U.S. patent application number 13/402772 was filed with the patent office on 2012-09-06 for systems and methods for feeding single sheets.
This patent application is currently assigned to Kirk-Rudy, Inc.. Invention is credited to Tommy W. Bhonn, Bryan Carbon, Harry V. Kirk, Jeffery T. Waldron.
Application Number | 20120223472 13/402772 |
Document ID | / |
Family ID | 46752831 |
Filed Date | 2012-09-06 |
United States Patent
Application |
20120223472 |
Kind Code |
A1 |
Kirk; Harry V. ; et
al. |
September 6, 2012 |
SYSTEMS AND METHODS FOR FEEDING SINGLE SHEETS
Abstract
A sheet feeder for feeding a single sheet of sheet material is
disclosed. The sheet feeder can utilize a specially designed cutout
and a suction cup to feed difficult, thin, or flimsy material one
sheet at the time. The cutout can be located on a shuttle table,
endless belt, or carousel, for example, and can be used in
conjunction with one or more suctions cups. The cutout can be
angled with respect to the sheet so that the leading edge of the
sheet is substantially supported. A slot in the cutout can enable
the suction cup to pull down the corner of the sheet. The slot can
then continue to slice, or peel, the sheet of the bottom of a stack
of sheets. The ability to pull only the corner of the sheet down
initially prevents stiction from a variety of sources and enables a
single sheet to be pulled from the stack.
Inventors: |
Kirk; Harry V.; (Acworth,
GA) ; Carbon; Bryan; (Woodstock, GA) ;
Waldron; Jeffery T.; (Canton, GA) ; Bhonn; Tommy
W.; (Marietta, GA) |
Assignee: |
Kirk-Rudy, Inc.
Woodstock
GA
|
Family ID: |
46752831 |
Appl. No.: |
13/402772 |
Filed: |
February 22, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61445289 |
Feb 22, 2011 |
|
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|
Current U.S.
Class: |
271/9.01 ;
271/99 |
Current CPC
Class: |
B65H 2701/1924 20130101;
B65H 3/0858 20130101; B65H 3/32 20130101 |
Class at
Publication: |
271/9.01 ;
271/99 |
International
Class: |
B65H 3/08 20060101
B65H003/08; B65H 3/04 20060101 B65H003/04 |
Claims
1. A machine for feeding single sheets of material comprising: a
first product tray for holding a plurality of sheets of material in
a first stack; a first angled slot comprising a special cutout
located at a first end of the slot; a first suction cup for
reciprocating proximate the special cutout for pulling a single
sheet from the bottom of the first stack through the special
cutout; and a device for creating relative motion between the first
stack and the first angled slot; wherein the relative motion
between the first angled slot and the first stack removes a single
sheet of material from the bottom of the first stack.
2. The machine of claim 1, wherein the device is a reciprocating
shuttle table.
3. The machine of claim 1, wherein the device is a rotating belt
comprising a plurality of angled slots.
4. The machine of claim 1, wherein the device is a rotating
carousel comprising a plurality of angled slots.
5. The machine of claim 1, wherein the special cutout is
triangular.
6. The machine of claim 1, further comprising: a first
spring-loaded pinch roller disposed on the underside of the device;
and a transport belt for pulling the single sheet off the bottom of
the first stack; wherein, when the suction cup pulls the single
sheet through the special cutout, the single sheet becomes trapped
between the first spring-loaded pinch roller and the transport belt
and is removed from the bottom of the first stack.
7. A machine for feeding single sheets of material comprising: a
chassis; a product tray for holding a plurality of sheets of
material in a stack; a shuttle table comprising: an angled slot
comprising a special cutout; one or more rollers for supporting the
shuttle table in rolling engagement with the chassis; and a
spring-loaded pinch roller disposed on the underside of the shuttle
table; a suction cup, reciprocating proximate the special cutout,
for pulling a single sheet from the bottom of the stack through the
special cutout; and a transport belt for pulling the single sheet
off the bottom of the stack; wherein when the suction cup pulls the
single sheet through the special cutout, the single sheet becomes
trapped between the spring-loaded pinch roller and the transport
belt and is removed from the bottom of the stack.
8. The machine of claim 7, wherein the special cutout is
triangular.
9. The machine of claim 7, wherein the first angled slot comprises
an angled parallelogram and the special cutout comprises a triangle
disposed on a first end of the parallelogram.
10. The machine of claim 7, wherein the shuttle table reciprocates
with respect to the chassis to pull a single sheet off of the
bottom of the stack.
11. The machine of claim 7, further comprising: a suction cup cam
comprising a first cam profile; and a suction cup arm for
reciprocating the suction cup in response to the first cam
profile.
12. A machine for feeding multiple, single sheets of material
comprising: a chassis; a carousel comprising: a plurality of angled
slots, each angled slots comprising a special cutout; a plurality
of spring-loaded pinch rollers disposed on the underside of the
carousel; one or more product trays, each tray for holding a
plurality of sheets of material in one or more stacks; and a
plurality of suction cups reciprocating proximate each of the
special cutouts, each suction cup for pulling a single sheet from
the bottom of the one or more stacks through the a plurality of
special cutouts; wherein, when each of the plurality of suction
cups pulls a single sheet through one of the a plurality of special
cutouts, the single sheet becomes trapped between a spring-loaded
pinch roller and the carousel and is dropped below the
carousel.
13. The machine of claim 12, wherein the transport belt comprises a
rotating flight chain rotating in the opposite direction as the
carousel.
14. The machine of claim 12, wherein each of the single sheets are
dropped below the carousel onto a transport belt.
15. The machine of claim 14, wherein the transport belt comprises a
rotating flight chain rotating in the same direction as the
carousel.
16. The machine of claim 14, further comprising: a first product
tray for holding a plurality of sheets of a first material in a
first stack; and a second product tray for holding a plurality of
sheets of a second material in a second stack; wherein the first
material and the second material are collated as they are dropped
below the carousel.
17. A machine for feeding multiple, single sheets of material
comprising: a chassis; a rotating belt comprising a plurality of
angled slots, each angled slots comprising a special cutout; one or
more product trays, each tray for holding a plurality of sheets of
material in one or more stacks, and disposed proximate a top
surface of the rotating belt; and a plurality of suction cups
reciprocating proximate each of the special cutouts, each suction
cup for pulling a single sheet from the bottom of the one or more
stacks through the a plurality of special cutouts; wherein, when
each of the plurality of suction cups pulls a single sheet through
one of the a plurality of special cutouts, the belt removes a
single sheet from the bottom of the one or more stacks to be
dropped below the belt.
18. The machine of claim 17, further comprising: a lugged collating
base dispose proximate a bottom surface of the rotating belt and
comprising a plurality of lugs for collating the plurality of
sheets.
19. The machine of claim 17, further comprising: a motor; and a
plurality of pulleys in mechanical engagement with the rotating
belt; wherein at least one of the plurality of pulleys is
detachably coupled to the motor to rotate the rotating belt.
20. The machine of claim 17, further comprising: a reciprocating
linkage mechanically coupling the plurality of suction cups for
timing the reciprocal motion of the plurality of suction cups.
Description
CROSS REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e), and the benefit of, U.S. Provisional Patent
Application No. 61/445,289 of the same title, filed 22 Feb. 2011,
which is incorporated herein in its entirety as if set forth
below.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a system and
method for feeding single sheets of product, and particularly to a
system and method for feeding single sheets of thin or flexible
paperstock from a stack.
[0004] 2. Background of Related Art
[0005] A variety of single-sheet feeders exist that are designed to
pull a single sheet of product from a stack of product. The product
can be, for example and not limitation, paper, plastic, or
cardstock. Feeders can be used in a variety of industries to pull
single articles out for further processing including, but not
limited to, printing, folding, sealing, or laminating. Kirk-Rudy
has manufactured single sheet feeders since 1967. The Kirk-Rudy
shuttle feeder uses vacuum to pull the bottom product under a gate
into oscillating pinch rollers to pull the product out from under
the stack. The Kirk-Rudy friction feeder, on the other hand, uses
friction belts and a friction retard roller to separate the bottom
product from the stack. The Kirk-Rudy rotary feeder uses suction
cups to pull the bottom product from the stack into rotating
gripper clamps that pull the product into a top and bottom belt
drive that pulls the product away from the stack.
[0006] These feeders work well enough on a wide range of products.
A problem occurs, however, when the product is particularly thin
and/or flimsy such as, for example, very thin paper, Mylar.RTM., or
napkins ("extra thin product"). With extra thin products, the
product is not stiff enough to overcome the attractive forces
between the bottom sheet (or, "object sheet") and the adjacent
sheet in the stack. In other words, the static cling and other
forces that tend to adhere one sheet to the next are greater than
the stiffness of the individual sheets making it difficult to
separate the sheets. This problem can be exacerbated in the
commercial setting because of the large stacks of product used,
which tend to magnify these forces. Due to these forces, when the
bottom sheet of product is pulled down to be separated from the
stack, one or more adjacent sheets tend to stick to the object
sheet.
[0007] As a result, rather than pulling the object sheet cleanly
off the bottom of the stack, two or more sheets are pulled off the
stack. This can result in jams in the feeder, or downstream
machines, and other problems that require clearing and maintenance.
If the product is being pulled out of the stack for printing (e.g.,
custom printed napkins), for example, this can result in alignment
problems or failure to print on each individual sheet because each
sheet is not being pulled and fed into the printer
individually.
[0008] Regardless of the downstream process being applied to the
product, therefore, it is desirable to have a reliable, fast method
for removing one sheet of extra thin product from the bottom of a
stack. It is to such a system and method that embodiments of the
present invention are primarily directed.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention relates generally to a system and
method for feeding single sheets of thin product, and particularly
to a system and method for feeding single sheets of thin, paper or
plastic product from the bottom of a stack.
[0010] Embodiments of the present invention can comprise a feeder
with a chassis, a shuttle table, and a product tray. In some
embodiments, the shuttle table can reciprocate with respect to the
chassis, while the product tray remains stationary. In other
embodiments, the shuttle table can remain stationary with respect
to the chassis, while the product tray reciprocates. The chassis
can further comprise one or more electric motors, a crank arm, and
one or more transport belts. The crank arm can further comprise a
suction cup cam for operating a reciprocating suction cup.
[0011] The shuttle table can further comprise one or more rollers,
a special cutout, and a spring-loaded pinch roller. The one or more
rollers can enable a stack of sheets located in the product tray to
remain stationary as the shuttle table reciprocates beneath it. The
special cutout can be angled with respect to the stack of sheets
and can further comprise a slot. In some embodiments, the slot can
be located at one end of the special cutout and can enable the
suction cup to pull a corner of the bottommost sheet (or, "object
sheet") down through the special cutout.
[0012] In some embodiments, the suction cup can reciprocate
vertically below the shuttle table such that it rises just above
the level of the shuttle table in a first position to grasp the
corner of the object sheet. The suction cup can then move downward
to a second position to pull the corner of the object sheet through
the special cutout and below the shuttle table. As the shuttle
table moves rearward, the object sheet can become trapped between
the spring-loaded pinch roller and the one or more transport belts.
The transport belt can pull the object sheet completely under the
table and off the stack. The object sheet can then be transported
to the next station for further processing or collating.
[0013] In some embodiments, the product can reciprocate and the
shuttle table can remain stationary. In this configuration, the
product tray can reciprocate over the special cutout in the shuttle
table to pull individual sheets off the stack. In other
embodiments, the special cutouts can be utilized in an endless belt
or carousel configuration. In this manner, multiple objects sheets
can be pulled at the same time.
[0014] Embodiments of the present invention can comprise a machine
for feeding single sheets of material. In some embodiments, the
machine can comprise a first product tray for holding a plurality
of sheets of material in a first stack, a first angled slot
comprising a special cutout located at a first end of the slot, a
first suction cup for reciprocating proximate the special cutout
for pulling a single sheet from the bottom of the first stack
through the special cutout, and a device for creating relative
motion between the first stack and the first angled slot. The
relative motion between the first angled slot and the first stack
can enable the slot to remove a single sheet of material from the
bottom of the first stack.
[0015] In some embodiments, the device can be a reciprocating
shuttle table. In other embodiments, the device can be a rotating
belt or a carousel comprising a plurality of angled slots. In a
preferred embodiment, the special cutout is triangular, though
other shapes, such as, for example and not limitation, a rectangle,
trapezoid, parallelogram, or circle are possible. In some
embodiments, the machine can further comprise a first spring-loaded
pinch roller disposed on the underside of the device, and a
transport belt for pulling the single sheet off the bottom of the
first stack. In this configuration, when the suction cup pulls the
single sheet through the special cutout, the single sheet can
become trapped between the first spring-loaded pinch roller and the
transport belt and can be removed from the bottom of the first
stack.
[0016] Embodiments of the present invention can also comprise a
machine for feeding single sheets of material. In some embodiments,
the machine can comprise a chassis, a product tray for holding a
plurality of sheets of material in a stack, and a shuttle table.
The shuttle table can comprise, for example, an angled slot
comprising a special cutout, one or more rollers for supporting the
shuttle table in rolling engagement with the chassis, and a
spring-loaded pinch roller disposed on the underside of the shuttle
table. The machine can further comprise, a suction cup,
reciprocating proximate the special cutout, for pulling a single
sheet from the bottom of the stack through the special cutout, and
a transport belt for pulling the single sheet off the bottom of the
stack. As before, when the suction cup pulls the single sheet
through the special cutout, the single sheet becomes trapped
between the spring-loaded pinch roller and the transport belt and
is removed from the bottom of the stack.
[0017] In a preferred embodiment, the first angled slot comprises
an angled parallelogram and the special cutout comprises a triangle
disposed on a first end of the parallelogram. In another preferred
embodiment, the shuttle table reciprocates with respect to the
chassis to pull a single sheet off of the bottom of the stack. In
some embodiments, the machine can further comprise a suction cup
cam comprising a first cam profile, and a suction cup arm for
reciprocating the suction cup in response to the first cam
profile.
[0018] Embodiments of the present invention can also comprise a
machine for feeding multiple, single sheets of material comprising
a chassis and a carousel. In some embodiments, the carousel can
comprise a plurality of angled slots, with each angled slots
comprising a special cutout, a plurality of spring-loaded pinch
rollers disposed on the underside of the carousel, one or more
product trays, each tray for holding a plurality of sheets of
material in one or more stacks, and a plurality of suction cups
reciprocating proximate each of the special cutouts, each suction
cup for pulling a single sheet from the bottom of the one or more
stacks through the a plurality of special cutouts. In this
configuration, each of the plurality of suction cups can pull a
single sheet through one of the plurality of special cutouts,
enabling the single sheet to become trapped between a spring-loaded
pinch roller and the carousel to be dropped below the carousel.
[0019] In some embodiments, each of the single sheets can be
dropped below the carousel onto a transport belt. In some
embodiments, the transport belt can comprise, for example, a
rotating flight chain rotating in the same direction as the
carousel. In other embodiments, the transport belt can comprises a
rotating flight chain rotating in the opposite direction as the
carousel. The machine can further comprise a first product tray for
holding a plurality of sheets of a first material in a first stack,
and a second product tray for holding a plurality of sheets of a
second material in a second stack. In this manner, the first
material and the second material can be collated as they are
dropped below the carousel.
[0020] Similarly, embodiments of the present invention can also
comprise a machine for feeding multiple, single sheets of material
comprising a chassis and a rotating belt. The rotating belt can
comprise a plurality of angled slots, each angled slots comprising
a special cutout. The machine can also comprise one or more product
trays, each tray for holding a plurality of sheets of material in
one or more stacks, and disposed proximate a top surface of the
rotating belt, and a plurality of suction cups reciprocating
proximate each of the special cutouts. Each suction cup can be used
to pull a single sheet from the bottom of the one or more stacks
through the plurality of special cutouts. As before, when each of
the plurality of suction cups pulls a single sheet through one of
the plurality of special cutouts, the belt can remove a single
sheet from the bottom of the one or more stacks to be dropped below
the belt.
[0021] In some embodiments, the machine can further comprise a
lugged collating base dispose proximate a bottom surface of the
rotating belt and comprising a plurality of lugs for collating the
plurality of sheets. In other embodiments, the machine can further
comprise a motor and a plurality of pulleys in mechanical
engagement with the rotating belt. At least one of the plurality of
pulleys can be detachably coupled to the motor to rotate the
rotating belt. In some embodiments, the machine can further
comprise a reciprocating linkage mechanically coupling the
plurality of suction cups for timing the reciprocal motion of the
plurality of suction cups.
[0022] These and other objects, features and advantages of the
present invention will become more apparent upon reading the
following specification in conjunction with the accompanying
drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 illustrates a perspective view of a feeding machine,
in accordance with some embodiments of the present invention.
[0024] FIGS. 2a and 2b illustrate top and bottom perspective views
of a shuttle table 110 for the feeding machine of FIG. 1, in
accordance with some embodiments of the present invention.
[0025] FIGS. 3-6 illustrate a side view of feeding machine of FIG.
1 in various positions of operation, in accordance with some
embodiments of the present invention.
[0026] FIG. 7a illustrates a top view of an endless belt
embodiment, in accordance with some embodiments of the present
invention.
[0027] FIG. 7b illustrates a side view of an endless belt feeder,
in accordance with some embodiments of the present invention.
[0028] FIG. 8 illustrates a side, perspective view of a
carousel-style feeder, in accordance with some embodiments of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Embodiments of the present invention relate generally to a
system and method for accurately feeding single sheets of thin
product, and particularly to a system and method for feeding single
sheets of thin paper or plastic products from the bottom of a stack
of thin product. The system can comprise, among other things, a
reciprocating shuttle table, a spring-loaded pinch roller, and a
specially designed cutout. The system can enable particularly thin
or flimsy articles ("extra thin product") to be pulled reliably
from the bottom of a stack. This enables thin products that
previously were not suitable for operations such as automatic
collating, sorting, or printing to be reliably and automatically
processed.
[0030] To simplify and clarify explanation, the system is described
below as a system for use with thin paper articles or sheets
("sheets"). One skilled in the art will recognize, however, that
the invention is not so limited. The system can be deployed to
handle a variety of thin or flimsy materials such as, for example
and not limitation, napkins, pamphlets, flyers, or foil that tend
to be flexible and/or stick together. In some embodiments, the
system can also be used for heavier items such as, for example and
not limitation, cardstock, cardboard, or paperboard provided the
necessary adjustments to the system are made (e.g., suction
strength).
[0031] The materials described hereinafter as making up the various
elements of the present invention are intended to be illustrative
and not restrictive. Many suitable materials that would perform the
same or a similar function as the materials described herein are
intended to be embraced within the scope of the invention. Such
other materials not described herein can include, but are not
limited to, materials that are developed after the time of the
development of the invention.
[0032] As described above, a problem with conventional sheet
feeding machines is that they are often unable to reliably pull a
single sheet of extra thin product off the bottom of a stack of the
material. This can be due to, among other things, the thickness of
the product itself, static cling, and/or friction. Puling more than
one sheet at a time can obviously result in jams, misalignments,
and misprints in the feeder itself and, more likely, in downstream
machines. This can create issues during production as jams needs to
be cleared, for example, while misprints and misalignments
represent costly product waste. As mentioned above, this problem
can be exacerbated in a commercial setting in which a large stack
of extra thin product can serve to increase the forces between the
bottommost sheet and the stack.
[0033] What is needed, therefore, is a machine that can reliably
and quickly pull a single sheet of product off the bottom of a
large stack of product. It is to such a machine that embodiments of
the present invention are primarily directed.
[0034] As shown in FIG. 1, embodiments of the present invention can
comprise an improved sheet feeding machine, or sheet feeder 100. In
some embodiments, the sheet feeder 100 can comprise a chassis 105,
a shuttle table 110, and a product tray 115. Product can be placed
in a stack on the shuttle table 110 and be held in place by the
product tray 115. The product tray 115 can be adjustable for, for
example and not limitation, the width and/or the length of the
product.
[0035] As discussed below, no provision is provided, or required,
to adjust for the thickness of the product as the machine 100
simply pulls the bottommost sheet off the stack regardless of
thickness. The feeding machine 100 can be driven, for example and
not limitation, by one or more electric, hydraulic, or pneumatic
motors. In some embodiments, various features of the feeder 100 can
be connected with a variety of mechanical linkages to enable one
motor to drive multiple operations on the feeder 100.
[0036] As shown in FIGS. 2a and 2b, the shuttle table 110 can
comprise a plurality of rollers 205, a special cutout 210, and a
spring loaded pinch roller 215. The special cutout 210 enables a
corner of the leading edge of the product to be pulled down, while
still supporting the remainder of the leading edge of the product.
This minimizes sticking between the object sheet and adjacent
sheets by minimizing the amount of friction and static cling. In
other words, the forces acting on the corner are lower than the
forces acting across, for instance, the entire leading edge or the
entire sheet. Bending the corner is also maximized by supporting
the remainder of the leading edge, which tends to better separate
the sheets. This combination of actions tends to prevent the object
sheet from sticking to and pulling down the adjacent sheet or
sheets (i.e., the sheets in the stack directly above the object
sheet).
[0037] As the shuttle table 110 moves rearward, the object sheet is
"sliced," or peeled, off the bottom of the stack, through the
cutout, or slot 210, and pulled below the table 110. Because the
slot 210 is angled, it slices across the leading edge of the
product gradually as the shuttle table 110 moves rearward. In this
manner, a portion of the leading edge of product is supported until
the entire leading edge has been peeled of the stack. As the
shuttle table 110 continues to move rearward, the product is
trapped by the spring-loaded pinch roller 215 located on the
underside of the shuttle table 110.
[0038] As shown in FIGS. 2a, 2b, and 3, in some embodiments, the
corner of the object sheet 305 can be pulled down with a suction
cup 310. The suction cup 310 can be disposed underneath the shuttle
table 110 in a slot 210a in the special cutout 210. The slot 210a
can be, for example and not limitation, rectangular, square, wound
or oblong. In a preferred embodiment, as shown in FIGS. 2a and 2b,
the slot 210a can be triangular. In some embodiments, the suction
cup 310 can reciprocate along a generally vertical path in a
suction cup guide 315 such that the suction cup 310 starts
approximately even with, or slightly proud of, the surface of the
shuttle table 110 and then moves below the table 110 to pull the
object sheet 305 down through the slot 210a. In other embodiments,
the suction cup 310 can travel along an arcuate path. Of course,
other suitable methods could be used to pull the corner down, such
as, for example and not limitation, a hook, a suitable adhesive, or
an air blast, and are contemplated herein.
[0039] The suction cup 310 can be made to reciprocate in a variety
of ways. In some embodiments, the suction cup 310 can be connected,
via one or more linkages, to a central crank arm 320. As shown, in
some embodiments, the crank arm 320 can be connected to the shuttle
table 110 and can be fitted with a suction cup cam 325 to provide
reciprocal motion for the suction cup 310. In some embodiments, the
suction cup 310 can be connected to a suction cup arm 322, which
reciprocates in response to the profile on the suction cup cam 325.
In other embodiments, the suction cup 310 or the suction cup arm
322, for example, can be directly connected to the crank arm 320.
Of course, a variety of cranks and linkages could be used to
achieve the same effect and are contemplated herein.
[0040] The sheet feeder 100 can further comprise one or more
transport belts 330. The transport belts 330 can be affixed to the
chassis 105 of the feeder 100 and can be driven by one or more
pulleys 335a, 335b and an electric motor 340, for example. As
shown, in some embodiments, the rear pulley 335a can be larger than
the front pulley 335b. In some embodiments, the pulleys 335a, 335b
can be equally sized, but mounted at an angle, for example. In this
manner, as the shuttle table 110 moves rearward, slicing off the
object sheet 305, the spring-loaded pinch roller 215 can contact
the transport belt 330, pinching the object sheet 305 between the
pinch roller 215 and the transport belt 330. Because the transport
belt 330 is rotating in a forward direction (in this case
clockwise), the object sheet 305 is also pulled forward. The
transport belt 330 can then carry the object sheet 305 forward, for
example, or drop in onto another belt or machine for further
processing.
[0041] The product tray 115 can be adjustable for width and/or
length of product. The product tray 115 can be adjusted to hold a
stack of product and prevent the stack from falling or skewing.
Because the object sheet 305 is being pulled off from the bottom,
however, no thickness adjustment is provided or necessary. The
suction cup 310 can simply pull the corner of a single sheet of
product 305 down into the slot 210a to be sliced off by the cutout
210 as the shuttle table 110 moves forward. In a preferred
embodiment, the plurality of rollers 205 on the shuttle table 110
can enable the shuttle table 110 to roll along the chassis 105 as
it reciprocates. The rollers 205 can also enable the stack to
remain stationary as the shuttle table 110 reciprocates below it.
The guides on the product tray 115 act to hold the stack in place
as the rollers 205 on the shuttle table 110 roll beneath it. Of
course, the product tray 115 could be designed to reciprocate with
the respect to the shuttle table 110 with similar results.
[0042] FIG. 3 depicts the starting, or rest, position for the sheet
feeder 100. As shown, the crank arm 320 can be in the rest position
such that the shuttle table 110 is in a forward position. In
addition, the suction cup arm 322 can be in contact with a flat on
the suction cup cam 325. In this position, the suction cup 310 is
in its highest position with respect to the shuttle table 110. In
this configuration, the spring-loaded pinch roller 215 can be out
of contact, or in slight contact, with the transport belt 330.
[0043] As shown in FIG. 4, as the feeder 100 begins to cycle, the
shuttle table 110 can begin its rearward motion. At the same time,
the lobe on the suction cup cam 325 begins to act on the suction
cup arm 322 causing it to move in a downward direction, away from
the shuttle table. As mentioned above, this pulls the corner of the
object sheet 305 down and begins to slice it off the bottom of the
stack. As the shuttle table 110 moves rearward, therefore, the
spring-loaded pinch roller 215 comes into contact with, or becomes
more loaded by, the transport belt 330 (i.e., depending on whether
the initial setting for the spring-loaded pinch roller 215 was out
of contact, or in slight contact, with the transport belt 330).
[0044] In FIG. 5, the shuttle table 110 is shown in the
substantially rearward position and the suction cup 310 has reached
its lowest position. At this point, the leading edge of the object
sheet 305 has been fully sliced off the stack and drawn under the
shuttle table 110 and into contact with the transport belt 330. At
the same time, the spring-loaded pinch roller 215 has moved
rearward enough to catch the leading edge of the object sheet 305
and pinch it between the roller 215 and the transport belt 330. The
transport belt 330 can then pull the object sheet 305 completely
out of the stack for further processing (e.g., printing, collating,
or folding).
[0045] In FIG. 6, the feeder 100 has returned to the rest position
and the object sheet 305 is traveling down the transport belt 330
for further processing. The transport belt 330 can, for example,
pull each sheet out individually to deposit them on a conveyor belt
for downstream processing. In some embodiments, the sheets can be
pulled out and deposited in a carousel for collating or other
functions. In other embodiments, the present invention can be
incorporated directly into, for example and not limitation,
folding, tabbing, or printing machines that then subject the object
sheet 305 to further processing including, but not limited to,
folding, sealing, laminating, or printing.
[0046] Embodiments of the system can be used in different
configurations to achieve different goals. For example, as shown in
FIGS. 7a and 7b, embodiments of the present invention can be
incorporated into an "endless belt" sheet feeder 700. In this
configuration, the special cutout 710, formerly in the shuttle
table 110, can be integrated into an endless belt 705 that can be
rotated by two or more pulleys 715 to act on multiple stacks of
product 720. A plurality of suction cups 725 can be mounted below
the belt 705 and, in some embodiments, can be connected via
mechanical linkages 730. As above, the suction cups 725 can be
timed such that they rise into the slot 710a in the special cutout
710 to pull the corner of the object sheets down as the slot 710a
passes. Each slot 710a can then peel off one object sheet from each
stack 720 as it passes, pulling off multiple (single) sheets at the
same time (i.e., one sheet from each stack). As shown, in some
embodiments, the sheets can be peeled of onto a lugged collating
base 735. This can enable the sheets to be collated into multiple
stacks for, for example, further processing.
[0047] In some embodiments, as shown in FIG. 8, the special cutout
810 can be incorporated into a carousel feeder 800. As shown, a
carousel 805 can comprise multiple cutouts 810 and multiple
suctions cups 815. Similar to the belt system 700, the carousel 805
can rotate to enable the special slots 810 to slice sheets off the
bottom of one or more product hoppers 820. In some embodiments, as
shown, the carousel 805 can comprise multiple product hoppers 820
enabling the carousel 805 to rotate, slicing off sheets from
multiple stacks disposed in a circular pattern above the carousel
805. As the carousel 805 rotates, therefore, it can slice a sheet
off of each stack, which can then be gravity fed into, for example
and not limitation, a hopper or a transport belt below.
[0048] In this configuration, the carousel 805 can, for example,
collate multiple sheets into a collated stack or can simply be used
to pull multiple sheets off onto multiple transport belts, for
example. In some embodiments, the sheets can drop onto a conveyor
belt, or flight chain 825, traveling in the same, or opposite,
direction as the carousel 805. In some embodiments, the carousel
805 can be direct driven by an electric, hydraulic, or pneumatic
motor. In other embodiments, as shown, the carousel 805 can be
chain or belt driven by an electric motor and sprocket system
830.
[0049] While several possible embodiments are disclosed above,
embodiments of the present invention are not so limited. For
instance, while several possible configurations have been disclosed
(e.g., the shuttle table configuration and the endless belt
configuration), other suitable materials and configurations could
be selected without departing from the spirit of embodiments of the
invention. In addition, the location and configuration used for
various features of embodiments of the present invention can be
varied according to, for example, the size or construction of the
feeding machine, space requirements, or article size and material.
Such changes are intended to be embraced within the scope of the
invention.
[0050] The specific configurations, choice of materials, and the
size and shape of various elements can be varied according to
particular design specifications or constraints requiring a device,
system, or method constructed according to the principles of the
invention. Such changes are intended to be embraced within the
scope of the invention. The presently disclosed embodiments,
therefore, are considered in all respects to be illustrative and
not restrictive. The scope of the invention is indicated by the
appended claims, rather than the foregoing description, and all
changes that come within the meaning and range of equivalents
thereof are intended to be embraced therein.
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