U.S. patent application number 14/152722 was filed with the patent office on 2014-07-17 for automated systems and methods for combining cards and products.
This patent application is currently assigned to Stork Fabricators, Inc.. The applicant listed for this patent is Stork Fabricators, Inc.. Invention is credited to Brian R. Stork, Jaye W. Walker.
Application Number | 20140196403 14/152722 |
Document ID | / |
Family ID | 51164086 |
Filed Date | 2014-07-17 |
United States Patent
Application |
20140196403 |
Kind Code |
A1 |
Stork; Brian R. ; et
al. |
July 17, 2014 |
Automated Systems and Methods for Combining Cards and Products
Abstract
According to various aspects, exemplary embodiments are
disclosed of an automated system for combining cards and products
for packaging. Also disclosed are exemplary automated methods for
combining cards and products for packaging. In an exemplary
embodiment, an automated system for combining cards and products
generally includes a card station and a merge station. The card
station is configured to form a card to a desired shape for
combining with a product. The card station includes at least one
roll former operable to fold at least a portion of the card. The
merge station is configured to receive the formed card from the
card station and combine the formed card with the package.
Inventors: |
Stork; Brian R.;
(Washington, MO) ; Walker; Jaye W.; (Washington,
MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Stork Fabricators, Inc. |
Washington |
MO |
US |
|
|
Assignee: |
Stork Fabricators, Inc.
Washington
MO
|
Family ID: |
51164086 |
Appl. No.: |
14/152722 |
Filed: |
January 10, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61751799 |
Jan 11, 2013 |
|
|
|
Current U.S.
Class: |
53/147 |
Current CPC
Class: |
B65B 43/14 20130101;
B65B 11/004 20130101; B65B 35/24 20130101 |
Class at
Publication: |
53/147 |
International
Class: |
B65B 5/06 20060101
B65B005/06 |
Claims
1. An automated system for combining cards and products for
packaging, the system comprising: a card station configured to form
a card to a desired shape for combining with a product, the card
station having at least one roll former operable to fold at least a
portion of the card; and a merge station configured to receive the
formed card from the card station and combine the formed card with
the product.
2. The system of claim 1, further comprising a guide configured to
position the formed card in a desired orientation for combining
with the product.
3. The system of claim 1, wherein the merge station includes a stop
configured to position the formed card in the merge station and
combine the formed card with the product.
4. The system of claim 1, further comprising a glue applicator
configured to apply glue to a portion of the card for coupling the
card to the product.
5. The system of claim 4, further comprising a guide configured to
position the formed card in an orientation for combining with the
product, such that the glue contacts at least part of the product
when the card is combined with the product.
6. The system of claim 5, further comprising a press configured to
contact the card when combining the card with the product to
thereby contact the glue with the at least part of the package.
7. The system of claim 1, wherein the card station includes a card
feeder and a conveyor, the conveyor operable to move the card from
the card feeder to the at least one roll former, and move the
formed card from the at least one roll former to the merge
station.
8. The system of claim 7, wherein the conveyor includes at least
one lug configured to contact the card and move the card from the
card feeder to the at least one roll former and from the at least
one roll former to the merge station.
9. The system of claim 8, wherein the at least one lug includes
first and second lugs configured to contact the card and move the
card, the first lug having a different height than the second
lug.
10. The system of claim 1, further comprising a feed station
configured to isolate the product from multiple products, and
transport the isolated product to the merge station.
11. The system of claim 10, wherein the feed station includes a
feed conveyor configured to transport the isolated product to the
merge station.
12. The system of claim 10, wherein the feed station includes a
simulation unit having a stop and a sensing device for isolating
the product from the multiple products.
13. The system of claim 1, further comprising a packaging station
configured to receive a combined card and product and shrink wrap
the combined card and product.
14. The system of claim 1, wherein the at least one roll former
includes a first roll former operable to form a first portion of
the card, and a second roll former operable to form a second
portion of the card.
15. An automated method of combining a card and a product for
packaging, the method comprising: applying glue to a portion of a
card at a card station for use in coupling the card to a product;
forming the card at the card station to a desired shape, based on a
shape of the product; conveying the formed card to a merge station;
conveying the product to the merge station; positioning the formed
card in a desired orientation in the merge station to receive the
product; and pressing the glue to a surface of the product, to
thereby combine the card and the product.
16. The method of claim 15, further comprising conveying the
combined card and product to a packaging station.
17. An automated system for combining cards and products for
packaging, the system comprising: a card station configured to form
a card to a desired shape for combining with a product, the card
station having a first roll former operable to fold a first portion
of the card and a second roll former operable to fold a second
portion of the card, to thereby form the card to a desired shape,
and a guide configured to position the formed card in a desired
orientation for combining with the product; a merge station
configured to receive the formed card from the card station and
combine the formed card with the package; and a feed station
configured to isolate the product from multiple products, and
transport the isolated product to the merge station.
18. The system of claim 17, wherein the card station further
includes a glue applicator configured to apply glue to a portion of
the card for coupling the card to the product; and wherein the
merge station includes a press configured to contact the card when
combining the card with the product to thereby contact the glue
with the at least part of the package.
19. The system of claim 18, wherein the card station further
includes further comprising a guide configured to position the
formed card in an orientation for combining with the product, such
that the glue contacts at least part of the product when the card
is combined with the product.
20. The system of claim 17, wherein the first roll former includes
a first series of rollers and a second series of rollers, and
wherein the second series of rollers gradually change in
orientation to thereby fold the first portion of the card.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This U.S. non-provisional patent application claims the
benefit of and priority to U.S. provisional patent application No.
61/751,799 filed Jan. 11, 2013. The disclosure of the application
identified in this paragraph is incorporated herein by reference in
its entirety.
FIELD
[0002] The present disclosure generally relates to automated
systems and methods for combining cards and products, for example,
for packaging.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Products are oftentimes sold in packages. For example,
products are sometimes shrink wrapped in or as a package.
SUMMARY
[0005] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0006] According to various aspects, exemplary embodiments of
automated systems and methods for combining cards and products for
packaging are disclosed. In one exemplary embodiment, an automated
system for combining cards and products generally includes a card
station and a merge station. The card station is configured to form
a card to a desired shape for combining with a product. The card
station includes at least one roll former operable to fold at least
a portion of the card. The merge station is configured to receive
the formed card from the card station and combine the formed card
with the package.
[0007] In another exemplary embodiment, an automated method
generally includes operations of applying glue to a portion of a
card at a card station for use in coupling the card to a product;
forming the card at the card station to a desired shape, based on a
shape of the product; conveying the formed card to a merge station;
conveying the product to the merge station; positioning the formed
card in a desired orientation in the merge station to receive the
product; and pressing the glue to a surface of the product, to
thereby combine the card and the product.
[0008] In another exemplary embodiment, an automated system
generally includes a card station configured to form a card to a
desired shape for combining with a product, where the card station
has a first roll former operable to fold a first portion of the
card and a second roll former operable to fold a second portion of
the card, to thereby form the card to a desired shape, and a guide
configured to position the formed card in a desired orientation for
combining with the product. The system also includes a merge
station configured to receive the formed card from the card station
and combine the formed card with the package, and a feed station
configured to isolate the product from multiple products, and
transport the isolated product to the merge station.
[0009] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples
in this summary are intended for purposes of illustration only and
are not intended to limit the scope of the present disclosure.
DRAWINGS
[0010] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0011] FIG. 1 is a block diagram of an exemplary embodiment of an
automated system for combining cards and products according to the
present disclosure;
[0012] FIG. 2 is a perspective view of a card station, a feed
station, and a merge station of the system of FIG. 1;
[0013] FIG. 3 is a top plan view of the card station, the feed
station, and the merge station of FIG. 2;
[0014] FIG. 4 is an enlarged perspective view of a portion of the
card station of FIG. 2;
[0015] FIG. 5 is an enlarged perspective view of a roll former of
the card station of FIG. 2; and
[0016] FIG. 6 is an enlarged perspective view of a portion of the
merge station of FIG. 2.
[0017] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0018] Disclosed herein are exemplary embodiments of automated
systems and methods for combining cards with products. Examples of
cards include (without limitation) paper cards, cardboards,
J-cards, U-boards, backer-boards, protective sleeves, cards made
from other materials, other cards, cards configured for covering
end portions of products (e.g., automotive air filters, other
products, etc.), etc. The cards may be blank, or they may include
information about the products, advertising, or other information.
In some aspects, the cards may also provide support/protection to
the products, for example, when shipping, storing, etc. the
products.
[0019] Exemplary embodiments of systems and methods of the present
disclosure generally place a card around a leading end portion of a
product (e.g., a rectangular end of the product, a square end of
the product, another portion of the product, etc.). As the card and
product combine (e.g., merge), the card is squared to the leading
end portion of the product, both vertically and horizontally. The
combined product and card can then be subsequently processed, as
desired, for example, shrink wrapped, or otherwise processed. This
accurate merging of the product and the card can provide for a very
nice, clean, marketable final product, and can allow operators of
the systems and methods to take full advantage of significant cost
reductions of packaging, transportation, labor, and material.
[0020] In various exemplary embodiments, systems generally include
various stations (or areas) of operation that work together,
simultaneously, to combine cards and products. In various aspects,
the stations/areas include automated components that can be
programmed to perform desired operations (e.g., form cards to
desired shapes, direct products to the formed cards, merge the
formed cards with the products, direct the merged products and
cards to subsequent possessing stations/areas, subsequently process
the merged products and cards, etc.). In addition, the various
stations (or areas) can be programmed to work together, with all
(or substantially all, or at least some) of the movements being
automated and/or synchronized, for example, by a system program
logic controller (PLC) program. As an example, product sizes can be
entered into a touchscreen, and adjustment scale settings may be
displayed for operators of the systems to use for setting up the
systems for various products. As such, product width, length, and
height dimensions can be handled by the systems within maximum and
minimum parameters. Once product dimensions are entered, adjustment
scale settings (e.g., three adjustment scale settings, etc.) are
displayed to the operators for any given product that falls within
the product ranges.
[0021] In various exemplary embodiments, systems generally include
card stations (e.g., U-board forming dual lug conveyor areas, etc.)
for forming cards to desired shapes, for merging with products. The
card stations generally include card feeders that operate to feed
various cards into the card stations, and conveyors that feed the
cards through the card stations. Glue applicators and roll forming
areas may also be provided in the card stations. As an example,
cards can be fed singularly, from the card feeders, into empty dual
height lug pockets along the conveyors, and then the conveyors can
index the cards forward, one lug spacing at a time. As the cards
advance from the lug spaces, with lugs pushing the cards, the glue
applicators dispense glue onto the cards (at desired locations on
the cards). As the cards further advance, they index through roll
formers, which gently fold the cards to desired shapes (e.g., form
flaps of the cards; form the cards to "J" shapes, "U" shapes, other
desired shapes, etc.; etc.). As the folded cards are advanced
further, flaps of the cards are guided to desired positions
(broadly, the cards are oriented) to allow for precise combining of
products with the folded cards.
[0022] In various exemplary embodiments, systems also (or
alternatively) generally include feed stations for directing,
delivering, etc. products to folded cards, and then for directing,
delivering, etc. combined cards and products to subsequent
processing operations. The feed stations may include one or more of
roller conveyors, lug conveyors, belt conveyors, indexing systems,
indexing product stops, and product take away conveyors. As an
example, products to be merged with cards can be fed from an
indexing accumulation system that holds back products (e.g., on a
minimum pressure accumulation conveyor using a singulation unit,
etc.) until desired for combining with the cards. To singulate the
products for combining, a gate (broadly, a stop, etc.) (e.g., of a
singulation unit, etc.) may be used to selectively allow passage of
the products. In so doing, the products can be indexed to combine
with pre-folded waiting cards (e.g., from a card station, etc.).
Once the products are placed into the cards, the combined products
and cards can be indexed toward a take away conveyor which, for
example, may feed them to a wrapping station (e.g., shrink
wrappers), or to other processing areas, etc.
[0023] In various exemplary embodiments, systems also (or
alternatively) generally include merge stations for combining
products and folded cards. The merge stations may include stops
and/or presses for use in conforming, combining, merging, etc.
pre-folded cards to products (e.g., aligning the products and the
cards, fitting the cards to the products, adhering the cards to the
products, etc.).
[0024] In various exemplary embodiments, systems generally include
combinations of card stations, feed stations, and merge stations.
For example, in some exemplary embodiments, systems may generally
include both card stations and merge stations. In other exemplary
embodiments, systems may include card stations, feed stations, and
merge stations. In other exemplary embodiments, systems may include
one or more of card stations, feed stations, and merge stations,
and one or more different and/or additional stations.
[0025] In various embodiments, methods generally include forming
cards to desired shapes, for example, at card stations, etc., based
on shapes of products to be combined with the cards. Methods may
also include feeding isolated products, for example, using a feed
station, etc., to a merge station for combining with pre-folded
cards. In some aspects, glue may be applied to portions of the
cards to help couple the cards to the products.
[0026] As will be appreciated, exemplary embodiments of the systems
and methods of the present disclosure can accommodate different
desired sizes of cards for use with desired products (e.g., via
manual operation, via automated operation, via adjustment of
components of the systems, via operation of the PLC program, etc.).
For example, cards may vary both by length and width because of
various product possibilities.
[0027] With reference now to the drawings, FIGS. 1-6 illustrate an
exemplary embodiment of an automated system 100 embodying one or
more aspects of the present disclosure. The system 100 is
configured to combine cards (see exemplary cards 101 in FIGS. 2 and
3) and products for packaging. Any suitable cards may be used with
the system 100 (e.g., cardboards, J-cards, U-boards, backer-boards,
protective sleeves, other cards, etc.). In addition, the cards may
be blank, or they may include information about the products,
advertising, or other information. In some aspects, the cards may
also provide support/protection to the products, for example, when
shipping, storing, etc. the products. Further, any suitable
products may be used in (or processed by) the system 100 (e.g.,
automotive air filters, other products, etc.).
[0028] As shown in FIGS. 1-3, the illustrated system 100 generally
includes a card station 102, a feed station 104, and a merge
station 106. The feed station 104 is configured to isolate a
product from multiple products, and transport the isolated product
to the merge station 106. The card station 102 is configured to
form a card to a desired shape for combining with the product at
the merge station 106. And, the merge station 106 is configured to
receive the formed card, from the card station 102, and combine the
formed card with the isolated product. The combined card and
product can then be transported, via the feed station 104, from the
merge station 106 to a packaging station 108 (FIG. 1), for further
processing. The packaging station 108 can include any suitable
station for further processing the combined card and product, and
may include, as an example, one or more apparatus capable of
packaging the combined card and product. For example, the packaging
station 108 may include a wrapping apparatus configured to shrink
wrap the combined card and product.
[0029] The card station 102 of the system 100 generally includes a
card feeder 110 and a conveyor 112. The card feeder 110 is operable
to provide the cards to the conveyor 112, and the conveyor 112 is
operable to move the cards through the card station 102. The card
feeder 110 may include any suitable apparatus for feeding,
delivering, providing, etc. the cards into the system 100, such as,
for example, a friction card feeder, etc. The conveyor 112 includes
a dual lug conveyor, having pairs of first and second lugs 114, 116
disposed on a belt drive for moving (e.g., pushing, etc.) the cards
through the card station 102 (e.g., via a stepper motor, other
drive source, etc.). Pockets (e.g., spacings, etc.) are defined
between each pair of the lugs 114, 116 for receiving the cards from
the card feeder 110, with each pocket configured to receive a
single card. The lugs 114, 116 then operate to move the cards,
positioned within the pockets, through the card station 102. In the
illustrated embodiment, the first and second lugs 114, 116 of each
pair have different heights, with the first lug 114 being generally
shorter than the second lug 116. It should be appreciated that lug
conveyors having more than or fewer than two lugs may be used with
the conveyor 112, and/or lug conveyers having groups (e.g., pairs,
etc.) of lugs with similar heights may be used. Further, in some
embodiments, conveyors other than lug conveyors may be used.
[0030] With additional reference to FIGS. 4 and 5, the card station
102 also includes a glue applicator 118 and first and second roll
formers 120, 122 located along the conveyor 112. The glue
applicator 118 is configured to apply glue (e.g., one or more dots
of glue, etc.) to one or more desired portions of the card, for
coupling the card to the product (at the merge station 106). Any
suitable glue applicator 118 may be used within the scope of the
present disclosure. Once the glue is applied to the card, the roll
formers 120, 122 are each configured to fold, bend, etc. at least a
portion of the card, to thereby form the card to a desired final
shape, for example, a "J" shape, a "U" shape, etc.
[0031] As shown in FIG. 5, the first roll former 120 includes a
first series of rollers, each roller indicated at 124, and a second
series of rollers, each roller indicated at 126. The first series
of rollers 124 operate to hold a central portion of the card
generally horizontally in the pocket of the conveyor 112 as the
conveyor 112 moves the card through the roll former 120. The second
series of rollers 126, which gradually change (e.g., consecutively
change, etc.) in orientation, then operate to fold a portion of the
card to a desired position as the card moves through the roll
former 120. For example, in the illustrated embodiment, the first
roll former 120 is configured to fold a right side portion of the
card generally upwardly (e.g., about ninety degrees, etc. to form a
first flap, etc.).
[0032] The second roll former 122 is similar to the first roll
former 120, but with the first and second rollers generally
reversed. As such, in the illustrated embodiment, the second roll
former 122 is configured to fold a left side portion of the card
generally upwardly (e.g., about ninety degrees, etc. to form a
second flap, etc.).
[0033] As shown in FIG. 2, a guide 128 is provided in the card
station 102, generally after the second roll former 122, to help
position the folded card in a desired orientation for precise
combining with a product in the merge station 106. The illustrated
guide 128 includes a ramp portion that operates to push the folded
side portions of the card generally downwardly, as the folded card
moves from the card station 102 to the merge station 106. This
allows the product to move generally into the folded card, without
interference from the folded side portions, and also positions the
folded side portion of the card having the glue generally over the
product when received in the card. In other embodiments, guides may
include structures other than ramps such as, for example,
actuators, etc. for positioning, orienting, aligning, etc. the
folded cards in desired positions to receive the products.
[0034] With reference again to FIGS. 2 and 3, the feed station 104
of the system 100 includes a conveyor 130 configured to transport
products to be combined with the folded cards through the system
100. An in-feed portion 130a of the conveyor 130 is configured to
receive the products from a supply 132 of the products (FIG. 1)
(e.g., a source of the products, a bin of the products, a product
feeder, etc.), and transport the products to the merge station 106.
And, a take away portion 130b of the conveyor 130 is configured to
transport combined cards and products from the merge station 106 to
the packaging station 108, after the cards and products are
combined.
[0035] The in-feed portion 130a of the conveyor 130 includes a
roller deck 134 and a lug conveyor 136. The roller deck 134
includes multiple rollers configured to allow the products received
from the supply 132 to easily move (e.g., via gravity, momentum,
forces applied to the rollers, etc.) to a singulation unit 138 of
the feed station 104, where the products are isolated. The roller
deck 134 also allows the singulation unit 138 to hold back,
accumulate, etc. products with minimum pressure. The lug conveyor
136 includes spaced apart lugs 140 disposed on a belt drive for
moving (e.g., pushing, etc.) the isolated products, along rollers,
from the singulation unit 138 to the merge station 106 (e.g., via a
stepper motor, other drive source, etc.). Pockets are defined
between each of the lugs 140 for receiving the isolated products
from the singulation unit 138, with each pocket configured to
receive a single product. The lugs 140 then operate to move the
products, positioned within the pockets, to the merge station 106.
In the illustrated embodiment, the lug conveyor 136 also includes
guides 142 disposed generally toward side portions of the lug
conveyor 136 for centering the products within the pockets. In some
aspects, the guides 142 are adjustable to help accommodate
different sizes of products. With that said, it should be
appreciated that lug conveyors having more than one lug at each
location along the lug conveyor may be used. Further, in some
embodiments, conveyors other than lug conveyors may be used.
[0036] The singulation unit 138 of the feed station 104 isolates
(or singulates) individual products received from the supply 132 of
products. In the illustrated embodiment, the singulation unit 138
includes a stop 144 (e.g., an overhead gate, etc.) and a sensing
device 146 (e.g., a photo eye; a camera, an infra-red device; other
suitable identifying, sensing, etc. devices; etc.). The sensing
device 146 operates to sense location of the products in the
singulation unit 138. And, the stop 144 is then moveable (e.g.,
generally vertically, etc.), based on location information from the
sensing device 146, to selectively block and allow movement of the
products from the singulation unit 138 to the lug conveyor 136. As
such, individual products are allowed to pass (e.g., are indexed,
etc.) by the stop 144 and into the pockets of the lug conveyor 136,
one at a time. As an example, a line of multiple products may be
provided to the feed station 104 from the supply 132 of products.
At the singulation unit 138, the stop 144 selectively retracts up
to allow accumulated products (e.g., products accumulated behind
the stop 144 when the stop 144 is down, etc.) to advance to the lug
conveyor 136. The first product in the line may get sped up to
create a gap between it and the next product. This product may be
timed to be placed in front of the lug 140 that will index it
through the system 100 before that lug 140 moves up to the
conveying surface. After the gap is sensed, for example, by the
sensing device 146, the stop 144 may go back down and stop the
other products from advancing until the stop 144 is signaled to
retract up again.
[0037] The take away portion 130b of the feed station conveyor 130
includes a lug conveyor 148 and a belt conveyor 150. The lug
conveyor 148 includes spaced apart lugs 152 disposed on a belt
drive for moving (e.g., pushing, etc.) the combined cards and
products, along rollers, from the merge station 106 to the belt
conveyor 150 (e.g., via a stepper motor, other drive source, etc.).
Pockets are defined between each of the lugs 152 for receiving the
combined cards and products from the merge station 106, with each
pocket configured to receive a single card and product. The lugs
152 then operate to move the combined cards and products,
positioned within the pockets, to the belt conveyor 150. The belt
conveyor 150 then operates to transition the combined cards and
products to the packaging station 108. Again, it should be
appreciated that lug conveyors having more than one lug at each
location along the lug conveyor may be used. Further, in some
embodiments, conveyors other than lug conveyors may be used.
[0038] With additional reference now to FIG. 6, the merge station
106 of the system 100 is disposed generally between the in-feed
portion 130a of the feed station conveyor 130 and the take away
portion 130b of the feed station conveyor 130. The merge station
106 includes a stop 154 (e.g., an overhead gate, blade, etc.) and a
press 156, operable to combine the folded cards from the card
station 102 with the isolated products. The stop 154 is moveable
(e.g., generally vertically, etc.) relative to the feed station
conveyor 130 to selectively block and allow movement of the
products. For example, when the stop 154 is in position to block
movement of a product (e.g., when the stop 154 is generally down,
etc.), a formed card from the card station 102 is moved into
position, and generally centered, against the stop 154, directly in
front of an advancing product. The product is then moved into the
formed card, thereby aligning the card with the product generally
horizontally and/or vertically. At this time, the stop 154 holds
the product and card together, generally still, and allows the
press 156 to impact an upward facing portion of the card and
contact the glue to the product (thereby coupling the card to the
product). The stop 154 then raises, and the merged product and card
are indexed to the take away portion 130b of the feed station
conveyor 130, as a package. As soon as the trailing end of the
product is clear, the stop 154 lowers and a waiting pre-folded card
is again indexed directly in front of the stop 154.
[0039] In the illustrated embodiment, the press 156 includes a
spring-loaded bar 158 that is moveable generally vertically to
selectively impact the card. In addition, the press 156 can be
vertically adjusted, as desired, to account for different product
sizes. And, the press 156 is configured to provide sufficient
pressure to the card to sufficiently adhere the card and the
product. Further, in some aspects, the press 156 helps guide the
card into position, relative to the stop 154, in preparation for
merging the card with a product. In other embodiments, other
suitable presses may be used, to couple cards and products
together.
[0040] With reference again to FIG. 1, a control 160 is provided
for controlling and/or coordinating operations of the system 100.
For example, the card station 102, the feed station 104, and the
merge station 106 may be programmed to work together, generally
simultaneously, to combine the card and product, with all (or
substantially all or at least some) of the actions of the stations
102, 104, 106 being automated and/or synchronized, for example, by
a system program logic controller (PLC) program. As an example,
sizes/dimensions of the products to be processed by the system 100
can be entered into a touchscreen of the control 160, and
adjustment scale settings may be displayed for operators of the
system 100 to use for setting up the system 100 for the products.
Product width, length, and height dimensions can be handled by the
system 100 within maximum and minimum parameters. Once the product
dimensions are entered, adjustment scale settings (e.g., three
adjustment scale settings, etc.) are then displayed to the
operators for any given product that falls within the product
ranges. In some embodiments, the control may also be configured to
control the supply of products and/or the packaging station
108.
[0041] In an exemplary operation of the illustrated system 100, a
card is fed singularly from the card feeder 110 into an empty
pocket in the conveyer 112, and the conveyor 110 then indexes the
card forward (with the lugs 114, 116 both pushing the card). As the
card advances toward the merge station 106, the glue applicator 118
initially dispenses glue dots onto a top, right side portion of the
card (as viewed in FIG. 2). The lugs 114, 116 then move the card
through the first roll former 120, which folds the right side
portion (broadly, a first portion) of the card, with the glue dots,
generally upward (e.g., about ninety degrees to generally form a
first flap, etc.). The second lug 116 then advances the folded card
through the second roll former 122, which folds a left side portion
(broadly, a second portion) of the card generally upward (e.g.,
about ninety degrees to generally form a second flap, etc.) and
forms the card into its final shape (e.g., a "J" shape, a "U"
shape, etc.). As the folded card is advanced further, the guide 128
moves the upper flaps of the card down and, at the appropriate
time, delivers, indexes, etc. the card to the stop 154 in the merge
station 106 (generally in front of a product to be merged with the
card).
[0042] At about the same time, the feed station 104 isolates an
individual product, at the singulation unit 138, and delivers the
isolated product into a pocket in the lug conveyor 136. The
isolated product then proceeds down the lug conveyor 136 to the
merge station 106, where it is placed into the waiting card at the
stop 154 and squared. The press 156 impacts the cards and seats the
glue dots against the product, and the stop 154 then moves to allow
the combined card and product to move to the packaging station 108
(via the take away portion 130b of the feed conveyor 130). As can
be seen, the card station 102, the feed station 104, and the merge
station 106 are configured to operate substantially
simultaneously.
[0043] It should be appreciated that the system 100, and the
stations 102, 104, 106 thereof, may have any suitable dimensions
within the scope of the present disclosure. For example, an overall
length of the automated system 100 (as measured from one end of the
feed station conveyor 130 to the other) may be about 190 inches. A
width of the automated system 100 (as measured from the card feeder
110 to one end of the merge station 106) may be about 143 inches. A
width of the card station 102 may be about 40 inches, and a width
of the feed station conveyor 130 may be about 29 inches. Further, a
length of the in-feed portion 130a of the feed station conveyor 130
may be about 102 inches, and a length of the take away portion 130b
of the feed station conveyor 130 may be about 47 inches. Other
example embodiments may have other dimensions without departing
from the scope of the present disclosure.
[0044] Example embodiments are provided so that this disclosure
will be thorough, and will fully convey the scope to those who are
skilled in the art. Numerous specific details are set forth such as
examples of specific components, devices, and methods, to provide a
thorough understanding of embodiments of the present disclosure. It
will be apparent to those skilled in the art that specific details
need not be employed, that example embodiments may be embodied in
many different forms, and that neither should be construed to limit
the scope of the disclosure. In some example embodiments,
well-known processes, well-known device structures, and well-known
technologies are not described in detail. In addition, advantages
and improvements that may be achieved with one or more exemplary
embodiments of the present disclosure are provided for purpose of
illustration only and do not limit the scope of the present
disclosure, as exemplary embodiments disclosed herein may provide
all or none of the above mentioned advantages and improvements and
still fall within the scope of the present disclosure.
[0045] Specific dimensions, specific materials, and/or specific
shapes disclosed herein are example in nature and do not limit the
scope of the present disclosure. The disclosure herein of
particular values are not exclusive of other values that may be
useful in one or more of the embodiments disclosed herein.
[0046] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a," "an," and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0047] When an element or layer is referred to as being "on,"
"engaged to," "connected to," or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to," or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0048] The term "about" when applied to values indicates that the
calculation or the measurement allows some slight imprecision in
the value (with some approach to exactness in the value;
approximately or reasonably close to the value; nearly). If, for
some reason, the imprecision provided by "about" is not otherwise
understood in the art with this ordinary meaning, then "about" as
used herein indicates at least variations that may arise from
ordinary methods of measuring or using such parameters. For
example, the terms "generally," "about," and "substantially," may
be used herein to mean within manufacturing tolerances. Or for
example, the term "about" as used herein when modifying a quantity
of an ingredient or reactant of the invention or employed refers to
variation in the numerical quantity that can happen through typical
measuring and handling procedures used, for example, when making
concentrates or solutions in the real world through inadvertent
error in these procedures; through differences in the manufacture,
source, or purity of the ingredients employed to make the
compositions or carry out the methods; and the like. The term
"about" also encompasses amounts that differ due to different
equilibrium conditions for a composition resulting from a
particular initial mixture. Whether or not modified by the term
"about," the claims include equivalents to the quantities.
[0049] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0050] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper" and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0051] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements, intended or stated uses, or features of a particular
embodiment are generally not limited to that particular embodiment,
but, where applicable, are interchangeable and can be used in a
selected embodiment, even if not specifically shown or described.
The same may also be varied in many ways. Such variations are not
to be regarded as a departure from the disclosure, and all such
modifications are intended to be included within the scope of the
disclosure.
* * * * *