U.S. patent application number 10/266028 was filed with the patent office on 2003-02-13 for article packaging system.
Invention is credited to Craig, Frank, Straeter, Joseph G., Weder, Donald E..
Application Number | 20030029136 10/266028 |
Document ID | / |
Family ID | 27503656 |
Filed Date | 2003-02-13 |
United States Patent
Application |
20030029136 |
Kind Code |
A1 |
Craig, Frank ; et
al. |
February 13, 2003 |
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.
PO BOX 16370
OKLAHOMA CITY
OK
73114
US
|
Family ID: |
27503656 |
Appl. No.: |
10/266028 |
Filed: |
October 4, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10266028 |
Oct 4, 2002 |
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09866401 |
May 25, 2001 |
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09866401 |
May 25, 2001 |
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09785891 |
Feb 16, 2001 |
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6311461 |
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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 ; 53/416;
53/449 |
Current CPC
Class: |
B65B 25/026
20130101 |
Class at
Publication: |
53/397 ; 53/449;
53/416 |
International
Class: |
B65B 011/58 |
Claims
What is claimed is:
1. A method of covering a potted plant comprising the steps of:
providing a first preformed cover having an interior space;
removing a second preformed cover from a set of nested preformed
covers, the second preformed cover having a frustoconical shape and
having an interior space; disposing the second preformed cover into
the interior space of the first preformed cover; providing a potted
plant; and disposing the potted plant into the interior space of
the second preformed cover after the second preformed cover has
been disposed within the interior space of the first preformed
cover.
2. The method of claim 1 further comprising the step of bondingly
connecting the potted plant to the second preformed cover via a
bonding material.
3. The method of claim 1 wherein, in the step of providing the
first preformed cover, the first preformed cover is composed of a
material selected from a group of materials consisting of paper
(untreated or treated in any manner), cellophane, foil, synthetic
organic polymeric film, fiber (woven or nonwoven or synthetic or
natural), cloth (woven or nonwoven or natural or synthetic), or
burlap.
4. The method of claim 1 wherein, in the step of providing the
second preformed cover, the second preformed cover is composed of a
material selected from a group of materials consisting of paper
(untreated or treated in any manner), cellophane, foil, synthetic
organic polymeric film, fiber (woven or nonwoven or synthetic or
natural), cloth (woven or nonwoven or natural or synthetic), or
burlap.
5. A method of covering a potted plant comprising the steps of:
providing a first preformed cover having an interior space;
removing a second preformed cover from a set of vested preformed
covers, the second preformed cover having a frustoconical shape and
having an interior space; disposing the second preformed cover into
the interior space of the first preformed cover; providing a potted
plant; disposing the potted plant into the interior space of the
second preformed cover after the second preformed cover has been
disposed within the interior space of the first preformed cover;
and bondingly connecting the potted plant to the second preformed
cover.
6. A method of covering a potted plant comprising the steps of:
providing a first preformed cover having an interior space;
removing a second preformed cover from a set of nested preformed
covers, the second preformed cover having a frustoconical shape and
having an interior space; disposing the second preformed cover into
the interior space of the first preformed cover; providing a potted
plant; disposing the potted plant into the interior space of the
second preformed cover after the second preformed cover has been
disposed within the interior space of the first preformed cover;
and bondingly connecting the potted plant to the second preformed
cover via a bonding material selected from the group consisting of
adhesive or cohesive materials, heat sealable materials, sonic
sealable material, vibratory sealable materials, ties, labels,
bands, ribbons, string, tape, staples, or combinations thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. Ser. No.
09/866,401, filed May 25, 2001, which is a continuation of U.S.
Ser. No. 09/785,891, filed Feb. 16, 2001, now U.S. Pat. No.
6,311,461, issued Nov. 6, 2001, which is a continuation of U.S.
Ser. No. 09/393,041 filed Sep. 8, 1999, now U.S. Pat. No.
6,189,295, issued on Feb. 20, 2001, which is a continuation of U.S.
Ser. No. 09/005,630, filed Jan. 9, 1998, now U.S. Pat. No.
6,006,500, issued on Dec. 28, 1999, which is a continuation of U.S.
Ser. No. 08/720,961, filed Oct. 10, 1996, now U.S. Pat. No.
5,706,628, issued on Jan. 13, 1998 which is a continuation of U.S.
Ser. No. 08/462,332, filed on Jun. 5, 1995, now U.S. Pat. No.
5,605,029, issued on Feb. 25, 1997 which is a divisional of U.S.
Ser. No. 08/417,477, filed Apr. 5, 1995, now U.S. Pat. No.
5,586,425, issued on Dec. 24, 1996 which is a continuation of U.S.
Ser. No. 954,635, filed on Sep. 30, 1992, now abandoned. of U.S.
Ser. No. 07/954,635, filed Sep. 30, 1992, now abandoned.
FIELD OF THE INVENTION
[0002] 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
[0003] FIG. 1 is a schematic of an article packaging system
constructed in accordance with the present invention.
[0004] FIG. 2 is a plan view of part of the packaging system of
FIG. 1 showing an automated greenhouse.
[0005] FIG. 3 is a perspective view of a manual sorting station
which may be used in the article packaging system of the present
invention.
[0006] FIG. 4 is a plan view of an automatic sorting station which
may be used in the article packaging system of the present
invention.
[0007] FIG. 5 is an elevational view of a gate constructed in
accordance with the present invention.
[0008] FIG. 6 is a plan view of one embodiment of a cover placing
station which may be used with the article packaging system of the
present invention.
[0009] FIG. 7 is an elevational view of the cover placing station
of FIG. 6.
[0010] FIG. 8 is an enlarged elevational view of a cover placing
sub-unit, in position to retrieve a cover.
[0011] FIG. 9 is the cover placing sub-unit of FIG. 8 in position
for receiving an article.
[0012] FIG. 10 is the cover placing sub-unit of FIG. 8 shown
immediately after receiving an article.
[0013] FIG. 11 is an elevational view of another embodiment of the
cover placing sub-unit, constructed in accordance with the present
invention.
[0014] FIG. 11A is a plan view of the cover placing sub-unit shown
in FIG. 11.
[0015] FIG. 12 is an elevational view of another embodiment of the
cover placing sub-unit, constructed in accordance with the present
invention.
[0016] FIG. 12A is a plan view of the cover placing sub-unit shown
in FIG. 12.
[0017] FIG. 13 is a plan view of yet another embodiment of the
cover placing sub-unit, constructed in accordance with the present
invention.
[0018] FIG. 14 is an elevational view of a sleeve constructed in
accordance with the present invention.
[0019] FIG. 15 is an elevational view of part of a sleeving station
showing a sleeve before the sleeve is inflated.
[0020] FIG. 16 is a perspective view of part of the sleeving
station of FIG. 15 showing an inflated sleeve.
[0021] FIG. 17 is an elevational view of the sleeving station with
parts removed for clarity.
[0022] FIG. 18 is a plan view of the sleeving station.
[0023] FIG. 19 is a perspective view of the sleeving station and
part of the sealing station.
[0024] FIG. 20 is an elevational view showing a sealing and a
placing station constructed in accordance with the present
invention.
[0025] FIG. 21 is a plan view showing the sealing and placing
station of FIG. 20.
[0026] FIG. 22 is a schematic of another embodiment of an article
packaging system constructed in accordance with the present
invention.
[0027] FIG. 23 is a side view of the packaging system of FIG.
22.
[0028] FIG. 24A is a perspective view of a sleeving station which
may be used in an article packaging system of the present
invention.
[0029] FIG. 24B is a perspective view of the sleeving station of
FIG. 24A indicating a sleeve positioned to receive a potted
plant.
[0030] FIG. 24C is a perspective view of the sleeving station of
FIG. 24A after the potted plant has been inserted into the
sleeve.
[0031] FIG. 24D is a perspective view of the sleeving station of
FIG. 24A showing the sleeved potted plant pushed onto a
conveyor.
[0032] FIG. 25 is a perspective view of a sleeving station modified
to push sleeved potted plants directly into a box.
[0033] FIG. 26 is a perspective view of a sleeving station modified
to transfer a sleeved potted plant by lifting it into a box.
[0034] FIG. 27A is a perspective view of a sleeving station
modified to receive a pot cover prior to receiving a potted
plant.
[0035] FIG. 27B is a perspective view of the sleeving station of
FIG. 27A prepared to receive the potted plant.
[0036] FIG. 28A is an elevational view of a cover supplying device
which may be used in an article packaging system of the present
invention.
[0037] FIG. 28B is a plan view of the cover supplying device of
FIG. 28A.
[0038] FIG. 29A is an elevational view of another cover supplying
device which may be used in an article packaging system of the
present invention.
[0039] FIG. 29B is a plan view of the cover supplying device of
FIG. 29A.
[0040] FIG. 30A is an elevational view of another cover supplying
device which may be used in an article packaging system of the
present invention.
[0041] FIG. 30B is an elevational view of the device of FIG. 30A
after a pot cover has been picked up.
[0042] FIG. 30C is a perspective view of the device of FIG. 30A
wherein a sleeve is readied to receive the pot cover.
[0043] FIG. 30D is a perspective view of the device of FIG. 30A
wherein the pot cover has been inserted into the sleeve.
[0044] FIG. 31 is a plan schematic view of another article
packaging system of the present invention.
[0045] FIG. 32 is an elevational view of a mobile sleeving station
for use with an article packaging system such as that in FIG.
31.
[0046] FIG. 33 is a plan view of a boxing system for use in an
article packaging system of the present invention.
[0047] FIG. 34 is a plan view of a portion of another article
packaging system in which a cover is applied directly to an article
by a cover forming apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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 mil to about 10 mils.
In a preferred embodiment, the sheet of material is constructed
from one sheet of man-made organic polymeric film having a
thickness in a range of from less than about 0.5 mil to about 2.5
mils.
[0054] 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
polymeric film, fiber (woven or nonwoven or synthetic or natural),
cloth (woven or nonwoven or natural or synthetic), burlap, or any
combination thereof.
[0055] The term "synthetic organic polymeric film" means a
synthetically made resin such as a polypropylene as opposed to
naturally occurring resins such as cellophane. A synthetic organic
polymeric 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 polymeric film is a substantially
linearly linked. Such films are synthetic polymers formed or
synthesized from monomers. Further, a relatively substantially
linearly linked processed organic polymeric film is virtually
waterproof which may be desirable in many applications involving
wrapping botanical items or potted plants.
[0056] Additionally, a relatively thin film of substantially
linearly linked processed organic polymer does not substantially
deteriorate in sunlight. Processed organic polymeric films having
carbon atoms both linearly-linked and cross-linked, and some
cross-linked polymeric 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 polymeric film is a polypropylene film.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] 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 polymeric film, or combinations
thereof. The term polymeric film as used herein means any polymeric
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.
[0066] 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.
[0067] 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
[0068] 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.
[0069] 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 a frame covered with a material
which will allow the radiant energy from the sun to reach the
potted plants 14 which are grown inside. Such structures are common
in the art. Within the greenhouse 12 are growing racks 16 (FIG. 2)
adapted for holding the potted plants 14 while they are grown. The
greenhouse 12 may be automated by installing conveyors 18 and 20
(also shown in FIG. 2) 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 18 and 20 are not required
herein as they are well known to persons of ordinary skill in the
art.
[0070] 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 the table 30 may select the
potted plant 14, in accordance with a predetermined grading
criterion such as size and grade, and place it on a conveyor 32 or
a conveyor 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 and 34 should begin near the manual sorting
station 26 and transport the potted plants 14 to the next area for
further processing.
[0071] In an alternative embodiment (not shown), the manual
operator at the manual sorting 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 the table 30.
[0072] In the automatic sorting station 28 of FIG. 4, the automatic
sorting station 28 may be any one several apparatuses for sorting
the potted plants 14. One embodiment of the 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 the conveyor 22.
[0073] Referring now to FIGS. 4 and 5, the first and second
positioning gates 36 and 38 are similar in construction. Each
positioning gate 36 and 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 a bearing 52,
to a motor 54. A collar 56 is secured to the rod 50 above the
bearing 52 by a set screw 58, thereby holding the arm 48 off the
upper surface of the conveyor 22. The bearing 52 is secured to a
brace 60 which is mounted to the side of the conveyor 22.
[0074] The first and second 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 first and
second 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.
[0075] 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.
[0076] Directly across conveyor 22 from the light source assembly
40 is the light sensor assembly 42.
[0077] The light switch 45 is located in front of the light source
assembly 40 and turns on the light source 66 when the 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 upon the size and density of the foliage on the
potted plant 14. The taller and more dense the foliage, the less
light reaches light sensor assembly 42.
[0078] The gate 46 is located downstream from the light sensor
assembly 42 near the end of the conveyor 22. The gate 46 is similar
in construction to the first positioning gate 36. The brace 60 of
gate 46 is positioned over the center of the conveyor 22. The gate
46 is pivoted to a first position 68 or a second position 70
depending on the amount of light hitting the light sensor assembly
42. The action of the 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.
[0079] While the potted plant 14 is between the light source 66 and
the photoelectric cell 43, the potted plant 14 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 22, for example, with the light readings taken at
different angles to the foliage, to derive an average of the
several readings.
[0080] 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 downstream from the brace 60 of the gate
46. A first end 74 and a second end 76 of the bar 72 extend off a
side of the conveyor 22 and onto an adjacent conveyor 32 or 34. The
first end 74 of the bar 72 extends from the conveyor 22 to the
conveyor 34. The second end 76 of the bar 72 extends from the
conveyor 22 to the conveyor 32. Conveyors 32 and 34 may lead to
similarly constructed processing lines and thus, only one such line
is described below.
[0081] 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 14.
If the tare weight of the pot and saturated soil contained therein
is known, this measurement can be subtracted from the 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.
[0082] 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.
[0083] 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.
[0084] The conveyor 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.
[0085] In the embodiment shown in FIGS. 6 and 7, 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 first and
second 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 first and second 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.
[0086] 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, the turnstile 88 and the cover denesting sub-unit
90 may be rolled to the side and replaced with a section of
conveyor (not shown) when covering the article is not a required
step.
[0087] 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 the 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.
[0088] 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 the second gear 118 mesh.
[0089] 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).
[0090] The first end 124 of the brace 122 is secured to the
turnstile axle 104 and is adapted for supporting the cylinder 123.
The cylinder 123 is secured to the second end 125 of the brace
122.
[0091] 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.
[0092] 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 first and second parallel 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.
[0093] A conveyor 144 having a first end 146 and a second end 148
(FIG. 19) is abutted at its first end 146 to the end of the belts
134 and 136 in a position to receive a cover 158 or a covered
potted plant from belts 134 and 136.
[0094] 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.
[0095] 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 a 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 the
cover 158 (FIGS. 8-10) from the cover dispenser housing 130.
[0096] Secured to the platform 92 directly below the suction
support arm 150 is a vacuum valve 160 and a support 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.
[0097] An alternate cover denesting sub-unit (automatic cover
supplying assembly) embodiment, herein designated by the reference
numeral 90A, is shown in FIGS. 11-11A. 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 herein
by reference. 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.
[0098] 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 forming 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.
[0099] Another cover denesting sub-unit embodiment, herein
designated by the reference numeral 90C, is shown in FIG. 13. The
cover denesting subunit 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),
the first and second gates 174 and 176 open, allowing the covered
potted plant (not shown) to proceed down conveyor 144 for further
processing.
[0100] At some point after the cover 158 has been denested and
positioned, a potted plant 14 is placed into the interior space of
the cover 158 producing a covered potted plant 180 (FIG. 7). The
potted plant 14 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.
[0101] 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 first and second
spring-loaded guides 186 and 188 (FIG. 18) receive the covered
potted plant 180 as it moves from the second end 148 of the
conveyor 144. A brace 190 is secured above the first and second
spring-loaded guides 186 and 188 to keep the potted plant 180
upright as it moves in direction 192 (FIG. 17) through the first
and second spring-loaded guides 186 and 188. Below the first and
second spring-loaded guides 186 and 188 are a first wicket 194 and
a second wicket 196 for holding a plurality of sleeves, such as a
sleeve 198 (FIGS. 14-16) 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.
[0102] 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 the sleeve 198 is shown in FIGS. 14-17 as
tubular, the shape of the 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 the
holes 216 and 218 may extend through both the front and back sides
208 and 212 of each sleeve 198.
[0103] Referring now in particular to FIGS. 15 and 16, the first
and second 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 that 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.
[0104] In an alternative embodiment of the sleeve opening assembly,
suction cups (not shown) may be employed to pull open the front
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.
[0105] As the covered potted plant 180 reaches the end 148 of the
conveyor 144 and moves in direction 192 through the chute between
the first and second spring-loaded guides 186 and 188 and the brace
190, it is deposited into the open sleeve 198 (FIG. 19) to provide
a sleeved potted plant 222 (also referred to in this instance as a
sleeved covered potted plant).
[0106] In an alternative embodiment (not shown), the covered potted
plant 180 may be formed into the sleeved covered potted plant 222
by wrapping a sheet of sleeving material (not shown) about the
covered potted plant automatically.
[0107] Referring now to FIGS. 1, 20 and 21, a gripping station 230,
also referred to as a transfer station, is positioned to remove the
sleeved potted plant 222 from the wickets 194 and 196. The gripping
station 230 comprises a turnstile 234, 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 of the conduit 240 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 240) 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.
[0108] 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.
[0109] Secured to the second end 254 of the turnstile axle 250 are
support arms 266A, 266B, 266C and 266D. Each support arm 266A-266D
includes the first gripping arm 236 and the 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.
[0110] In an alternative embodiment, the first gripping arm 236
includes a heating element (not shown) adapted to seal the upper
end 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 gripping
arms 236 and 238 grasp the sealed sleeved potted plant 272, thereby
freeing the sealed sleeved potted plant 272 from the 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.
[0111] Positioned to receive the sleeved potted plant 222 or the
sealed sleeved potted plant 272 is the placing station 274 (FIGS.
20-21). The placing station 274 comprises a lowering arm 276, a
first pinching arm 278, a second pinching arm 280 and a cylinder
282.
[0112] 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 sleeved potted plant 222 or the
sealed sleeved potted plant 272 at a receiving position 284 (FIG.
21). A small cylinder 288 is secured between the lowering arm 276
and the first pinching arm 278. The cylinder 288 is adapted to
allow the pinching arms 278 and 280 to grasp and release the sealed
sleeved potted plant 272 or the sleeved potted plant 222.
[0113] 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 of the rail 290 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 so that
upon 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.
[0114] A carton placing conveyor 308 is adapted to move the carton
306 into position for receiving the sleeved potted plant 222 or the
sealed sleeve potted plant 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 a 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.
[0115] In Operation
[0116] Articles 14, which may be potted plants as shown, for
example in FIG. 3, are placed on the conveyor 22, then are moved to
the 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 the conveyor 32 or 34, which will carry the articles
14 to the next station.
[0117] 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 312 between the article 14 and a
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 assembly 42.
[0118] 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 the light switch 45. Movement of the light
switch 45 activates the light source 66 in the housing 62.
[0119] Light leaving the housing 62 through the 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 the 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.
[0120] 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 the conveyor
32. The article covering station 82 is mounted on the platform 92
with the 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.
[0121] In the preferred operational embodiment, the article 14 will
first encounter the first and second gates 84 and 86 (FIGS. 6-7).
The first and second 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 the cylinder 123 and the
turnstile 88 begins to turn in a counterclockwise direction 314
(FIG. 6).
[0122] When the transfer assembly 120A is in a 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 a
position 318, the suction support arm 150 has been lowered by the
cylinder 152, suctionly bringing with it the cover 158 from the
cover dispensing housing 130 (see FIG. 9). When the transfer
assembly 120A reaches a 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 depress the
support spring 162, thus lowering the covered article 180 onto
conveyor belts 134 and 136 (see FIG. 10).
[0123] As the support 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 144 (FIG. 7), and thus out
of the carrying unit 121. As the turnstile 88 resumes rotation, and
as the transfer assembly 120A passes through a position 322 (FIG.
6), cylinder 124 retracts the carrying unit 121, thereby raising
the first arm 126 and the second arm 128 of the carrying unit 121
into position for receiving the next article 14 from the conveyor
32.
[0124] The covered article 180 is directed from the first and
second parallel belts 134 and 136 to the conveyor 144 (FIG. 7), and
continues to the sleeving station 184 (FIG. 17). As the covered
article 180 reaches the second end 148 of the conveyor 144, it
drops gravitationally through the pair of spring-loaded guides 186
and 188 (FIG. 18). The brace 190 supports the upper side of the
covered article 180 as it drops from the conveyor 144 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 the opened sleeve 198 (FIG. 19).
[0125] 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 lowermost sleeve 198 in preparation for receiving a
covered article 180. The added weight of the covered article 180
dropping from the conveyor 144 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 first and
second gripping arms 236 and 238 (FIG. 19) of the gripping
(transfer) station 230 (FIGS. 20 and 21).
[0126] The turnstile 234 then rotates, thus pulling the sleeve 198
from the wicket 194 and 196. In one embodiment, as the turnstile
234 continues to rotate, heating elements (not shown) in the first
gripping arm 236 heat the gripped portions of the sleeve 198,
sealing the front and the back sides 208 and 212, respectively, 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 the receiving position 284,
the first and second gripping arms 236 and 238, still carrying the
sleeved covered article 222 or the sealed sleeved article 272 (as
the case may be), move between the first pinching arm 278 and the
second pinching arm 280 of the placing station 274 (FIGS.
20-21).
[0127] Once the first and second gripping arms 236 and 238 are
between the first pinching arm 278 and the second pinching arm 280,
the first and second pinching arms 278 and 280 close to pinch the
sleeve 148 of the sleeved covered article 222 or of the sealed
sleeved covered article 272 (as the case may be) and the first and
second gripping arms 236 and 238 are opened slightly. Thus, the
sleeved potted plant 222 or the sealed sleeve potted plant 272 is
now held by the first and second pinching arms 278 and 280 of the
placing station 274. Immediately thereafter, the cylinder 282 is
pulled along the rail 290 via the motor 296 and chain 304 (FIGS.
20-21) from the receiving position 284 to the position 326 and the
sleeved potted plant 222 or the sealed sleeved potted plant 272 is
lowered into the carton 306. The first and second pinching arms 278
and 280 are then released and the lowering arm 276 is raised and
returned to the receiving position 284 to accept the next sleeved
potted plant 222 or sealed sleeved potted plant 272.
[0128] Each sleeved potted plant 222 or sealed sleeved potted plant
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 mechanism not shown). The
conveyor 308 moves as necessary to allow placing of the sleeved
potted plant 222 or the sealed sleeved potted plant 272 in the
carton 306.
[0129] 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 a
carton closing station 330 (FIG. 1) and then a 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 FIGS. 22-34
[0130] Attention is now directed to an article packaging system
designated by the reference numeral 350 and represented in FIGS. 22
and 23. The article 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 article
packaging system 350 automatically places a covered potted plant
into a protective sleeve and then places the sleeved pot into a box
or carton for shipping and distribution.
[0131] 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.
[0132] A cover supplying station 362 comprises an automatic cover
supplying assembly 364 (FIGS. 28A-B) for selecting a pot cover 366
and placing the pot cover 366 in an application position for
receiving the potted plant 352, thereby forming a covered potted
plant 368. The covered potted plant 368 is then placed on a
conveyor 370.
[0133] A sleeving station 372, constructed much the same as the
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 383 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 covered potted
plants 376 in preparation for boxing. In an alternative embodiment,
either the gate station 380 or the gathering station 386, or both
the gate station 380 and the gathering station 386, are
optional.
[0134] 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 covered potted plants 376. A boxing
station 404 pushes or conveys the sleeved covered potted 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
article packaging system 350. The article packaging system 350 may
comprise a second processing stream 412 for processing other potted
plants sorted at the sorting station 360.
Embodiments of Cover Supplying Stations
[0135] 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 a base 428 of one of the pot covers 366 resting in the 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 the conveyor 370. 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 the potted plant 422. The conveyor 370
may be equipped with guide walls 434 to guide the pot cover 366 to
a gate 436 to restrain the pot cover 366 in a stationary position.
At this position, the potted plant 422 is disposed within the pot
cover 366 to form the covered potted plant 368.
[0136] 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.
[0137] 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 one of the
pot covers 366 from the bin 418 and transferring the pot cover 366
to a receiving position 420a for receiving the potted plant 422. In
this embodiment, the grasping end 424a of the arm 416a comprises a
suction cup 424a which places a suction on an 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.
[0138] The conveyor assembly 444 comprises a first parallel belt
446 and a second parallel belt 448 having a gap 450 extending
lengthwise therebetween. The grasping end 424a 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 424a
continues its downward motion, the pot cover 366 is rested gently
on the conveyor assembly 444 and is carried by the parallel belts
446 and 448 in direction 452 through the guide walls 434 to the
gate 436.
[0139] At the gate 436, the pot cover 366 is held stationary while
the potted plant 422 is disposed manually or automatically within
the pot cover 366, thereby providing the 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 and 444 and gates 436.
Embodiments of Sleeving Stations
[0140] Turning now to FIGS. 24A-D, a 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 a 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 one of the sleeves 466 for loosening and separating the
first side 470 from a second side 472 of the sleeve 466 to provide
an opening 474 at the upper end of the sleeve 466 (FIGS. 24A, 24B
and 24D).
[0141] 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 the covered potted plant 368. The inflator tube
476 is retracted by an inflator cylinder 477 or by another
retracting device (FIG. 24B). One of the covered potted plants 368
is then deposited into the open sleeve 466. The covered potted
plant 368 may be automatically deposited in the sleeve 466 via a
mechanism similar to that shown in FIGS. 17-18 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, the potted plant 422 without the cover 366
may be inserted into the sleeve 466, thereby by passing the cover
supplying assembly 364.
[0142] The suction tube 468 is then retracted into a suction
cylinder 478. A resulting sleeved covered potted plant 480 will
then slide, via gravity, down the wickets 462 and 464 in direction
482 to a position 483 over the conveyor 378 (FIG. 24C). The sleeved
covered 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 covered potted plant 480, be carried by the
conveyor 378 away from the sleeving station 372.
[0143] Alternatively, the sleeving apparatus 460 may be equipped
with a disengaging assembly comprising an extendable pushing arm
486 to push the sleeved covered potted plant 480 in direction 485
off the wickets 462 and 464 onto the conveyor 378 (FIG. 24D). The
sleeved covered potted plant 480 is thereby conveyed upon the
conveyor 378 downstream and is ultimately packed into the carton
400. The extendable pushing arm 486 is then retracted by a pushing
arm cylinder 488 in preparation for the next sleeved covered 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 covered potted
plants 480 on the conveyor 378.
[0144] 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
[0145] Referring now to FIGS. 25-26, the sleeved covered potted
plants 480 may be boxed at the 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 covered
potted plant 480 off the wickets 462 and 464, proceeds to push the
sleeved covered potted plant 480 in direction 504 into the
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 (FIG. 22) 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 covered
potted plant 480.
[0146] In another embodiment of the boxing station 404 (FIG. 26), a
boxing assembly 510 has a pivotable automatic gripping arm 512
having a gripping end 514. The gripping end 514 of the gripping arm
512 grips an upper portion 516 of the sleeved covered potted plant
480. The gripping arm 512 is retractable by a cylinder 518 attached
to a pivoting brace 520. The pivoting 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 covered potted
plant 480 into the carton 400a. The carton 400a can then be closed
and secured for shipping. Alternatively, rather than having the
gripper arm 512 move the sleeved covered potted plant 480 to a
specific location in the carton 400a, the gripper arm 512 may only
lift the sleeved covered potted plant 480 and the carton 400a may
be automatically moved beneath the lifted sleeved covered potted
plant 480 to be properly positioned to accept the sleeved covered
potted plant 480 lowered thereinto.
[0147] Another embodiment of a boxing assembly is designated by the
reference numeral 530 and is shown in FIG. 33. Sleeved covered
potted plants 480 are individually directed into the open-sided
carton 400 with a pushing arm 532 in direction 534. Sensors (not
shown) detect the positions of the sleeved covered 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. The 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
[0148] Turning now to FIGS. 27A-B and 30A-D, instead of the potted
plant 422 being covered by one of the pot covers 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 a cover/sleeve combination
552 in the same 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.
[0149] 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 one of the pot covers 366 from a bin
418a 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
protective 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
[0150] 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 shown in FIGS. 22-30
and 33 except that the 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 article
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.
[0151] 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 as 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 the first conveyor 574 by a restraining
gate 578 or on the second conveyor 576 by a 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 578 or 580 is opened.
[0152] 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 the 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 which are then
closed and secured for shipment.
[0153] 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 first, second
and third conveyors 600a, 600b and 600c manually or automatically
for the purpose of supplying sleeves 606 to 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 of the
first, second and third conveyor 600a, 600b or 600c and category of
potted plants to reduce the cost and space required for the system
564.
[0154] Alternatively, rather than having a plurality of separate
conveyors such as the first, second and third conveyors 600a-600c
conveying covered potted plants 590 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 or
covered potted plants 590.
[0155] The single sleeving station indicated in FIG. 32 is shown as
having separate conveyors 608a-608c for conveying the covered
potted plants 590 to the appropriate boxing station 596. Each
conveyor 608a-608c could direct the sleeved potted plants to a
single conveyor (not shown) leading to a single boxing station.
Alternatively, each conveyor 608a-608c could direct the sleeved
potted plants to a separate boxing station.
[0156] 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 could be applied to the potted plant
prior to accumulation on the first and second conveyors 574 or 576
by restraining gates 578 or 580, respectfully; or, the pot cover
could be placed into the open sleeve 606 prior to the introduction
of the potted plant into the sleeve 606, as indicated in the
embodiment shown in FIGS. 27A-B.
Embodiment of FIG. 34
[0157] 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 the
covered potted plant 616 having a cover which may or may not be
bonded to the external surface of the potted plant 612, as
described herein.
[0158] The cover forming apparatus 614 which could be used, for
example, is one described in U.S. Pat. No. 5,291,721 entitled
"Cover Forming Apparatus Having Pivoting Forming Members", the
specification of which is hereby expressly 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.
[0159] After the potted plant 612 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 621 having an extendable
pushing arm 622 or by some other device adapted for moving the
covered potted plant 616 to the conveyor 618.
[0160] 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.
* * * * *