U.S. patent application number 11/323184 was filed with the patent office on 2006-07-06 for container guide for packaging machine.
Invention is credited to John W. III Cash, Shawn A. Murray.
Application Number | 20060144015 11/323184 |
Document ID | / |
Family ID | 36676934 |
Filed Date | 2006-07-06 |
United States Patent
Application |
20060144015 |
Kind Code |
A1 |
Cash; John W. III ; et
al. |
July 6, 2006 |
Container guide for packaging machine
Abstract
A container guide for preventing bottles or other containers
from overturning as the bottles are loaded into cartons includes
guide bars mounted above a container conveyor and in parallel
alignment with lane dividers for directing bottles from the
container conveyor and into the cartons, which are conveyed on a
carton conveyor. The guide bars support the upper portions of the
bottles as the bottles cross a potentially uneven transition region
extending between the two conveyors and beyond the extent of the
lane dividers. Each guide bar has a guiding edge for supporting the
upper portion of the bottles, which may be tapered or shouldered
thereby requiring the guiding edge to be offset somewhat from the
lane dividers. Each guide bar also has an outfeed end that is
relatively thinner than its infeed end to facilitate the outfeed
end clearing the upper edges of the end flaps of the cartons.
Inventors: |
Cash; John W. III; (Dallas,
GA) ; Murray; Shawn A.; (Marietta, GA) |
Correspondence
Address: |
PARKS KNOWLTON LLC
1117 PERIMETER CENTER WEST
SUITE W307
ATLANTA
GA
30338
US
|
Family ID: |
36676934 |
Appl. No.: |
11/323184 |
Filed: |
December 30, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60640364 |
Dec 30, 2004 |
|
|
|
Current U.S.
Class: |
53/251 ;
198/836.1 |
Current CPC
Class: |
B65B 21/04 20130101;
B65G 2201/0244 20130101; B65G 21/2072 20130101 |
Class at
Publication: |
053/251 ;
198/836.1 |
International
Class: |
B65B 5/00 20060101
B65B005/00 |
Claims
1. An article guide for preventing articles from overturning as
said articles are loaded into a carton by a packaging machine, the
packaging machine including a carton conveyor for conveying cartons
along a carton path in a direction of machine flow, an article
conveyor for transporting said articles along an article path, and
at least one lane defined by a pair of lane dividers that are
disposed above said article conveyor for directing said articles
from said article conveyor toward said carton conveyor, the article
guide comprising: a guide bar mounted above said article conveyor,
said guide bar comprising: an outfeed end that extends at least
partially across a transition region between an end of one of said
lanes and an open end of one of said cartons, said outfeed end
including a support surface that guides an upper portion of each of
said articles as said article crosses over said transition
region.
2. The article guide of claim 1, wherein said guide bar extends
beyond said end of said one of said lanes.
3. The article guide of claim 1, wherein said transition region
comprises the region in which an article leaving said at least one
lane loses the support of one or both lane dividers before entering
a carton.
4. The article guide of claim 1, wherein the support surface of
said guide bar is offset from at least one of said pair of lane
dividers.
5. The article guide of claim 1, wherein said guide bar is
substantially parallel to at least one of said pair of lane
dividers.
6. The article guide of claim 1, wherein said outfeed end of said
guide bar comprises a distal edge that is angled so as to be
generally parallel to the direction of machine flow of said carton
conveyor.
7. The article guide of claim 1, wherein said guide bar further
comprises an infeed end, and the thickness of said infeed end is
substantially greater than the thickness of said outfeed end.
8. The article guide of claim 7, wherein said guide bar is
adjustably mounted so as to repositionable to guide articles of
varying sizes and shapes.
9. The packaging machine of claim 1, wherein said open end of said
carton is defined at least in part by a fold line hingedly
connecting an end flap of said carton and a carton wall.
10. A packaging machine for loading articles into cartons, each
carton having an open end, and each article having a base and a
relatively smaller upper portion, comprising: a carton conveyor for
conveying cartons along a carton path in a direction of machine
flow; an article conveyor for transporting said articles along an
article path; at least one lane defined by a pair of lane dividers
that are disposed above said article conveyor for directing said
articles from said article conveyor toward said carton conveyor; a
transition region, comprising the area between an outfeed end of
one of said pair of lane dividers and an adjacent edge of said open
end of said carton; and an article guide for supporting said upper
portion of each article as said article moves at least partially
across said transition region and toward one of said cartons
conveyed on said carton conveyor, said article guide comprising: a
guide bar mounted above said article conveyor, said guide bar
comprising an outfeed end that extends at least partially across
said transition region, said outfeed end including a support
surface that guides an upper portion of each of said articles as
said article crosses over said transition region.
11. The packaging machine of claim 10, wherein said edge of said
open end of said carton is defined at least in part by a fold line
hingedly connecting an end flap of said carton and a carton
wall.
12. The packaging machine of claim 10, wherein said guide bar is
substantially parallel to at least one of said pair of lane
dividers.
13. The packaging machine of claim 12, wherein said guide bar is
offset with respect to said at least one of said pair of lane
dividers
14. The packaging machine of claim 11, wherein said carton wall
rests on the surface of the carton conveyor.
15. An article conveyor for transporting said articles along an
article path, said article conveyor comprising: a conveying
surface; at least one lane defined by a pair of lane dividers that
are disposed over said conveying surface; a transition region
including the area between an outfeed end of one of said pair of
lane dividers and the adjacent edge of said conveying surface; and
a guide bar mounted above said conveying surface, said guide bar
comprising: an outfeed end that extends beyond said outfeed end of
said one of said pair of lane dividers and at least partially
across said transition region, said outfeed end of said guide bar
including a support surface that guides an upper portion of each of
said articles as said article moves at least partially across said
transition region.
Description
RELATED APPLICATION
[0001] This application claims the benefit of the filing of
Provisional Patent Application Ser. No. 60/640,364, entitled
"Container Guide for Packaging Machine" and filed on Dec. 30, 2004,
the entirety of which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates generally to machines for loading
containers into cartons or other packages, and more particularly,
to an article guide that prevents containers from overturning
during the carton loading process.
BACKGROUND OF THE INVENTION
[0003] Automatic packaging machines are commonly configured to
rapidly load one or more lanes of cylindrical containers such as
bottles, into cartons to facilitate distribution and ultimate use
of the product within the containers. For example, certain
packaging machines include article conveyors that convey bottles
along multiple lanes in which the bottles are grouped according to
the package configuration. Then the bottles are directed off of the
article conveyor and into one or both ends of sleeve-type
paperboard cartons. Such automatic packaging machines operate at
high speeds to maximize the efficiency of the packaging operation.
Furthermore, the bottles must be pushed into the carton with
sufficient force to overcome the friction caused by the top and
base of each bottle contacting the respective upper and lower inner
surfaces of the carton, as only very small gaps therebetween can be
tolerated to yield a snug package.
[0004] Unfortunately, propelling bottles forward at high speeds
into a relatively snug carton yields an unacceptably high
probability that bottles will frequently overturn. This is
particularly the case when the bottles are inherently relatively
unstable. For example, Polyethylene Terephthalate (PET) bottles
that commonly have petaloid bases, or bottles having a relatively
high ratio of height to diameter, are inherently relatively
unstable. Overturned bottles are costly in time and resources. The
entire machine may have to be shut down to clear overturned
bottles, packages may be improperly loaded or damaged, and bottles
may rupture and spill their contents. Ruptured bottles often
contain sugary beverages that are difficult to clean from the
packaging machine components and surroundings.
[0005] Bottles frequently overturn at the critical transition
region between the angled outfeed ends of lane dividers that guide
the bottles along conveyor surface of an article conveyor and into
the opening of a carton on a carton conveyor. Each bottle on the
article conveyor surface is conveyed along an article path in the
general direction of travel or machine flow of the product conveyor
until the bottle reaches the angled lane dividers. The lane
dividers are typically angled with respect to the direction of
travel or machine flow of the continuously moving article conveyor
to direct the bottles toward, and over, an edge of the article
conveyor. The bottles move from the outfeed end of a lane, over a
transition region, and into a carton. The transition region
includes the area between the end of a lane and an adjacent open
end of a carton. The carton typically moves on a carton conveyor at
a comparable pace as the article conveyor. As grouper lugs on the
product conveyor push each group of bottles forward, the angled
lane dividers support and redirect the bottles off of the article
conveyor and into the carton. In the transition region, each bottle
travels beyond the extent of one or both of the adjacent lane
dividers, which cannot extend across the transition region without
interfering with the passage of the minor flaps of the cartons on
the carton conveyor. As it crosses the transition region, each
bottle is propelled by the force of other bottles, but is no longer
guided on both sides by the adjacent lane dividers that define the
lane. During this interval, maneuvering small gaps and differences
in elevation between any of the conveyors, the carton surface, or
the transition region can cause a bottle (such as the first bottle
in the first row that is loaded into each carton) to overturn.
[0006] Previous attempts at addressing the problem of overturning
bottles require tight tolerances or frequent adjustment and
maintenance, as the attempts have focused on minimizing gaps and
minimizing variations in elevation between the various conveyors,
carton surfaces, and the transition region, or on stabilizing
mechanisms such as brushes that apply pressure to top flaps or
walls of the carton. These solutions, although time consuming and
resource intensive, fail to eliminate the problem of bottles
overturning.
[0007] Thus, there is a need for a solution that reduces the
incidence of containers overturning in high-speed packaging
machines.
SUMMARY OF THE INVENTION
[0008] The various embodiments of the present invention overcome
the shortcomings of the prior art by providing a packaging machine
that implements systems and methods for guiding a container or
other article so as to prevent the container from overturning as
the container is conveyed from an article conveyor and loaded into
a carton or other package. The embodiments described illustrate the
various features of an exemplary container guidance system that can
be implemented in a packaging machine for loading containers into
cartons or similar packages.
[0009] When erected, the exemplary carton comprises a top wall, a
pair of opposed side walls connected to opposing side edges of the
top wall, at least one end wall interconnecting the side walls, and
a bottom wall interconnecting respective lower edges of the side
walls and the end walls. During the container loading process, the
carton may be partially erected such that at least one end of the
carton is open.
[0010] Generally, a packaging machine equipped with the article
guide of the present invention includes one or more substantially
rigid guide bars that are each mounted above a lane. The lane
guides products driven on the surface of and by an article
conveyor. In the exemplary embodiments, at least a portion of the
article conveyor is in parallel alignment with a carton conveyor,
and both are simultaneously driven at substantially similar or
complementary speeds. Each guide bar angles toward the carton
conveyor, extends beyond the end of at least one of a pair of
angled lane dividers that define the respective lane, and extends
at least partially across a transition region. The transition
region includes the area between the outfeed end of a lane and the
open end of a carton on the carton conveyor. The transition region
can be small or relatively expansive, depending primarily on the
clearance required to prevent the lane dividers from striking the
flaps of the cartons on the carton conveyor. In general, the
transition region can be defined as the region in which an article
leaving the product conveyor loses the support of one or both lane
dividers that define the lane along which the article travels. The
transition region may include, but is not limited to, a stationary
component of the packaging machine that separates the product and
carton conveyors, or may include a gap between the two
conveyors.
[0011] According to an aspect of the invention, each guide bar can
be mounted to a component of the packaging machine, such as a lane
divider or an overhead boom structure. The mounting position of the
guide bar is at least vertically adjustable to accommodate bottles
of different heights. Each guide bar is substantially parallel to
the angle of the lane dividers, and maybe offset somewhat such that
at least one side of the guide bar is not in vertical alignment
with any surface of any lane divider, to compensate for containers
having caps with smaller diameters than their sides. This offset is
not needed if the articles have constant diameters, e.g., beverage
cans. Preferably, the guide bar is also horizontally adjustably
mounted to facilitate adjustment of the offset distance to
accommodate bottles having various diameters or widths. The infeed
end of the guide bar can extend as far upstream, with respect to
the flow of bottles, as necessary to provide convenient mounting at
some point along its length to a fixed component. It is
advantageous for at least a portion of the proximal edge of the
infeed end of the container guide to be angled, tapered, and/or
rounded to avoid obstructing incoming bottles.
[0012] According to another aspect of the invention, each guide bar
is machined or otherwise shaped such that at least a portion of an
edge of the guide bar provides a support surface that aligns
closely with, and preferably matingly engages a surface of the
upper portion of the bottle, such as the outer surface of a bottle
cap. This portion of the guide bar is herein after referred to as
the guiding edge. The guiding edge is parallel to the direction of
travel of the bottle within the lane, and is preferably vertically
positioned no higher than an upper edge of the carton. The guiding
edge provides support to the upper portion of the bottle until the
bottle has substantially crossed over the transition region and
entered the carton, thereby countering the tendency of the bottle
to overturn as it crosses the transition region.
[0013] According to another aspect of the invention, a distal edge
of the outfeed end of the guide bar is positioned so as to
vertically align with the top of the open end of each carton as the
carton travels through the loading station, and can be angled to be
parallel to the direction of machine flow of the carton
conveyor.
[0014] According to another aspect of the invention, the guide bar
also includes a leading edge opposite the guiding edge. The shape
and configuration of the leading edge enables the guide to avoid
interfering with the passage of the minor side flaps of the carton
as the carton travels through the loading station. In certain
embodiments, at least a portion of a leading edge of the guide bar
is tapered proximal to the outfeed end of the guide bar, and
relative to the guiding edge. In certain other embodiments, the
guide bar is a thin (for example, about 1/4 inch) polygonal,
cylindrical, or tubular rod fashioned from material with sufficient
strength to provide enough support to guide bottles into the
carton. Examples of suitable materials for guide bars include
stainless steel and other ferrous or non-ferrous alloys, or any
other material having yield strength sufficient to resist
deformation.
[0015] Yet another aspect of the invention provides means for each
guide bar to dynamically adjust for guiding and supporting
containers or other articles having varying heights, widths, and
shapes. Examples of means for dynamically adjusting include
spring-loaded or slotted mounting brackets that allow fluctuations
in the elevation and angular orientation of the guide bar with
respect to a horizontal plane defined by the container
conveyor.
[0016] According to another aspect of the invention, the guide bars
may be detachable, adjustable, or interchangeable to be compatible
with various container and package types and configurations.
[0017] The foregoing has broadly outlined some of the aspects and
features of the present invention, which should be construed to be
merely illustrative of various potential applications of the
invention. Other beneficial results can be obtained by applying the
disclosed information in a different manner or by modifying the
disclosed embodiments. Accordingly, other aspects and a more
comprehensive understanding of the invention may be obtained by
referring to the detailed description of the exemplary embodiments
taken in conjunction with the accompanying drawings, in addition to
the scope of the invention defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a plan view of the exemplary embodiment of a blank
for forming a carton of the present invention.
[0019] FIG. 2 is a perspective view of the carton formed from the
blank of FIG. 1.
[0020] FIG. 3 is a plan view of an exemplary guide bar according to
certain of the various embodiments of the container guide
invention.
[0021] FIG. 4 is a side elevation view of the guide bar of FIG.
3.
[0022] FIG. 4b is a end elevation view of the guide bar of FIG.
3
[0023] FIG. 5 is a simplified plan view showing certain components
of an exemplary packaging machine, including an exemplary
embodiment of an article guide.
[0024] FIG. 6 is a partial perspective view of the packaging
machine of FIG. 5.
[0025] FIG. 7 shows the packaging machine of FIGS. 5 and 6, as
viewed from the perspective of the outfeed end of the exemplary
guide bar.
[0026] FIG. 8 is a side elevation of a carton passing through the
loading station of a packaging machine.
[0027] FIG. 9 is a side elevation of an alternative guide bar
according to certain embodiments of the invention.
[0028] FIG. 10 is a side elevation of another alternative guide bar
according to certain embodiments of the invention.
[0029] FIG. 11 is a side elevation of yet another alternative guide
bar according to certain embodiments of the invention.
[0030] FIG. 12 is a side elevation of yet another alternative guide
bar according to certain embodiments of the invention.
DETAILED DESCRIPTION
[0031] As required, detailed embodiments of the present invention
are disclosed herein. It will be understood that the disclosed
embodiments are merely examples to illustrate aspects of the
invention that may be embodied in various and alternative forms.
The figures are not necessarily to scale, and some features may be
exaggerated or minimized to show details of particular components.
In other instances, well-known materials or methods have not been
described in detail to avoid obscuring the present invention.
Therefore, specific structural and functional details disclosed
herein are not to be interpreted as limiting, but as a basis for
the claims and for teaching one skilled in the art to variously
employ the present invention.
[0032] Referring now to the drawings in which like numerals
indicate like elements throughout the several views, the drawings
illustrate certain of the various aspects of exemplary embodiments
of an article guide according to the teachings of the present
invention. In the embodiments described herein, the term
"container" refers to any cylindrical article or receptacle having
a circular, elliptical, or polygonal base with or without a tapered
or relatively narrower upper portion, where the container is solid
or encloses a liquid, semi-liquid, gaseous, or solid substance,
such as a consumable product. The term "package" refers, for the
non-limiting purpose of illustrating the various features of the
invention, to a carton for enclosing, carrying, and dispensing
articles such as beverage bottles. However, it is contemplated that
any suitable package could be loaded via the systems and methods of
the various embodiments of the invention.
[0033] The features and aspects of the systems and methods of the
invention are described with reference to a carton 200 formed from
a foldable sheet material such as paperboard, corrugated board,
plastic, laminates, any combination thereof, or the like. To
encourage an understanding of the various aspects of the invention,
the construction of an exemplary carton will now be described in
some detail. The foldable sheet material is typically provided as a
unitary blank 100, the inside surface of which is shown in FIG. 1.
The blank 100 includes a first side panel 102 hingedly connected
along longitudinal fold line 105 to a top panel 104, which is
hingedly connected along fold line 106 to a second side panel 108,
which is hingedly connected along fold line 110 to a bottom panel
112, which is hingedly connected along fold line 114 to an edge
flap 116. Each of the panels is hingedly connected, respectively,
to minor end flaps 118a, 120a, 136a or end wall panels 122a, 124a
defined in part by transverse fold lines 126a, 128a, 130a, 132a,
138a disposed along one edge of the blank 100. At the opposite edge
of the blank 100, the panels may also include hinged connections to
similar minor end flaps 118b, 120b, 136b or end wall panels 122b,
124b defined in part by transverse fold lines 126b, 128b, 130b,
132b, 138b. More specifically, top panel 104 is hingedly connected
to end wall panels 122a, 122b along respective fold lines 128a,
128b. Second side panel 108 is hingedly connected to end flaps
120a, 120b along respective fold lines 130a, 130b. Bottom panel 112
is hingedly connected to end wall panels 124a, 124b along
respective fold lines 132a, 132b. First side panel 102 is hingedly
connected to end flaps 118a, 118b along respective fold lines 126a,
126b. In certain embodiments, edge flap 116 is hingedly connected
to end flaps 136a, 136b along respective fold lines 138a, 138b.
[0034] To erect the carton 200 shown in FIG. 2, the first side
panel 102 is glued or is otherwise secured to the edge flap 116 to
form the first side wall 202 of carton 200, which is at this point
open-ended and tubular. End flaps 136a, 136b are secured to
respective end flaps 118a, 118b to form composite end flaps
118a/136a and 118b/136b. The top panel 104 becomes the top wall 204
of the erected carton 200. Similarly, the second side panel 108
becomes the second side wall 208, and the bottom panel 112 forms
the bottom wall 212 of the erected carton 200. In this collapsed
state, the open-ended carton can be fed into the packaging machine,
where the carton 200 is partially erected and placed on a carton
conveyor, which is described in greater detail below. After the
articles are grouped and loaded through either or both of the open
ends of the carton 200, the end flaps 118a/136a, 120a and end wall
panels 122a, 124a are folded and secured together to form an end
closure structure 210 while the end flaps 118b/136b, 120b and end
wall panels 122b, 124b are folded and secured together to form the
other end closure structure 214.
[0035] FIG. 3 shows a plan view of the exemplary guide bar 300
according to certain embodiments of the invention. Generally
described, the guide bar 300 is substantially longer than it is
wide, and thus, has two relatively long side edges 302, 304 and two
relatively shorter end edges 306, 308. End edge 308 is angled so as
to be parallel with the direction of machine flow 506 of a
container conveyor 502 (best shown in FIGS. 5 and 6). End edge 306
at infeed end 310 of the guide bar 300 includes a lead-in angle
and/or a radius, which is useful to avoid interfering with the flow
of containers 504.
[0036] With regard to FIGS. 3 and 4, side edge 302 is hereinafter
referred to as the leading edge of the guide bar 300 and side edge
304 is hereinafter referred to as the guiding edge of the guide bar
300. Portions of respective leading and guiding edges 302 and 304,
near the outfeed end 312 of the guide bar 300, are tapered. Stated
differently, the surface height A of at least a portion of edges
302, 304 are tapered or otherwise gradually diminished near the end
edge 308 so that the surface height A at the end edge 308 is
substantially less than the surface height B of most of each of the
edges 302, 304, as can also be seen in FIG. 4b. This arrangement
provides the guide bar 300 with a chamfered, or beveled, surface
402 that extends from an angled edge 314 on a lower surface 322
toward an upper surface 320, and toward the angled end edge 308. In
alternative embodiments, the surface height B of the guiding edge
304 may remain constant along the length of the guide bar 300 on
condition that it is sufficient to provide a support surface for
supporting an upper portion 700 of a container 504 (as best shown
in FIG. 7) as the container 504 crosses a transition region, as
discussed in further detail below. As also will be discussed in
more detail below, tapering the leading edge 302 and the guiding
edge 304, to at least partially define the beveled surface 402, is
advantageous to ensure that the guide bar 300 clears the uppermost
edges of end flaps 118a/136a, 120a as the open-ended cartons 200
move through the loading station.
[0037] Referring to FIGS. 3 and 4, infeed end 310 of guide bar 300
includes means for facilitating attachment of guide bar 300 to a
stationary component of the packaging machine, such as drilled
holes 318 for receiving connecting means such as bolts, pins, or
screws, and the like (not shown). As shown, each of upper and lower
surfaces 320 and 322 of guide bar 300 is flat and smooth. The upper
surface 320 is greater in length than the lower surface 322.
However, in alternative embodiments, each of the upper surface 320
and the lower surface 322 may taper or curve, and they each may
have the same length.
[0038] An article conveyor 502 transports at least one container
504, in a direction of machine flow 506, along an article path and
through a loading station. A portion of the loading station is
represented by FIGS. 5, 6, 7 and 8. The carton conveyor 508 is
positioned parallel to the article conveyor 502, and is spaced from
the article conveyor 502 at a width W. The carton conveyor 508
simultaneously transports cartons 200 (FIG. 8), each being disposed
on its bottom wall 212, along a carton path that follows the same
direction of machine flow 506. For example, the carton 200 is
placed on the carton conveyor 508 such that first side wall 202 is
perpendicular to and opposes the direction of machine flow 506 and
top wall 208 is perpendicular to and faces the direction of machine
flow 506. Prior to reaching an infeed end of the angled lane
dividers 510, the direction of travel of each of the containers may
be substantially the same as the direction of machine flow 506.
When the containers 504 enter the carton loading station, the
containers 504 are metered or grouped by grouper lugs 812 (best
shown in FIG. 8), elevated flight bars, or other means for grouping
containers. The guide bars of the present invention are
contemplated in packaging machines having grouping means that span
all or part the width of the article conveyor 502, or that extend
beyond either edge of the article conveyor. Each lane is defined by
two successive parallel lane dividers 510. The outfeed end of each
pair of lane dividers 510 is angled so as to alter the direction of
travel of the individual containers 504, thereby causing the group
of containers 504 to move from the outfeed end of the respective
lane, across a transition region, and toward an open end of a
carton 200 (FIG. 8) that is transported on the carton conveyor
508.
[0039] The transition region includes the area between the outfeed
end of a lane, defined by two parallel lane dividers 510, and the
open end of a carton 200. More specifically, the transition region
is the area in which one or both of the parallel lane dividers 510
ceases to support the container 504 as it moves toward and into a
carton 200. The transition region may include a portion of the
container conveyor 502 and, additionally, can encompass a
stationary or mobile element that is disposed in a gap, of width W,
between container conveyor 502 and carton conveyor 508.
Alternatively, there may be no element other than the gap W,
between the conveyors 502, 508.
[0040] In the exemplary embodiment, the transition region includes
the upper surface of a bridge panel 514. Bridge panel 514, which is
normally a dead plate, separates the moving parts of container
conveyor 502 and carton conveyor 508. The bridge panel 514 provides
an upper surface for supporting containers 504 as they slide into
the carton 200. The bridge panel 514 may also position the end wall
panel 124a so that the distal end portion of the end wall panel
124a is placed under the bridge panel 514 while each carton is
moved through the loading station of the packaging machine.
[0041] One or more guide bars 300 are mounted or otherwise attached
to stationary components in the loading station of the packaging
machine. Any suitable stationary component may be utilized to
support each guide bar 300 including, but not limited to, a lane
divider 510 or an overhead boom (not shown). As can be seen in
FIGS. 5, 6, and 7, each guide bar 300 is mounted using a bracket
505, which may be adjustable with respect to height, and with
respect to distance from or angle between an adjacent lane divider
510, so that the guiding edge 304 of the guide bar 300 rests
against the cap or upper portion of each container 504 flowing
along the lane. Each guide bar 300 forms an angle with respect to
the direction of machine flow 506. The angle of the guide bar 300
preferably approximates the angle of the closest lane divider 510,
which is also angled with respect to the direction of machine flow
506. The guide bar 300 extends from the outfeed end of a lane and
at least partially across the transition region. The guide bar 300
preferably, but not necessarily, extends no further than an edge of
the open end of each carton 200 where the upper and lower edges of
the open end of the carton 200 are defined by respective fold lines
132a and 128a.
[0042] FIG. 7 shows a section view, taken from the perspective of
line VII-VII in FIG. 5, wherein a container 504 travels across the
transition region. The guide bar 300 is preferably offset with
respect to the lane divider 510, such that the guiding edge 304 of
the guide bar 300 is not aligned with either side of the nearest
lane divider 510. The amount of offset is engineered to place the
guiding edge 304 matingly in contact with a surface of an upper
portion 700 of a container 504. The exemplary container 504 has an
upper portion 700 that is tapered, stepped down, or otherwise made
narrower than the base 702 of the container 504. For instance, a
container 504 may have shoulders that distinguish the upper portion
700 from the base 702. The surface of the upper portion 700 of the
container 504 matingly engages the guiding edge 304 of one of the
guide bars 300 after such time as at least a portion of the
container 504 has traveled beyond the extent of, or is otherwise
not supported by, one or both of the adjacent lane dividers
510.
[0043] As shown in FIG. 8, prior to each carton 200 entering the
loading station, the distal end portion of the lower end wall panel
124a is folded out of the way by an end wall panel guide (not
shown) into the position under the bridge panel 514. The bridge
panel 514 is capable of supporting containers 504 between the
container conveyor 502 and the carton conveyor 508. Those skilled
in the art will readily appreciate that, as containers 504 move
across the fold line 132a between end wall panel 124a and wall 212,
the containers 504 may tip easily due to variations in elevation
and surface texture. Thus, it is desirable for the guide bar 300 to
extend as close to this point as possible, without interfering with
passage of the cartons 200 on the carton conveyor 508. Fold line
132a is then presented as the bottom edge of the open end of the
carton 200, and is positioned at the edge of the carton conveyor
508 or otherwise at scoreline position 602 (shown in FIGS. 5 and
6). In alternative embodiments, the width W is substantially small
such that the article conveyor 502 is adjacent to the carton
conveyor 508. More specifically, the scoreline position 602 is
substantially side edge 511 of the container conveyor.
[0044] Upper end wall panel 122a may be folded at least slightly
upward by an upper end wall panel guide (not shown), thereby
exposing the uppermost edges 808, 810 of end flaps 118a/136a and
120a as the open ended cartons 200 move through the loading
station. The leading edge 302 of guide bar 300 clears the uppermost
edge 808 of end flap 120a, containers 504 are pushed into the
carton 200 guided by guiding edge 304, and then the leading edge
302 of the guide bar 300 clears the upper edge 810 (not shown) of
end flap 118a/136a (not shown).
[0045] It will be appreciated that the size and shape of the guide
bar 300 is preferably engineered to correspond to the respective
shapes and amount of clearance between end flaps 118a/136a and 120a
and end wall panel 122a, which in the nonlimiting exemplary
embodiments shown, have angled upper edges 808, 810. The primary
objectives are to provide a guide bar with an outfeed end portion
that is shaped so as to easily clear carton end flaps while
providing stability to the upper portions of containers flowing
into the cartons. To that end, the guide bar can assume any shape
that is suitable for the application, including but not limited to
the shapes shown in FIGS. 9 through 12. Each of FIGS. 9 through 12
illustrates a side elevation of an alternative guide bar 900, 1000,
1100, 1200 that has been angled, tapered, chamfered, or otherwise
shaped to meet the objectives of the exemplary embodiments
described herein. In FIGS. 9 and 10, the guide bar 900, 1000 has a
relatively thinner outfeed end and a relatively thicker infeed end
which increases the overall strength of the guide bar without
obstructing the carton flaps. At least a portion of the leading
edge of the guide bar may be thinner as compared to at least a
portion of the guiding edge of the guide bar. In FIGS. 11 and 12,
the entire length of the guide bar 1100, 1200 has a constant or
graduated thickness, the guide bar having an elliptical,
triangular, or polygonal cross section. A guide bar having a
constant thickness should be constructed of a material strong
enough to guide containers without yielding, such that the guide
bar can be thin enough to avoid obstructing carton end flaps, but
thick enough to matingly contact and provide support to
containers.
[0046] Furthermore, any number of guide bars may be required to
accomplish the objective of preventing containers from overturning.
For example, one or more guide bars may be provided for each lane,
or a single guide bar may be sufficient to guide containers in
multiple lanes.
[0047] The present invention has been illustrated in relation to
particular embodiments which are intended in all respects to be
illustrative rather than restrictive. Those skilled in the art will
recognize that the present invention is capable of many
modifications and variations without departing from the scope of
the invention. For example, as used herein, directional references
such as "top", "base", "bottom", "end", "side", "inner", "outer",
"upper", "middle", "lower", "front" and "rear" do not limit the
respective walls of the carton to such orientation, but merely
serve to distinguish these walls from one another. Any reference to
hinged connection should not be construed as necessarily referring
to a junction including a single hinge only; indeed, it is
envisaged that hinged connection can be formed from one or more
potentially disparate means for hingedly connecting materials.
[0048] Those skilled in the art will also appreciate that the
packaging machine described represents only one example of the
various packaging machine types and configurations that will be
suitable for implementation of the various embodiments of the
invention. Each of the conveyors described with reference to the
packaging machine can consist of a series or conveyors or other
means for transporting articles or cartons from one location to
another, with the speed and ultimate direction of flow of each
conveyor being consistent with the synchronization and direction of
machine flow. Accordingly, the scope of the present invention is
described by the claims appended hereto and supported by the
foregoing.
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