U.S. patent application number 10/223398 was filed with the patent office on 2003-06-12 for continuous circular motion case packing and closure apparatus and method.
Invention is credited to Dillard, Robert Leslie, Hartness, Thomas Patterson, Scott, David Lee, Wiernicki, Richard M..
Application Number | 20030106288 10/223398 |
Document ID | / |
Family ID | 46281055 |
Filed Date | 2003-06-12 |
United States Patent
Application |
20030106288 |
Kind Code |
A1 |
Hartness, Thomas Patterson ;
et al. |
June 12, 2003 |
Continuous circular motion case packing and closure apparatus and
method
Abstract
A packing apparatus which includes a feed conveyor adapted to
convey articles to a pick up station and a case conveyor adapted to
sequentially convey cases, having an open top and a plurality of
flaps, to a feed station. Pick up and grid heads are provided and
are adapted to pick up successive slugs of the articles at the pick
up station and to sequentially deposit the slugs in each of the
cases while they are in the release station. A removal conveyor is
provided to successively receive the slug filled cases from the
release station and pass them onto a case sealing apparatus which
is arranged over the removal conveyor and is operative to apply an
adhesive to certain of the flaps and to then move the flaps over
the open top into a secured closed position.
Inventors: |
Hartness, Thomas Patterson;
(Greenville, SC) ; Wiernicki, Richard M.;
(Roebuck, SC) ; Dillard, Robert Leslie; (Easley,
SC) ; Scott, David Lee; (Greenville, SC) |
Correspondence
Address: |
MCNAIR LAW FIRM
P.O. BOX 10827
GREENVILLE
SC
29603-0827
US
|
Family ID: |
46281055 |
Appl. No.: |
10/223398 |
Filed: |
August 19, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10223398 |
Aug 19, 2002 |
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09418619 |
Oct 15, 1999 |
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09418619 |
Oct 15, 1999 |
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09301394 |
Apr 28, 1999 |
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09301394 |
Apr 28, 1999 |
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09137327 |
Aug 20, 1998 |
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09137327 |
Aug 20, 1998 |
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08736376 |
Oct 24, 1996 |
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5797249 |
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08736376 |
Oct 24, 1996 |
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08338026 |
Nov 10, 1994 |
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5588282 |
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Current U.S.
Class: |
53/473 |
Current CPC
Class: |
B65B 21/183
20130101 |
Class at
Publication: |
53/473 |
International
Class: |
B65B 005/06 |
Claims
What is claimed is:
1. A packer comprising: a delivery for moving articles into a pick
up position; a take-away for removing cases of said articles; a
plate rotating about a single axis located between said delivery
and take-away, said plate being operative to move sequentially said
cases into a deposit position for receiving said articles from said
pick up position and to move each said case of articles to said
take-away.
2. Apparatus according to claim 1 including a frame and a rotating
tower said rotating tower carrying said plate.
3. Apparatus according to claim 2 including pickup and grid heads
carried by said tower for movement about said axis and for relative
vertical movement.
4. Apparatus according to claim 3 including a cam carried by said
frame for controlling said pickup and grid heads through said
relative vertical movement.
5. Apparatus according to claim 1 including a second delivery for
moving said cases to a dispensing position.
6. Apparatus according to claim 5 wherein said second delivery
includes a rotating conveyor and a dispenser, said conveyor being
operative to move said cases to said dispensing position, said
disperser being operative to release in timed sequence said cases
onto said rotating plate.
7. Apparatus according to claim 1 including a support frame carried
by said tower, said support frame supporting said plate.
8. Apparatus according to claim 7 wherein said plate includes a
plurality of pins for positioning said cases relative to said
pickup and grid heads during movement on said plate about said
axis.
9. Apparatus according to claim 7 including an adjusting member
carried by said tower, said adjusting member being operative to
adjust said plate circumferentially of said support frame.
10. Apparatus according to claim 9 wherein said adjusting member
includes a rack and pinion.
11. Apparatus according to claim 2 including arcuate inner and
outer guide rails positioned above and adjacent edges of said
plate, said guide rails being operative to individually position
said cases radially on said plate during movement into said deposit
position.
12. Apparatus according to claim 11 including guide rail mounting
structure for connecting said guide rails with said frame.
13. Apparatus according to claim 12 wherein said guide rail
mounting structure mounting said outer guide rail includes
adjustable linkage for allowing radial adjustment of said outer
guide rail.
14. An apparatus for transferring articles comprising: a frame
supporting a tower for rotation about a single axis; said tower
carrying a plurality of pickup heads for vertical and rotational
movement between a pick up and a deposit position; a circular plate
carried by said tower for movement about said tower and through
said deposit position; a first conveyor for continuously moving
articles into a pick up position adjacent said plate in the form of
slugs; a second conveyor for moving cases sequentially onto said
plate; wherein, each said pickup head is controlled to move onto
and to pick up a slug of said articles when moving through said
pick up position and to move to deposit said slug into a case of
said cases when both said case and said pickup head are moving
through said deposit position.
15. Apparatus according to claim 14 including a third conveyor,
said third conveyor being adapted to receive and remove filled of
said cases from said plate.
16. Apparatus according to claim 14 including a plurality of
positioning pins carried by said plate in spaced circumferential
positions radially spaced from said axis.
17. Apparatus according to claim 15 including an adjusting member
for circumferentially adjusting said positioning pins relative to
said pickup and grid heads.
18. Apparatus according to claim 14 including inner and outer guide
rails carried by said frame in radially spaced positions above said
plate.
19. Apparatus according to claim 18 including adjustable mounting
members for radially adjusting at least one of said guide
rails.
20. A packer apparatus comprising: a frame; a rotating plate
carried by said frame adapted to receive successive cases, each of
said cases having front, rear and side flaps maintained in folded
position adjacent vertical sides thereof, said plate moving said
cases through a deposit position and a removal position; pickup and
grid heads carried by said frame and movable along vertical and
circular paths, said pickup and grid heads being operative to move
into a lower position to deposit a slug of articles into each said
case when passing through said deposit position; and flap
separators carried by said frame, said separators being operative
to move to separate and lift said flaps of said slug containing
case as said pickup and grid heads move vertically away from said
lower position.
21. The packer apparatus of claim 20 including positioning members
carried by said frame, said positioning members being operative to
fold down and hold said front and rear flaps from said lifted
position as said slug containing case is moved from said deposit
position and into said removal position.
22. The packer apparatus of claim 20 wherein each said separator is
pivotally mounted with said grid head; a control mechanism carried
by said pickup and grid heads, said control mechanism being
operative to locate said separator in selective positions relative
to said vertical sides during movement of said pickup and grid
heads wherein; said separators act to first separate said flaps and
secondly to elevate said front and rear flaps.
23. The packer apparatus of claim 22 wherein said control mechanism
includes a cam carried by said pickup head and a spring carried by
said grid head.
24. The packer apparatus of claim 21 wherein said positioning
members include a positioning rail arranged adjacent said removal
position, said positioning rail acting to fold said front flap
down.
25. The packer apparatus of claim 21 wherein said positioning
members include a rotating positioning disk, said rotating
positioning disk being operative to engage and fold down said rear
flap as said case moves through said removal position.
26. A packing apparatus comprising: a frame; a conveyor adapted to
carry successive cases through a deposit position and a removal
position, each said case having connected front, rear and side
flaps held against its vertical sides; a removal conveyor adapted
to receive said cases from said removal position; article carrying
heads moving in sequence with cases carried on said conveyor and
being operative to deposit a slug of said articles in said cases
when in said deposit position; flap separators for separating and
raising said flaps of said cases containing said articles; and,
positioning members arranged adjacent said conveyor, said
positioning members being operative to fold down said raised front
and rear flaps as said cases containing said articles move through
said removal position and onto said removal conveyor.
27. The packing apparatus of claim 26 wherein said positioning
members include a rotating positioning disk which is operative to
engage and fold down said raised rear flaps of said cases
containing said articles exiting said deposit position.
28. The packing apparatus of claim 26 wherein said positioning
members include a positioning rail positioned to engage and fold
down said raised front flaps of said cases exiting said deposit
position.
29. The packing apparatus of claim 28 wherein said positioning rail
extends from said removal position over a sufficient portion of
said removal conveyor to hold down said front and rear flaps when
each said case is fully exited from said removal position of said
conveyor.
30. The packing apparatus of claim 26 including a case sealing
apparatus arranged about said removal conveyor adjacent said
removal position.
31. The packing apparatus of claim 30 wherein said sealing
apparatus includes guide and support rails arranged adjacent said
removal conveyor, said guide and support rails having a support
zone and a positioning zone, said guide and support rails being
operative to locate said side flaps for receiving an adhesive in
said support zone.
32. The packing apparatus of claim 31 wherein said sealing
apparatus includes adhesive applicators operative to applying
adhesive onto said side flaps supported by said guide and support
rails in said support zone.
33. The packing apparatus of claim 31 wherein said guide and
support rails are operative to elevate said side flaps in said
positioning zone.
34. The packing apparatus of claim 33 wherein said case sealing
apparatus includes side flap depressing arms which engage said
elevated side flaps leaving said positioning zone and urge said
side flaps into a closed position.
35. The packing apparatus of claim 34 wherein said case sealing
apparatus includes a press zone positioned over said removal
conveyor adjacent said positioning zone, said sealing apparatus
acting to press and hold said side flaps in position against said
front and rear flaps until said adhesive secures said side, front
and rear flaps in position.
36. The packing apparatus of claim 34 wherein said sealing
apparatus comprises a flexible weight.
37. A packing apparatus comprising: a feed conveyor adapted to
convey containers to a pick up station; a case conveyor adapted to
sequentially convey cases, having an open top and a plurality of
flaps to a feed station; pickup and guide grids adapted to pick up
successive slugs of articles at said pick up station and to
sequentially deposit said slugs in said cases while in a deposit
station; a removal conveyor adapted to successively receive said
slug filled cases from said deposit station; and case sealing
apparatus associate with said removal conveyor, said case sealing
apparatus being operative to apply an adhesive to at least certain
of said flaps, to move said flaps over said open top and into a
secured closed position.
38. A continuous motion packing, depacking apparatus having pick up
and deposit positions comprising: a stationary frame supporting a
tower rotating about a vertical axis; a plate including
circumferentially spaced indexing members carried for rotation with
said tower; a dispenser located adjacent said plate, said dispenser
being operative to sequentially deliver receptacles onto said
plate, said receptacles being positively positioned
circumferentially of said plate by said indexing members for
movement through one of said pick up and deposit positions; a
receptacle located adjacent said plate in one of said pick up and
deposit positions, said receptacle being operative to receive
successive slugs of articles; a plurality of pickup heads carried
by said tower above said plate; and, a motion mechanism causing
each said pickup head to move vertically and pivotally while
rotating with said tower about said axis through one of said pick
up and deposit positions.
39. The apparatus according to claim 38 including a conveyor
adapted to deliver said articles forming said slugs to said
receptacle for pick up by said pickup heads for deposit in said
cases.
40. The apparatus of claim 38 wherein each of said cases contain a
slug of said articles and said pickup heads are operative to pick
up said slugs from successive of said cases for deposit in said
receptacle.
41. The apparatus of claim 40 including a conveyor adapted to
remove said slug of articles from said receptacle.
42. A method of controlling pickup and grid heads in a packing and
de-packaging machine including: providing a circular plate and
rotating said plates about a single axis; providing a pickup
station and continuously moving articles into said picking station
in the form of a slug; rotating said pickup and grid heads in a
circular path about said axis and, through said pick up station;
and, causing said pickup and grid heads to move vertically and to
pivot during rotational movement through said pick up station
causing said pickup heads to move in a generally straight line
through said pick up station.
43. The method of packing articles into a case including: providing
a release station; providing a pick up station and continuously
feeding articles to the pick up station; providing a plurality of
pickup heads and rotating the pickup heads in a circular path about
a single axis through the pick up station and the deposit station;
providing a circular plate beneath said pickup heads and rotating
said plate about said axis and through said pick up and release
stations; continuously moving cases onto said plate for movement
through said release station; causing said pickup heads to pick up
a plurality of said articles during movement through said pick up
station and to deposit said articles in said cases during movement
through said release station; and removing said cases from said
plate.
44. The method of claim 43 causing said pickup heads to move
vertically and pivotally while moving in the circular path through
the pick up station.
Description
[0001] This is a continuation-in-part of a co-pending application
Ser. No. 09/418,619, filed on Oct. 15, 1999 entitled CONTINUOUS
CIRCULAR MOTION CASE PACKING AND DEPACKING APPARATUS AND METHOD,
which is a continuation-in-part of Ser. No. 09/301,394, filed Apr.
28, 1999, entitled Continuous Motion Case Packing Apparatus And
Method; which is a continuation-in-part of application Ser. No.
09/137,327, filed Aug. 20, 1998, entitled Continuous Motion Case
Packing Apparatus, now abandoned; which is a continuation of
application Ser. No. 08/736,376, filed on Oct. 26, 1996, entitled
Continuous Motion Case Packing Apparatus, which is now U.S. Pat.
No. 5,797,249 issued on Aug. 25, 1998; which is a
continuation-in-part of application Ser. No. 08/338,026, filed on
Nov. 10, 1994, entitled Continuous Motion Case Packing Apparatus,
which is now U.S. Pat. No. 5,588,282 issued on Dec. 31, 1996; and
the above applications and patent disclosures are incorporated
herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an apparatus and method for
transferring articles into and out of cases using continuous
motion, and particularly, where the continuous motion is basically
circular and at higher transfer speeds with a small footprint.
[0003] In the art of case packing, large numbers of articles must
be grouped and packaged rapidly by an apparatus that will function
dependably without damage to the articles processed. When unpacking
articles from cases, the articles are already grouped in a pattern
in the case reducing some of the problems of article pick up. Case
packing apparatus has been generally categorized as either
intermittent case packing or continuous case packing. In
intermittent case packing the article flow and/or case flow is
interrupted during article pick up and/or release. Most recently,
attention has been directed to continuous case packing in order to
increase production. However, the continuous case packing has
brought increased problems with handling the processed articles
without breakage, damage, or interruption.
[0004] In the continuous case packing apparatus, articles are
grouped together in successive slugs at a pick up position. The
slugs are typically picked up at the pick up position by article
grippers carried by an orbital handling machine rotating about two
vertical axes. The slugs are transferred to a case loading position
where the grippers release the slug of articles into a case. The
articles can be released either simultaneously or sequentially as
the case is conveyed beneath the slug of articles. Apparatus of
this type may be either of the "drop packer" type or "placement
packer type." In the drop packer type, the articles are allowed to
drop at least a small distance into the case after release. In the
placement packer type, the drop, if any, is minimal and the
articles are essentially placed gently onto the bottom of the
case.
[0005] Continuous motion machines rotating about a single
horizontal axis are shown in U.S. Pat. Nos. 5,375,395, 5,257,888,
and 5,313,764 using articulating arms and pickup heads. A set of
article grippers is carried on the ends of the articulating arms.
However, during the angular descent from the pick up position to
the case packing position, both horizontal and vertical
accelerations are typically encountered by the articles which are
gripped only at their tops or necks. Intermittent circular machines
rotating about a single vertical axis are shown in U.S. Pat. Nos.
3,780,492 and 2,807,125.
[0006] Various other case packers, generally of the continuous
motion type, using a vertical orbital conveyor are shown in U.S.
Pat. Nos. 5,212,930; 4,541,524; and 4,294,057. The first patent
shows depositing the articles sequentially and individually, rather
than as a group or slug, into partitioned cases without positively
gripping the articles. The latter two patents use gripper devices
to grip and place the articles. U.S. Pat. No. 4,457,121 discloses a
continuous motion bottle packer wherein a plurality of grids are
mounted individually on spokes of a vertical wheel so that each
grid moves through an article in feed position where groups of
articles are fed into the grid without interrupting the forward
speed. Angular and horizontal accelerations of the articles and
their contents are encountered due to the rotary wheel motion
during the transfer which may be detrimental to the article and/or
contents.
[0007] Continuous case packers are also known in which a horizontal
rotary carousel is used to move vertically reciprocating gripper
sets in a horizontal plane about two vertical axes. The
reciprocating gripper sets pick up a slug of articles at one
position and transfer the slug of articles to a second position
where the gripper set is lowered to deposit the articles into a
case. Typically the pickup and release stations are on opposite
sides of the carousel, requiring parallel conveyors on each side.
However, the disposition of the rotary carousel in a horizontal
plane requires an inconvenient floor layout, which also occupies a
large amount of floor space. The parallel conveyor arrangements
needed for the in feed and out feed of articles adds to the floor
space problem. The path of the gripper sets between the slug pick
up position and the case packing position is also typically curved
producing angular and acceleration forces on the articles. The
curved article transfer path intersects the path of the conveyed
case only for a brief interval making timing a factor. In various
of the rotary carousel types, it is known to deposit the articles
by lowering the articles, already gripped by the gripper set,
through resilient fingers that guide the articles into partitioned
cases.
[0008] Case packers, generally of the intermittent type, are shown
in U.S. Pat. Nos. 3,553,932 and 3,505,787 which also disclose using
combinations of a lifting head having suction cups and bottle grids
having pockets for picking up containers and depositing them into
cases. The containers and the cases are conveyed on parallel
conveyors rather than in-line conveyors, and the transfer from the
pick up position to the case loading position is lateral, or
transverse, to the flow of containers and cases. U.S. Pat. No.
2,277,688 discloses another case packer using an arrangement of a
gripper set and a bottle guide set to package the containers into a
case. These type of case packers are generally non-continuous as
compared to the continuous motion in-line transfer case packers
described above where neither the flow of articles nor the flow of
the cases is interrupted during operation of the packer.
[0009] Accordingly, an object of the invention is to provide an
improved continuous case packing and depacking apparatus having a
characteristic circular motion.
[0010] Another object of the invention is to provide a continuous
motion apparatus and method which moves in a circular motion to
provide high speeds of operation.
[0011] Another object of the invention is to provide a continuous,
circular motion case packing or depacking apparatus and method
which rotates about a single axis to provide a small footprint and
high speed operation.
[0012] Another object of the invention is to provide a continuous,
circular motion case packing apparatus and method in which slugs or
groups of articles are picked up and transferred to a release
station where the motion of the pickup heads is converted to a
substantially straight-line motion along a pick up section during
which time the articles are picked up.
[0013] Still another object of the invention is to provide a
continuous, circular motion case packing or depacking apparatus and
method wherein the articles are either picked up or released over a
circular plate disposed below the path of the pickup heads and
rotating about the same axis.
[0014] Yet another object of the invention is to provide a
continuous motion apparatus and method in which a revolving turret
moves a plurality of transfer arms and a transfer plate in a
circular path about a single vertical axis as reciprocating article
pickup heads and grid heads, carried by the transfer arms, pick up
and release the articles wherein either the pick up or release
occurs over a circular plate disposed below the pickup heads moving
in a circular motion for high speed, reliable operation.
[0015] Still another object of the invention is to provide a
packing apparatus with a continuous motion circular plate which
moves through a case pick up position, an article pick up position,
an article deposit position and a case removal position.
[0016] Still another object of the invention is to provide a
continuous motion packing apparatus which includes a plurality of
conveyor belts separated by a rotating plate.
[0017] Yet another object of the invention is to provide a
continuous motion apparatus and method in which a revolving plate
moves successive filled cases onto a sealing section where each
case is closed and sealed.
[0018] Yet another object of the invention is the provision of a
continuous operation of packing articles into cases, removing the
packed cases onto a closure section where the case flaps are moved
into sealed positions.
SUMMARY OF THE INVENTION
[0019] The invention is directed to a packer which includes a
delivery for moving articles into a pick up position and a
take-away for removing cases filled with the articles. A plate is
located between the delivery and the take-away and is arranged to
rotate about a single axis. The plate is operative to move
sequentially the cases into a deposit or release position for
receiving the article from the pick up position and to move the
cases to the take-away. A rotating tower which carries the plate is
supported by a frame member.
[0020] Pickup and grid heads are carried by the tower for movement
about the axis and for relative vertical movement. A cam is carried
by the frame and is operative to control pickup and grid heads
through their relative vertical movements.
[0021] A third delivery is provided for moving the case to a
dispensing position. The third delivery includes a rotating belt
and a dispenser. The belt is operative to move the cases to the
dispensing position where they are held and released in timed
sequence onto the rotating plate. A plurality of radially spaced
pins secured with the upper surface of the plate engage and
circumferentially locate the cases on the plate. The tower includes
a support frame which acts to support the plate. An adjusting
member which is carried by the tower is provided for adjusting the
plate circumferentially relative to the support frame and pickup
and grid heads. Preferably the adjusting member is a rack and
pinion arrangement.
[0022] Arcuate inner and outer guide rails are positioned above and
adjacent the edges of the plate. The guide rails are operative to
engage and individually position each case radially on the plate
during movement toward and through the deposit position. The guide
rails are adjustably mounted with the frame. Adjustment of the
guide rails allows the apparatus to accommodate different case
sizes.
[0023] An apparatus for transferring articles which includes a
frame which supports a tower for rotation about a single axis. The
tower carries a plurality of paired grid and pickup heads for
vertical and rotational movement between a pick up and a release or
deposit position. A circular plate is carried by the tower for
movement about the tower and through the deposit position.
[0024] A first conveyor is provided for moving articles into a pick
up position adjacent the plate in the form of article slugs. A
second conveyor is provided for moving the cases sequentially onto
the plate.
[0025] The paired grid and pickup heads are controlled to move onto
and to the pick up of a slug of the articles when moving through
the pick up position to then move to the deposit position to
deposit the slug of articles into a case when both the case and the
pickup and guide grids are moving through the deposit or release
position.
[0026] A third conveyor is provided to receive and remove the
filled cases away from the plate.
[0027] A plurality of positioning pins carried by the plate in
spaced circumferential positions and radially spaced from the axis.
The pins are adapted to circumferentially position the cases during
movement on the plate. An adjusting member is provided for
circumferentially adjusting the positioning pins relative to the
pickup and grid heads.
[0028] Inner and outer guide rails are provided and are carried by
the frame in radially spaced positions above the plate. Adjustable
mounting members secure the guide rails in radially adjustable
positions.
[0029] A packer apparatus comprising a frame carrying a rotating
plate which is adapted to receive successive cases. Each of the
cases includes front, rear and side flaps which are in folded
position adjacent vertical sides of the case. The plate moves the
cases through a deposit position and a removal position.
[0030] Pickup and grid heads which are carried by the frame are
moved along vertical and circular paths between a lower position to
deposit or release a slug of articles into each case as it passes
through the deposit ore release position. The apparatus includes
flap separators which are carried by the frame and are operative to
move to separate and lift the flaps of the case during movement of
the pickup and grid heads vertically away from the lower release
position.
[0031] Positioning members are provided to fold down and hold the
front and rear flaps from their lifted position as the filled cases
are moved from the deposit position and into a take-away or removal
position.
[0032] The separators are pivotally mounted with the grid head. A
control mechanism which is carried by the pickup and grid heads is
operative to locate each separator in selective positions relative
to the vertical sides of the case during movement of the pickup and
grid heads which allows the separators to first separate the flaps
and secondly to elevate the front and rear flaps. The control
mechanism comprises a cam carried by the pickup head and a spring
carried by the grid head.
[0033] The positioning members include a positioning rail arranged
adjacent the removal position which acts to fold said front flap
down. The positioning members also include a rotating positioning
disk which is operative to engage and fold down the rear flap as
the carton moves through the removal position.
[0034] Case sealing apparatus is located over the removal conveyor
adjacent the removal position. The sealing apparatus includes guide
and support rails which are arranged adjacent the removal conveyor.
The guide and support rails include a support zone and a
positioning zone. The sealing apparatus also includes adhesive
applicators which apply adhesive onto the side flaps as they are
supported by the guide and support rails in the support zone. The
guide and support rails are operative to elevate the side flaps of
the case in the positioning zone. The case sealing apparatus
includes side flaps depressing arms which engage the elevated side
flaps leaving the positioning zone and urge them into a closed
position. The case sealing apparatus also includes a press zone
which is located over the removal conveyor adjacent the positioning
zone, the sealing apparatus acts to press and hold down the side
flaps in position against the front and rear flaps until the
adhesive secures them in position. The sealing apparatus is
preferably an elongated flexible weight.
[0035] The invention further includes the method of moving pickup
and grid heads in an article handling machine to include the steps
of providing a pickup station and continuously moving articles into
the pickup station; providing a circular plate and rotating the
plate about an axis; rotating said pickup and grid heads in a
circular path about the axis, through the pickup station and
causing the pickup heads to also move in a generally straight line
during rotational movement through the pickup station.
DESCRIPTION OF THE DRAWINGS
[0036] The construction designed to carry out the invention will
hereinafter be described, together with other features thereof.
[0037] The invention will be more readily understood from a reading
of the following specification and by reference to the accompanying
drawings forming a part thereof, wherein an example of the
invention is shown and wherein:
[0038] FIG. 1 is a perspective view of a circular, continuous
motion packing and depacking apparatus;
[0039] FIG. 2 is a top plan sectional view of the apparatus of FIG.
1 taken generally along line 2-2;
[0040] FIG. 3 is a top plan sectional view similar to FIG. 2
showing case feeding, removing and closing apparatus;
[0041] FIG. 4 is an exploded sectional view showing the plate
adjusting apparatus;
[0042] FIG. 5A is a perspective view of a pickup head support and
actuator mechanism;
[0043] FIG. 5B is a perspective view illustrating the translatory
drive for the pickup and grid heads which controls the oscillating
motion of the heads over the pick up section allowing the straight
line motion of the heads;
[0044] FIG. 5C is a top plan view illustrating the translatory
drive for the pick up section;
[0045] FIG. 5D is a schematic view illustrating a closed cycle path
of the pickup and grid heads wherein their circular motion is
compounded to include a straight line motion;
[0046] FIG. 5E is a simplified side elevational view illustrating
the circular turret, the head support frames and the circular cam
tracks for controlling the vertical movement of the pickup and grid
heads;
[0047] FIG. 6A is an exploded sectional perspective of the flap
separator;
[0048] FIG. 6B is similar to FIG. 6A showing the separator in its
lowermost position relative to the case;
[0049] FIG. 6C is similar to FIG. 6A showing the separator in
position behind the flap prior to separation;
[0050] FIG. 6D is similar to FIG. 6A showing the separator raising
the end flap after separation;
[0051] FIG. 7A is an exploded sectional perspective view showing
the rear flap fold down positioning disk;
[0052] FIG. 7B is similar to FIG. 7A showing the positioning disk
in engagement with the rear flap;
[0053] FIG. 8A is an exploded view of the entry of the sealing
apparatus with the positioning rail folding down the raised front
flap;
[0054] FIG. 8B is a progression of FIG. 8A showing the front and
rear flaps being moved to and held in the closed position;
[0055] FIG. 8C is similar to FIG. 8 showing flap control arms and
the adhesive applying members;
[0056] FIG. 8D is a progression of FIG. 8C showing the top flap
closing structure;
[0057] FIG. 8E is a progression to FIG. 8D showing the retaining
structure for holding the closed flaps in position allowing the
adhesive to set.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0058] Referring now to the drawings, the invention will be
described in more detail. As can best be seen in FIG. 1, apparatus
and method for packing articles into cases, or depacking articles
from cases, in a simple, continuous circular motion, is illustrated
generally as A. The apparatus includes a rotating turret B which
rotates about a single vertical axis Y, and a stationary central
column 10. A plurality of article transfer arms 20 are carried by
the rotating turret, as can best be seen in FIGS. 2 and 5E. A
plurality of reciprocating grid heads 22 and article pick up heads
24, are carried on the transfer arms by way of support frames 12.
The pickup and grid heads themselves may be of conventional
construction to form no part of the instant invention. They,
therefore, will not be further described. FIGS. 1, 2 and 3
illustrate the embodiment of the invention in the form of a case
packing apparatus and method in which articles are packed into
cases. In the illustrated embodiment, the pickup and grid heads are
slidably carried on the transfer arms and reciprocate in a linear
motion for picking up the articles at a pickup station, designated
generally as 16. The invention can also be utilized in the form of
a case depacking apparatus and method wherein the articles are
removed from cases. Presently, and because the inventive aspects of
the pickup and deposit motions are generally the same whether the
machine is used for packing or depacking, the invention will be
described in relation to the case packing embodiment of the
apparatus and method shown in FIGS. 1 and 2.
[0059] An article feeder, designated generally as C, is illustrated
for conveying articles 13 to pick up station 16. Article feeder C
may be a slug feeder having a metering section, as disclosed in
U.S. Pat. No. 5,797,249 ("the '249 patent"), incorporated herein by
reference. The slug metering section receives a continuous flow of
articles 13 which are conveyed from a laner section. The metering
section breaks the articles up into a desired number of articles
having a pattern which corresponds to the pattern of the case into
which the articles are to be packed. The articles are picked up at
pickup station 16 and deposited into empty cases 28 at a release or
deposit station, designated generally as 18, which constitutes a
case packing station in the embodiment of FIGS. 1 and 2. For this
purpose, a case indexing conveyor, designated generally as D, is
disposed below slug feeder C to provide a continuous flow of
indexed cases 28 to release station 18 where the articles are
generally deposited in the case. The case conveyor includes a
dispensing section for sequentially moving the cases onto plate 26.
Pins 27 act to position for movement the indexed cases about turret
B with plate 26. Dispensing section 30 includes bar 32 which is
operated in sequence with shaft 10 to release in timed sequence
cases 28 onto plate 26 which inturn moves the case to release or
deposit station 18. The configuration of the plate is circular.
When used as a case depacker, the article feeder constitutes an
indexing case conveyor which conveys indexed cases of empty
articles for removal.
[0060] As can best be seen in FIG. 5E, turret B includes a top
frame member 34 and bottom frame member 36 between which transfer
arms 20 are affixed. Transfer arms 20, in the illustrated form of
steel beams, are circumferentially spaced around the frame members
to generally define the turret B which rotates in circular path 39
(FIG. 2). As illustrated, there are ten transfer arms spaced around
the turret. The number of arms may vary depending on the
application. Turret B is constructed and driven in the manner
described in detail in co-pending application 09/418,619 Ser. No.
afore referred to. Turret B is rotated clockwise as illustrated.
The turret may be also be rotated counter clockwise if the
apparatus is designed that way. A gear motor may be utilized to
drive case conveyor D through a suitable belt drive arrangement, so
that the turret and transfer operation are synchronized with the
conveying of indexed cases to be packed or depacked.
[0061] Within the interior of turret B, as defined by the turret
cage of transfer arms 20, is stationary central column or support
40 supported by the column 10. Affixed to stationary support 40 is
a cam support drum having a plurality of vertical braces which are
affixed to the stationary support 40 in suitable manner. Central
column 10 extends through a clearance hole formed in top and bottom
turret plates 34, 36. Circular cams 42, 44 encircle and are affixed
to the braces and form part of a vertical position mechanism E that
controls the vertical positions of pickup and grid heads 24, 22.
The drum braces, cams, intermediate plates, and central column may
be affixed together in any suitable manner, such as conventional
bolts, to define a stationary structure about which turret B
rotates. Other suitable means of reinforcing and securing the
operative construction together may be utilized, such as welding
and the like, as will be apparent to a mechanic of average skill in
the art.
[0062] Vertical motion mechanism E preferably includes circular
cams 42 and 44 carried to control the positions of pickup heads 24
and grid heads 22, as can best be seen in FIGS. 5E. For this
purpose, cam rollers 42a and 44a are carried respectively by pickup
and grid heads 24, 22 which ride on cams 42 and 44, respectively.
Pickup heads 24 and grid heads 22 slide on transfer arms 20 by
means of guide bearings which carries support frame 12 on which
pickup and grid heads 22 and 24 are pivotally and slidably carried.
Cam rollers 42a and 44a are secured to the guide bearing carried by
support frames 12. In this manner, the vertical positions of the
pickup head 24 and grid head 22 are controlled as the cam rollers
follow circular cams 42 and 44 to provide the desired operational
positioning. In essence, a sequencing and control of the vertical
positions of pickup heads 24 and grid heads 22 may be provided like
that disclosed in the incorporated '249 patent or co-pending
application Ser. No. 09/418,619 in regard to the picking up and
releasing steps of operation.
[0063] As can best be seen in FIG. 5D, pickup heads 24 and grid
heads 22 move in a closed cyclic path, designated as 60 as they are
rotated by turret B. Along pick up station, the heads move over the
articles fed in by article feeder C. For this purpose, the circular
motion of the pickup and grid heads is compounded by pivoting the
pickup heads about axis 68 converting their movement to a
straight-line motion over this section so that the pickup heads
reliably align with and pick up the articles over the pickup
station 16. For this purpose, a motion converter, designated
generally as F is best seen in FIGS. 5B and C, is provided for
causing pickup heads 24 and grid heads 22 (or pickup heads 24
alone) to move in the straight-line motion through the pick up
section 16 during the time the pickup heads descend and grip the
articles for transfer to the release station. The pick up section
16 is measured over a pre-determined arc of rotation of turret B
which, in the illustrated embodiment, is an arc of about 30 degrees
of turret rotation. The 30 degrees includes 15 degrees either side
of a radius line 66 perpendicular to a tangent at the pickup
station.
[0064] Motion converter F, as can best be seen in FIGS. 5A-5D, will
now be described in more detail. First, it is noted that pickup
head frame 24a, which mounts the pickup fingers, is slidably
carried in a horizontal frame on pickup head support frame 12 and
functions about a swivel or pivotal axis 68. Grid head frame 22a is
likewise slidably supported on a grid head support frame 12. Each
support frame 12 includes a bottom ledge and an upper ledge between
which a curved bearing member 44 of head frame 22a, 24a is
sandwiched on both sides of the frame. Preferably curved bearing 44
is constructed of a suitable bearing material such as a high
molecular weight plastic. By this means, the pickup and grid heads
are allowed to slide in a combined swivel and translatory motion
within their respective support frames. Thus, in operation, the
pickup heads (and grid heads) rotate about turret axis Y as they
are carried by turret B; and pivot about a swivel pivot axis 68
during circular motion. Motion converter F further includes a
plurality of connector mechanisms, connected between the rotating
turret and an associated set of pickup and grid heads to control
movement of the pickup and grid heads so they move in a
straight-line motion along pick up section 16. As can best be seen
in FIG. 5B, connector mechanism F includes a first linkage
arrangement 92 connected to one side of the pickup head and grid
head; and a second linkage arrangement 94 connected to an opposing
side of the pickup head and grid head. By this means, the heads are
moved in unison. The linkage arrangements include rotary-motion
transfer cam shafts 92a, 94a which are carried vertically between
top and bottom turret plates 34 and 36. Upper arm links 92b and 94b
are received about upper ends of the cam shafts and are secured
thereto against rotation. In this manner, actuation of upper arm
links 92b, 94b causes rotation of the cam shafts. First and second
lower arm links 92c, 94c, and 92d, 94d are slidably carried on cam
shaft 92 and 94, respectively. First lower arm links 92c, 94c are
secured to opposing sides of pickup heads 24 and second lower arm
links 92d, 94d are connected to grid heads 22. Cam followers 92e
and 94e carried by the upper arm links 92b, 94b follow a cam plate
which is affixed to the top of stationary column 40. The cam
followers ride in a cam groove and follow the cam plate to actuate
the first and second lower arm links to move the pickup heads and
grid heads in a combination swivel and translatory motion to
maintain the pickup and grid heads in a straight-line motion over
the pick up section 16 for reliable pick up of articles 13. The cam
plate may be stationarily mounted on the central support.
Basically, the heads are maintained in a straight-line motion over
a linear distance that corresponds to a predetermined arc of about
30 degrees of turret rotation. Other means of providing the
combination motion of the pickup and/or grid heads may also be used
other than illustrated mechanism F. For example, use of position
sensors and control through an electronic gear motor may be had, or
hydraulic control systems, as well as other mechanical
arrangements.
[0065] Referring now to FIGS. 1 and 5A. An unlatching device 14 is
likewise carried by support frame 12, whose operation will not be
described hereinafter. The unlatching drive is described in detail
in earlier filed co-pending application Ser. No. 09/418,619.
[0066] In operation, at release station 18 the unlatching device
actuates the gripping members of pickup head 24 to release articles
13 into cases 28.
[0067] Thus, it can be seen that a highly advantageous apparatus
and method for a continuous case packing and depacking machine can
be had according to the present invention wherein a small foot
print, turret may be rotated continuously to pick up and release
articles at a high speed while requiring only a small floor area.
The transfer of articles occurs at high speeds yet the motion is
balanced and smooth since it is basically circular. The dynamic
forces produced by orbital machines having straight runs and radial
ends is avoided. By converting the motion of the pickup heads from
circular to translational when the articles are picked up, reliable
pick up of the scrambled articles is provided for reliable
insertion into a partitioned case. The case packing may occur over
an arcuate section of the conveyor immediately after pick up by
using congruent case and pick up head paths at increased
speeds.
[0068] Turning to FIGS. 3, 4 and 5E it can be seen secure with the
rotating turret B and adjacent to lower frame member 36 there is
provided a circular support frame 38. Support frame 38 is provided
with a circumferential shelf in the form of radically extending
fingers 38' which extend outwardly to substantially align with
support frames 12.
[0069] Plate 26, is formed with a central opening 26' which is of a
size to fit over column 10 and frame member 36. Plate 26 is
positioned over column 10 to be freely supported by fingers 38' as
best seen in FIGS. 4 and 5E.
[0070] An adjusting device 50, is provided for adjusting the
circumferential position of plate 26, on shelf 38' relative to the
fixed circumferential position of heads 22, 24. The adjusting
device includes a ratchet wheel 51 which engages with teeth 52
secured with plate 26. Actuation of the handle member rotates wheel
51 which causes plate 26 to slide in a circumferential direction
relative to column 10 and support frame 38.
[0071] This movement constitutes a circumferential adjustment of
the position of heads 22, 24 relative to pins 27 of plate 26. This
adjustment is necessary to accommodate a change in article and case
sizes. Ratchet mechanism 46 also functions to maintain plate 26 and
support frame 38 in fixed relative positions during operation of
the packing device.
[0072] Turning to FIG. 3, case conveyor D, which may comprise an
endless belt, operates to continuously urge cases 28 to dispensing
section 30. Dispensing bar 32 is positioned across the path of the
oncoming cases. A control, driven in sequence with the main drive,
acts to sequentially pivot bar 32 downward which releases
successive cases onto guide platform 33 and onto plate 26.
[0073] Arranged above and adjacent the outer and inner peripheries
of plate 26 are guide rails 46 and 48. Inner guide rail 48 is
pivoted at it forward end 49 and generally urged outwardly. This
allows guide rail 48 always be in contact with a case 28 and to
urge the cases against outr rail 46. Outer guide rail 46 is locked
in position at one end with platform 33 and adjacent its opposite
end is held by adjustable mount 47.
[0074] In the event of a change in article and case size guide rail
47 is adjusted inwardly, adjusting the radial position of the cases
in the release or deposit station relative to heads 22, 24.
[0075] In operation, as a case is pushed from dispensing section 30
onto plate 26, a pin 26 engages with its rear end circumferentially
locating the case relative to heads 22, 24. Further rotation of
plate 26 moves the case into contact with guide rails 46, 48 which
act to radially and longitudinally adjust the case relative to
heads 22, 24. In this manner the case is controlled to be in proper
position for the deposit of articles therein at the release
station.
[0076] When an article size change is called for, heads 22, 24 are
exchanged to accommodate the selected size, either smaller or
larger. Pins 27 of plate 26 are then circumferentially adjusted by
ratchet 46 and rail 46 is radially adjusted so that the new size
case will be properly located relative to the re-sized heads in the
release position.
[0077] Each case 28 includes a bottom, opposed sides, opposed ends
and an open top. Front, rear and side flaps 28a, 28b are in a down
position adjacent the case sides and are interconnected and held in
this position by a pair of tabs 29 as best shown in FIGS. 1 and
6B-6D. Tabs 29 are located at opposed corners and insure that the
flaps do not interfere with the operation of heads 22, 24 during
the deposit of the articles into the cases as they pass through the
release station.
[0078] The device thus far described operates in the following
manner. Articles 13 are supplied to the pickup station 16 and
grouped into a slug of articles. Empty cases are moved to the
dispensing section 30 by conveyor D and are retained there by bar
32. Turret B rotates about axis Y carrying heads 22, 24 and plate
26 through pickup station 16, and release 18. The heads are carried
on a rotary path and simultaneously with this rotary motion through
a vertical motion and an oscillating motion.
[0079] As the guide and pickup heads move through the pickup
station the pickup heads are controlled to pick up a slug of
articles. In sequence with this action bar 32 releases a case onto
plate 26 where it is positioned in alignment with heads 22, 24. As
the heads move through the deposit or release position, the heads
move vertically to deposit the articles into the case.
[0080] A separating assembly G for separating or cutting tabs 29
and for elevating the front and rear flaps is provided at opposed
corners of heads 22, 24, see FIG. 5A. Each separator includes an
arm 54 pivotally mounted with grid head 22 and urged toward an end
of case 28 by spring 56. Attached to the lower end of each arm 54
is a positioning blade 58. The upper end of arm 54 carries cam
55.
[0081] Pickup head 24 carries a pair of downwardly depending arms
60 each formed to include a cam surface 61. Each arm 60 is
stationarily located in a position aligned with arm 54.
[0082] As shown in FIGS. 5A, 6B, C and D, as grid head 24 moves
into its lowermost position in the release station, blade 58 slides
down the outer end of case 28 into a position beneath flap 28a.
Spring 56 maintains blade 58 in continued contact with the case
end. After the articles are released into the case, grid head 22
begins its upward motion causing blade 58 to move up and beneath
flap 28a which acts to sever tab 29 and release flaps 28a and 28b
for pivotal movement. Further relative movement between grid head
22 and pickup head 24 brings cam 61 of arm 60 to engage with cam 55
causing arm 54 to pivot moving blade 58, which is now behind the
associated flap 28b, away from the end of case 28 causing end flap
28b to be pivoted upward. See FIG. 6D.
[0083] It is understood that an identical action occurs
simultaneously at each of the diagonally opposed corners of case
28.
[0084] Turning now to FIGS. 3, 7A, 7B, take away or removal station
70 is provided to receive filled cases 28 with their front and rear
flaps raised from the release station 18. The removal station
includes a pair of end flap positioning members. A first of the
positioning members comprises a rotating plate or disc 72 located
adjacent the exit area of the release station. Plate or disc 72 is
carried by shaft 74 which is rotated in timed sequence with turret
B and plate 26. Disc 72 is vertically adjustable along shaft 74 to
accommodate different size articles and cases.
[0085] Plate 72 includes a wedge-shaped outer edge 80 which, as
shown in FIGS. 7A and 7B, increases in length from front to rear.
Plate 72 is also substantially wedge-shaped with its periphery
comprising about 1/8 of the circumferential arc along which outer
edge 80 moves.
[0086] An adjustment assembly 79 secures plate 72 with shaft 74 in
a desired vertical position.
[0087] In operation, case 28 moves from release or deposit station
18 into take away station 70 with its rear flap in the slightly
raised position brought about by positioning blade 58. As the case
moves into the takeaway station the rear flap 28a is engaged by the
forward end of disc 72 and through rotation of the disc is moved to
a substantially closed position by edge 80. Because disc 72 is
moving faster than case 28 is moving, it passes over the case
pushing the rear flap into the closed position while the case is
being directed to the take away station 70.
[0088] Simultaneously with this action the forward end of case 28
with the forward flap 28b, also slightly raised, moves under a
second positioning member which comprises rail 76 which engages and
folds down the forward flap. See FIGS. 7A, B and FIG. 8A. Further
movement of case 28 positions folded down rear flap under rail
76.
[0089] Turning now to FIGS. 3, 8A-D, guide 78, is connected with
frame 92 adjacent the receiving end of takeaway or removal conveyor
90 and extends across plate 26 at removal station 70. Guide 78,
which is aligned with the inner rail 82' of takeaway conveyor 90,
acts to deflect each case 28 onto the takeaway conveyor. During the
time in which guide 78 is deflecting the case onto the conveyor,
positioning rail 76, 76' is positioned to hold down front and rear
flaps 28b.
[0090] As case 28 continues to be moved by conveyor 90 into sealing
station 80 flaps 28b continue to be held down by positioning rail
extension 76'.
[0091] Sealing station 80 includes a pair of guide and support
rails arranged on each side of conveyor 90 and identified as 86,
86'. The guide and support rails included forward extensions which
are attached at their forward ends with frame 93. Forward
extensions 82, 82' are ramped upward to merge with the guide and
support rails which extend along a run which is horizontal and
substantially parallel with the height of case 28 and indicated at
83, 83'. Rail 82' begins in a position adjacent the end of guide 78
and extends parallel with the inner side of conveyor 90 up to
horizontal run 83' while rail 82 extends an equal distance along
the opposite side of conveyor 90.
[0092] The guide and support rails comprise a pair of parallel
rails spaced about three inches apart or of a width sufficient to
support side flaps 28a in a substantially fixed position. Other
arrangements such as a flat sheet could be used along the
horizontal run.
[0093] An upper guide assembly comprising an upper rails 84, 84'
which are positioned slightly above guide and support rails 86, 86'
act to position each side flap 28b onto the guide and support rails
during movement of the case through horizontal run 83, 83'.
[0094] A plurality of adhesive applicators are located over the
horizontal run 83 in position to apply adhesive onto side flaps 28b
as case 28 is moved through horizontal run 83.
[0095] The sealing operation, thus far described, operates in the
following manner. Guide 78 deflects filled case 28 onto conveyor 90
with front and rear flaps 28b held in the closed position by rail
76. As the case is moved away from plate 26 side flaps 28b are
engaged by extensions 82, 82' of the guide and support rails and
brought into a substantially horizontal position as the case is
moved along horizontal run 83, 83'. Simultaneously upper guide
rails 84, 84' engage with the upper sides of side flaps 28b to
maintain them in a substantially fixed position during this
movement through the horizontal run.
[0096] Substantially simultaneously with the positioning of the
side flaps in the horizontal position, adhesive applicators 96 are
actuated to apply adhesive onto the upwardly surface of side flaps
28b.
[0097] Immediately adjacent the downstream end of horizontal run
83, 83' there is provided a pair of inwardly and upwardly directed
wedges 88. Wedges 88 are designed to engage beneath the outwardly
extending side flaps as they leave harizontal runs 83, 83' and urge
them upwardly into a substantially vertical position during
continued movement of the case and best shown in FIG. 8D.
[0098] A pair of spring biased arms 95 are pivotally mounted on
supports 94' carried by rails 86, 86'. Arms 95 are arranged to be
resiliently urged into a downwardly and inwardly directed
position.
[0099] Arranged adjacent and slightly over the downstream ends of
arms 95 is the sealing apparatus which comprises a chain 96 carried
by support arm 100 and frame 93 in a position over takeaway
conveyor 90. Secured with the under side of chain 96 is a flexible
pad 98.
[0100] In operation case 28, with adhesive applied to opposed ends
of flaps 28b, is moved from horizontal run 83 and over wedges 88.
As the case advances, wedges 88 engage the under sides of flaps 28b
and guide them upwardly into a substantially vertical position. At
this point the case has advanced into position where depressing
arms 95 adjacent supports 94' engage with the outer sides of the
vertically positioned flaps. Continued movement of the case causes
arms 95 to push on wedge flaps 28b into the closed position as best
seen in FIG. 8D.
[0101] Immediately following the closing action brought about by
arms 95, case 28 moves beneath pad 98 of the sealing apparatus. Due
to the weight of chain 96, flaps 28b are firmly urged against end
flaps 28a and held in this position during movement through the
sealing apparatus. The duration of the movement beneath chain 96 is
dependent upon the time required for the adhesive to set and seal
the flaps in the closed position.
[0102] Sealed cases carried on conveyor 90 emerge from the sealing
station 80 and are directed for further distribution
[0103] While a preferred embodiment of the invention has been
described using specific terms, such description is for
illustrative purposes only, and it is to be understood that changes
and variations may be made without departing from the spirit or
scope of the following claims.
* * * * *