U.S. patent application number 13/341515 was filed with the patent office on 2012-07-05 for bulk pack napkin separator.
This patent application is currently assigned to C.G. Bretting Manufacturing Co., Inc.. Invention is credited to James R. Michler, Thomas W. Schneider.
Application Number | 20120167527 13/341515 |
Document ID | / |
Family ID | 45440341 |
Filed Date | 2012-07-05 |
United States Patent
Application |
20120167527 |
Kind Code |
A1 |
Michler; James R. ; et
al. |
July 5, 2012 |
BULK PACK NAPKIN SEPARATOR
Abstract
A bulk pack napkin separator and method utilize various
combinations of simultaneous compression of several bulk packs and
various forms of bulk pack accumulators for improving speed and
functionality of the separator.
Inventors: |
Michler; James R.; (Ashland,
WI) ; Schneider; Thomas W.; (Grand View, WI) |
Assignee: |
C.G. Bretting Manufacturing Co.,
Inc.
Ashland
WI
|
Family ID: |
45440341 |
Appl. No.: |
13/341515 |
Filed: |
December 30, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61428771 |
Dec 30, 2010 |
|
|
|
Current U.S.
Class: |
53/429 ;
53/116 |
Current CPC
Class: |
B65B 63/02 20130101;
B65H 2301/34112 20130101; B65B 25/145 20130101; B65H 2701/1924
20130101; B65H 2301/4223 20130101; B65H 31/30 20130101 |
Class at
Publication: |
53/429 ;
53/116 |
International
Class: |
B65B 63/04 20060101
B65B063/04 |
Claims
1. A bulk pack napkin separator apparatus configured for operative
connection between a folder and a wrapper, with the separator
apparatus having a backstop and a paddle gate and being further
configured for receiving two or more independent streams of folded
napkins along separate parallel folded sheet paths from the folder
and separating the independent streams of napkins into uncompressed
bulk packs of the folded napkins disposed in a space between the
backstop and a paddle gate and arranged in a parallel array of bulk
packs extending substantially perpendicular to the folded sheet
paths, the apparatus comprising at least one of the arrangements
from the group of arrangements consisting of: a movable backstop
arrangement wherein the backstop is movable to simultaneously
compress the bulk packs in the parallel array of bulk packs in the
space between the backstop and the paddle gate into an array of
bulk packs in a compressed state; a compressed pack transport
arrangement for transporting the compressed bulk packs in the array
of bulk packs in the compressed state to the wrapper; a small
accumulator for receiving one array of the bulk packs from the
space between the backstop and the paddle gate and storing the
received array of bulk packs for a period of time prior to
delivering the bulk packs in the stored array of bulk packs to the
wrapper, to thereby allow the wrapper to operate at a different
speed than the folder and separator; a large accumulator for
receiving one or more arrays of the bulk packs from the space
between the backstop and the paddle gate and storing the received
array(s) of bulk packs for a period of time prior to delivering the
bulk packs in the stored array(s) of bulk packs to the wrapper, to
thereby allow the wrapper to operate at a different speed than the
folder and separator; and a small accumulator for alternatively
receiving one array of the bulk packs from either the space between
the backstop and the paddle gate or the large accumulator and
storing the received array of bulk packs for a period of time prior
to delivering the bulk packs in the stored array of bulk packs to
the wrapper, to thereby allow the wrapper to operate at a different
speed than the folder and separator.
2. The apparatus of claim 1, wherein, the wrapper does not include
a bulk pack compression arrangement, and the separator apparatus
delivers the bulk packs to the wrapper in a compressed state.
3. The apparatus of claim 1, wherein: the wrapper includes an
infeed path extending generally parallel to the folded sheet paths;
and the arrays of bulk packs are transported out of the space
between the backstop and paddle gate to the infeed path by the
transport arrangement in a direction generally perpendicular to the
folded sheet paths;
4. The apparatus of claim 3, wherein, the wrapper does not include
a bulk pack compression arrangement, and the separator apparatus
delivers the bulk packs to the wrapper in a compressed state.
5. The apparatus of claim 1, wherein: the wrapper includes an
infeed path extending generally parallel to the folded sheet paths;
the small accumulator stores the array of bulk packs in a direction
extending parallel to the infeed path; and the arrays of bulk packs
are transported out of the space between the backstop and paddle
gate to the small accumulator by the transport arrangement in a
direction generally perpendicular to the folded sheet paths;
6. The apparatus of claim 5, wherein, the wrapper does not include
a bulk pack compression arrangement, and the separator apparatus
delivers the bulk packs to the wrapper in a compressed state.
7. The apparatus of claim 1, wherein: the wrapper includes an
infeed path extending generally parallel to the folded sheet paths;
the small accumulator stores the array of bulk packs in a direction
extending parallel to the infeed path; the large accumulator store
the array(s) of bulk packs in a direction extending generally
perpendicular to the folded sheet paths with each array of the one
or more arrays being disposed in an array of rows disposed from one
another in a direction parallel to the folded sheet paths; the
arrays of bulk packs are transported out of the space between the
backstop and paddle gate to the small accumulator by the transport
arrangement in a direction generally perpendicular to the folded
sheet paths; the arrays of bulk packs are alternatively first
transported out of the space between the backstop and paddle gate
the transport arrangement in a direction generally perpendicular to
the folded sheet paths and then inserted as adjacent rows into the
large accumulator in a direction parallel to the folded sheet
paths.
8. The apparatus of claim 7, wherein, the transport arrangement
receives the rows of bulk packs from the large accumulator in a
direction opposite to the folded sheet path
9. The apparatus of claim 7, wherein, the wrapper does not include
a bulk pack compression arrangement, and the separator apparatus
delivers the bulk packs to the wrapper in a compressed state.
10. The apparatus of claim 1, comprising: the movable backstop
arrangement; and the small accumulator for receiving one array of
the bulk packs from the space between the backstop and the paddle
gate and storing the received array of bulk packs for a period of
time prior to delivering the stored array of bulk packs to the
wrapper, to thereby allow the wrapper to operate at a different
speed than the folder and separator; wherein, the small accumulator
receives the array of bulk packs in a compressed state from the
space between the backstop and the paddle gate, maintains the
compressed bulk packs in the compressed state and delivers the bulk
packs to the wrapper in the compressed state.
11. The apparatus of claim 10, further comprising a large
accumulator operatively connected to the small accumulator and the
space between the backstop and paddle gate by the compressed pack
transport arrangement for receiving the array of bulk packs in a
compressed state from the space between the backstop and the paddle
gate, maintaining the compressed bulk packs in the compressed state
and returning the array of compressed bulk packs to the compressed
pack transport arrangement in the compressed state.
12. A method for operating a bulk pack napkin separator apparatus
configured for operative connection between a folder and a wrapper,
with the separator apparatus having a backstop and a paddle gate
and being further configured for receiving two or more independent
streams of folded napkins along separate parallel folded sheet
paths from the folder and separating the independent streams of
napkins into uncompressed bulk packs of the folded napkins disposed
in a space between the backstop and a paddle gate and arranged in a
parallel array of bulk packs extending substantially perpendicular
to the folded sheet paths, the method comprising at least one of
the steps from the group of steps consisting of: operating a
movable backstop arrangement wherein the backstop is movable to
simultaneously compress the bulk packs in the parallel array of
bulk packs in the space between the backstop and the paddle gate
into an array of bulk packs in a compressed state; operating a
compressed pack transport arrangement for transporting the
compressed bulk packs in the array of bulk packs in the compressed
state to the wrapper; operating a small accumulator for receiving
one array of the bulk packs from the space between the backstop and
the paddle gate and storing the received array of bulk packs for a
period of time prior to delivering the bulk packs in the stored
array of bulk packs to the wrapper, to thereby allow the wrapper to
operate at a different speed than the folder and separator;
operating a large accumulator for receiving one or more arrays of
the bulk packs from the space between the backstop and the paddle
gate and storing the received array(s) of bulk packs for a period
of time prior to delivering the bulk packs in the stored array(s)
of bulk packs to the wrapper, to thereby allow the wrapper to
operate at a different speed than the folder and separator; and
operating a small accumulator for alternatively receiving one array
of the bulk packs from either the space between the backstop and
the paddle gate or the large accumulator and storing the received
array of bulk packs for a period of time prior to delivering the
bulk packs in the stored array of bulk packs to the wrapper, to
thereby allow the wrapper to operate at a different speed than the
folder and separator.
13. A method for operating a bulk pack napkin separator apparatus
configured for operative connection between a folder and a wrapper,
with the separator apparatus being configured for receiving two or
more independent streams of folded napkins along separate parallel
folded sheet paths from the folder and separating the independent
streams of napkins into uncompressed bulk packs of the folded
napkins, the method comprising simultaneously compressing the bulk
packs in the independent streams into a compressed state prior to
delivering the bulk packs to the wrapper.
14. The method of claim 13, further comprising, storing the bulk
packs in the compressed state in an accumulator prior to delivering
the compressed bulk packs to the wrapper.
15. The method of claim 14, wherein, the apparatus includes a
controller operatively connected between the folder, the wrapper
and the separator and the method further comprises controlling the
apparatus with the controller to operate the folder and separator
at a lower speed when bulk packs are being exchanged with the
accumulator.
16. The method of claim 13, further comprising, simultaneously
compressing several bulk packs with a movable backstop.
17. A bulk pack napkin separator apparatus configured for operative
connection between a folder and a wrapper, with the separator
apparatus being configured for receiving two or more independent
streams of folded napkins along separate parallel folded sheet
paths from the folder and separating the independent streams of
napkins into uncompressed bulk packs of the folded napkins, the
apparatus further including a simultaneous pack compression
arrangement for simultaneously compressing the bulk packs in the
independent streams into a compressed state prior to delivering the
bulk packs to the wrapper.
18. The apparatus of claim 17, further comprising, an accumulator
for storing the bulk packs in the compressed state in the
accumulator prior to delivering the compressed bulk packs to the
wrapper.
19. The apparatus of claim 18, further comprising, a controller
operatively connected between the folder, the wrapper and the
separator for controlling the speed of the folder wrapper and
separator relative to one another.
20. The apparatus of claim 19, wherein, the controller operates the
folder and separator at a lower speed when bulk packs are being
exchanged with the accumulator.
21. The apparatus of claim 20, wherein, the simultaneous pack
compression arrangement includes a movable backstop for
simultaneously compressing the bulk packs in the independent
streams.
22. A bulk pack napkin separator apparatus configured for operative
connection between a folder and a wrapper, with the separator
apparatus being configured for receiving two or more independent
streams of folded napkins along separate parallel folded sheet
paths from the folder and separating the independent streams of
napkins into an array of uncompressed bulk packs of the folded
napkins, the apparatus further including an accumulator for storing
an array of the bulk packs in the accumulator prior to delivering
the bulk packs to the wrapper.
23. The apparatus of claim 22, wherein, the accumulator is a large
accumulator storing one or more array(s) of the bulk packs in the
accumulator prior to delivering the bulk packs to the wrapper.
24. The apparatus of claim 22, further comprising, a controller
operatively connected between the folder, the wrapper and the
separator for controlling the speed of the folder wrapper and
separator relative to one another.
25. The apparatus of claim 24, wherein, the controller operates the
folder and separator at a lower speed when bulk packs are being
exchanged with the accumulator.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims the benefit of U.S.
Provisional Patent Application No. 61/428,771, filed Dec. 30, 2010,
the entire teachings and disclosure of which are incorporated
herein by reference thereto.
FIELD OF THE INVENTION
[0002] This invention relates to apparatuses and methods for
producing bulk packs of napkins and the like from a stack of folded
sheets, and more particularly to a separating apparatus and method
for separating a continuously building stack of sheets into bulk
packs at a rate allowing equipment upstream and downstream from the
separator to operate continuously at optimal speeds.
BACKGROUND OF THE INVENTION
[0003] Napkin folders use a separator to isolate a specified number
of sheets into packs and send the packs to a wrapper. Packs larger
than a certain size, typically about 160 napkins, are known as bulk
packs. Bulk pack separators handle the packs with the napkins
oriented vertically, and sometimes compress the packs one at a time
before they enter the wrapper.
[0004] A bulk pack separator begins by separating a continuous
stack of folded napkins into bulk packs. Prior bulk pack separators
then transport the bulk packs to a compression area, compress the
packs one at a time, and transport the compressed packs to the
wrapper infeed conveyor. With recent improvements in high speed
napkin folding, and high speed wrappers, the separator is a choke
point in a bulk pack napkin folding line.
[0005] In commonly assigned U.S. Pat. No. 6,832,886, titled
"Apparatus and Method for Stacking Sheets Discharged from a
Starwheel Assembly," to Michler et al., separator fingers move
through starwheels to separate packs.
[0006] In commonly assigned U.S. Pat. No. 7,470,102, titled
"Apparatus and Method for Stacking and Separating Sheets Discharged
From a Starwheel Assembly," to Gendron et al., split count fingers
are used to separate the bulk packs.
[0007] Prior bulk pack napkin separators typically make the initial
separation using the separator fingers as described in U.S. Pat.
Nos. 6,832,886 and 7,470,102. After initial separation, the
uncompressed bulk packs are moved to a paddle gate area, after
which the paddle gate closes, and the separator fingers retract.
The packs are then confined between a paddle gate, a backstop, and
the plates of a paddle conveyor. The paddle conveyor moves the
uncompressed packs to a compression station in the separator or the
wrapper. The paddle and compression operation is done one pack at a
time. After compression, each compressed pack is transferred to the
wrapper infeed conveyor. Since the transfer--compress--transfer
process is done one pack at a time, it is inherently slow.
[0008] Prior separators of the type described above typically are
limited to a maximum speed of about 30 packs per minute. What is
needed is a bulk pack separator that is faster than existing bulk
pack napkin separators.
BRIEF SUMMARY OF THE INVENTION
[0009] The invention provides an improved bulk pack napkin
separator and method having several innovative aspects including
simultaneous compression of several bulk packs and a bulk pack
accumulator, in various forms of the invention.
[0010] In some forms of the invention, the separator simultaneously
compresses multiple bulk packs formed in parallel lanes by the
separator, utilizing a movable backstop for simultaneously
compressing the multiple bulk packs against a paddle gate of the
separator.
[0011] Some forms of the invention include a small accumulator that
allows a wrapper downstream from the separator to run continuously,
instead of stopping at every separation as was required in prior
approaches.
[0012] Some forms of the invention include a large accumulator
which allows a folder upstream from the separator, and the
separator to keep running during short wrapper downtimes inherent
in operation of a wrapper, such as for clearing jams or changing
sleeve stock rolls. In some forms of the invention, a large
accumulator, according to the invention, also allows the wrapper to
keep running during a short downtime of a folder upstream from the
separator.
[0013] In some forms of a bulk pack napkin separator apparatus
configured for operative connection between a folder and a wrapper,
the separator apparatus may be configured for receiving two or more
independent streams of folded napkins along separate parallel
folded sheet paths from the folder and separating the independent
streams of napkins into an array of uncompressed bulk packs of the
folded napkins Such an apparatus may further include an accumulator
for storing an array of the bulk packs in the accumulator prior to
delivering the bulk packs to the wrapper. The accumulator may be a
small accumulator for storing only one array of bulk packs. The
accumulator may be a large accumulator storing one or more array(s)
of the bulk packs in the accumulator prior to delivering the bulk
packs to the wrapper. In some forms of the invention, the
accumulator may include both a small and a large accumulator.
[0014] In forms of the invention having either or both a small or a
large accumulator, the separator may include a controller
operatively connected between the folder, the wrapper and the
separator for controlling the speed of the folder wrapper and
separator relative to one another. In some forms of the invention,
the controller may operate the folder and separator at a lower
speed when bulk packs are being exchanged with the accumulator.
[0015] According to one aspect of the invention, a bulk pack napkin
separator apparatus is configured for operative connection between
a folder and a wrapper, with the separator apparatus having a
backstop and a paddle gate and being further configured for
receiving two or more independent streams of folded napkins along
separate parallel folded sheet paths from the folder and separating
the independent streams of napkins into uncompressed bulk packs of
the folded napkins disposed in a space between the backstop and a
paddle gate and arranged in a parallel array of bulk packs
extending substantially perpendicular to the folded sheet paths.
Such an apparatus may include at least one of the arrangements from
the group of arrangements consisting of:
[0016] a movable backstop arrangement wherein the backstop is
movable to simultaneously compress the bulk packs in the parallel
array of bulk packs in the space between the backstop and the
paddle gate into an array of bulk packs in a compressed state;
[0017] a compressed pack transport arrangement for transporting the
compressed bulk packs in the array of bulk packs in the compressed
state to the wrapper;
[0018] a small accumulator for receiving one array of the bulk
packs from the space between the backstop and the paddle gate and
storing the received array of bulk packs for a period of time prior
to delivering the bulk packs in the stored array of bulk packs to
the wrapper, to thereby allow the wrapper to operate at a different
speed than the folder and separator;
[0019] a large accumulator for receiving one or more arrays of the
bulk packs from the space between the backstop and the paddle gate
and storing the received array(s) of bulk packs for a period of
time prior to delivering the bulk packs in the stored array(s) of
bulk packs to the wrapper, to thereby allow the wrapper to operate
at a different speed than the folder and separator; and
[0020] a small accumulator for alternatively receiving one array of
the bulk packs from either the space between the backstop and the
paddle gate or the large accumulator and storing the received array
of bulk packs for a period of time prior to delivering the bulk
packs in the stored array of bulk packs to the wrapper, to thereby
allow the wrapper to operate at a different speed than the folder
and separator.
[0021] In some forms of the invention, the wrapper does not include
a bulk pack compression arrangement, and the separator apparatus
delivers the bulk packs to the wrapper in a compressed state.
[0022] In forms of the invention where the wrapper includes an
infeed path extending generally parallel to the folded sheet paths,
the arrays of bulk packs may be transported out of the space
between the backstop and paddle gate to the infeed path by the
transport arrangement in a direction generally perpendicular to the
folded sheet paths. Where the wrapper includes an infeed path
extending generally parallel to the folded sheet paths, the small
accumulator may store the array of bulk packs in a direction
extending parallel to the infeed path, and the arrays of bulk packs
may be transported out of the space between the backstop and paddle
gate to the small accumulator by the transport arrangement in a
direction generally perpendicular to the folded sheet paths.
[0023] In other forms of the invention, where the wrapper includes
an infeed path extending generally parallel to the folded sheet
paths:
[0024] the small accumulator may store the array of bulk packs in a
direction extending parallel to the infeed path;
[0025] the large accumulator may store the array(s) of bulk packs
in a direction extending generally perpendicular to the folded
sheet paths with each array of the one or more arrays being
disposed in an array of rows disposed from one another in a
direction parallel to the folded sheet paths;
[0026] the arrays of bulk packs may be transported out of the space
between the backstop and paddle gate to the small accumulator by
the transport arrangement in a direction generally perpendicular to
the folded sheet paths; and
[0027] the arrays of bulk packs may be alternatively first
transported out of the space between the backstop and paddle gate
the transport arrangement in a direction generally perpendicular to
the folded sheet paths and then inserted as adjacent rows into the
large accumulator in a direction parallel to the folded sheet
paths.
[0028] The transport arrangement in some forms of the invention may
receive the rows of bulk packs from a large accumulator in a
direction opposite to the folded sheet path
[0029] A separator apparatus, according to some forms of the
invention, may include a movable backstop arrangement, and a small
accumulator for receiving one array of the bulk packs from the
space between the backstop and the paddle gate and storing the
received array of bulk packs for a period of time prior to
delivering the stored array of bulk packs to the wrapper, to
thereby allow the wrapper to operate at a different speed than the
folder and separator.
[0030] The small accumulator may receive the array of bulk packs in
a compressed state from the space between the backstop and the
paddle gate, maintains the compressed bulk packs in the compressed
state and delivers the bulk packs to the wrapper in the compressed
state.
[0031] An apparatus, according to the invention, may further
include a large accumulator operatively connected to the small
accumulator and the space between a backstop and paddle gate by the
compressed pack transport arrangement, for receiving the array of
bulk packs in a compressed state from the space between the
backstop and the paddle gate, maintaining the compressed bulk packs
in the compressed state and returning the array of compressed bulk
packs to the compressed pack transport arrangement in the
compressed state.
[0032] The invention may also take the form of a method for
operating a bulk pack napkin separator apparatus configured for
operative connection between a folder and a wrapper, with the
separator apparatus having a backstop and a paddle gate and being
further configured for receiving two or more independent streams of
folded napkins along separate parallel folded sheet paths from the
folder and separating the independent streams of napkins into
uncompressed bulk packs of the folded napkins disposed in a space
between the backstop and a paddle gate and arranged in a parallel
array of bulk packs extending substantially perpendicular to the
folded sheet paths. Such a method may include at least one of the
steps from the group of steps consisting of:
[0033] operating a movable backstop arrangement wherein the
backstop is movable to simultaneously compress the bulk packs in
the parallel array of bulk packs in the space between the backstop
and the paddle gate into an array of bulk packs in a compressed
state;
[0034] operating a compressed pack transport arrangement for
transporting the compressed bulk packs in the array of bulk packs
in the compressed state to the wrapper;
[0035] operating a small accumulator for receiving one array of the
bulk packs from the space between the backstop and the paddle gate
and storing the received array of bulk packs for a period of time
prior to delivering the bulk packs in the stored array of bulk
packs to the wrapper, to thereby allow the wrapper to operate at a
different speed than the folder and separator;
[0036] operating a large accumulator for receiving one or more
arrays of the bulk packs from the space between the backstop and
the paddle gate and storing the received array(s) of bulk packs for
a period of time prior to delivering the bulk packs in the stored
array(s) of bulk packs to the wrapper, to thereby allow the wrapper
to operate at a different speed than the folder and separator;
and
[0037] operating a small accumulator for alternatively receiving
one array of the bulk packs from either the space between the
backstop and the paddle gate or the large accumulator and storing
the received array of bulk packs for a period of time prior to
delivering the bulk packs in the stored array of bulk packs to the
wrapper, to thereby allow the wrapper to operate at a different
speed than the folder and separator.
[0038] According to another aspect of the invention, a method is
provided for operating a bulk pack napkin separator apparatus
configured for operative connection between a folder and a wrapper,
with the separator apparatus being configured for receiving two or
more independent streams of folded napkins along separate parallel
folded sheet paths from the folder and separating the independent
streams of napkins into uncompressed bulk packs of the folded
napkins, with the method including simultaneously compressing the
bulk packs in the independent streams into a compressed state prior
to delivering the bulk packs to the wrapper.
[0039] In some forms of the invention, the bulk packs may be stored
in the compressed state in an accumulator prior to delivering the
compressed bulk packs to the wrapper, and optionally or preferably
the apparatus may include a controller operatively connected
between the folder, the wrapper and the separator and the method
may further comprise controlling the apparatus with the controller
to operate the folder and separator at a lower speed when bulk
packs are being exchanged with the accumulator.
[0040] A method according to the invention may further comprise
simultaneously compressing several bulk packs with a movable
backstop.
[0041] In an apparatus according to the invention including a bulk
pack napkin separator apparatus configured for operative connection
between a folder and a wrapper, with the separator apparatus being
configured for receiving two or more independent streams of folded
napkins along separate parallel folded sheet paths from the folder
and separating the independent streams of napkins into uncompressed
bulk packs of the folded napkins, the apparatus may include a
simultaneous pack compression arrangement for simultaneously
compressing the bulk packs in the independent streams into a
compressed state prior to delivering the bulk packs to the
wrapper.
[0042] The apparatus may further comprise, an accumulator for
storing the bulk packs in the compressed state in the accumulator
prior to delivering the compressed bulk packs to the wrapper.
[0043] An apparatus according to the invention may further
comprise, a controller operatively connected between the folder,
the wrapper and the separator for controlling the speed of the
folder wrapper and separator relative to one another. The
controller may operate the folder and separator at a lower speed
when bulk packs are being exchanged with an accumulator according
to the invention.
[0044] Simultaneous pack compression arrangements according to the
invention may include a movable backstop for simultaneously
compressing the bulk packs in the independent streams.
[0045] Other aspects, objects and advantages of the invention will
be apparent from the following detailed description and
accompanying drawings of exemplary embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The accompanying drawings illustrate several aspects of the
present invention and, together with the description, serve to
explain the principles of the invention. In the drawings:
[0047] FIGS. 1-5 are perspective schematic illustrations of a first
exemplary embodiment of a separator, according to the invention
operatively disposed between a folder and a wrapper, and having a
movable backstop for compressing a parallel array of bulk packs
between the backstop and a paddle gate, with FIGS. 1-5 sequentially
illustrating operation of the movable backstop to simultaneously
compress the bulk packs.
[0048] FIGS. 6-10 illustrate a second exemplary embodiment of a
separator apparatus, according to the invention disposed between a
folder and a wrapper, with the second exemplary embodiment of the
apparatus including both a movable backstop for simultaneous
compression of eight bulk packs in conjunction with a small
accumulator, according to the invention, with FIGS. 6-10
sequentially illustrating operation of the movable backstop and
small accumulator of the separator.
[0049] FIGS. 11-17 are schematic perspective illustrations of a
third exemplary embodiment of a separator apparatus, according to
the invention. The third exemplary embodiment of the separator
apparatus includes a movable backstop, according to the invention,
in combination with a small accumulator, according to the
invention, and also a large accumulator, according to the
invention, with FIGS. 11-17 sequentially illustrating operation of
the movable backstop, small accumulator, and a large accumulator of
the third exemplary embodiment of the separator.
[0050] FIGS. 18-22 are perspective illustrations of a fourth
exemplary embodiment of a separator apparatus, according to the
invention. FIGS. 18-22 show the fourth exemplary embodiment of the
separator apparatus from various directions. The fourth exemplary
embodiment of the separator apparatus includes a movable backstop
for simultaneously compressing four bulk packs (not shown), and a
small accumulator, according to the invention. The small
accumulator also includes a pack turner arrangement, in the fourth
exemplary embodiment of the separator apparatus to rotate the
compressed packs degrees into an orientation more amenable to use
with a particular wrapper.
[0051] The invention may also take the form of a method for
operating a bulk pack napkin separator apparatus configured for
operative connection between a folder and a wrapper, with the
separator apparatus being configured for receiving two or more
independent streams of folded napkins along separate parallel
folded sheet paths from the folder and separating the independent
streams of napkins into uncompressed bulk packs of the folded
napkins Such a method, according to the invention, may include
simultaneously compressing the bulk packs in the independent
streams into a compressed state prior to delivering the bulk packs
to the wrapper. A method according to the invention may also
include storing the bulk packs in the compressed state in an
accumulator prior to delivering the compressed bulk packs to the
wrapper.
[0052] While the invention will be described in connection with
certain preferred embodiments, there is no intent to limit it to
those embodiments. On the contrary, the intent is to cover all
alternatives, modifications and equivalents as included within the
spirit and scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0053] Four exemplary embodiments of bulk pack separator
apparatuses 100, 200, 300 and 400 are discussed below, with
reference to respective drawing views. In all of these exemplary
embodiments, the bulk pack separator apparatuses 100, 200, 300 and
400 are disposed between a multi-lane folder A and a wrapper B.
[0054] It will be appreciated that, in practicing the invention,
that bulk pack separator arrangements, such as the exemplary
embodiments 100, 200, 300, 400 may use the same separator finger
system as prior bulk pack separators, such as those disclosed in
commonly assigned U.S. Pat. Nos. 6,832,886 and 7,470,102. These
separators typically have a series of separator fingers operating
in conjunction with a paddle gate and a backstop to gather
individual folded sheets from the multiple lanes of a folder and
form an array of uncompressed bulk packs which are transferred by
the separator fingers to a space between the backstop and the
paddle gate. The array of uncompressed bulk packs is then typically
transferred sideways out of the space between the backstop and the
paddle gate to an infeed conveyor of a wrapper. The wrapper or
separator typically includes a compression station at which one
bulk pack at a time is compressed prior to being wrapped.
[0055] The present invention differs both structurally and
functionally, as compared to the teachings and disclosure of prior
separator apparatuses and methods such as those disclosed in
commonly assigned U.S. Pat. Nos. 6,832,886 and 7,470,102, with
regard to how the bulk packs are handled downstream from the paddle
gate.
[0056] As will be discussed in greater detail below, all four of
the exemplary embodiments of bulk pack separator apparatuses 100,
200, 300 and 400 include a novel moveable backstop arrangement to
simultaneously compress all of the newly separated packs in a
particular array of packs against the paddle gate. After
simultaneous compression, a bulk pack transport arrangement in the
form of a paddle conveyor moves the compressed packs to a wrapper
infeed conveyor. Because the packs are already compressed when they
reach the wrapper infeed conveyor, the one-at-a-time pack
compression station and operation required in prior separators or
wrappers can be eliminated. Those having skill in the art will
appreciate that by simultaneously compressing an entire array of
bulk packs and by eliminating the need for the one-at-a-time pack
compression station utilized in prior separator and wrapper
arrangements, the present invention provides for significant
increases in operational speed in the production of wrapped,
compressed bulk packs.
[0057] The first exemplary embodiment 100 includes only the
simultaneous pack compression with a movable backstop aspect of the
invention. The other three exemplary embodiments 200, 300, 400 also
include other aspects of the invention using one or more
accumulators, according to the invention, in combination with the
movable backstop. It will be understood, however, that the various
movable backstop and accumulator aspects of the invention can be
used independently from one another, or in other combinations, in
other embodiments of the invention.
[0058] FIGS. 1-5 show the first exemplary embodiment of a separator
100, according to the invention, in simplified block form.
[0059] As shown in FIGS. 1-5 the first exemplary embodiment of the
separator 100, is operatively disposed between an eight lane folder
A and a wrapper B. The separator 100 includes a movable backstop
102 for compressing a parallel array of bulk packs 104 between the
backstop 102 and a paddle gate 105. In FIGS. 1-5, the eight lane
folder is represented by the block A on the left, the wrapper is
the block B on the right, and the separator 100 is in the
middle.
[0060] As discussed in greater detail below, FIGS. 1-5 sequentially
illustrate specific operation of the movable backstop 102 to
simultaneously compress the bulk packs 104, in the first exemplary
embodiment of the bulk pack separator 100. Structure and operation
of the movable backstops 202, 303, 402 in the other exemplary
embodiments are similar to the movable backstop 102 of the first
exemplary embodiment 100.
[0061] Those having skill in the art will recognize that the folder
A of the first exemplary embodiment is an eight-lane folder,
producing eight, parallel, continually moving, independent streams
of folded napkins along separate parallel folded sheet paths, in a
direction generally indicated by arrow 118 in FIG. 1. The separator
100 includes a plurality of separator fingers (not shown) of the
type known in the art for receiving the independent streams of
folded napkins, and forming the array of bulk packs 104. The
separator fingers also transport the array of bulk packs 104 to the
space 101 between the movable backstop 102 and the paddle gate
105.
[0062] As will be described in more detail below, the first
exemplary embodiment of the separator apparatus 100 also includes a
bulk pack transfer arrangement, in the form of an overhead paddle
conveyor 107, for transporting the array of bulk packs 104 out of
the space 101 between the movable backstop 102 and paddle gate 105
in a direction perpendicular to the folded sheet path 118, as
generally indicated by arrow 120 in FIG. 1. The overhead paddle
conveyer 107 is not shown in FIGS. 2-5 for clarity.
[0063] As also illustrated in FIG. 1, the bulk packs 104 in the
first exemplary embodiment of the separator apparatus 100 travel
along the wrapper infeed conveyor 116 in a direction substantially
parallel to the folded sheet path 118, as indicated by arrow 122 in
FIG. 1.
[0064] FIG. 1 shows the array of newly separated bulk packs 104
passing under the open paddle gate 105 toward the backstop 102. The
wrapper infeed conveyor 116, loaded with compressed bulk packs 104,
is shown in the rear of FIG. 1. For clarity of illustration, the
separator fingers that are supporting the packs 104 are not shown,
nor are side guides and table slots that are typically present in
separators and wrapper infeed conveyors of the type known in the
art.
[0065] FIG. 2 shows the newly separated bulk packs 104 in the
paddle gate area 101, and the paddle gate 105 closed. The backstop
102 is ready to start the simultaneous compression of the array of
bulk packs 104.
[0066] In FIG. 3, the simultaneous compression of the packs 104
into their compressed state is complete. The paddle conveyor 107
(represented by the rectangular block of dashed lines above the
compressed packs in FIG. 1) starts to push the compressed packs 104
toward the wrapper infeed conveyor 116.
[0067] In FIG. 4, the compressed packs 104 are almost clear of the
paddle gate area 101 between the paddle gate 105 and the backstop
102, and the next separation is beginning Both the compressed pack
paddle conveyor 107 and the wrapper infeed conveyor 116 operate in
indexing mode. The paddle conveyor 107 moves one lane center to the
next bulk pack in the array, and then the wrapper infeed conveyor
116 moves one bucket pitch to advance a bulk pack 104 into the
wrapper B.
[0068] FIG. 5 shows the compressed packs 104 clear of the paddle
gate area 101. The next batch of uncompressed bulk packs 104 are
separated and approaching the paddle gate 105. The paddle gate 105
is raising up to let the uncompressed packs 104 through.
[0069] It will be recognized that the specific references to
relative speed, operational modes or stopping of the folder A,
separator 100 and wrapper B herein above are for exemplary purposes
only to explain the invention. In other embodiments of the
invention, other relative speeds and stopping protocols may be
utilized in practicing the invention.
[0070] Some forms of the invention may also include and utilize a
controller (not shown in FIGS. 1-5, but shown in FIGS. 18-22 and
discussed below with regard to the fourth exemplary embodiment 400
of the invention) operatively connected between the folder, the
wrapper and the separator for controlling the speed of the folder
wrapper and separator relative to one another.
[0071] Small Accumulator
[0072] The speed of the separator 100 disclosed above is partly
limited by the speed of the wrapper B. Another speed limiter is the
time needed to close the paddle gate 105, lower the separator
fingers of the separator 100, and compress the uncompressed packs
104. That time interrupts the steady flow of compressed packs 104
to the wrapper infeed conveyor 116. The maximum throughput is less
than the steady state wrapper speed could otherwise be.
[0073] It is desired that throughput of the separator 100 be equal
to the steady state wrapper speed. This can be done by adding a
small accumulator 206 to a separator 200, according to the
invention, in the manner shown in the second exemplary embodiment
of a separator apparatus 200 allowing the wrapper B to run
continuously at its maximum speed. Operation and construction of
the small accumulator 206 is shown in FIGS. 6-10.
[0074] FIGS. 6-10 illustrate the second exemplary embodiment of a
separator apparatus 200, according to the invention disposed
between a folder A and a wrapper C. The exemplary embodiment of the
apparatus 200 includes both a movable backstop 202 for simultaneous
compression of eight bulk packs 204 in conjunction with a small
accumulator 206, according to the invention. FIGS. 6-10
sequentially illustrate operation of the movable backstop 202 and
small accumulator 206 of the separator 200.
[0075] FIG. 6 shows an eight lane folder A and a wrapper B in
combination with a bulk pack separator 200 that includes the small
accumulator 206. The folder A is represented by a block A on the
far left, the wrapper by a block B on the far right, with the small
accumulator 206 next to the wrapper infeed conveyor 216. The
wrapper infeed conveyor 216 is full, as shown in FIG. 6, and the
first compressed pack 204 is starting to enter the small
accumulator 206, with a newly separated set of uncompressed packs
204 being compressed between the movable backstrap 202 and the
paddle gate 205.
[0076] FIG. 7 shows the small accumulator 206 partly loaded with
compressed packs 204 and the wrapper infeed conveyor 216 partly
empty. The newly separated packs 204 are compressed and partly
transferred out of the pack compression area 201.
[0077] FIG. 8 shows the small accumulator 206 fully loaded, the
wrapper infeed 216 conveyor almost empty, and the compressed packs
204 almost fully transferred out of the compression area 201.
[0078] In FIG. 9, the packs 204 in the small accumulator 206 are
being transferred into the wrapper infeed conveyor 216. This occurs
during a normal dwell of the wrapper infeed conveyor 216. A newly
separated set of uncompressed packs 204 are entering the paddle
gate area 201.
[0079] In FIG. 10, a pusher 211 of the small accumulator 206 is
retracted and the first compressed pack 204 is entering the
accumulator 206. One separation cycle is complete, and the wrapper
B runs continuously at its rated speed.
[0080] It will be recognized that the specific references to
relative speed, operational modes or stopping of the folder A,
separator 200 and wrapper B herein above are for exemplary purposes
only to explain the invention. In other embodiments of the
invention, other relative speeds and stopping protocols may be
utilized in practicing the invention.
[0081] Some forms of the invention may also include and utilize a
controller (not shown in FIGS. 6-10, but shown in FIGS. 18-22 and
discussed below with regard to the fourth exemplary embodiment 400
of the invention) operatively connected between the folder, the
wrapper and the separator for controlling the speed of the folder
wrapper and separator relative to one another.
[0082] Large Accumulator
[0083] Wrappers B need to make frequent stops to clear jams and
change sleeve stock rolls. These stops may only last two or three
minutes, but they also force the folder A to stop. When the folder
A stops and restarts, it typically rejects at least one set of
packs. This waste can be prevented by adding an accumulator between
the separator and the wrapper infeed conveyor which is capable of
holding several rows of arrays of bulk packs. This type of
accumulator will be referred to herein as a "large
accumulator."
[0084] Such an accumulator is shown in FIGS. 11-17. It is located
after the compressed pack paddle conveyor 307 and before the
wrapper infeed conveyor 316. While the figures show a small
accumulator 306 (of the type described above with reference to
FIGS. 6-10) after the large accumulator 308, the small accumulator
306 is not necessary for operation of the large accumulator
308.
[0085] FIGS. 11-17 are schematic perspective illustrations of a
third exemplary embodiment of a separator apparatus 300, according
to the invention. The third exemplary embodiment of the separator
apparatus 300 includes a movable backstop 302, according to the
invention, in combination with a small accumulator 306, according
to the invention, and also a large accumulator 308, according to
the invention. FIGS. 11-17 sequentially illustrate operation of the
movable backstop 302, small accumulator 306, and a large
accumulator 308 of the third exemplary embodiment of the separator
300.
[0086] FIG. 11 shows normal running mode of operation. A set of
uncompressed packs 304 has been separated, with the packs 304 about
to pass under the paddle gate. The wrapper infeed conveyor 316 is
almost empty, and is ready to be loaded from the small accumulator
306. The compressed pack paddle conveyor 307 is shown in dashed
lines only in FIG. 11, and omitted in FIGS. 12-17 for clarity of
illustration. It extends from the pack compression area 301 to the
small accumulator 306.
[0087] In FIG. 12, the wrapper B has stopped, stopping the wrapper
infeed conveyor 316. The folder A slows down to half speed. One set
of compressed packs 304, located between the compression area 301
and the small accumulator 306, are starting to transfer into the
large accumulator 308.
[0088] In FIG. 13, the wrapper B is still shut down, and two sets
of compressed packs 304 are stored in parallel rows extending
perpendicular to the folded sheet path 318 in the large accumulator
308. The folder A continues to run at half speed. Another set of
uncompressed packs 304 are starting to pass under the paddle gate
305.
[0089] FIG. 14 shows the large accumulator 308 containing three
sets of compressed packs 304. The wrapper B now starts up at full
speed. The folder A continues to run at half speed. The set of
packs 304 most recently transferred into the large accumulator 308
will now be transferred back to the paddle conveyor 307. The small
accumulator 306 will load the wrapper infeed conveyor 316.
[0090] FIG. 15 shows the large accumulator 308 with two sets of
packs 304 stored in parallel rows. The folder A is running at half
speed, the wrapper B at full speed. The set of packs 304 recently
separated from the folder A are on the compressed pack paddle
conveyor 307. There is gap behind those packs. That gap will be
filled by the first row of packs 304 in the large accumulator 308.
A subsequent set of uncompressed packs 304 have just been
separated, and are moving toward the paddle gate 305.
[0091] In FIG. 16, the first row of packs 304 in the large
accumulator 308 is moving into the paddle conveyor 307 in a
direction opposite the folded sheet path 318. The array of
compressed packs 304 between the backstop 302 and paddle gate 305
is the same array of uncompressed packs 304 shown in FIG. 15.
[0092] FIG. 17 shows the last row of packs 304 transferring from
the large accumulator 308 to the paddle conveyor 307 while another
array of packs 304 from the compression area 301 between the
backstop 302 and the paddle gate 305 follow immediately behind. The
folder A now speeds up to full speed. The large accumulator 308 is
empty, and stays empty until the wrapper B is shut down again.
[0093] It will be recognized that the specific references to
relative speed, operational modes or stopping of the folder A, the
third exemplary embodiment of the separator 300 and wrapper B
herein above are for exemplary purposes only to explain the
invention. In other embodiments of the invention, other relative
speeds and stopping protocols may be utilized in practicing the
invention.
[0094] Some forms of the invention may also include and utilize a
controller (not shown in FIGS. 11-17, but shown in FIGS. 18-22 and
discussed below with regard to the fourth exemplary embodiment 400
of the invention) operatively connected between the folder, the
wrapper and the separator for controlling the speed of the folder
wrapper and separator relative to one another.
[0095] FIGS. 18-22 show a fourth exemplary embodiment 400 of a
four-lane separator apparatus, according to the invention, having
movable backstop 402 and a small accumulator 406 according to the
invention. The small accumulator 406 also includes a pack turner
arrangement 413.
[0096] FIGS. 18-22 show the fourth exemplary embodiment of the
separator apparatus 400 from various directions. The fourth
exemplary embodiment of the separator apparatus 400 includes a
movable backstop 402 for simultaneously compressing four bulk packs
(not shown), and a small accumulator 406, according to the
invention. The movable backstop 402 simultaneously compresses the
multiple bulk packs between the backstop 402 and a movable paddle
gate 405 to simultaneously compress the bulk packs.
[0097] The separator 400 utilizes a folder having four starwheel
arrangements 430 to form a continuously building stack of folded
sheets which are then separated into individual bulk packs and
transported to a bulk pack transfer area 401 between the backstop
402 and the paddle gate 405 by separator finger arrangements 403.
Once the bulk packs are compressed in the bulk pack transfer area
401 between the movable backstop 402 and the paddle gate 405, a
bulk pack transfer arrangement in the form of a paddle conveyor 407
transports the compressed bulk packs to the small accumulator 406.
The small accumulator 406 includes a lower paddle conveyor 409 for
transporting the compressed bulk packs from the first paddle
conveyor 407 to an overhead paddle conveyor 411 which feeds the
compressed bulk packs to an infeed conveyor of the wrapper (not
shown).
[0098] In all embodiments of the invention, a controller such as
controller 450 of FIG. 19, may be operatively connected between the
folder, the separator and the wrapper for controlling speeds
operational modes and functionality of those elements.
[0099] It will be recognized that the specific references to
relative speed, operational modes or stopping of the folder A,
separator 400 and wrapper B herein above are for exemplary purposes
only to explain the invention. In other embodiments of the
invention, other relative speeds and stopping protocols may be
utilized in practicing the invention.
[0100] The small accumulator 406 also includes a pack turner
arrangement 413, in the fourth exemplary embodiment of the
separator apparatus 400 to rotate the compressed packs 90 degrees
into an orientation more amenable to use with a particular wrapper.
Those having skill in the art will readily recognize that in other
embodiments of the invention, such a pack turner may not be
utilized, or other pack turning arrangements may be utilized.
[0101] All references, including publications, patent applications,
and patents cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0102] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) is to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the invention.
[0103] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *