U.S. patent application number 12/892576 was filed with the patent office on 2011-03-31 for method and apparatus for sealing containers.
This patent application is currently assigned to Ross Industries, Inc.. Invention is credited to William Martin Clowater, V. MICHAEL DANIEK, Benjamin Hobgood, Andrew William Jones, James Ross Kennedy, Binu George Thomas.
Application Number | 20110072764 12/892576 |
Document ID | / |
Family ID | 43778747 |
Filed Date | 2011-03-31 |
United States Patent
Application |
20110072764 |
Kind Code |
A1 |
DANIEK; V. MICHAEL ; et
al. |
March 31, 2011 |
METHOD AND APPARATUS FOR SEALING CONTAINERS
Abstract
A sealing system configured to receive a container and seal the
container with a lidding. The system comprises an in-feeder that is
configured to receive a plurality of containers and transport a
batch of containers that are selected from the plurality of
containers; and a modular seal assembly that is configured to seal
the batch of containers with a lidding, wherein the modular seal
assembly comprises: a docking station that is configured to hold a
plurality of sealing modules; and a sealing module that is
configured to be removable from the docking station without
removing any other one of the plurality of sealing modules.
Inventors: |
DANIEK; V. MICHAEL;
(Warrenton, VA) ; Clowater; William Martin;
(Gordonsville, VA) ; Jones; Andrew William;
(Remington, VA) ; Kennedy; James Ross;
(Fredericksburg, VA) ; Thomas; Binu George;
(Warrenton, VA) ; Hobgood; Benjamin; (Oxford,
NC) |
Assignee: |
Ross Industries, Inc.
Midland
VA
|
Family ID: |
43778747 |
Appl. No.: |
12/892576 |
Filed: |
September 28, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61247350 |
Sep 30, 2009 |
|
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|
Current U.S.
Class: |
53/556 |
Current CPC
Class: |
B29C 66/8221 20130101;
B29C 66/8432 20130101; B29C 66/81465 20130101; B29C 65/7841
20130101; B29C 66/849 20130101; B65B 7/2878 20130101; B65B 61/065
20130101; B29C 66/8412 20130101; B29C 65/18 20130101; B29C 66/81431
20130101; B65B 59/04 20130101; B29C 66/112 20130101; B26D 7/2614
20130101; B29C 66/8242 20130101; B65B 41/16 20130101; B26F 1/44
20130101; B29C 66/0014 20130101; B29C 66/876 20130101; B29C
66/24244 20130101; B29C 66/8167 20130101; B65B 7/164 20130101; B65B
43/46 20130101; B65B 51/14 20130101; B65B 31/028 20130101; B29C
66/8322 20130101; B29C 66/81415 20130101; B29C 65/7451 20130101;
B29C 66/131 20130101; B29C 65/305 20130101; B29C 66/00141 20130101;
B29C 66/81427 20130101; B29C 66/53461 20130101 |
Class at
Publication: |
53/556 |
International
Class: |
B65B 53/00 20060101
B65B053/00 |
Claims
1. A sealing system that is configured to receive a container and
seal the container with a lidding, the system comprising: an
in-feeder that is configured to receive a plurality of containers
and transport a batch of containers that are selected from the
plurality of containers; and a modular seal assembly that is
configured to seal the batch of containers with a lidding, wherein
the modular seal assembly comprises: a docking station that is
configured to hold a plurality of sealing modules; and a sealing
module that is configured to be removable from the docking station
without removing any other one of the plurality of sealing
modules.
2. The sealing system of claim 1, wherein the docking station
comprises a docking station frame that is configured to supply a
first gas to the sealing module.
3. The sealing system of claim 2, wherein the docking station frame
comprises: an upper frame part; and a lower frame part.
4. The sealing system of claim 2, wherein the sealing module
comprises: a channel that is configured to receive the first gas
from the docking station frame and to supply the first gas to a
lower tool cavity, or to receive a second gas from the lower tool
cavity and to supply the second gas to the docking station
frame.
5. The sealing system of claim 4, wherein the channel is configured
to supply the first gas only to the lower tool cavity or to remove
the second gas only from the lower tool cavity.
6. The sealing system of claim 1, wherein the modular seal assembly
further comprises: a channel duct that is configured to carry a
first gas from a gas supply source.
7. The sealing system of claim 6, wherein the docking station
comprises the channel duct.
8. The sealing system of claim 6, wherein the channel duct is
further configured to supply the first gas to the sealing
module.
9. The sealing system of claim 1, wherein the in-feeder comprises a
spacing-pacing conveyor, the sealing system being configured to
transfer a batch of containers from the spacing-pacing conveyor on
the fly, without stopping the spacing-pacing conveyor.
10. The sealing system of claim 7, wherein the docking station
attaches to a top plate that is configured to carry a first gas
from a gas supply source.
11. The sealing system of claim 1, wherein the docking station
comprises: a docking station frame that is configured to hold the
plurality of sealing modules, wherein the docking station frame
comprises a mounting guide that is configured to slidably support
the docking station frame, wherein the mounting guide is further
configured to guide the docking station frame during removal of the
docking station frame from the sealing system and during
replacement of the docking station into the sealing system.
12. The sealing system of claim 1, the system further comprising: a
utility connector that is configured to be coupled to the sealing
module and a docking station frame.
13. A sealing system that is configured to receive a container and
seal the container with a lidding, the system comprising: a
container transferor that is configured to receive a batch of
containers and transport the batch of containers to a sealing
assembly; and a modular seal assembly that is configured to seal
the batch of containers with a lidding, wherein the modular seal
assembly comprises a sealing module that is configured to be
removable from the modular seal assembly without removing any other
one of a plurality of sealing modules in the modular seal
assembly.
14. The sealing system of claim 13, wherein the sealing module
comprises a piston that is coupled to one of a cutter and a sealer,
and wherein the sealing module is configured to: supply a first gas
to a head cavity, supply a second gas to a container cavity, and
supply a third gas to a lower tool cavity, wherein the head cavity,
the container cavity and the lower tool cavity are configured to
prevent the first gas, the second gas, and the third gas from
traveling between any of the head cavity, the container cavity and
the lower tool cavity.
15. A sealing system that is configured to receive a container and
seal the container with a lidding, the system comprising: a modular
seal assembly that is configured to seal a batch of containers with
a lidding; and an in-feeder that is configured to supply the batch
of containers to the modular seal assembly, wherein the in-feeder
comprises a spacing-pacing conveyor that is configured to receive a
plurality of containers and positively space the plurality of
containers to a predetermined pitch.
16. The sealing system of claim 15, wherein the in-feeder further
comprises: an acceleration conveyor that is configured to carry the
plurality of containers at varying speeds.
17. The sealing system of claim 15, wherein the in-feeder further
comprises: a batching conveyor that is configured to provide a
sufficient number of containers to complete the batch of
containers.
18. The sealing system of claim 15, wherein the in-feeder further
comprises: an acceleration conveyor that is configured to carry the
plurality of containers at varying speeds; and a batching conveyor
that is configured to provide a sufficient number of containers to
complete the batch of containers, wherein the acceleration conveyor
and the batching conveyor are configured to manipulate a spacing
between each of the plurality of containers, without either the
acceleration conveyor or the batching conveyor having to stop.
19. The sealing system of claim 15, wherein the spacing-pacing
conveyor is configured to receive the plurality of containers from
the acceleration conveyor and positively space the plurality of
containers to a predetermined pitch.
20. The sealing system of claim 15, wherein the system is
configured to engage and lift a batch of containers from the
spacing-pacing conveyor on the fly, without stopping the
spacing-pacing conveyor.
21. The sealing system of claim 15, further comprising: a lidding
feeder that includes a dancer roll assembly; and a counterweight
lift assembly.
Description
CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application No. 61/247,350,
filed Sep. 30, 2009, and titled "Modular Top Sealing Assembly," the
disclosure of which is expressly incorporated by reference herein
in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to an apparatus, a system and
a method for mating and/or sealing containers. The present
disclosure also relates to an apparatus, a system and a method for
transporting containers.
BACKGROUND OF THE DISCLOSURE
[0003] Thin film materials of a variety of sorts are being used in
the packaging industry as a "lidding" material (or film). In many
instances, the thin film is applied to the tops of rigid trays or
cups in order to hermetically close and seal the contents of the
trays or cups. The film may be applied by a heat sealing process,
where a sealing die sandwiches a tray and a film for a
predetermined period of time, with a predetermined pressure and a
predetermined sealing temperature.
[0004] In cases where the lidding (or film) material is not a
"Pre-die cut lid," but, rather, a film that is unwound from a film
roll, it may be necessary to trim the film after it has been mated
to the trays or cups. In most of these cases, the film is trimmed
along the contours of the trays or cups. In some cases, the
characteristics of the lidding require a heated blade to be used to
complete the cutting process or cut the lidding and shrink the
lidding edge back so there is little or no "film overhang" over a
tray contour. The current state of technology requires equipping
the blades with a separate heater component, which is part of a
separate electrical circuit, or attaching a plurality of blades to
a single heating plate.
[0005] U.S. Pat. No. 5,475,965, issued Dec. 19, 1995 to Mondini,
discloses a "Machine for Sealing Containers by Applying a Covering
Film." U.S. Pat. No. 7,017,321, issued Mar. 28, 2006 to Salvoni,
also discloses a "Machine for Sealing Containers by Applying a
Covering Film." U.S. Pat. No. 5,097,939, issued Mar. 24, 1992 to
Shanklin et al., discloses a "Synchronous Position Product Feed
System."
[0006] The present disclosure provides an apparatus, a system and a
method for transporting, as well as mating and/or sealing
containers.
SUMMARY OF THE DISCLOSURE
[0007] According to an aspect of the disclosure, a sealing system
is disclosed that is configured to receive a container and seal the
container with a lidding. The system comprises: an in-feeder that
is configured to receive a plurality of containers and transport a
batch of containers that are selected from the plurality of
containers; and a modular seal assembly that is configured to seal
the batch of containers with a lidding, wherein the modular seal
assembly comprises: a docking station that is configured to hold a
plurality of sealing modules; and a sealing module that is
configured to be removable from the docking station without
removing any other one of the plurality of sealing modules. The
docking station may comprise a docking station frame that is
configured to supply a first gas to the sealing module. The docking
station frame may comprise: an upper frame part; and a lower frame
part. The sealing module may comprise a channel that is configured
to receive the first gas from the docking station manifold and to
supply the first gas to a lower tool cavity, or to receive a second
gas from the lower tool cavity and to supply the second gas to the
docking station frame. The channel may be configured to supply the
first gas only to the lower tool cavity or to remove the second gas
only from the lower tool cavity. The modular seal assembly may
further comprise a channel duct that is configured to carry a first
gas from a gas supply source. The docking station may comprise the
channel duct. The channel duct may be further configured to supply
the first gas to the sealing module. The modular seal assembly may
attach to a top plate that is configured to carry a first gas from
a gas supply source. The docking station may comprise: a docking
station frame that is configured to hold the plurality of sealing
modules, wherein the docking station frame comprises a mounting
guide that is configured to slidably support the docking station
frame, wherein the mounting guide is further configured to guide
the docking station frame during removal of the docking station
from the sealing system frame and during replacement of the docking
station into the sealing system. The sealing system may further
comprise a utility connector that is configured to be coupled to
the sealing module and a docking station frame.
[0008] According to a further aspect of the disclosure, a sealing
system is disclosed that is configured to receive a container and
seal the container with a lidding. The system comprises: a
container transferor that is configured to receive a batch of
containers and transport the batch of containers to a sealing
assembly; and a modular seal assembly that is configured to seal
the batch of containers with a lidding, wherein the modular seal
assembly comprises a sealing module that is configured to be
removable from the modular seal assembly without removing any other
one of a plurality of sealing modules in the modular seal assembly.
The sealing module may comprise a piston that is coupled to one of
a cutter and a sealer, and wherein the sealing module is configured
to: supply a first gas to a head cavity, supply a second gas to a
container cavity, and supply a third gas to a lower tool cavity,
wherein the head cavity, the container cavity and the lower tool
cavity are configured to prevent the first gas, the second gas, and
the third gas from traveling between any of the head cavity, the
container cavity and the lower tool cavity.
[0009] According to a still further aspect of the disclosure, a
sealing system is disclosed that is configured to receive a
container and seal the container with a lidding. The system
comprises: a modular seal assembly that is configured to seal a
batch of containers with a lidding; and an in-feeder that is
configured to supply the batch of containers to the modular seal
assembly, wherein the in-feeder comprises a spacing-pacing conveyor
that is configured to receive a plurality of containers and
positively space the plurality of containers to a predetermined
pitch. The in-feeder may comprise an acceleration conveyor that is
configured to carry the plurality of containers at varying speeds.
The in-feeder may comprise a batching conveyor that is configured
to provide a sufficient number of containers to complete the batch
of containers. The in-feeder may further comprise: an acceleration
conveyor that is configured to carry the plurality of containers at
varying speeds; and a batching conveyor that is configured to
provide a sufficient number of containers to complete the batch of
containers, wherein the acceleration conveyor and the batching
conveyor are configured to manipulate a spacing between each of the
plurality of containers, without either the acceleration conveyor
or the batching conveyor having to stop. The spacing-pacing
conveyor may be configured to receive the plurality of containers
from the acceleration conveyor and positively space the plurality
of containers to a predetermined pitch. The sealing system may
further comprise: a lidding feeder that includes a dancer roll
assembly; and a counterweight lift assembly. The sealing system may
be configured to engage and lift a batch of containers from the
spacing-pacing conveyor on the fly, without stopping the
spacing-pacing conveyor.
[0010] Additional features, advantages, and embodiments of the
disclosure may be set forth or apparent from consideration of the
following attached detailed description and drawings. Moreover, it
is to be understood that both the foregoing summary of the
disclosure and the following attached detailed description are
exemplary and intended to provide further explanation without
limiting the scope of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are included to provide a
further understanding of the disclosure, are incorporated in and
constitute a part of this specification, illustrate embodiments of
the disclosure and together with the detailed description serve to
explain the principles of the disclosure. No attempt is made to
show structural details of the disclosure in more detail than may
be necessary for a fundamental understanding of the disclosure and
the various ways in which it may be practiced. In the drawings:
[0012] FIG. 1 shows an example of a sealing system, which is
constructed according to the principles of the disclosure;
[0013] FIG. 2 shows an example of an in-feed system that may be
used with the sealing system of FIG. 1;
[0014] FIG. 3 shows an example of a multi-lane configuration of the
in-feed system of FIG. 2;
[0015] FIG. 4 shows another example of an in-feed system that is
constructed according to the principles of the disclosure;
[0016] FIG. 5 shows an example of a multi-lane configuration of the
in-feed system of FIG. 4;
[0017] FIG. 6 shows a yet another example of an in-feed system that
is constructed according to the principles of the disclosure;
[0018] FIG. 7 shows a perspective view of the in-feed system of
FIG. 6;
[0019] FIG. 8 shows an example of a state of the art container
transferor in an open configuration, which may be operated by a
transferor drive process that is configured according to principles
of the disclosure;
[0020] FIG. 9 shows an example of a transferor drive process,
according to the principles of the disclosure;
[0021] FIGS. 10A to 10D show various stages of operation of the
container transferor of FIG. 8 by the transferor drive process of
FIG. 9;
[0022] FIG. 11 shows an example of the container transferor that is
constructed according to the principles of the disclosure;
[0023] FIG. 12 shows another example of a transferor drive process,
according to the principles of the disclosure;
[0024] FIG. 13 shows another example of a container transferor in
an open configuration, which is constructed according to principles
of the disclosure;
[0025] FIG. 14 shows yet another example of a container transferor
that is constructed according to principles of the disclosure;
[0026] FIGS. 15A to 15B show two phases of operation of a still
further example of a container transferor, constructed according to
the principles of the disclosure;
[0027] FIG. 16 shows an example of a multi-lane configuration of
the container transferor of FIGS. 15A to 15B, constructed according
to the principles of the disclosure;
[0028] FIGS. 17A to 17C show examples of an engaging member,
constructed according to the principles of the disclosure;
[0029] FIGS. 18A to 18B show perspective top and bottom views,
respectively, of an example of an upper tool, which is constructed
according to the principles of the disclosure;
[0030] FIGS. 19A and 19B show perspective views of opposite sides
of an example of a sealing module that is constructed according to
principles of the disclosure;
[0031] FIG. 20 shows a cross-section view of a state-of-the-art
dual-zone head in contact with a lower tool, which may be used in
the upper tool assembly of the present disclosure;
[0032] FIG. 21 shows an example of gas flow in the dual-zone head
of FIG. 20;
[0033] FIG. 22A shows a cross-section view of the head of FIG. 20
in contact with another example of a lower tool, according to the
principles of the disclosure;
[0034] FIG. 22B shows a cross-section view of an example of a head
and a lower tool, which are constructed according to the principles
of the disclosure;
[0035] FIG. 22C shows a cross-section view of an example of the
head of FIG. 22B in contact with the lower tool of FIG. 22B;
[0036] FIG. 22D shows a cross-section view of an example of the
head of FIG. 22B and a portion of a docking station frame separated
from a top plate, according to principles of the disclosure;
[0037] FIG. 22E shows a cross-section view of another example of
the head of FIG. 22B separated from the docking station frame that
remains affixed to the top plate;
[0038] FIG. 22F shows a cross-section front view of a plurality of
heads mounted in the docking station frame and affixed to the top
plate, according to principles of the present disclosure;
[0039] FIG. 22G shows a cross-section front view of an example of a
docking station frame and plurality of heads removed from the top
plate, according to the principles of the disclosure;
[0040] FIG. 22H shows a cross-section front view of one of the
plurality of heads being removed from the docking station frame,
according to the principles of the disclosure;
[0041] FIG. 22I shows a cross-section, detailed view of the sealing
module body of FIG. 22B;
[0042] FIG. 22J shows a cross-section, detailed view of another
example of a sealing module body, which is constructed according to
the principles of the disclosure;
[0043] FIG. 23 shows an example of gas flow in the triple-zone head
and lower tool configuration of FIG. 22A;
[0044] FIG. 24 shows a cross-section view of another example of a
triple-zone head and lower tool configuration that is constructed
according to the principles of the disclosure;
[0045] FIG. 25 shows a cross-section view of yet another example of
a triple-zone head and lower tool configuration that is constructed
according to the principles of the disclosure;
[0046] FIG. 26 shows a cross-section view of still further example
of a triple-zone head and lower tool configuration that is
constructed according to the principles of the disclosure;
[0047] FIG. 27 shows a perspective partial view of an example of a
lower tool;
[0048] FIG. 28 shows a perspective exploded partial view of the
example of the lower tool of FIG. 27;
[0049] FIG. 29 shows a perspective partial underside view of an
example of a carrier insert, constructed according to the
principles of the disclosure;
[0050] FIGS. 30A-30C show various examples of existing,
state-of-the-art cutting blades that may be used in the sealing
assembly of FIG. 18A;
[0051] FIGS. 31A-31B show various views of an example of a cutting
blade, constructed according to the principles of the
disclosure;
[0052] FIG. 32 shows another example of a cutting blade that is
constructed according to the principles of the disclosure;
[0053] FIG. 33 shows yet another example of a cutting blade that is
constructed according to the principles of the disclosure;
[0054] FIG. 34 shows an example of a blade clip that is constructed
according to principles of the disclosure;
[0055] FIG. 35 shows a perspective partial view of an example of a
blade that is fastened to a mounting base by means of one or more
of the blade clips, according to principles of the disclosure;
[0056] FIG. 36 shows a partial cross-section view of the mounting
base of FIG. 35;
[0057] FIG. 37 shows another example of a blade clip that is
constructed according to principles of the disclosure;
[0058] FIG. 38 shows a perspective partial view of another example
of a blade that is fastened to a mounting base by means of a
bridge, according to the principles of the disclosure;
[0059] FIG. 39 shows a partial cross-section view of the blade of
FIG. 38 fastened to the mounting base by means of the blade
clip;
[0060] FIG. 40 shows an example of a cutting assembly that is
constructed according to the principles of the disclosure;
[0061] FIG. 41 shows an example of the cutting assembly of FIG. 40
in a seal-cut position;
[0062] FIG. 42 shows a partial three-dimensional perspective view
of an example of the cutting assembly of FIG. 41 configured in a
pre-seal and a pre-cut position, which is constructed according to
the principles of the disclosure;
[0063] FIG. 43 shows a partial three-dimensional perspective view
of the cutting assembly of FIG. 42 configured in a sealing and a
cutting position;
[0064] FIG. 44 shows an example of a lift that is constructed
according to the principles of the disclosure;
[0065] FIG. 45 shows the lift of FIG. 44 in a full-lift
position;
[0066] FIG. 46 shows another example of a lift that is constructed
according to the principles of the disclosure;
[0067] FIG. 47 shows the lift of FIG. 46 in a full-lift
position;
[0068] FIG. 48 shows yet another example of a lift that is
constructed according to the principles of the disclosure;
[0069] FIG. 49A shows still a further example of a lift that is
constructed according to the principles of the disclosure;
[0070] FIG. 49B shows still a further example of a lift that is
constructed according to the principles of the disclosure;
[0071] FIG. 49C shows the lift of FIG. 49B in the lowered
position;
[0072] FIG. 49D shows still a further example of a lift that is
constructed according to the principles of the disclosure;
[0073] FIG. 49E shows the lift of FIG. 49D in the lowered
position;
[0074] FIG. 50 shows a perspective view of an example of a lidding
unwind system that is constructed according to the principles of
the disclosure;
[0075] FIG. 51 shows a side view of the lidding unwind system of
FIG. 50 with a plurality of dancer rollers located at an upper
position, that is above a predetermined lower end position;
[0076] FIG. 52 shows a side view of the lidding unwind system of
FIG. 50 with the dancer rollers located at the predetermined lower
end position;
[0077] FIG. 53 shows a side view of the lidding unwind system of
FIG. 50 with the upper rollers and the dancer rollers configured in
a threading configuration, according to the principles of the
disclosure;
[0078] FIG. 54 shows a perspective view of the lidding system of
FIG. 50 with the upper rollers and the dancer rollers configured in
the threading configuration;
[0079] FIG. 55 shows an example of a lidding roll centering system
that is constructed according to the principles of the
disclosure;
[0080] FIG. 56 shows an exploded view of the lidding roll centering
system of FIG. 55; and
[0081] FIG. 57 shows a side view of the lidding roll centering
system of FIG. 55.
[0082] The present disclosure is further described in the detailed
description that follows.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0083] The embodiments of the disclosure and the various features
and advantageous details thereof are explained more fully with
reference to the non-limiting embodiments and examples that are
described and/or illustrated in the accompanying drawings, and
detailed in the following attached description. It should be noted
that the features illustrated in the drawings are not necessarily
drawn to scale, and features of one example may be employed with
other embodiments as the skilled artisan would recognize, even if
not explicitly stated herein. Descriptions of well-known components
and processing techniques may be omitted so as to not unnecessarily
obscure the embodiments of the disclosure. The examples used herein
are intended merely to facilitate an understanding of ways in which
the disclosure may be practiced and to further enable those of
skill in the art to practice the embodiments of the disclosure.
Accordingly, the examples and embodiments herein should not be
construed as limiting the scope of the disclosure, which is defined
solely by the appended claims and applicable law. Moreover, it is
noted that like reference numerals represent similar parts
throughout the several views of the drawings.
[0084] A "computer", as used in this disclosure, means any machine,
device, circuit, component, or module, or any system of machines,
devices, circuits, components, modules, or the like, which are
capable of manipulating data according to one or more instructions,
such as, for example, without limitation, a programmable logic
controller (PLC), a motion controller, a processor, a
microprocessor, a central processing unit, a general purpose
computer, a super computer, a personal computer, a laptop computer,
a palmtop computer, a notebook computer, a desktop computer, a
workstation computer, a server, or the like, or an array of
processors, microprocessors, central processing units, general
purpose computers, super computers, personal computers, laptop
computers, palmtop computers, notebook computers, desktop
computers, workstation computers, servers, or the like. Further,
the computer may include an electronic device configured to
communicate over a communication link. The electronic device may
include, for example, but is not limited to, a mobile telephone, a
smart telephone, a cellular telephone device, a satellite telephone
device, a cordless telephone, a software defined radio (SDR), a
two-way radio, a personal data assistant (PDA), a mobile computer,
a stationary computer, mobile station, a game console, a game
controller, user equipment, or the like.
[0085] A "network," as used in this disclosure, means an
arrangement of two or more communication links. A network may
include, for example, the Internet, a local area network (LAN), a
wide area network (WAN), a metropolitan area network (MAN), a
personal area network (PAN), a campus area network, a corporate
area network, a global area network (GAN), a broadband area network
(BAN), any combination of the foregoing, or the like. The network
may be configured to communicate data via a wireless and/or a wired
communication medium. The network may include any one or more of
the following topologies, including, for example, a point-to-point
topology, a field bus topology, a bus topology, a linear bus
topology, a distributed bus topology, a star topology, an extended
star topology, a distributed star topology, a ring topology, a mesh
topology, a tree topology, or the like.
[0086] A "communication link", as used in this disclosure, means a
wired and/or wireless medium that conveys data or information
between at least two points. The wired or wireless medium may
include, for example, a metallic conductor link, a radio frequency
(RF) communication link, an Infrared (IR) communication link, an
optical communication link, or the like, without limitation. The RF
communication link may include, for example, WiFi, WiMAX, IEEE
802.11, DECT, 0G, 1G, 2G, 3G or 4G cellular standards, Bluetooth,
or the like.
[0087] The terms "including", "comprising" and variations thereof,
as used in this disclosure, mean "including, but not limited to",
unless expressly specified otherwise.
[0088] The terms "a", "an", and "the", as used in this disclosure,
means "one or more", unless expressly specified otherwise.
[0089] Devices that are in communication with each other need not
be in continuous communication with each other, unless expressly
specified otherwise. In addition, devices that are in communication
with each other may communicate directly or indirectly through one
or more intermediaries.
[0090] Although process steps, method steps, algorithms, or the
like, may be described in a sequential order, such processes,
methods and algorithms may be configured to work in alternate
orders. In other words, any sequence or order of steps that may be
described does not necessarily indicate a requirement that the
steps be performed in that order. The steps of the processes,
methods or algorithms described herein may be performed in any
order practical. Further, some steps may be performed
simultaneously.
[0091] When a single device or article is described herein, it will
be readily apparent that more than one device or article may be
used in place of a single device or article. Similarly, where more
than one device or article is described herein, it will be readily
apparent that a single device or article may be used in place of
the more than one device or article. The functionality or the
features of a device may be alternatively embodied by one or more
other devices which are not explicitly described as having such
functionality or features.
[0092] A "computer-readable medium", as used in this disclosure,
means any medium that participates in providing data (for example,
instructions) which may be read by a computer. Such a medium may
take many forms, including non-volatile media, volatile media, and
transmission media. Non-volatile media may include, for example,
optical or magnetic disks and other persistent memory. Volatile
media may include dynamic random access memory (DRAM). Transmission
media may include coaxial cables, copper wire and fiber optics,
including the wires that comprise a system bus coupled to the
processor. Transmission media may include or convey acoustic waves,
light waves and electromagnetic emissions, such as those generated
during radio frequency (RF) and infrared (IR) data communications.
Common forms of computer-readable media include, for example, a
floppy disk, a flexible disk, hard disk, magnetic tape, any other
magnetic medium, a CD-ROM, DVD, any other optical medium, punch
cards, paper tape, any other physical medium with patterns of
holes, a RAM, a PROM, an EPROM, a FLASH-EEPROM, a compact flash
card, a thumb drive, any other memory chip or cartridge, a carrier
wave as described hereinafter, or any other medium from which a
computer can read.
[0093] Various forms of computer readable media may be involved in
carrying sequences of instructions to a computer. For example,
sequences of instruction (i) may be delivered from a RAM to a
processor, (ii) may be carried over a wireless transmission medium,
and/or (iii) may be formatted according to numerous formats,
standards or protocols, including, for example, WiFi, WiMAX, IEEE
802.11, DECT, 0G, 1G, 2G, 3G or 4G cellular standards, Bluetooth,
or the like.
[0094] FIG. 1 shows an example of a sealing system (or sealer) 1,
which is constructed according to the principles of the disclosure.
The sealing system 1 includes an input system 10, an in-feed system
(or in-feeder) 20, a container sealer 30, and an output system 40.
As seen in FIG. 1, unsealed containers (not shown) may be received
via the input system 10 into the in-feed system in the direction of
the arrow "IN." The in-feed system transports the unsealed
containers to the container sealer 30, which then seals the
containers with a lidding. The sealed containers may then be output
from the container sealer 30 via the output system 40 in the
direction of the arrow "OUT." The lidding may include, for example,
a film or a sheet that may be used to seal a container.
[0095] The input system 10 is configured to receive containers,
such as, for example, trays, cups, cans, tubs, or the like, and
forward the containers to the in-feed system 20. The input system
10 may include a transport mechanism such as, for example, a
conveyor belt, a slide, a plurality of rollers, or the like.
[0096] The output system 40 is configured to receive sealed
containers from the container sealer 30 and forward the sealed
containers for further processing (such as, e.g., labeling,
transport, storage, or the like).
[0097] Alternatively, the input system 10 may be removed and the
containers may be provided directly to the in-feed system 20.
Similarly, the output system 40 may be removed and the sealed
containers maybe output directly from the container sealer 30 for
further processing.
[0098] U.S. Pat. No. 4,974,392, issued Dec. 4, 1990 to Mondini,
titled "Apparatus for Closing Containers with a Sealing Lamina,"
describes an intermittent conveyor 3 and a continuous conveyor 7
that may be used to provide a predetermined spacing between a
plurality of containers C prior to heat-sealing the containers. The
continuous conveyor 7 and intermittent conveyors 3 and 7, which are
described, for example, at column 2, lines 34-57 of the patent, may
be included in the in-feed system 20.
[0099] U.S. Pat. No. 5,097,939, issued Mar. 24, 1992 to Shanklin et
al., titled "Synchronous Position Product Feed System," describes a
controlled product feed system for delivering discrete products at
high speed to a downstream industrial operation which requires
accurate speed and position of delivery.
[0100] FIG. 2 shows an example of an in-feed system 20. The in-feed
system 20 may comprise a pair of conveyors, including a
spacing-pacing conveyor 210 and an input conveyor 220. The
spacing-pacing conveyor 210 may be substantially similar to, or the
same as the first (or intermittent) conveyor 3 In U.S. Pat. No.
4,974,392, and the input conveyor 220 may be substantially similar
to, or the same as the continuous conveyor in U.S. Pat. No.
4,974,392. The in-feed system 20 may comprise an in-feed controller
(not shown) that controls the in-feed system 20. The in-feed system
20 may further comprise a plurality of sensors 215, 225. The
in-feed controller includes a computer (not shown). The sensors
215, 225, may include transducers (not shown) that are configured
to accurately and reliably sense the location of the containers 250
as a function of time. The sensors 215, 225 may be coupled to the
in-feed controller via a communication link (not shown) that
carries sensor data from the sensors 215, 225 to the in-feed
controller. The communication link may carry control data from the
in-feed controller to the sensors 215, 225. The transducers may be
constructed to sense and convert electrical, electro-mechanical,
electromagnetic, photonic, or photovoltaic energy, so as to detect
and track the position of each container 250 as it moves through
the in-feed system 20.
[0101] Alternatively, the in-feed system 20 may include the product
feed system described in U.S. Pat. No. 5,097,939.
[0102] The input conveyor 220 may include a plurality of conveyor
rolls 222, 223, including at least one drive roll 222 for driving
the input conveyor 220. The input conveyor 220 may receive a series
of unsealed containers 250 traveling in the direction 230 from the
input system 10 (shown in FIG. 1) and transport the containers 250
to the spacing-pacing conveyor 210. The input conveyor 220 may be
part of the in-feed system 20 or a part of the input system 10.
[0103] The spacing-pacing conveyor 210 may include a plurality of
conveyor rolls 212, 213, including at least one drive roll 212 for
driving the spacing-pacing conveyor 210. The spacing-pacing
conveyor 210 may receive the containers 250 from the input conveyor
220 and positively space the containers 250 to a predetermined
pitch, so that the containers 250 may be picked up by a container
transferor 280 (for example, shown in FIG. 8). In this regard, the
drive roll 212 may be driven by a motor (not shown) under the
control of the in-feed controller, which may track and ensure
proper positioning and pitch of the containers 250 on the
spacing-pacing conveyor 210.
[0104] The sensor 225 may be located upstream of the spacing-pacing
conveyor 210 and proximate to the input conveyor 220. The sensor
225 may detect the incoming containers 250, track the position of
each container 250 and ensure via the in-feed controller (not
shown) that there are enough containers 250 provided to the
container transferor 280 to process a full batch.
[0105] The sensor 215 may be located proximate to the
spacing-pacing conveyor 210. The sensor 215 may detect the incoming
containers 250 and send sensor data to the in-feed controller,
which may process the sensor data and adjust a motion profile of
the spacing-pacing conveyor 210, so that a predetermined spacing
(or pitch) may be achieved and maintained between the containers
250. The motion profile may include, for example, a velocity
magnitude, an acceleration magnitude, a deceleration magnitude, and
the like. The spacing-pacing conveyor 210 may have a high
coefficient of friction (sticky) to assist in maintaining the
predetermined spacing between the containers 250 until the
containers 250 are received by the container transferor 280.
[0106] The sensors 215, 225 may be configured to sense and measure
the velocity of the spacing-pacing conveyor 210 and the velocity of
the input conveyor 220. A steady, randomly spaced supply of
containers 250 on the input conveyor 220 may be received and
precisely positioned to a predetermined pitch by the spacing-pacing
conveyor 210.
[0107] FIG. 3 shows an example of an in-feed system 20' constructed
according to the principles of the disclosure. As seen, the in-feed
system 20' may include a pair of spacing-pacing conveyors 210 and a
multi-lane (or multi-track) input conveyor 220'. The multi-lane
input conveyor 220' may include one or more lane dividers 227,
which are configured to separate the lanes, and a plurality of the
sensors 225, including at least one sensor 225 for each lane. The
multi-lane input conveyor 220' may also include a lane gate 228
that may be moved to direct the flow of containers 250 to a desired
one or more of the lanes of the multi-lane input conveyor 220'.
Although shown as comprising two lanes, it is noted that the
multi-lane input conveyor 220' may include three, four, or more
lanes.
[0108] FIG. 4 shows another example of an in-feed system 20''
constructed according to the principles of the disclosure. The
in-feed system 20'' may include four conveyors, including the
spacing-pacing conveyor 210, an acceleration conveyor 260, a
batching conveyor 270, and the input conveyor 220. The acceleration
conveyor 260 and the batching conveyor 270 may be configured to
manipulate spacing of the containers 250 prior to forwarding the
containers 250 to the spacing-pacing conveyor 210. The in-feed
system 20'' is configured to facilitate high throughput rates of
the containers 250, without any of the conveyors 210, 260, 270 or
220 having to stop.
[0109] The batching conveyor 270 may be configured to ensure that
there are a sufficient number of containers 250 to complete a full
batch. The batching conveyor 270 may be controlled by the in-feed
controller, so that it may be actuated and driven to receive a
random, intermittent supply of containers 250 from the input
conveyor 220 and provide a reliable stream of containers to the
acceleration conveyor 260. The batching conveyor 270 may be
actuated and controlled by the in-feed controller based on a motion
detection signal received from a motion sensor (not shown) located
proximate the input conveyor 220 or the sensor data received from
the sensor 225, which may include a motion detection signal.
[0110] The acceleration conveyor 260 may be configured to receive a
substantially steady stream of containers 250 from the batching
conveyor 270 and accelerate (or decelerate) the containers 250 so
as to pull a gap, which may be substantially consistent, between
the containers 250 before forwarding the spaced containers 250 to
the spacing-pacing conveyor 210. The acceleration conveyor 260 may
be actuated and controlled by the in-feed controller based on a
motion detection signal received from a motion sensor (not shown)
located proximate the batching conveyor 270 and/or the input
conveyor 220. Alternatively (or additionally), the acceleration
conveyor 260 may be controlled by the in-feed controller based on a
motion detection signal received from the sensor 225 and/or sensor
215.
[0111] FIG. 5 shows yet another example of an in-feed system 20''
constructed according to the principles of the disclosure. The
in-feed system 20'' may include a plurality of multi-lane
conveyors, including a plurality of spacing-pacing conveyors 210, a
plurality of acceleration conveyors 260, a plurality of batching
conveyors 270, and one or more input conveyors 220'. For example,
as seen in the figure, the in-feed system 20''' may include a pair
of spacing-pacing conveyors 210, a pair of acceleration conveyors
260, a pair of batching conveyors 270, and a multi-lane input
conveyor 220'.
[0112] FIG. 6 shows still another example of an in-feed system
20'''' constructed according to the principles of the disclosure.
Further to the above description of the in-feed system 20''', the
in-feed system 20'''' includes a gathering conveyor 290 and a
sensor 235. The gathering conveyor 290 may be configured to provide
greater control and accommodate higher speeds, while requiring less
energy, a smaller servomotor, and lower power consumption to
operate. The sensor 235 may be positioned proximate a upstream end
of the gathering conveyor 290. The sensor 235 may be substantially
the same (or different) as the sensor 225. The sensor 235 (or the
in-feed controller) may count the number of containers 250 and
forward a data signal to the in-feed controller. The in-feed
controller may determine the ideal time to stop (or slow) the
acceleration conveyor 260. The decision may be based on, for
example, a detected disruption in the flow of containers 250, or a
determination of an inadequate number of containers to complete a
full batch.
[0113] When an inadequate quantity of containers 250 is detected,
the in-feed controller may stop (or slow) the acceleration conveyor
260 and allow the gathering conveyor 290 and the batching conveyor
270 to run, thereby causing any incoming container 250 to stop as
it contacts the surface of the acceleration conveyor 260. When a
determination is made by the in-feed controller (or the sensor
235), based on, for example, the sensor data from the sensor 235,
that a sufficient quantity of containers 250 have been collected to
complete a full batch, the acceleration conveyor 260 may be started
(or accelerated) and pitching of the containers 250 may resume.
[0114] FIG. 7 shows a perspective view of the in-feed system
20''''.
[0115] FIG. 8 shows an example of a state-of-the-art container
transferor 280, which may be operated according to the principles
of the disclosure. The container transferor 280 comprises a pair of
grippers 282, 284, which may be configured to engage and transfer
one or more of the containers 250 to the container sealer 30, and
to engage and transfer one or more sealed containers 250 from the
container sealer 30 to the output system 40. The grippers 282 and
284 are linked to each other and driven simultaneously. The
grippers 282, 284 include gripper portions 2821, 2822 and 2841,
2842. The gripper portions 2821, 2841 may be configured to engage
and transfer one or more of the containers 250 from the
spacing-pacing conveyor 210. The gripper portions 2822, 2842 may be
configured to engage and transfer one or more of the containers 250
from the container sealer 30 to the output system 40 (shown in FIG.
1).
[0116] FIG. 9 shows an example of an on-the-fly transferor drive
process 800, according to principles of the disclosure.
[0117] FIGS. 10A-10D show various stages of the container
transferor 280 driven according to the drive process 800.
[0118] Referring to FIGS. 9 and 10A-10D, the grippers 282, 284 may
be initially positioned in a home position, as shown in FIG. 10A
(Step 805). As seen in the figure, the grippers 282, 284 may begin
a machine cycle at the home position where the first distal ends
2832, 2834 of the grippers 282, 284, respective, may be located
past an upstream end portion of the accelerator conveyor 260.
[0119] While the grippers 282, 284 are in the home position (shown
in FIG. 10A), the in-feed system 20 may continue to transport the
containers 250, spacing the containers 250 at a predetermined pitch
that corresponds substantially to the pitch of the recesses in the
grippers 282, 284 (Step 810). When a complete batch of containers
250 is gathered and the batch of containers 250 has reached a
predetermined point in the in-feed system 20, as sensed by the
sensor 215, the grippers 282, 284 may be actuated, moving the
grippers 282, 284 in the direction 230, as shown in FIG. 10B (Step
815). The grippers 282, 284 are accelerated to a speed that
substantially matches the speed of the pacing-spacing conveyor 210,
as shown in FIG. 10C (Step 820). When the recesses in the gripper
portions 2821, 2841 are aligned with the batch of containers 250
and the speed of the moving grippers 282, 284 substantially matches
the speed of the batch of containers 250, the gripper portions 282,
284 may be actuated to close and engage the batch of containers
250, as shown in FIG. 10D (Step 825). The point at which the
grippers 282, 284 close may be timed such that the gripper portions
2821, 2841 are aligned with the containers 250 on the
pacing-spacing conveyor 210 at substantially the same time that the
gripper portions 2822, 2842 are aligned with the sealed containers
250 in the container sealer 30.
[0120] The engaged batch of containers 250 may then be transported
from the in-feed system 20 to the container sealer 30 (Step 830).
Simultaneously, the batch of processed containers 250 may be
engaged by the gripper portions 2822, 2842 and transported from the
container sealer 30 to the output system 40. The grippers 282, 284
may then be returned to the home position (shown in FIG. 10A) to
engage the next batch of containers 250 on the conveyor 210 (Step
835). The gripper portions 2822, 2842 may be synchronized with the
pacing-spacing conveyor 210 just before and during engagement of
the batch of containers 250 on the conveyor 210. After the batch of
containers 250 have been lifted from the pacing-spacing conveyor
210, the gripper portions 2822, 2842 may be accelerated (or
decelerated) to move faster (or slower) than the pacing-spacing
conveyor 210 as needed.
[0121] Optionally, the velocity of the conveyor (not shown) in the
output system 40 may be synchronized to, for example, the container
transferor 280.
[0122] As seen in FIGS. 10A-10D, the grippers 282 and 284 may be
configured such that they are operated at substantially the same
time by a common drive mechanism (not shown). The drive mechanism
may include a pneumatic, a hydraulic, an electromechanical, or the
like, mechanism, as is known in the related arts.
[0123] According to an aspect of the disclosure, a computer
readable medium may be provided that embodies a computer program,
which, when executed on, for example, the computer in the in-feed
controller, may cause each of the Steps 805 to 835 to be carried
out. The computer readable medium may include a section (or
segment) of code (or instructions) for each of the Steps 805 to
835.
[0124] FIG. 11 shows an example of a container transferor 2900 that
is constructed according to the principles of the disclosure. The
container transferor 2900 includes grippers 291-294. The grippers
291 and 293 may be linked to each other and driven at substantially
the same time by a common drive mechanism (not shown). The grippers
292 and 294 may be linked to each other and driven at substantially
the same time by a common drive mechanism (not shown), which may be
different from (or the same as) the drive mechanism that drives the
grippers 291, 293. The grippers 291, 293 may be driven
independently of the grippers 292, 294. For example, the grippers
291, 293 may be moved (or stopped) at different times than the
grippers 292, 294, and the grippers 291, 293 may be closed (or
opened) at different times than the grippers 292, 294. The drive
mechanisms may include a pneumatic, a hydraulic, an
electromechanical, or the like, mechanism, as is known in the
related arts.
[0125] The container transferor 2900 is configured to buffer the
containers 250 on the spacing-pacing conveyor 210 with regard to
the containers 250 in the container sealer 30. For example, a batch
of containers 250 may be in position on the spacing-pacing conveyor
210 to be engaged by the grippers 291, 293 before the containers
250 in the container sealer 30 have been fully processed. In this
instance, the grippers 291, 293 may be actuated to engage the
containers 250 on the spacing-pacing conveyor 210 while the
grippers 292, 294 remain open until the containers 250 in the
container sealer 30 are ready to be removed. The grippers 291, 293
may begin transport of the containers 250 from the spacing-pacing
conveyor 210 before the grippers 292, 294 engage the sealed
containers 250.
[0126] The grippers 291, 293 and 292, 294 may be equipped with a
short stroke lift system where the containers 250 may be suspended
for a time above the spacing-pacing conveyor 210 to allow time for
the spacing-pacing conveyor 210 to process the next batch of
containers 250.
[0127] FIG. 12 shows an on-the-fly transferor drive process 800',
according to the principles of the disclosure. Steps 805 through
835 of the process 800' may be carried out to operate the grippers
291, 293 (shown in FIG. 11) in substantially the same manner
described above with reference to FIG. 9. The grippers 292, 294,
however, may be operated independently of the grippers 291,
293.
[0128] Referring to FIGS. 11-12, and further to the description
provided above with regard to FIG. 9, a decision may be taken
whether to move the grippers 292, 294 (Step 840), independent of
the decision to move the grippers 291, 293 (Step 815). When the
process of sealing the containers 250 has been determined to be
completed (YES at Step 840), then the grippers 292, 294 may be
actuated to engage the containers 250 in the container sealer 30
(Step 845). Optionally, after engaging the sealed containers 250
(Step 845), the speed of movement of the grippers 292, 294 may be
matched to the speed of the output conveyor (not shown) in the
output system 40 (Step 850). After engaging the sealed containers
250 (Step 845), the sealed containers 250 may be transferred from
the container sealer 30 to the output system 40 (Step 855). The
grippers 292, 294 may then be returned to their home position
(shown in FIG. 11) to engage the next batch of sealed containers
250 in the container sealer 30 (Step 860).
[0129] During the process of transferring the containers 250 from
the pacing-spacing conveyor 210 (Step 830), or during the process
of transferring the sealed containers 250 from the container sealer
30 (Step 855), the containers 250 may be lifted and suspended for a
period of time before being transferred to the container sealer 30
or the output system 40, respectively, thereby allowing buffering
of the containers 250 on the input side of the container sealer 30
with regard to the sealed containers 250 on the output side of the
container sealer 30.
[0130] According to an aspect of the disclosure, a computer
readable medium may be provided that embodies a computer program,
which, when executed on the computer of, for example, the in-feed
controller, may cause each of the Steps 805 to 860 of the process
800' to be carried out. The computer readable medium may include a
section (or segment) of code (or instructions) for each of the
Steps 805 to 860.
[0131] FIG. 13 shows another example of a container transferor
2900' that is constructed according to principles of the
disclosure. The transferor 2900' includes a pair of grippers 295,
296, which may be linked to each other and a common drive mechanism
(not shown). The grippers 295, 296 may be moved at substantially
the same time. The grippers 295, 296 may include gripper portions
291', 293' that are configured to correspond to the shape of the
containers 250, as seen in FIG. 8. The grippers 295, 296 may
further include gripper portions 292', 294' that are not configured
to correspond to the shape of the containers 250, but instead have
substantially smooth, flat, longitudinal surfaces, including a push
edge 2921', 2941', and a lip 2922', 2942' to help support the
sealed containers 250. The gripper portions 292',294' may include,
for example, the engagement member 2990 (or 2990') shown in FIG.
17A. The configuration of the gripper portions 292', 294' may allow
for quicker disengagement of the sealed containers 250. Further,
the speed of movement of the grippers 295, 296 may be substantially
different from the speed of the conveyor (not shown) in the output
system 40. The container transferor 2900' may be operated according
to the drive process 800 shown in FIG. 9.
[0132] FIG. 14 shows yet another example of a container transferor
2900'' that is constructed according to the principles of the
disclosure. The container transferor 2900'' is similar to the
container transferor 2900 shown in FIG. 11, except that the
engaging portions of the grippers 292'', 294'' are configured
similar to those of the grippers 292', 294' shown in FIG. 13. The
container transferor 2900'' may be operated according to the drive
process 800' shown in FIG. 12.
[0133] According to a further aspect of the disclosure, the
container transferors 280 (shown in FIG. 8), 2900 (shown in FIG.
11), 2900' (shown in FIG. 13) or 2900'' (shown in FIG. 14) may be
implemented with a multi-lane configuration, such as, for example,
the multi-lane configuration shown in FIG. 5, or any other
multi-lane configuration that will be obvious to those having
ordinary skill in the art, without departing from the scope or
spirit of the disclosure.
[0134] FIGS. 15A to 15B show two phases of operation of an example
of a container transferor 2900''' having grippers 2861, 2862,
constructed according to the principles of the disclosure. The
grippers 2861, 2862 are configured to engage and transport the
containers 250 from the spacing-pacing conveyor 210 to the
container sealer 30, as well as engage and transport sealed
containers 250 from the container sealer 30 to the output conveyor
410. The grippers 2861, 2862 may be controlled and moved at a
velocity that is matched to the velocity of the spacing-pacing
conveyor 210 just before and during engaging of the containers 250
on the spacing-pacing conveyor 210.
[0135] FIG. 16 shows an example of a container transferor 2900''''
having a plurality of multi-lane grippers 282', 284', constructed
according to the principles of the disclosure. As seen, the
container transferor 2900'''' may be configured to simultaneously
(or independently) engage a plurality of batches of containers 250
on a plurality of spacing-pacing conveyors 210 and/or in the
container sealer 30.
[0136] FIGS. 17A to 17C show examples of engaging members 2990 and
2990' constructed according to the principles of the disclosure.
The engaging members 2990 or 2990' may be used in the grippers of
the container transferor 280, 2900, 2900', 2900''', or 2900''''
described above. The engaging member 2990 (2990') may be configured
to engage the container 250 and provide a high degree of static
friction to prevent the container 250 from moving while it is
transported, such as, e.g., to, or from the container sealer 30.
The engaging member 2990 (2990') may be constructed to minimize its
weight while optimizing performance. In this regard, the engaging
member 2990 may be constructed as two or more engaging member
portions 2990' to facilitate easier removal, installation, or
handling of the engaging member 2990.
[0137] FIG. 17A shows a perspective front view of the engaging
member 2990. The engaging member 2990 may include a plurality of
longitudinal ribs 2995 to facilitate optimal engagement with the
containers 250 while maintaining a lighter weight construction of
the engaging member 2990. The longitudinal ribs 2995 may be
configured to handle containers 250 of varying heights. In
particular, the channels between the ribs may be configured to
receive and engage a flange of the varying height containers 250 to
be transported. The engaging member 2990 (or 2990') may be
constructed from a lightweight, durable material such as, for
example, aluminum, plastic, fiberglass, or the like. The engaging
member 2990 may be configured to be easily affixed to (or removed
from), for example, a gripper (such as, for example, the grippers
2861, 2862, shown in FIG. 15A, or the grippers 292', 294', 292'',
294'', shown in FIGS. 13, 14). Alternatively, the engaging member
2990 may be affixed directly to the transferor as a gripper.
[0138] FIG. 17B shows a perspective front view of a pair of
engaging member portions 2990' that may be assembled instead of a
single engaging member 2990, according to the principles of the
disclosure. As seen, the engaging member 2990 may be assembled from
a plurality of smaller engaging member portions 2990'. This
configuration may be practical where the engaging members 2990 are
large and difficult for an operator to handle alone. FIG. 17C shows
a perspective exploded view of the engaging member portions
2990'.
[0139] While the transferor of the examples shown in FIGS. 8,
10A-11, and 13-16 may include a single set of grippers (for
example, shown in FIGS. 15A, 15B) or a double set of grippers (for
example, shown in FIG. 8, 10A-11, or 13-16), it is noted that the
transferor may include three or more sets of grippers, as will be
understood by those having ordinary skill in the art.
[0140] FIG. 18A shows a perspective top view of an example of an
upper tool 3100, which is constructed according to the principles
of the disclosure. The upper tool 3100 may be included, for
example, in the container sealer 30 (shown in FIG. 1). The upper
tool 3100 includes a docking station frame 3120 that may be removed
from, for example, the container sealer 30 and one or more sealing
modules 3110. The docking station frame 3120 includes a lower frame
part 3130, and an upper frame part 3140. The lower frame part 3130
and the upper frame part 3140 may be integrally formed with, or
coupled to form the docking station frame 3120 by means of, for
example, fasteners (not shown), seals (not shown), and the like.
The docking station frame 3120 may include a pair of mounting
guides 3150 at each end of the docking station frame 3120, as seen
in FIG. 18A. The mounting guides 3150 may be configured to slide
into complementary grooves (not shown) in the container sealer
30.
[0141] The upper tool 3100 is configured to allow easy swap-out of
the individual sealing modules 3110 from the docking station frame
3120, as well as to allow easy swap-out of the docking station
frame 3120 from the container sealer 30. The docking station frame
3120 may include one or more sealing module receivers (not shown)
for receiving and holding a respective one or more removable
sealing modules 3110. The sealing modules 3110 may be removably
coupled to the docking station frame 3120 by a sealing module
fastener (not shown), which may include, for example, a head
receiver guide (not shown), a tongue, a groove, a bolt, a nut, a
screw, a pin, a clip, or the like.
[0142] The lower frame part 3130 (or upper frame part 3140) may
include, for example, pneumatic supply/return lines, vacuum
supply/return lines, fluid supply/return lines, and the like. The
upper frame part 3140 (or lower frame part 3130) may include, for
example, electric power supply lines, control lines, data lines,
and the like. The lower frame part 3130 may be configured to align
with a top plate (not shown) in the container sealer 30. The top
plate may include a plurality of channels (not shown) for supplying
or returning a gas, a fluid, a communication link, a power supply,
or the like. The channels may align with corresponding channels in
the lower frame part 3130 (or upper frame part 3140).
[0143] Each of the sealing modules 3110 may be coupled to a utility
connector 3115 (shown in FIG. 18B). The sealing module fastener
(not shown) may be configured to securely attach the sealing module
3110 in the docking station frame 3120. All of the sealing modules
3110 may be substantially the same and interchangeable with each
other, so that any of the sealing modules 3110 may be placed in any
of the sealing module receivers of the docking station frame 3120.
Hence, the sealing modules 3110 are not position-sensitive with
regard to the docking station frame 3120, or the upper tool 3100.
Should any one or more of the sealing modules 3110 require repair
or replacement, the sealing module(s) 3110 may be readily removed
from the docking station frame 3120 (or upper tool 3100) and
repaired or replaced.
[0144] While all of the sealing modules 3110 may be substantially
the same in a given upper tool assembly 3100, the sealing modules
3110 may vary significantly between any different upper tool
assemblies 3100. In this regard, the outer configurations of the
associated docking station frames 3120 may be substantially the
same to facilitate interchangeability in the container sealer 30,
but the inner configurations of the docking station frames 3120 may
vary significantly to accommodate the different sizes, types, and
configurations of the sealing modules 3110 that may be used.
Accordingly, the different sizes, types, and configurations of
containers 250 may be processed in the container sealer 30 by
simply replacing one upper tool assembly 3100 having a first set of
sealing modules 3110 with a second upper tool assembly 3100 having
a second set of sealing modules that are optimal for sealing the
containers 250. It is noted that it may be necessary to also
replace the transferor and/or lower tool to match the sealing
modules 3110 in the second upper tool assembly 3100.
[0145] A plurality of the upper tool assemblies 3100 may be
included in the container sealer 30 (shown in FIG. 1). Where the
container sealer 30 includes a plurality of upper tool assemblies
3100, all of the corresponding docking station frames 3120 may be
substantially the same and interchangeable with each other, so that
any of the docking station frames 3120 may be placed in any docking
station receiver (not shown) in the container sealer 30.
[0146] Although shown as having an in-line configuration, it is
noted that the upper tool 3100 may have any configuration,
including, e.g., a planar configuration (e.g., n.times.m matrix of
sealing modules 3110, where n and m are non-zero positive integers
that may have the same or different values), or a multi-planar
array structure (e.g., n.times.m.times.p, where p is an integer
greater than 1), or any other configuration, as understood by those
having ordinary skill in the art, without departing from the scope
or spirit of the disclosure.
[0147] FIG. 18B shows a perspective bottom view of the upper tool
3100. As seen, the up per tool 3100 may include a plurality of
sealing modules 3110 coupled to the docking station frame 3120.
[0148] FIGS. 19A and 19B show perspective views of opposite sides
of an example of a sealing module 3110 that is constructed
according to principles of the disclosure. The sealing module 3110
includes a tower 3111, a chamber 3112, a utility connector 3117,
and a port 31155 for connection to the utility connector 3115. The
sealing module 3110 may further include a recess or groove 3125 to
reduce the weight and cost of the sealing module 3110, as well as
provide a handle for manipulation of the sealing module 3110. The
utility connector 3117 may supply a gas to the sealing module 3110
and/or extract a gas from the sealing module 3110. The utility
connector 3115 may include a communication link that may carry, for
example, data signals, control signals, electric power, and the
like. The chamber 3112 may include a plurality of seals 3128, 31281
for providing a hermetic seal between the chamber 3112 and a
container carrier, such as, for example, the container carrier
4120' shown in FIG. 22C.
[0149] The tower 3111 and chamber 3112 may be constructed from two
or more pieces, as seen in FIGS. 19A, 19B. In this case, the tower
3111 and chamber 3112 may include seals sandwiched there-between to
prevent gas or fluid leaks.
[0150] Alternatively, the tower 3111 and chamber 3112 may be
machined from a single piece, thereby avoiding any need for seals,
as seen, for example, in FIG. 22I.
[0151] The utility connector 3117 (or 3115) may be integrated into
the tower 3111 and chamber 3112.
[0152] FIG. 20 shows a cross-section view of an existing,
state-of-the-art dual-zone head 4100 in contact with a lower tool
4101, which may be used in the upper tool assembly 3100 (shown in
FIGS. 18A-18B). A similar dual-zone head assembly may be found in
INPACK S Series Tray Sealers.TM. made by Ross.RTM. Industries,
Inc., and specially designed for modified atmosphere packages
(MAP). The head 4100 includes a sealing module body 4110, which
houses a sealer 4140 and an optional cutter 4150. The sealer 4140
may be operated to seal a lidding 4170 to a container 250. The
sealer 4140 may use, for example, temperature, time and/or pressure
to affix the lidding 4170 to the container 250. The cutter 4150 may
be included and implemented where it is desirable to cut the
lidding 4170.
[0153] The container 250 may be nested in the lower tool 4101,
which may include a container carrier 4120 and a chamber block
4130. The container 250 may be supported by a lift table 253. The
container carrier 4120 may be hermetically (or airtight) sealed to
the chamber block 4130 by, for example, a seal 4138 (such as, for
example, a gasket, or the like). The container 250 may include a
flange 251, which may rest on, for example, a container seal 4122
(such as, for example, a gasket formed of rubber, silicone, or the
like). A contact seal 4128 may be provided on the container carrier
4120 (and/or the sealing module body 4110) to provide a hermetic
(or airtight) seal between the sealing module body 4110 and the
container carrier 4120 when the sealing module body 4110 and the
lower tool 4101 are positioned in the sealing position (shown in
FIG. 20).
[0154] The lidding 4170 may be stretched between the lower tool
4101 and the sealing module body 4110, thereby separating a head
cavity (or zone) 4142 from a container cavity (or zone) 4144. The
container cavity 4144 may include the container 250.
[0155] In the sealing position, gas (for example, air) may be
evacuated from the lower tool cavity 4146, the container cavity
4144 and the head cavity 4142. A gas may be received from, for
example, channels in the top plate 4190, which is part of the
container sealer (for example, container sealer 30, shown in FIG.
1) and injected to the container cavity 4144 and the head cavity
4142 to preserve or enhance certain characteristics of the contents
of the container 250. In some applications, the gas may be allowed
to enter the head cavity 4142 to equalize the pressure above and
beneath the lidding 4170. The gas is injected into the container
cavity 4144 indirectly through the lower tool cavity 4146. The
injected gas may include an inert gas, such as, for example,
nitrogen, a blended gas, or the like. In the case of food products,
the injected gas may preserve and enhance characteristics, such as,
for example, freshness, color, shelf life, or the like. The gas may
be evacuated from the head cavity 4142, the container cavity 4144
and the lower tool cavity 4146 through channels 4196 and 4198. The
channel 4192 may be used to inject the replacement gas to the
container cavity 4144 thru the lower tool cavity 4146.
[0156] FIG. 20 shows an example of a vertical configuration of gas
evacuation and injection channels 4192, 4194, 4195, 4196, and 4198
in the sealing module body 4110 and the top plate 4190. The channel
4194 provides a conduit for evacuating (or removing) gases from,
and injecting (or supplying) gases to a cavity 4162 above a piston
4160, which is rendered substantially air-tight by a piston seal
4168. The channel 4195 provides a conduit for evacuating gases
from, and injecting gases to a cavity 4164 below the piston 4160.
The channel 4196 provides a conduit for evacuating gases from, and
injecting gases to the head cavity 4142. The channel 4198 provides
a conduit for evacuating gases from the lower tool cavity 4146 and
the container cavity 4144. The cavities 4142 and 4146 may be sealed
from each other to prevent gases from flowing freely between the
cavities. The cavities 4144 and 4146 are sealed from the cavity
4142 by the lidding 4170. The piston cavity 4164 is sealed from the
head cavity 4142 with a piston seal (not shown). As seen in FIG.
20, the top plate 4190 may be hermetically sealed to the sealing
module body 4110 by means of, for example, a plurality of seals
4180.
[0157] FIG. 21 shows an example of gas flow in the dual-zone head
4100 and the lower tool 4101. For example, air from the container
cavity 4144 may be evacuated through the channel 4198 and up
through the top plate 4190 (not shown in FIG. 21) to a vacuum valve
(not shown). A replacement gas may be injected from, for example, a
gas valve (not shown) through the top plate 4190 and down through
the channel 4192 to the container cavity 4144 through the lower
tool cavity 4146. The channel configuration shown in FIGS. 20 and
21, however, may render the head 4100 susceptible to restrictions
on gas flow due to the configurations of the channels 4192 and
4198. Furthermore, a disadvantage of the dual-zone configuration
may be that the container cavity 4144 is not separated from the
lower tool cavity 4146 that is formed under the container 250 and
within the chamber block 4130. In this regard, the entire volume of
the gas in the cavities 4144 and 4146 should be evacuated and
replaced with a replacement gas. Accordingly, every cycle of the
sealing process, gas in the cavity 4146 is unnecessarily vented to
the surrounding atmosphere and replacement gas is injected into the
cavity 4146.
[0158] Referring to FIG. 21, in a MAP process the air is
substantially always evacuated from the lower tool cavity 4146, as
well as the container cavity 4144. In this dual zone approach,
replacement gases, such as, for example, are supplied to both the
container cavity 4144 and lower tool cavity 4146, thereby resulting
in unnecessary waste of the replacement gas and larger resource
needs to supply and remove the wasted replacement gas.
[0159] FIG. 22A shows a cross-section view of the head 4100 in
contact with another example of a lower tool 4201, according to the
principles of the disclosure. The lower tool 4201 configuration
allows for the creation and maintenance of three separate zones (or
cavities) 4142, 4144, 4146, each of which may have a different (or
the same) pressure from the other two zones.
[0160] Further to the description provided above with regard to
FIG. 20, the channel configuration of the lower tool 4201 differs
from that of the lower tool 4101. For instance, the portion of the
channels 4192' and 4198' in the container carrier 4120' are
configured so that three separate cavities (or zones) 4142, 4144,
and 4146, may be formed when the head 4100 contacts the lower tool
4201. The lower tool cavity 4146, which includes portions of the
container carrier 4120' and the chamber block 4130', is configured
to include a port 4132 for evacuating (or releasing) or injecting
(or supplying) gas into the lower tool cavity 4146. Furthermore,
the channels 4192' and 4198' may be provided with plugs 4123 (as
seen in FIG. 22A) to allow for selection between dual-zone and
triple-zone operation of the head 4100 when it contacts the lower
tool 4201.
[0161] Where only triple-zone operation is desired, the container
carrier 4120' may be formed to eliminate the ports 4125.
[0162] It is noted that while the port 4132 is shown in the lower
chamber block 4130 for simplicity, the port 4130 may be located in
the sealing module body 4110.
[0163] In triple-zone operation, the plugs 4123 may be placed in
the channel ports 4125 of the channels 4192' and 4198' (as seen in
FIG. 22A), thereby closing access to the channels 4192' and 4198'
from lower tool cavity 4146 and preventing gas from escaping or
being injected through the ports 4125. The lidding 4170, when
stretched between the sealing module body 4110 and the container
carrier 4120', may create a membrane that separates the head cavity
4142 from the container cavity 4144. Since there are no open
airways through the carrier 4120' from the lower tool cavity 4146,
and because the container 250 is nested in the container carrier
4120' and is supported by the seal 4122, the container 250 may
function as a barrier that seals the container cavity 4144 from the
lower tool cavity 4146. A sealing pressure may be created when the
gas (e.g., air) begins to evacuate from the lower tool cavity 4146.
Small differences in pressures between the container cavity 4144
and the lower tool cavity 4146 may be sufficient to pull the
container 250 against the seal 4122 and hermetically seal off the
cavities 4144 and 4146 from each other.
[0164] FIG. 22B shows a cross-section view of an example of a head
4200 and a lower tool 42011, which are constructed according to the
principles of the disclosure. A sealing module body 41101, a
channel duct 4210, and a top plate 41901 may include a horizontal
configuration of gas evacuation and injection channels 41921,
41941, 41951, 41961, and 41981, as seen in the figure. The head
4200 may include a cutter 41501. The channels 41921, 41941, 41951,
41961, and 41981, may be formed in the sealing module body 41101,
the channel duct 4210, and the top plate 41901. The channel duct
4210 may be a part of, or formed in, for example, the lower frame
part 3130 (or upper frame part 3140) of the docking station frame
(shown in FIGS. 18A, 18B). The top plate 41901 may be a part of the
container sealer 30 (shown in FIG. 1). The channels 41921, 41941,
41951, 41961, and 41981 may perform substantially the same function
as the channels 4192', 4194, 4195, 4196, and 4198 (shown in FIG.
22A).
[0165] It is noted that some or all of the channels 41921, 41941,
41951, 41961, and 41981, may be formed in only the lower tool
42011.
[0166] Referring back to FIGS. 18A-18B, either the lower frame part
3130 or the upper frame part 3140 may include the channel duct
4210. The channel duct 4210 may be coupled to all of the sealing
modules 3110 in the docking station frame 3120. The channel duct
4210, which may be "gun-drilled" throughout its entire length, may
provide all (or some) of the gas (or fluid) supply/return lines to
the sealing modules 3110.
[0167] The head 4200 may contact the lower tool 42011 to seal the
lidding 4170 to the container 250. The lower tool 42011 may include
a container carrier 41201, which may include portions of the
channels 41921 and 41981, and a chamber block 41301.
[0168] FIG. 22C shows a cross-section view of an example of the
head 4200 in contact with the lower tool 42011, according to the
principles of the disclosure.
[0169] FIG. 22D shows a cross-section side view of an example of
the head 4200 and docking station frame 3120 (shown in FIGS. 18A,
18B) separated from the top plate 41901. In this example, the
channel duct 4210 is provided with the head 4200 when the head 4200
contacts the top plate 41901. The channel duct 4210 may be
integrally formed with, or in the lower frame part 3130 (or upper
frame part 3140) of the docking station frame 3120, or affixed to
the lower frame part 3130 (or upper frame part 3140) by means of
fasteners, such as, for example, screws, bolts, pins, rivets, nuts,
spot welds, adhesives, or the like. A seal 41908 may be provided
between the channel duct 4210 and the top plate 41901 to provide a
hermetic seal of the channels 41921, 41941, 41951, 41961,
41981.
[0170] FIG. 22E shows a cross-section side view of another example
of the head 4200 being removed from the channel duct 4210 and the
top plate 41901. In this example, the docking station frame 3120
(shown in FIGS. 18A, 18B) remains in place with regard to the top
plate 41901, but the sealing module associated with the head 4200
is removed from the docking station frame 3120. A seal 41907 may be
provided between the channel duct 4210 and the sealing module body
41101.
[0171] FIG. 22F shows a cross-section, front view of the plurality
of heads 4200 (shown in FIG. 22B) mounted in, for example, the
docking station frame 3120, which is attached to the top plate 4190
of the container sealer 30 (shown in FIG. 1). The upper tool
assembly includes three separate heads, each of which may be
connected to the channel duct 4210.
[0172] FIG. 22G shows a cross-section front view of the plurality
of heads 4200 (shown in FIG. 22D) removed from the top plate 41901
together with the channel duct 4210. The docking station frame 3120
may include the common channel duct 4210 that may be removed from
the top plate 4190. In this example, the channel duct 4210 is a
single structure comprising channels (not shown) for each of the
plurality of heads. As seen, the channel duct 4210 is separable
with the heads.
[0173] FIG. 22H shows a cross-section front view of one of the
plurality of heads 4200 (shown in FIG. 22E) removed from the
channel duct 4210. Each of the heads 4200 may be configured to be
removable from the channel duct 4210. Meanwhile, the docking
station frame 3120, including the channel duct 4210, is configured
to be removable from the top plate 4190.
[0174] FIG. 22I shows a cross-section, detailed view of the sealing
module body 41101, which is constructed according to the principles
of the disclosure.
[0175] FIG. 22J shows a cross-section, detailed view of another
example of a sealing module body 41102, which is constructed
according to the principles of the disclosure. The sealing module
body 41102 may include an upper portion 41103 and a lower portion
41104, which may be affixed to each other by a fastener (not
shown). The fastener may include, for example, a screw, a bolt, a
pin, a rivet, a nut, a spot weld, an adhesive, or the like.
[0176] FIG. 23 shows an example of gas flow in the triple-zone head
4100 and lower tool body 4201, shown in FIG. 22A. For example, air
from the container cavity 4144 may be evacuated through the channel
4198' and up through the top plate 4190 (shown in FIG. 22A) to a
vacuum valve (not shown). The vacuum valve may be connected to the
lower frame part 3130 (shown in FIGS. 18A, 18B). A replacement gas
may be injected from, for example, a gas valve (not shown), through
the top plate 4190 and down through the channel 4192' to the
container cavity 4144. Gas may be prevented from flowing from (or
to) the channels 4192', 4198' and/or the container cavity 4144 to
(or from) the lower tool cavity 4146 by placement of the plugs 4123
in the channel ports 4125. Gas may be permitted to flow into and
out from the lower tool cavity 4146 through the port 4132. The
plugs 4123 are provided in the instance where a portion of channel
4198' is drilled from the side into the carrier 4120'. However, the
carrier 4120' may be machined such that the plugs 4123 are not
necessary, as understood by those having ordinary skill in the
art.
[0177] The option of removable plugs 4123 may offer a channel
configuration, as seen in FIGS. 22 and 23, that allows for
selection between dual-zone and triple-zone operation of the
sealing assembly, should it be desired.
[0178] FIG. 24 shows an example of gas flow in the triple-zone head
4200 and lower tool body 42011, shown in FIG. 22B. Further to the
description provided above with regard to FIG. 22B, the channel
configuration of the lower tool body 42011 may differ from that the
lower tool body shown in FIGS. 22-23 in that the portions of the
channels 4192'' and 4198'' in the carrier 4120'' may be configured
to inject (or evacuate) gas to (or from) the container cavity 4144
with minimal restrictions to the flow of gas through the channels
4192'' and 4198''. Although shown as including a "sharp" 90.degree.
elbow in the portions of each of the channels 4192'' and 4198'' in
the carrier 4120'', the 90.degree. elbow may be configured to
include a "soft" 90.degree. turn that gradually changes the
direction of the gas flow through the channels 4192'' and 4198'',
thereby minimizing disturbances to the flowing gas in the channels
4192'' and 4198''.
[0179] FIG. 25 shows a cross-section view of yet another example of
a triple-zone head 4100'' and a lower tool that are constructed
according to the principles of the disclosure. Further to the
description provided above with regard to FIGS. 20-24, the channel
configuration of the lower tool body may differ from that of the
lower tool body shown in FIG. 24 in that it may further include a
gas plate 4121, which may be sandwiched between the sealing module
body 4110 and the carrier 4120'''. Seal 4128' may be placed between
the sealing module body 4110 and a first surface of the gas plate
4121 to provide a substantially air-tight seal. Seals 4128 may be
placed between a second surface of the gas plate 4121 and the
carrier 4120''' to provide a substantially air-tight seal.
[0180] As seen in FIG. 25, the 90.degree. elbows of the channels
4192''' and 4198''' may be provided in the gas plate 4121. For
example, the gas plate 4121 may be machined from one side to
provide channels with optimal gas flow. The carrier 4120''' may not
include any portion of the channels 4192''' or 4198'''. The gas
plate 4121 may be affixed to the carrier 4120''' by means of, for
example, bolts, screws, pins, nuts, or the like. The channel
configuration shown in FIG. 25 may be practical where it is
difficult or impossible to machine channels in the carrier 4120'''
due to, for example, space or tool restrictions, or where it may be
desirable to alter the channel configuration proximate the
container cavity 4144. Furthermore, this channel configuration
offers the advantage of easy disassembly (or assembly) and removal
(or replacement) of the gas plate 4121 for cleaning purposes, such
as, for cleaning of the portions of the channels 4192''' and
4198''' in the gas plate 4121.
[0181] FIG. 26 shows a cross-section view of still further example
of a triple-zone head 4100''' and the lower tool body constructed
according to the principles of the disclosure. Further to the
description provided above with regard to FIGS. 20-25, the channel
configuration of the lower tool body may differ from that shown,
for example, in FIG. 24, in that it may further include a carrier
insert 4124, which may be placed in a complementary carrier recess
4126 provided in the carrier 4120''''. The carrier insert 4124 may
be removed from the carrier recess 4126 and the portions of the
channels 4192'''' and 4198'''' cleaned before replacement, or the
carrier insert 4124 may be replaced with another carrier insert
4124, where the carrier insert 4124 has been damaged or a different
channel configuration is desired for the portions of the channels
4192'''' and 4198'''' in the carrier insert 4124.
[0182] The carrier insert 4124 may be fastened or interlocked to
the carrier 4120'''' to help maintain the position of the carrier
insert 4124 in the carrier recess 4126 during operation of the head
4100'''. The carrier insert 4124 may be fastened to or interlocked
with the carrier 4120'''' by means of, for example, an adhesive, a
tongue-and-groove coupling, or the like. The carrier insert 4124
may be made from a material such as, for example, a metal, a
plastic, a rubber, or the like, or a combination of the foregoing.
Further, the material may include an elastic material, such as, for
example, silicone, or similar material, to enable the carrier
insert 4124 to function as a seal and thereby prevent gas from
escaping to the outside of the container cavity 4144.
[0183] It is noted that the sealer 4140 and/or cutter 4150 may be
driven by the piston 4160, or any other mechanism capable of
driving the sealer 4140 and/or cutter 4150, including, for example,
a servomotor, a linear actuator, a linear motor, a pneumatic
actuator, or the like.
[0184] FIG. 27 shows a perspective partial view of an example of
the lower tool 4300, constructed according to the principles of the
disclosure. As seen in FIG. 27, the carrier insert 4124 may include
a plurality of channel portions 4198'''' and a corresponding
plurality of inlet/outlet ports 4127.
[0185] FIG. 28 shows a perspective exploded partial view of the
example of the lower tool 4300. The carrier insert 4124 may be
provided with a tongue portion 41241 and the carrier recess 4126
may be provided with a complementary groove 41261, which is
configured to receive the tongue portion 41241.
[0186] FIG. 29 shows a perspective partial underside view of an
example of the carrier insert 4124, constructed according to the
principles of the disclosure. It is noted that the cross-section of
the area of the outlet and inlet ports may vary. For example, the
carrier insert 4124 on the gas injection side may have smaller
channels 4127 than the channels 4127 on the gas vacuuming side of
the carrier insert 4124. In this regard, a venturi effect may be
created, causing the gas to increase speed while flowing above the
product in the container 250. A higher flow speed of the gas will
result in lower pressure of the gas stream, which would assist in
removing the air at the bottom of the container 250 and therefore
speed up the "MAP" process.
[0187] FIGS. 30A-30C show various examples of existing,
state-of-the-art cutting blade assemblies 450, 450', 450'',
respectively, any of which may be used in the upper tool 3100
(shown in FIG. 18A).
[0188] Referring FIG. 30A, the cutting blade assembly 450 includes
a mounting base 452, at least one piece of blade 456 and bolts 454
for securing the blade(s) 456 to the mounting base 452.
[0189] Referring FIG. 30B, the cutting blade 450' includes a
mounting base 452', at least one piece of blade 456', bolts 454',
and mounting tabs 458. The mounting tabs 458 are a part of, or
attached to the blades 456'. The mounting tabs 458 are attached to
the mounting base 452' by means of the bolts 454'.
[0190] Referring to FIG. 30C, the cutting blade 450'' includes the
mounting base 452, at least one piece of blade 456'', and a pair of
set-screws 454'' for securing the blades 456'' to the mounting base
452.
[0191] FIGS. 31A-31B show two views of an example of a cutting
blade assembly 4500, constructed according to the principles of the
disclosure. Referring to FIG. 31A, the cutting blade assembly 4500
may include a mounting base 4510, a blade 4520, a blade clip 4530,
and a fastener 4540. The fastener 4540 may include, for example, a
bolt, a pin, a set-screw, a nut, or the like. One end of the blade
clip 4530 may be secured to the mounting base 4510 by means of the
fastener 4540. The other end 4535 of the blade clip 4530 may be
inserted into an opening 4525 of the corresponding blade 4520.
[0192] FIG. 31B shows an example where a pair of blade clip ends
4535 are removed from the openings 4525 in the blade 4520, thereby
releasing the blade 4520 for removal from the cutting blade
assembly 4500. The blade clip ends 4535 may be configured to fit
into and through the openings 4525 to engage and fasten to the
mounting base portions 4515 of the mounting base 4510. The blade
clips 4530 may be manufactured from, for example, sheet metal with
spring-like properties, or from a variety of materials, such as,
for example plastic, metal, or the like. The blade clips 4530 may
be pulled from the openings 4525 without removing the fastener
4540.
[0193] FIG. 32 shows another example of a cutting blade assembly
4500' constructed according to the principles of the disclosure.
The cutting blade assembly 4500' may include a mounting base 4510',
a blade 4520', a blade clip 4530', and a fastener 4540'. The
fastener 4540' may include, for example, a bolt, a pin, a
set-screw, a nut, or the like. One end of the blade clip 4530' may
be secured to the mounting base 4510' by means of the fastener
4540'. The other end 4535' of the blade clip 4530' may be inserted
into and through the opening 4525' to engage and fasten to the
blade portion 4522 of the blade 4520'.
[0194] FIG. 33 shows yet another example of a cutting blade
assembly 4500'' constructed according to the principles of the
disclosure. The cutting blade assembly 4500'' may include a
mounting base 4510'', a blade 4520'', a blade clip 4530'', and a
fastener 4540''. The fastener 4540'' may include, for example, a
bolt, a pin, a set-screw, a nut, or the like. One end of the blade
clip 4530'' may be inserted into and through an opening 4512 of the
mounting base 4510'' and secured to the mounting based 4510'' by
means of the fastener 4540''. The other end 4535'' of the blade
clip 4530'' may be inserted into and through the opening 4525'' to
engage and fasten to the blade portion 4522' of the blade
4520''.
[0195] FIG. 34 shows an example of a blade clip 453 constructed
according to principles of the disclosure. The blade clip 453 may
have an elongated rod-like configuration. The blade clip 453 may
include a mounting hole 4531, a mounting base engagement portion
4534 and a blade engagement portion 4532. The mounting hole 4531
may be configured to receive a fastener 4536 (shown in FIG. 35),
such as, for example, a bolt, a screw, a pin, or the like. The
mounting base engagement portion 4534 and the blade engagement
portion 4532 may form a recess 4533 therebetween.
[0196] FIG. 35 shows a perspective partial view of an example of a
blade 4520''' fastened to a mounting base 4510''' by means of one
or more of the blade clips 453, according to principles of the
disclosure. The mounting base 4510''' may include an opening 4517
for receiving and engaging the mounting base portion 4534, and the
blade 4520''' may include an opening 4525''' for receiving and
engaging the blade engagement portion 4532 of the blade clip 453.
The blade clip 453 may be secured in position by the fastener
4536.
[0197] FIG. 36 shows a partial cross-section view of the blade
4520''' fastened to the mounting base 4510''' by means of the blade
clip 453, including a cross-section view of the blade clip 453.
[0198] FIG. 37 shows another example of a blade clip 453'
constructed according to principles of the disclosure. The blade
clip 453' may have a generally planar shape. The blade clip 453'
may include an opening 4531', a mounting base engagement portion
4534' and a blade engagement portion 4532'. The opening 4531' may
be configured to receive a fastener 4536' (shown in FIG. 38), such
as, for example, a bolt, a screw, a pin, or the like.
[0199] FIG. 38 shows a perspective partial view of another example
of a blade 4520'''' fastened to a mounting base 4510'''' by means
of a bridge, which includes one or more of the blade clips 453' and
a mounting base leg 4539, according to the principles of the
disclosure. The mounting base 4510'''' may include an opening 4517'
for receiving and engaging the mounting base portion 4534', and the
blade 4520'''' may include an opening 4525'''' for receiving and
engaging the blade engagement portion 4532' of the blade clip 453'.
The blade clip 453' may be affixed to the mounting base leg 4539,
which may affixed to the mounting base 4510'''' at an upper portion
and a blade support frame 45209 on a lower portion. The blade
4520'''' may be attached to and supported by the blade support
frame 45209. The blade clip 453' may be secured in position by the
fastener 4536. The mounting base leg 4539 may also be secured in
position by the fastener 4536.
[0200] It is noted that the mounting leg 4539 may be left out. The
mounting leg 4539 is not needed for the blade clip 453 to function.
The blade 4520'''' may be attached directly to the mounting base
4510''''.
[0201] FIG. 39 shows a partial cross-section view of the mounting
base 4510'''' fastened to the blade support frame 45209 by means of
the blade clip 453, including a cross-section view of the blade
clip 453.
[0202] FIG. 40 shows an example of a cutting/sealing assembly 4600
that is constructed according to the principles of the disclosure.
The cutting/sealing assembly 4600 is shown in a pre-cut, pre-seal
position, before the heat-seal die 4640 or the blade 4620 have
engaged the lidding 4170. The cutting/sealing assembly 4600 may
include a mounting base 4610, a blade 4620, a bridge 4630, and a
heat-seal die 4640. The heat-seal die 4640 may include an imbedded
heater element 4645. The cutting/sealing assembly 4600 may include
a blade support frame 4650 that is configured to hold the blade
4620. The cutting/sealing assembly 4600 may be used in operations
where the lidding 4170 is not, for example, a "Pre-die cut lid",
but a lidding that is unwound from, for example, a roll and should
be trimmed along outer contours of the container 250. The blade
4620 may be configured to the contours of the container 250.
[0203] FIG. 41 shows an example of the cutting/sealing assembly
4600 in the seal-cut position, after the heat-seal die 4640 and the
blade 4620 have engaged the lidding 4170.
[0204] FIG. 42 shows a partial three-dimensional perspective view
of an example of the cutting/sealing assembly 4600, which is
constructed according to the principles of the disclosure. The
heat-seal die 4640 is shown in this figure in a seal, pre-cut (or
post-cut) configuration, where an engaging portion 4642 of the
heat-seal die 4640 extends below the blade 4620 to engage and heat
the lidding 4170, thereby causing the lidding 4170 to adhere to,
and hermetically seal the contents of the container 250.
[0205] The mounting base 4610 may include a substantially planar
surface 4612, and the heat-seal die 4640 may include, for example,
substantially planar surfaces 4644 and 4646 (shown in FIG. 43).
Alternatively, non-planar surfaces 4612, 4644, 4646 may be used. In
the cut position (shown in FIG. 43), when the blade 4620 is
completely extended as seen in the figure, the heat-seal die
assembly surface 4644 may contact the mounting base surface 4612 to
ensure that no gaps exist between the mounting base surface 4612
and the heat-seal die assembly surface 4644. The heat-seal die
assembly surface 4644 may include, for example, a material that is
a poor heat conductor to minimize the transfer of heat from the
heat-seal die 4640 to the mounting base 4610. The bridges 4630 may
also be made from a good thermo-insulating material to minimize the
transfer of heat from the blade support frame 4650 to the mounting
base 4610.
[0206] Further, the heat-seal die 4640 may include, for example,
the substantially planar surface 4646, and the blade support frame
4650 may include, for example, a substantially planar surface 4652.
In the pre-cut position (shown in FIG. 42), when the blade 4620 is
completely retracted as seen in the figure, the heat-seal die
surface 4646 may contact the blade support surface 4652 to ensure
that no gaps exist between the blade support surface 4652 and the
heat-seal die surface 4646. The blade support frame 4650 and the
blade 4620 may be made from materials that have good heat
conductive characteristics to ensure rapid heating of the blades
4620 when the blade support surface 4652 contacts the heat-seal die
surface 4646. Furthermore, the blade support frame 4650 may be
configured to be as small as possible to maximize the efficiency of
transfer of heat from heat-seal die 4640 to the blade 4620. Thus,
the blade 4620 may be heated by the heat-seal die 4640 while
resting in the pre-cut position (shown in FIG. 42), so as to
provide a hot-cut of the lidding 4170. In this regard, the blade
4620 may receive heat from the heat-seal die 4640 through the blade
support frame 4650, as well as heat received directly from the
heat-seal die 4640 by the proximity of the heated engaging portion
4642 to the blade 4620.
[0207] The contact between the blade support surface 4652 and
heat-seal die surface 4646, as well as the contact between the
mounting base surface 4612 and heat-seal die assembly surface 4644,
may be facilitated or carried out using mechanical components (not
shown), pneumatic components (not shown), hydraulic components (not
shown), electromechanical components (not shown), or the like, as
known in the relevant arts.
[0208] FIG. 43 shows a partial three-dimensional perspective view
of the cutting/sealing assembly 4600 of FIG. 42 configured in a
post-seal, cut configuration, where the heat-seal die 4640 is
retracted and the blade 4620 is extended to engage and cut the
lidding 4170. The cutting/sealing assembly 4600 may be used in
operations where the lidding 4170 is not, for example, a "Pre-die
cut lid", but a lidding that is unwound from, for example, a roll
and should be trimmed along outer contours of the container
250.
[0209] Referring to FIGS. 40-43, the heat-seal die 4640, including
the imbedded heater element 4645, may be connected to and powered
by a remote power source (not shown), which may be located, for
example, on the docking station 3120 (shown in FIG. 18A). The power
source may include an electrical power source, which may supply
power to multiple cutting assemblies provided in the sealing
modules 3110 (shown in FIG. 18A).
[0210] FIG. 44 shows an example of a lift 4700 that is constructed
according to the principles of the disclosure. The lift 4700 may
include a top lift member 4710, a base lift member 4720, a weight
lever 4730 and a weight 4740. The lift 4700 may further include a
plurality of linear guides (or actuators) 4712, 4723, a plurality
of shafts 4722, 4713, a top scissor member 4715, a base scissor
member 4725, a weight support member 4732, a weight guide member
4734, and a weight lever guide 4736. The weight lever guide 4736
may include, for example, a cam roller (shown in FIG. 44), a rod,
or the like, that is positioned in a guide 4738 of the weight guide
member 4734, where the guide 4738 may include, for example, a
groove, a bearing, or the like. The weight support member 4732 may
include, for example, a column that is pivotally affixed to the
weight lever 4730. The weight support member 4732 may include, for
example, bearings to reduce the friction experienced by the weight
lever 4730 while pivoting on the weight support member 4732. The
linear guides 4712, 4723 may include, for example, electromagnetic
actuators that cause the shafts 4722, 4713, respectively, to move
up or down the longitudinal axis of the guides 4712, 4723.
Alternatively (or additionally), the scissor members 4715, 4725 may
be coupled to, for example, a motor shaft, a gear box, or the like,
to drive the scissor members 4715, 4725 to expand or contract. The
shaft 4722 may be configured as a linear shaft and the linear guide
4712 may be configured as a linear bearing, or the like.
[0211] As seen in FIG. 44, the lift 4700 may include counterweights
4740 on either side of the lift 4700. The mass of the
counterweights 4740 may be matched to the mass that is to be lifted
by, for example, the top lift member 4710. While two counterweights
4740 are shown in FIG. 44, the number of counterweights and their
location in the lift 4700 may vary, as recognized by those having
ordinary skill in the art. Further, the mass of the counterweights
4740 may depend on the length of the weight lever 4730 used and the
point at which the weight lever 4730 is pivotally affixed to the
weight support member 4732.
[0212] For instance, in the example shown in FIG. 44, the weight
lever 4730 is pivotally affixed to the weight support member 4732
to provide about a 1:2 lever ratio, thereby cutting down the mass
of the counterweight 4740 by about one-half. For example, if a
total mass to be lifted is about 400 lbs and the lever ratio is
about 1:1, then each of a pair of counterweights 4740 should be
about 200 lbs. However, if a 1:2 lever ratio is used, then each of
the pair of counterweights 4740 should be about 100 lbs to
counterbalance the 400 lb mass to be lifted.
[0213] FIG. 45 shows the lift 4700 in a full-lift position, where
the scissor members 4715, 4725 are substantially fully extended.
The scissor members 4715, 4725 may be locked in the upper position
by a locking mechanism (not shown).
[0214] FIG. 46 shows another example of a lift 4700' that is
constructed according to the principles of the disclosure. As seen,
the lift 4700' may include a scissor linkage 4726 that links a
first pair of scissor members 4715, 4725 to a second pair of
scissor members 4715, 4725. One end of the scissor linkage 4726 may
be pivotally coupled to an end of the shaft 4713. The linear guide
4723 may be pivotally coupled to a guide support 4727. It is noted
that the guide support 4727 may be attached to the top lift member
4710 or the base lift member 4720.
[0215] FIG. 47 shows the lift 4700' in a full-lift position, where
the scissor members 4715, 4725 are substantially fully extended.
The scissor members 4715, 4725 may be locked in the upper position
by a locking mechanism (not shown).
[0216] FIG. 48 shows yet another example of a lift 4700'' that is
constructed according to the principles of the disclosure. Further
to the description provided above with regard to FIG. 44, the lift
4700'' may include a pivot member 4735 instead of the weight guide
member 4734 and the weight lever guide 4736.
[0217] FIG. 49A shows still a further example of a lift 4700'''
that is constructed according to the principles of the disclosure.
Further to the description provided above with regard to FIG. 46,
the lift 4700''' may include the pivot member 4735 instead of the
weight guide member 4734 and the weight lever guide 4736.
[0218] FIG. 49B shows still a further example of a lift 4700''''
that is constructed according to the principles of the disclosure.
The lift 4700'''' is shown in the lift position. Further to the
description provided above with regard to FIGS. 45 and 48, the lift
4700'''' may include the scissor linkage 4726, the linear guide
4723 and the guide support 4727. FIG. 49C shows the lift 4700''''
in the lowered position.
[0219] FIG. 49D shows still a further example of a lift 4700'''''
that is constructed according to the principles of the disclosure.
The lift 4700''''' is shown in the lift position. Further to the
description provided above with regard to FIG. 45, the lift
4700''''' may include the scissor linkage 4726, a locking and
releasing actuator 4723' and the guide support 4727. FIG. 49E shows
the lift 4700''''' in the lowered position.
[0220] FIG. 50 shows a perspective view of an example of a lidding
unwind system 4800 that is constructed according to the principles
of the disclosure. The lidding unwind system 4800 includes a
lidding roll 4810 mounted to a lidding unwind mandrel (not shown),
which may protrude through the lidding roll core 4820.
Alternatively, the lidding roll 4810 may be placed atop a plurality
of cradle rollers (not shown). The lidding roll 4810 is wound with
a lidding 4830 that may be unwound in, for example, a direction
4835. In this regard, the lidding unwind mandrel (or plurality of
cradle rollers) may be driven so as to spin a predetermined number
of revolutions, depending on the lidding length needed, and supply
the lidding 4830 to, for example, a sealing assembly (not shown) to
seal a plurality of containers 250.
[0221] The lidding unwind system 4800 further includes a plurality
of free rotating upper rollers 4840 (including upper rollers 4842,
4844, 4846), a plurality of free rotating dancer rollers 4850
(including dancer rollers 4852, 4854), a driven free feeding roller
4860, and a pincher roller 4870. The feeding roller 4860 and the
pincher roller 4870 may function together as a pair of feeding
rollers 4860, 4870. An apparatus for sealing a container 250, such
as, for example, the container sealer 30 (shown in FIG. 1), may
require a predetermined length of the lidding 4830 for operation.
The feeding roller 4860 may be coupled to a driver (not shown),
such as, for example, a motor, to draw the lidding 4830 from the
upper rollers 4840 and the dancer rollers 4850.
[0222] The upper rollers 4840 and the dancer rollers 4850 are
configured to function as a buffer between the lidding roll 4810
and the feeding rollers 4860, 4870, to store a predetermined length
of lidding 4830. In particular, the dancer rollers 4850 may be
configured to freely move with gravity or to be actively driven,
moving downwards (as shown in FIG. 50) with the unwinding lidding
4830 under light tension until the dancer rollers 4850 reach a
predetermined lower end position (shown in FIG. 52), thereby
storing a predetermined length of lidding 4830 between the dancer
rollers 4850 and the upper rollers 4840. Thus, dancer rollers 4850
function to buffer differences in the rate of unwinding of the
lidding 4830 from the lidding roller 4810 with respect to the rate
of lidding 4830 required by the apparatus, with the dancer rollers
4850 moving downward when the unwind speed of the lidding roller
4810 is great than the in-feed speed of the lidding 4830 fed into
the apparatus, and the dancer rollers 4850 moving upward when the
unwind speed of the lidding roller 4810 is less than the in-feed
speed of the lidding 4830 fed into the apparatus.
[0223] During operation, the feeding rollers 4860 and 4870 may turn
and feed the lidding 4830 into the apparatus after the length of
lidding 4830 that is needed is generated by the dancer rollers
4850. The buffering of the lidding 4830 may take place while the
apparatus is sealing the containers 250 and the feeding roller 4860
is standing still. Should the machine cycle of the apparatus be
short, the lidding 4830 may be buffered while the feeding roller
4860 feeds the lidding 4830 to the container sealer, as described
above.
[0224] The lidding unwind system 4800 may further include a dancer
roller position sensor (not shown) that may be configured to sense
when the dancer rollers 4850 reach the predetermined lower end
position. The dancer roller position sensor also may be configured
to sense when the dancer rollers 4850 are in an uppermost position.
The dancer roller position sensor may be coupled to a lidding feed
controller (not shown) via a communication link. The lidding feed
controller may be configured to stop the lidding roller 4810 from
supplying additional lidding 4830 when the dancer rollers 4850
reach the predetermined lower end position, or start the lidding
roller 4810 to supply additional lidding 4830 when the dancer
rollers 4850 reach the uppermost position. The lidding feed
controller may include a computer. Further, the lidding feed
controller may be separate from, or integral with the in-feed
controller.
[0225] The example of the lidding unwind system 4800 shown in FIG.
50 includes a pair of dancer rollers 4852, 4854. It is noted,
however, that the lidding unwind system 4800 may include more than
two dancer rollers 4850 to provide additional buffering capacity
for the lidding 4830.
[0226] It is known in the art to use a single dancer roller moving
vertically or horizontally, or a pair of rollers mounted on a
single pivoting lever that are configured to move in an arc. For
example, the INPACK S Series Tray Sealers.TM. made by Ross.RTM.
Industries, Inc., includes a single dancer roller. However, a
single dancer roller can only buffer half of the length of the
lidding 4830 as compared to the dual dancer rollers 4852, 4854 for
the same length of travel of the dancer rollers. Furthermore, the
single dancer roller would have to move at twice the speed of the
dual dancer rollers 4852, 4854 to provide the same length of
lidding 4830 to the apparatus, thereby increasing a likelihood of
overstretching or tearing of the lidding 4830.
[0227] The dancer rollers 4850 (e.g., 4852, 4854) may be connected
together and guided in a substantially vertical direction in order
to ensure substantially simultaneous sinking and rising of the
dancer rollers 4850. Alternatively, the dancer rollers 4850 may be
independent from each other. The dancer rollers 4850 may be guided
by means of, for example, linear bearings (not shown), gears and
racks (not shown), guide rollers or cams (not shown), guide blocks
(not shown), linear actuators (not shown), or the like. It is noted
that any number greater than or equal to two dancer rollers 4850
may be used, depending on the desired buffering capacity for the
lidding 4830 and available space for travel of the dancer rollers
4850.
[0228] Although the lidding unwind system 4800 is disclosed as a
supply source for the lidding 4830 used by an apparatus, such as,
for example, the container sealer 30 (shown in FIG. 1), it is noted
that substantially the same system 4800 may be used to rewind (or
take up) used up lidding 4830 from the apparatus, except that the
direction of movement of the used up lidding 4830 would be in a
direction that is opposite to the direction 4835 (shown in FIG.
50). The rewind dancer assembly (not shown) may optionally leave
out the driven feeding roller 4860 and the pincher roller 4870.
[0229] FIG. 51 shows a side view of the lidding unwind system 4800
with the dancer rollers 4850 located at an upper position, that is
above the predetermined lower end position.
[0230] FIG. 52 shows a side view of the lidding unwind system 4800
with the dancer rollers 4850 located at the predetermined lower end
position.
[0231] Referring to FIGS. 51 and 52, before the lidding 4830 is fed
via the feeding rollers 4860, 4870, to the apparatus (e.g., the
container sealer 30, shown in FIG. 1), the dancer rollers 4850 may
be retracted (or lifted) to their upper position(s) (shown in FIG.
51), so that the dancer rollers 4850 will have capacity to store a
predetermined length of the lidding 4830 between the dancer rollers
4850 and the upper rollers 4840. The lidding roller 4810 may be
unwound until the dancer rollers 4850 reach the predetermined lower
end position.
[0232] As soon as the feeding rollers 4860, 4870 start to pull the
lidding 4830, with the feeding roller 4860 being driven in a
direction 4635, the dancer rollers 4850 may start to move upward
and the lidding roller 4810 may be controlled to increase its
rotational speed in the direction 4835. When the dancer rollers
4850 move downward and reach the predetermined lower end position,
the lidding roller 4810 may be controlled to stop or slow down its
rotational speed in the direction 4835.
[0233] FIG. 53 shows a side view of the lidding unwind system 4800
with the upper rollers 4840 and the dancer rollers 4850 configured
in a threading configuration. As seen in the figure, the upper
rollers 4840 may be fixed while the dancer rollers 4850 may be
configured to move above the threading axis T, to allow for the
lidding 4830 to be drawn between the upper rollers 4840 and the
dancer rollers 4850. The upper rollers 4840 may be configured as
fixed rotating rollers that do not move up or down. The dancer
rollers 4850 may be configured to be lifted above the upper rollers
4840. After a length of lidding 4830 is drawn from the lidding roll
4810 and fed into the feeding rollers 4860, 4870, the dancer
rollers 4850 may be lowered below the upper rollers 4840.
[0234] According to an alternative embodiment of the lidding unwind
system 4800, the upper rollers 4840 may be configured to move up or
down.
[0235] FIG. 54 shows a perspective view of the lidding system 4800
with the upper rollers 4840 and the dancer rollers 4850 configured
in the threading configuration.
[0236] FIG. 55 shows an example of a lidding roll centering system
4900 that is constructed according to the principles of the
disclosure. The lidding roll centering system 4900 may include a
set of cradle rollers 4910, 4920, a common bar 4930, and a pair of
guide rollers 4940, 4950 (shown in FIG. 56). The cradler roller
4910, 4920 may be part of the container sealer 30 (shown in FIG.
1). The guide rollers 4940, 4950 may be vertically aligned and
rotationally affixed to the common bar 4930 so as to provide a
desired space between the vertically oriented rollers 4940, 4950
for the lidding roll 4810 and to guide the lidding roll 4810 as it
unwinds (or winds). Each of the guide rollers 4940, 4950 may be
configured to rotate about its respective longitudinal axis without
imposing any kind of negative resistance to the lidding roll 4810
as it spins. As seen in the figure, the guide rollers 4940, 4950
are configured to contact a side portion of the lidding roll 4810,
and the contact area of the guide rollers 4940, 4950 is configured
to move in substantially the same direction as the area on the
lidding roll 4810 that is contacted by the guide roller 4940 (or
4950).
[0237] FIG. 56 shows an exploded view of the lidding roll centering
system 4900. The common bar 4930 may include a pair of guide
openings 4945 that are configured to receive and hold the guide
rollers 4940, 4950. In particular, each of the guide rollers 4940,
4950 may have an engaging portion 4942, 4952, respectively that may
be inserted into and held in place by the guide opening 4945. The
guide openings 4945 may include, for example, bearings to minimize
friction between the engaging portions 4942, 4952 and the common
bar 4930.
[0238] Alternatively (or additionally), the engaging portions 4942,
4952 may be fixedly inserted into the guide openings 4945 (or
affixed to the common bar 4930). In this regard, each of the guide
rollers 4940, 4950 may include at least two separate portions,
including a rotating contact portion that is rotationally mounted
to a respective engaging portion 4942, 4952, and the fixed engaging
portion 4942, 4952. Each of the rotating contact portions may
include, for example, a bearing.
[0239] FIG. 57 shows a side view of the lidding roll centering
system 4900. As seen in FIG. 57, the longitudinal axis of each of
the guide rollers 4940, 4950 may be aligned with the central axis
of the lidding roll 4810, which is substantially perpendicular to
the longitudinal axes of the guide rollers 4940, 4950.
[0240] The guide rollers 4940, 4950 may be configured to be easily
removed, so as to allow for efficient replacement in case one (or
both) of the guide rollers 4940, 4950 is defective, damaged, or a
guide roller of a different dimension is desired (e.g., a
larger/smaller diameter and/or a longer/shorter length). The
removable configuration of the guide rollers 4940, 4950 may assist
in loading the lidding roll 4810 into the lidding roll centering
system 4900. For example, the guide roller 4940 may be removed and
the lidding roll 4810 inserted into the lidding roll centering
system 4900, with the other guide roller 4950 functioning as a stop
to prevent the lidding roll 4810 from moving further than the
contact surface of the guide roller 4950. Then, the guide roller
4940 may be affixed to the common bar 4930.
[0241] Although the example of the lidding roll centering system
4900 is disclosed to include a pair of cradle rollers 4910, 4920,
the system may, instead, include a mandrel (not shown) which
protrudes through the center core of the lidding role 4810. In this
alternative embodiment, different types of spacers may be used to
center the lidding roll 4810 on the mandrel, as understood by those
having ordinary skill in the art.
[0242] It is noted that container transferors, grippers, and the
like, described herein may be operated using various types of
actuators, including pneumatic, hydraulic, servo-motoric, or the
like. It is further noted that the in-feed controller and/or the
lidding feed controller may be coupled to a network to allow for
remote monitoring and/or control. Further, the in-feed controller
and/or the lidding feed controller may be configured to receive a
computer-readable medium comprising a computer program, which, when
executed on the in-feed controller and/or the lidding feed
controller may cause each of the processes described herein to be
carried out. The computer-readable medium may include a dedicated
section of code for each of the processes described herein.
[0243] It is further noted that some of the parts disclosed herein,
which include, for example, stainless steel, steel, aluminum, or
the like, may be coated with, for example, NEDOX.RTM. from General
Mangaplate Corp., of New Jersey, and 202 series coatings such as,
for example, 202P from Endura Coatings LLC. These coatings may
give, for example, aluminum parts the appearance of stainless
steel, high resistance against harsh chemicals, high resistance
against wear, exceptional harness (e.g., up to Rc 68), very low
friction (e.g., as low as 0.09), and the like.
[0244] While the disclosure has been described in terms of
exemplary embodiments, those skilled in the art will recognize that
the disclosure can be practiced with modifications in the spirit
and scope of the appended claim, drawings and attachment. The
examples provided herein are merely illustrative and are not meant
to be an exhaustive list of all possible designs, embodiments,
applications or modifications of the disclosure.
* * * * *