateral movement of the upper
article sub-group 22 across the divider sheet 24 top surface. The
lateral rail 170 extends a predetermined distance downstream to
stabilize the lateral edge region of the divider sheet 24 prior to
lateral merging of the upper group 22 across the divider sheet 24.
The structure of the divider hold down assembly 168 has been shown
to yield a substantially flat divider sheet 24 for improved article
group 22 merging thereacross, especially in paperboard divider
sheets 24 constructed with recycled materials which tend not to lay
flat when unstabilized.
[0065] Referring again to FIGS. 5, 6 and 13, the second or high
article supply mechanism 14 provides a plurality of input
individual articles 20 to the apparatus 10 at a second
predetermined level or height and at a predetermined point
downstream from the low article supply mechanism 13. The mechanism
14 is also shown to comprise a pair of conveyors 100 and 101, each
being disposed about a drive sprocket/shaft assembly and an idler
sprocket/shaft assembly. The conveyors 100 and 101 may consist of a
plurality of individual tracks or paths or alternatively a unitary,
wider path or belt. Articles 20 transported on the top, forward run
of the conveyors 100 and 101 are separated into a plurality of
single file paths by lane separators 102. Each lane separator 102
is shown to be an upstanding wall of a height sufficient to guide
the flow of one or more containers 20 on the conveyors 100 and 101,
and which is suspended above the conveyors 100 and 101. The lane
separators 102 form product conveyance lanes which angle towards
the article group selection and conveyance mechanism 12 at an
approach angle of approximately 20-25 degrees with respect to the
longitudinal axis of the mechanism 12. The conveyors 100 and 101
are disposed parallel with the article group selection and
transport conveyor 12. Conveyor 101 is further disposed immediately
adjacent the article group selection and transport conveyor 12 to
allow for article 20 movement thereinbetween. A dead plate region
is also preferably utilized. Each lane separator 102 has a terminal
portion 103 of a predetermined length, such that it extends into
the path of the article group selection and transport mechanism 12
a predetermined distance. Each terminal portion 103 is constructed
such that it allows the longitudinally transported flight
structures 74 of the article group selection and transport
mechanism 12 to pass through the angled conveyance lanes. As the
flight structures 74 mesh with and pass through the lane separator
end portions 103, they engage articles 20 disposed in lanes and
rake them onto the longitudinal conveyance path of the mechanism
12.
[0066] The combination of forces exerted by the flight bars 74,
lane ends 103, and conveyors 100, 101 and 73 serve to select and
meter individual articles 20 into predetermined upper article
groups 22 which are merged onto the divider sheet 24 on top of the
lower or base article group 21 traveling on the article group
selection and transport mechanism 12. The size, orientation and
peripheral dimensions of the resultant upper product groups 22 is
dependent upon the number of infeed lanes, product dimensions, and
the configuration and spacing of the flight bars 74. The divider
sheet 24 provides a low friction base surface upon which the upper
group 22 is transversely, slidably moved to form a stacked group
23. Lanes may be blocked off by closure means 104 to alter the
group 22 size and/or orientation. The lane separators 103 and the
flight bars 74 are adjustable to provide full variability of
product group parameters.
[0067] Referring to FIGS. 32 and 33, a portion of an alternative
embodiment of the stacked article cartoning apparatus 205 is shown
wherein upper article sub-groups 206 are deposited on the top
surface of divider sheet 207 on lower article sub-group 200 to form
a stacked article group 209. In this embodiment, an upper stream
210 of article sub-groups 206 is disposed above and in longitudinal
alignment with a lower stream 211 of article sub-groups 208. The
upper stream 210 is shown to include a dead plate 212 across which
the upper article sub-groups 206 are moved by the action of upper
pusher bars 213. The lower stream 211 includes a conveyor 214 and
flight bars 215. As shown, the upper article sub-groups 206 are
dropped directly, vertically on top of the divider sheet 207 as
they move over the terminal edge 216 of the dead plate.
Longitudinal movement of the upper and lower article sub-groups 206
and 208 is synchronized.
[0068] The article group lateral transfer or crossloading mechanism
16 is synchronized with the aforementioned apparatus 10 elements to
move completed, stacked article groups 23 traveling on the article
group selection and transport conveyor 12 into aligned cartons 25
traveling on the carton supply and transport conveyor 11. Referring
to FIGS. 7, 18, 22 and 26-30, the crossloading mechanism 16
basically comprises a plurality of loader arm assemblies 110, a
flight chain and guide tube assembly 111 to which the loader arm
assemblies 110 are attached at predetermined intervals, and which
provides a longitudinal movement component thereto, and a control
cam assembly 112 which provides a predetermined transverse motion
component to the loader arm assemblies 110.
[0069] The flight chain and guide tube assembly 110 has a forward
or top run 113 and a return or bottom run 114 and comprises drive
and idler sprocket/shaft assemblies 115 and 116 and a pair of
spacially parallel flight chains 117 and 118 which are connected to
and revolve about the sprocket/shaft assemblies 115 and 116. The
flight chains 117 and 118 are maintained in a rectilinear
configuration on both the top and bottom runs 113 and 114 by chain
guides 119 and 120, which are linked to the frame 17 via vertical
support members 121.
[0070] Pairs of elongated guide tubes 122 are disposed at
predetermined intervals along the flight chains 117 and 118, each
guide tube 122 being directly connected at one end to the outer
flight chain 118, and at its opposite end to the inner flight chain
117 so that they are oriented transversely with respect to the axis
of the apparatus 10 and to the downstream or forward run of the
crossloader 16. The guide tubes 122 have a low friction exterior
surface to provide slidable support of the loader arm assemblies
110. The pairs of closely spaced tubes 122 increase the stability
of transverse movement of the arm assemblies 110. Further stability
is attained by the guide blocks 123 (connected to the inner ends of
the guide tubes 122 via set screws) traveling in a longitudinally
oriented guide rail 124 which is linked to the frame 17 via a
support 125. As best shown in FIG. 29, lateral retainers 126 are
mounted on the top of each guide block 123 to guide the
transversely moving arm assemblies 110. The spacing between
successive sets (pairs) of tubes 122 corresponds to the spacing
between the flight bars 74 of the article group selection and
transport conveyor 12 and of the flight lugs 56 of the carton
transport conveyor 11 so that the arm assemblies 110 are aligned to
push product groups 23 from between the flight bars 74 into the
cartons 25.
[0071] The loader arm assemblies 110 are movably mounted on the
guide tubes 122, and in a transverse orientation with respect to
the axis of the apparatus 10. The arm assemblies 110 are conveyed
in a downstream, longitudinal direction while they simultaneously
reciprocate in a transverse direction under the control of a cam
mechanism 112 described below. Each loader arm assembly 110
basically comprises an elongated, rectilinear base plate 127 and a
loading head 128 located at one end of the base plate 127. The base
plate 127 is shown to have a rigid, flat, elongated structure which
is oriented horizontally. A rigid stiffing bar 129 is connected to
the top surface of the base plate 127, vertically oriented, to
increase the rigidity and strength of the arm assembly 110.
Preferably, a plurality of bores are disposed in the stiffing bar
129 to reduce its weight. The inwardly disposed end of the base
plate 127 is slidably supported by the lateral retainers 126 of the
guide block 123. A first or outer bushing block 130 is connected to
the bottom of the base plate 127 at its opposite end. The first
bushing block 130 has a pair of apertures, including bushings,
through which the guide tubes 122 are slidably extended. A second
or inner bushing block 131 is similarly connected to the base plate
127 and interfaces with the guide tubes 122 a short distance from
the first bushing block 130. The bushing blocks 130 and 131 are
further connected by a spreader bar 132 which is oriented and rides
in the space between the guide tubes 122. A rotatable cam follower
133 is connected to the bottom of the spreader bar 132. The
longitudinally traveling cam follower 133 cooperates with the cam
guide assembly 112 to cause the arm assembly 110 elements to
transversely reciprocate on the guide tubes 122 and through the
lateral retainers 126 of the guide block 123.
[0072] The loading head 128 is shown to have two fixed, flat face
members 134 and 135. As the arm assemblies 110 move forward, the
face members 134 and 135 push the article groups forward from the
article group selection transport conveyor 12 into the cartons 25.
A support roller 144 is disposed on the bottom of the head 128 to
provide support when the head 128 is extended across the article
group selection and transport mechanism 12. Additionally, a
t-shaped guide pin 145 is disposed on the bottom of the base plate
127 of the arm assembly 110 to mate with the slot 155 in slide
plate 154 to laterally stabilize the arm member 110 during high
speed operation. The loading head 128 configuration is variable to
interface with a wide range of product group 23 configurations.
Although in the instant embodiment the head 128 is configured for
use with a stacked configuration, the head 128 can be modified for
cartoning various other product and product group arrangements,
including non-stacked configurations. Head 128 modification is
accomplished by changes in the configuration of the face members
134 and 135. A transition conveyor 29, shown in FIGS. 2 and 22, is
disposed between the crossloading mechanism 16 and the carton
transport mechanism 12 to provide a moving base for the movement of
the article groups 23 into the longitudinally conveyed cartons 25.
A fixed dead plate may alternatively be used. The bottom member 84
of the flight bars 74 is elongated to extend across the top run of
the transition conveyor 29 to guide or funnel article groups 23
across the conveyor 29 and into the cartons 25, between the carton
end panels 44.
[0073] The loader control cam assembly 112 controls the transverse,
reciprocal motion of the arm assemblies 110. The loader control cam
assembly 112 is generally oriented longitudinally with respect to
the overall crossloading mechanism 16, and has a top or forward run
136 and a bottom or return run 137 corresponding to the revolving
arm assemblies 110. The top run 136 basically comprises an inwardly
sloping approach segment 137, an apex 138, and an outwardly sloping
return segment 139. In the approach segment 137, the cam follower
133 is urged inwardly, and drives each arm assembly 110 into moving
engagement with a product group 23 until it is loaded in a carton
25. A lag segment 146 of decreased slope is disposed at a
predetermined point where the loading head 128 first contacts the
article group 23 to provide gentle, even pressure at this initial
contact point. In the return segment 139, the face 128 is retracted
from the carton 25 prior to its being reset in the return run 137
of the cam assembly 112. The forward run 136 of the cam assembly
112 comprises an outer rail 140 and an inner rail 141 which is
spaced from the inner rail 140 a distance equivalent to the
diameter of the cam follower 133. The follower 133 is disposed in a
cam pathway formed between the outer and inner rails 140 and 141 to
effectuate transverse, inward motion to the arm assemblies 110.
Preferably, the outer rail 140 is connected to a pivot point 142 at
one end and to a release mechanism, such as a pressure release
cylinder and piston 143 proximate its opposite end. The release
mechanism 143 is controlled by a sensing mechanism, for example, a
photoeye or capacitive proximity sensor, such that if an excessive
force is placed on the outer rail 140, for example due to a jamming
of the arm assembly 110, the release mechanism 143 will be actuated
releasing the outer rail 140 which pivots about point 142.
[0074] The bottom or return run 136 of the cam assembly 112
includes circular guide plates 148 and 149, and a bottom cam rail
147 which contacts the cam follower 133 to further retract and
reset the loader arms 110 for further loading cycles. Since the
loader arms 110 are substantially extended when they revolve around
sprocket/shaft assembly 115, it is critical that they be stabilized
by the guide pin 145 in slide plate 154 groove 155 during high
speed operation.
[0075] As shown in FIGS. 2, 6, 7, 9 and 23, lateral and medial flap
tuckers 30 and 31 are disposed adjacent each side of the carton
transport mechanism 11, one anterior to the loading region to
provide a closed carton backside against which the loaded
containers may nest, and one posterior to the loading region to
allow article group 23 ingress to the carton 25 through its open,
unglued end flaps 44.
[0076] Referring to FIGS. 1 and 12, an overhead carton squaring
station 33 is shown disposed immediately downstream of glue
stations 37, immediately above the carton supply and transport
mechanism 12, and extending a predetermining longitudinal distance
downstream. The overhead station 33 assists in maintaining the
squareness of the loaded cartons. The overhead compression station
preferably comprises an endless chain 201 with a plurality of
vertical lugs 202 having a bottom downstream run of a predetermined
longitudinal distance and being disposed a predetermined vertical
distance above the article transport conveyor 12. The vertically
disposed lugs 202 have a predetermined configuration such that they
aid in maintaining the squareness of the cartons 26. One or more
compression belts (not shown) may additionally be added for package
control purposes.
[0077] As shown in FIGS. 1, 6,24 and 25, gluing, side compression
and discharge mechanisms 32 and 37, 34 and 35 are disposed
consecutively, further downstream and adjacent the carton supply
and transport mechanism 11 to complete the carton flap securement
process.
[0078] As many changes are possible to the embodiments of this
invention utilizing the teachings thereof, the descriptions above,
and the accompanying drawings should be interpreted in the
illustrative and not the limited sense. The descriptions above and
the accompanying drawings should be interpreted in the illustrative
and not the limited sense. While the invention has been disclosed
in connection with the preferred embodiment or embodiments thereof,
it should be understood that there may be other embodiments which
fall within the scope of the invention as defined by the following
claims. Where a claim, if any, is expressed as a means or step for
performing a specified function it is intended that such claim be
construed to cover the corresponding structure, material, or acts
described in the specification and equivalents thereof, including
both structural equivalents and equivalent structures,
material-based equivalents and equivalent materials, and act-based
equivalents and equivalent acts.
* * * * *