Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS FOR LOADING BOTTOM-LOADING
BASKET-STYLE CARRIER
The invention relates to bottom-loading basket-style carriers for articles
such
as beverage bottles.
Previous methods and apparatus for loading bottles into basket -style carriers
from the bottom are disclosed in US patent number 2,276,129 to Wesselman, US
patent number 2,603,924 to Currie et al., US patent number 3,521,427 to Masch,
US
patent number 3,627,193 to Helms, US patent number 3,698,151 to Arneson, US
patent number 3,751,872 to Helms, US patent number 3,747,294 to Calvert et
al.,
US patent number 3,805,484 to Rossi, US patent number 3,842,571 to Focke et
al.,
US patent number 3,848,519 to Ganz, US patent number 3,924,385 to Walter, US
patent number 3,940,907 to Ganz, US patent number 4,915,218 to Crouch et aI.,
US
patent number 4,919,261 to Lashyro et al., US patent number 5,234, 103 to
Schuster, and US patent number Re. 27,624.
Turning in particular to US 3 848 519 to Ganz, which discloses the pre-
characterising portion of claim 1, there is shown a seating mechanism for open
bottomed carriers aligned over transported groupings of articles. The
mechanism
comprises a plurality of seating members that engage a handle on the carrier.
The
seating members are carried by endless chain to engage the handles and impel
the
carriers in a downward direction.
The present invention provides a method and apparatus for the continuous
opening and loading of basket-style bottom-loading carriers.
One aspect of the invention provides a mechanism for seating open-bottomed
carriers aligned over transported groupings of predetermined numbers of
containers.
The mechanism comprises at feast one seating member adapted for engaging a
respective one of the carriers mounted in synchronous downward and forward
motion
in operable disposition above the transported groupings of predetermined
numbers of
containers. The at least one seating member travels through the synchronous
downward and forward motion. The at least one seating member engages the
respective one of the carriers and impels the respective carrier downwardly in
relation to the containers during continuous forward movement.
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According to an optional feature of this aspect of the invention, the at least
one seating member may engage a top most region of a respective one of the
carriers. Preferably, the top-most region of the carriers may be a handle
structure
and a bottom surface of the at least one seating member includes a groove
extending longitudinally therethrough.
According to another optional feature of this aspect of the invention the at
least one seating member may be spring-loaded such that the at least one
seating
member retracts away from the respective carrier if substantial resistance to
impelling the respective carrier downward is incurred.
According to yet another optional feature of this aspect of the invention the
at
least one seating member may travel through a synchronized rotary motion, and
engages the carrier through the lower arc of the rotary motion. Preferably,
the at
least one seating member may be mounted upon a planet gear of a planetary gear
mechanism.
In a second aspect of the invention, there is provided a system for seating
open-bottomed carriers with respect to groupings of predetermined numbers of
containers. The system comprises a conveyor transporting a column of the
groupings
of predetermined numbers of containers with the open-bottomed carriers aligned
thereover, and a mechanism according to the first aspect of the invention, or
any of
its preferred features.
A third aspect of the invention provides an apparatus for loading containers
into open-bottomed carriers, the carriers having a pair of opposing bottom
panels
adjoining side walls thereof. The apparatus comprises a container feeder
assembly
having conveyor mechanism for translating at least one column of a series of
groupings of predetermined numbers of containers along a first level; a
carrier feeder
for retrieving the carriers from a carrier infeed supplier; a carrier timer-
transport
assembly disposed in operative communication with the carrier feeder for
receiving
the carriers from the carrier feeder and initiating transport of the carriers
in
synchronous parallel motion with the at least one column of a series of
groupings of
predetermined numbers of containers at a second level above the first level
such that
the carriers are aligned over respective ones of the groupings of
predetermined
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numbers of containers; a gripper assembly for grasping and pulling the bottom
panels of the carriers outwardly with respect to a centerline thereof such
that the
bottom panels are substantially transversely disposed with respect to side
walls of
the carriers as the carriers are translated; a declination belt assembly
having a
downwardly-declining pair of opposing elongated endless belt pairs in face-to-
face
relationship forming a pathway therebetween for receiving transversely
extending
bottom panels of the carriers and transporting the carriers in synchronous
downwardly-declining linear motion over respective ones of the groupings of
predetermined numbers of containers; a mechanism for seating open bottomed
carriers; according to the first aspect of the invention or any of its
preferred features
and a bottom panel closure mechanism for securing the bottom panels of each
carrier
together.
Exemplary embodiments of the invention will now be described, by way of
example only, with reference to the accompanying drawings in which: -
Fig. 1 is an isometric illustration of a carrier suitable for loading by an
apparatus for loading bottom-loading basket-style carriers according to a
preferred embodiment of the invention;
Fig. 2 is a plan view of a blank for forming the carrier of Fig. 1:
Fig. 3 is an illustration of the carrier of Fig. 1 in collapsed condition;
Fig. 4 is a schematic illustration of an apparatus for loading bottom-loading
basket-style carriers according to a preferred embodiment of the invention.
Figs. 5 and 6 are schematic representations of the panel-gripper assembly of
the apparatus of Fig. 4 in operation.
Fig. 7 is an end elevational illustration of the nip belt assembly and panel-
gripper assembly of the apparatus of Fig. 5 engaging a carrier.
Fig. 8 is a side elevational illustration of a panel gripper in engagement
with a
camming track of the apparatus of Fig. 5.
Figs. 9, 10 and 11 are illustrations of the cooperation between the opening
rollers and opening ramp member of the panel-gripper assembly of the
apparatus of Fig. 5.
Fig. 12 is an Isometric Illustration of the bottle transport conveyor of the
apparatus of Fig. 5.
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Fig. 13 is a side elevation a! view of declination and seating assemblies of
the
apparatus of Fig. 4.
Figs. 14 and 15 are end elevational views from the declination belt section of
the apparatus of Fig. 4.
Fig. 16 is an Isometric illustration of an alternate version of a declination
block
of the apparatus of Fig. 4.
Fig. 17 is an elevational illustration of a planetary gear version of the
carrier
seating assembly of the apparatus of Fig. 4.
Fig. 18 is an isometric illustration of a folder-gluer assembly of the
apparatus
of Fig. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Carrier 10 described herein as the preferred embodiment of the invention is
particularly suitable for loading carriers such as the bottom-loading basket-
style
carrier 3 shown in Fig. 1. Although use of the method and apparatus 10 of the
subject invention is not limited to the carrier 3 described below, the
features of the
invention are very clearly described by reference to the invention's handling
and
loading of the carrier 3 illustrated. A blank 906 for forming the carrier 3 is
shown in
Fig. 2. Fig. 3 is a plan view of the collapsed carrier 3 of Fig. 1.
The carrier 3 is of the nature described in US patent number 5,547,074 issued
August 20, 1996. That patent is also owned by the owner of the present
invention
application. The carrier 3 and blank 906 for forming the carrier 3 are
described
below to facilitate understanding of the invention. First, reference is made
to Figs. 1
and 2 simultaneously. The carrier3 illustrated is generally designed to
accommodate
two rows of bottles. The examples of carriers 3 discussed herein describe use
of the
invention with carriers 3 that accommodate two rows of three bottles and two
rows
of four bottles, that is, a six-pack version and an eight-pack version.
However, the
invention may also be practiced to accommodate rows of other multiples of
bottles.
Both sides of the carrier are the same. Thus, the features described with
respect to
the side shown in Fig. 1 are equally applicable to the unseen side. The side
wall
920, 930 has a cut-out portion that generally defines a lower side wall band
921, 931
and an upper side wall band 923, 933. Foldably connecting the lower 921,931
and
upper 923, 933 bands to respective end walls 940, 942, 950, 952 are respective
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corner tabs 922, 932,924,934. The corner tabs 922, 932, 924, 934 respectively
form bevelled corners at the intersections of the side walls 920, 930 and end
walls
940, 942, 950, 952. The cut -way area also defines a center portion 928, 938
left
intact in the side wall 920, 930. A center cell is formed on each side of the
carrier
by cell bands 925, 935, comer tabs 926, 936 foldably connected to the cell
bands
and a central cell portion 927,937 integrally formed with the sidewall 920,
930.
Riser panels 960, 962, 970, 972 extend between the bottom of the carrier 3 and
the
handle structure formed by panels 980, 982, 990, 992. A handhold flap 984 is
also
visible from the view shown. Cut lines between center cell portions of side
walls
920, 930 and respective handle structure panels 980, 982, 990, 992 terminate
in
respective curved cut lines 986, 988, 996, 998. Cut lines between the upper
bands
923, 933 of respective side walls 920, 930 and corresponding center cell
portions
terminate in respective curved cut lines 987,989,997,999. In collapsed
condition (as
shown in Fig. 3) the carrier 3 has nick members 929, 939 strategically located
upon
cut lines between the side wall and center cell at the bevelled corner tabs.
This
feature is not evident in the fully erected carrier but can be seen in the
blank 906 of
Fig. 2 and collapsed carrier 3 shown in Fig. 3. The blank 906 is essentially
symmetric about a perforated fold fine dividing the handle panels 980, 982,
990,
992, and halves, of the carrier 3 from one another. One of the two bottom wall
panels 910, 912 is widthwise greater than the other and for convenience is
designated the greater bottom wall 912. The other bottom wall panel is
conveniently designated the lesser bottom wall panel 910. Each side wall 920,
930
has a cut-out, or cut-away, area which helps define a lower side wall band
921, 931
with adjacent corner tabs 922, 932 and a top band 923, 933 with adjacent
corner
tabs 924, 934. Elements for forming a center cell are central cell bands 925,
935,
central cell corner tabs 926, 936 and center cell central portions 927, 937
which are
integral with the respective side walls 920, 930. Solid nick members 929, 939
connect top sidewall bands 923,933 and respective center cell corner tabs 926,
936.
End walls 940, 942, 950, 952 lie adjacent respective side walls 920, 930
connected
thereto by respective side wall corner tabs 922, 932, 924,934. Riser panels
are
connected to respective end walls 940, 942, 950, 952 along perforated fold
lines.
Support tabs 981, 983, 971, 973 for attachment to the bottom wall panels 91 0,
912
are foldably connected to the lower edges of respective riser panels
960,962,970,972. A suitable carrier for loading by the invention may also have
the
support tabs connected to the lower edges of respective end walls 940, 942,
950,
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952 along fold lines without departing from the scope hereof. The center cell
bands
925, 935 are connected along perforated fold lines to the lower portions of
respective
handle panels 980, 982, 990, 992. Handhold apertures 981, 983, 991, 993 are
formed in the respective handle panels 980, 982, 990, 992. Cut lines
separating
center cell bands 925, 935 and accompanying center cell terminate corner tabs
926,
936 from respective handle panels in curved cut lines 986, 988,996, 998. Cut
lines
separating the top bands 923,933 and accompanying corner tabs 924, 934 from
respective center cell bands 925, 935 and accompanying center cell corner tabs
926,
936 terminate in curved cut lines 987, 989, 997,999 in the respective side
walls 920,
930. Handhold flaps 984, 994 are connected along perforated fold lines to
respective
handle panels 980,990 within the respective handhold apertures 981, 991
thereof.
Curved cut lines 986, 987, 988, 989, 996, 997, 998, 999 help direct stress
away
from strategic termination points of cut lines in the carrier 3.
As previously mentioned, the method and apparatus described herein are
particularly suitable for loading carriers having the general characteristics
of the type
described above. The elements of the carrler3 enable it to be fanned in
collapsed
condition, shipped, loaded into the apparatus described herein, and then
erected and
loaded with bottles. Although several types of bottles are suitable for
handling and
loading by the invention, the invention is particularly useful for loading so-
called
contoured PET bottles into the carrier 3 illustrated.
The carrier 3 is received by the apparatus of the invention in collapsed
condition, as illustrated in Fig. 3, with the bottom wall panels 910, 912
pivoted
upwardly into face contacting relationship with the side walls of the carrier
3. In this
condition, the carrier 3 is easily loaded into and subsequently erected and
loaded by
the apparatus of the invention. However, the support tabs 961, 963, 971, 973
are
exposed and may be damaged when the carrier is transported in this condition.
The
invention includes a suitable means of preparing carriers 3 for loading into
the
apparatus. As a means "for preventing damage to the support tabs 961, 963,
971,
973 of the carrier 3 during shipment to the loading site and as a means to
facilitate
loading of the carriers 3 into the apparatus (as described below), the
carriers 3 are
packaged in a container 5, essentially upside-down. In this condition the
handle
portion is positioned downward and the lower edge is upwardly oriented. The
end
walls 2 and side walls 4 of the container 5 for the carriers 3 extend above
the
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exposed, protruding support tabs 961, 983, 971, 973 and thereby protect the
tabs
981, 963.
Overview of Apparatus and Method
Referring first to the schematic illustration in Fig. 4 of the overview of the
apparatus 10 according to a preferred embodiment of the invention, the
apparatus
is constructed upon an elongated frame. In the illustration the direction of
10 movement of bottles 1 and carriers 3 is from left to right. As a general
overview,
bottles move through the apparatus 10 in two rows along an essentially linear
path.
As the bottles move along their defined path, carriers (in collapsed condition
with
bottom wall panels folded upwardly flat against the sides of the collapsed
carrier) are
moved along the hopper 30 to a point of interface with the carrier feeder 50.
The
feeder 50 moves individual carriers 3 from the hopper 30 to a timing section
60. A
timing-transport section meters out carriers at set intervals and a
predetermined rate
of speed. In one embodiment, the timing-transport section consists of two
consecutive assemblies. The first segment of the two is a timing section 60 in
which
each carrier 3 is removed from suction cups 54 of the feeder 50 and conveyed
at a
predetermined stagger to the downstream components of the apparatus 10. In
what
may generally be referred to as the transport segment of the timing-transport
section a path is defined between a pair of vertically oriented belts. More
specifically,
this segment is referred to as a nip belt assembly 70. The vertical nip belts
72 are a
pair of opposing endless belts that pinch, or "nip," the handle area of each
carrier
(the carrier's topmost portion) and move the carriers in a defined linear path
down
the apparatus 10. In an alternate embodiment of the timing-transport section
the
timing and transport functions are less distinct. In the second embodiment the
carriers 3 are engaged through the hand-hole openings in their handles and
transported thereby. Timing and transport are achieved by reciprocal movement
of a
hand-hole insert mounted upon earn-engaging rods. The rods in turn are in
slidable
engagement with an endless chain. When the carriers 3 are in the hopper 30,
they
are in collapsed condition with the bottom wall panels 910, 912 pivoted up and
lying
flat against the sides of the carrier 3. Upon removal from the hopper 30, the
bottom
wall panels 910, 912 of the carrier 3 fall away from their position flat
against the
sides of the carrier 3. As a carrier 3 moves through the timing section the
bottom
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wall panels 910, 912 are engaged and pulled outward to open the carrier 3 for
loading. As the carriers 3 are being pulled open along the carrier path of the
apparatus 10, bottles are moved along in a path beneath the carriers. In the
lower
path (the bottle path) a star wheel 105 on either side of the apparatus 10
meters a
row of bottles 3 into distinct groups for loading. For example, groups of
three or four
bottles in each row. An endless chain with lugs is one of the means for
transporting
bottles after they have been metered by the staIWheeli 05. Bottle grippers 113
(moving in conveying fashion such as upon an endless chain) immediately follow
the
star wheels 114 and maintain the spacing and alignment of each bottle
grouping. As
the bottles 3 move further along the length of the apparatus 10 the bottle
grippers
113 assure the spacing between bottles and groups of bottles. At the same
time, the
carriers 3 move to a position whereby each bottom wall panel 910, 912 is
received
by a pair of downwardly-sloping declination belts 92,94 & 93,95. An overhead
conveyor mechanism such as an endless overhead chain assembly 100 is aligned
over the centrally located handles of the carriers 3 in parallel alignment
with the
declination belt assembly 90. Block members 102 mounted upon the overhead
chain
engage the tops of the handle portions of the carriers 3. The declination belt
assembly 90 and overhead chain assembly 100 move the carriers 3 forward and
downward over the dual-row groups of bottles. The lowering work of the
declination
belt assembly 90 and overhead chain assembly 100 is completed by the pusher
wheel assembly 120. The pusher wheel assembly 120 has block members 122
mounted upon it to push downwardly upon the tops of the handles of the
carriers 3,
thereby fully lowering the carriers onto respective groups of bottles. As the
carriers
3 move from the pusher wheel assembly 120 a package conveyor 130 such as side
lugs 134 mounted upon respective opposing endless chains 132 engage the
trailing
end panel of the carriers 3/packages 7 and push them further along the
apparatus
10. As the carriers 3 are moved along by the package conveyor 130, a bottom
panel
locking section 140 folds carrier support tabs 961, 963, 971, 973 and bottom
wall
panels 910, 912 into position for attachment of the support tabs 961, 963,
971, 973
to the bottom wall panels 910,912 and for closure of the bottom of the carrier
3.
The bottle panels 910, 912 are drawn together for proper alignment and held in
that
position while closure of the bottom of the carrier 3 is completed by a
rotating punch
lock mechanism. The loaded, fully closed carrier is then ejected from the
apparatus
10.
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Bottle Infeed Conveyor
Referring to Fig. 4, bottles are brought into the apparatus 10 by an infeed
conveyor assembly 20. Infeed conveyors typically used in the beverage
packaging
industry are suitable. In the preferred embodiment illustrated the conveyor
assembly 20 has partitions 22 that segregate incoming bottles into two rows.
Conveyor means such as an endless belt or chain move bottles through the
apparatus 10 for loading into carriers 3. Different endless chains or belts
and a
combination of different endless chains or belts is used for effecting
movement of
bottles. The carriers 3 and bottles are moved part of the way through the
apparatus
10 simultaneously in separate paths, with the carriers 3 proceeding in a path
disposed above the path of bottles. Then, as will be described further below,
the two
paths become one when the carriers 3 are moved downwardly over groups of
bottles.
Carrier Feeder
Referring momentarily to Fig. 4, as previously noted, the layout of the
apparatus is generally linear with bottles and carriers 3 being moved along
separate
linear paths, one over the other, part of the way through the apparatus 10,
and then
packages formed of the loaded carriers moving along a single path the rest of
the
way through the apparatus 10. Referring now to Fig. 5, the carrier feeder 50
removes carriers 3 from the hopper 30 and passes them on to elements in a
linear
carrier path disposed over the bottle path.
Timina-Transport Section
The first version is described referring to Fig. 4. As previously mentioned,
the
timing-transport section moves carriers 3 from the feeder 50 to downstream
components of the apparatus 10. The timing-transport section staggers the
carriers
3 a predetermined distance apart and begins their travel at a predetermined
rate of
speed. This timed spacing of carriers 3 causes the carriers 3 to begin
synchronized
aligned movement with respective groups of bottles as the carriers 3 and
bottles
move downstream.
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The first version of the timing-transport section achieves timing and
transport
in two distinct segments, namely, a timing assembly 60 and a transport section
for
convenience herein referred to as a nip-belt assembly 70. The timing assembly
60
has conveyor-driven carrier support fingers for engaging and moving carriers 3
at
predetermined intervals and inserting the carriers into nip belts at the
predetermined
intervals. The carrier support conveyor 60 is a pair of an upper 61 and a
lower 63
endless timing chain. Each timing chain 61, 63 contains respective sets of
lugs, or
fingers, that engage portions of a collapsed carrier 3 as the carrier is
released by the
suction cups 54 of the feeder 50. The upper timing chain 61 has a series of
upper
engagement lugs 62 one of which en gages the trailing edge of the handle
portion of
an engaged carrier 3. In the preferred embodiment illustrated an upper
engagement
lug 62 engages the carrier 3 at the intersection of the handle portion and the
wall
panels. The corner formed at the intersection provides a stable point of
engagement.
The lower timing chain 63 has a set of lower engagement lugs 64, 65, 66 that
work
in tandem with each upper engagement lug 62 of the upper chain 61 to hold the
carrier 3 steady and guide it into the nip belt assembly 70. Although several
combinations of lower engagement lugs in the set would be effective, in the
preferred
embodiment illustrated there are three lower engagement lugs 64, 65, 66 in
each
set. All three lugs 64, 65, 66 support the carrier from the bottom. The
trailing lower
engagement lug 66 is especially effective in helping push the collapsed
carrier 3
forward. The nip belt assembly 70 receives collapsed carriers 3 from the
feeder 50
and timing assembly 60. The nip belt assembly 70 moves carriers 3 along at the
predetermined spacing initiated by the timing section 60 as the bottom panels
910,
912 of the carrier 3 are gripped and moved outwardly to open the bottom of the
carrier 3 for loading. Referring now to Fig. 5, the nip belt assembly 70 has a
pair of
endless belts 72 mounted upon respective elongated rods of rollers 74. The
belts 72
press together in an elongated vertical plane whose direction of movement 71
with
respect to an engaged carrier 3 is downstream of the apparatus. The topmost
portion of the handles of the carriers 3 are sandwiched between the belts 72
and
translated along the path between the moving belts 72. An upper belt guide 76
directs the top portion of handles of carriers 3 into the pathway between the
belts
72. The lower belt guide 78 extends along the length of the belts 72. The
opening
to the lower belt guide 78 directs the downwardly-extending support tabs 961,
971,
963, 973 of carriers 3 into the guide 78. Referring now also to Fig. 4, as the
top
portion of the handles of carriers 3 are pinched and translated along by the
belts 72,
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the support tabs 961, 971, 963, 973 travel along through the lower belt
assembly
guide 78.
Bottom-Panel Grinpers
Referring to Fig. 4, in a panel-gripper assembly 80, panel-grippers open the
collapsed carrier 3 in preparation for loading. As the carriers 3 move through
a
timing-transport section (which are described above) carrier-panel grippers 82
moving on conveyors in a parallel path beneath the timing section grasp the
bottom
panels 910, 912 and pull them outward to open the carrier 3. Each carrier
gripper
82 is a clamp that grasps a respective bottom panel 910, 912. Referring now
again
particularly to Fig. 4, the grippers 82 are mounted upon two sets of conveyors
(endless chains) 84, 86. Each set of chains 84, 86 is a pair of opposing
endless
chains that are respectively positioned on each side of the collapsed carriers
3
moving through the timing section. Referring now also to Figs. 5 and 6 the
opening
motions of the elements of the gripper assembly are schematically illustrated.
The
grippers 82 on both sets of gripper chains 84, 86 move outwardly of the
centerline
901 of the carrier 3 in the direction indicated by the direction arrow denoted
81. At
the same time, each chain 84, 86 rotates in the downstream direction indicated
by
direction arrow 83. The grippers 82 and chains of the first set of chains 84
open
carriers 3 by pulling outwardly upon the bottom panels 910, 912 of the
carriers. The
first set of chains 84 and grippers 82 opens carriers 3 from the fully
collapsed
condition and 13 to an open condition. The chains 84 in the first set of
chains 84
move at a greater speed than the relative speed of the carriers 3 as they are
moved
by the transport mechanisms of either the nip belts 72 or the inserts 262. (In
turn,
the movement of the carriers 3 by the timing-transport section of the
apparatus is in
timed sequence with the movement of the bottles in a parallel path below the
carriers.) As can be seen in Fig. 5, the collapsed carrier 3 is folded in a
collapsed
condition in a manner resembling the bellows of an accordion wherein the front
portion of the collapsed carrier projects outwardly and the rear portion is
folded
inwardly. The greater relative speed of the first set of chains 84 enables the
panels
910, 912 to be pulled forward faster than the carrier 3 itself is moving
forward. This
movement enables the carrier to become opened in a squared-up condition
wherein
the bottom panels 910, 912 "catch up" with the center portion of the carrier
3. After
the carrier 3 has been erected in the first gripper chain 84 section the panel
grippers
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82 of the second set of gripper chains 86 engage the bottom panels 910, 912 of
the
carrier 3 and pull the carrier 3 open further to the maximally-opened
condition
illustrated in Figs. 6 and 7. The second set of chains 86 of the gripper
assembly also
passes opened carriers 3 on to the next carrier-handling portion of the
apparatus 10,
namely, the carrier lowering section 90. The grippers 82 and chains 84 of the
second
set of gripper chains do not move at a greater relative speed than the carrier
transport mechanism but move in synchronous downstream motion (as indicated by
the direction arrow 83) with the nip belts 72 or inserts 262. The grippers 82
continue to hold the respective bottom panels 910, 912 outward during
movement.
Figs. 6 and 7 illustrate the end of carrier 3 opening in which the carrier 3
is fully
opened and ready to be passed on to the declination belt assembly 90. Fig. 4
is an
elevational illustration of a fully-opened carrier 3 engaged by elements of
the nip belt
assembly 70 and panel grippers 82. Referring now momentarily to Fig. 5, a pair
of
opposing conveyors in the form of endless chains 88 assist in passing opened
carriers
3 from the first set of chains 84 to the second set of chains 86. As carriers
3 leave
the first set of chains 84, lugs 89 mounted upon the chains 88 engage the
front and
rear of open carriers to help them maintain their opened position as the
bottom
panels 910, 912 are again grasped by the grippers 82 of the second set of
chains 86.
Referring now also to Fig. 8, the structure of a panel gripper 82 suitable for
use with the panel-gripper assembly described above is described in greater
detail.
In the gripper 82 an upper arm 284 and a lower arm 286 form clamping jaws that
are pivotally 283 connected to one another and meet at a clamping point where
each
arm 284, 286 terminates in a respective pad 285, 287. Each gripping pad 285,
287
is made of a substance that has a high coefficient of friction relative to the
smooth
surface of a carrier. A suitable substance is rubber. The pads 285, 287 may
also
have a corrugated surface or a surface otherwise containing ribs or other
protruding
structures to enhance friction. The arms 284, 286 are spring-biased 288 in a
closed,
clamping position for the gripper 82. The arms 284, 286 are mounted upon a
truck
296 which in turn is mounted upon and transported by a gripper chain 84 or 86.
The
arms 284, 286 are translatable with respect to the truck 296 through the
cooperation
of V-shaped rollers 294 mounted on the truck and a roller engagement member
298
which has V-shaped edges and which is attached to the lower gripper arm 286. A
cam follower 290 is attached to the lower arm 286 and rides within a camming
groove (or track) 292 that defines the translational movement of the arms 284,
286.
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The manner in which the gripper's 82 upper arm 284 is made to pivot to open
and close with respect to the bottom arm 286 to clamp and release the bottom
panels 910, 912 of the carrier 3 is described with reference to Figs. 9, 10
and 11.
Figs. 20, 21 and 22 are representations of the movement of the gripper 82 as
it is
transported by its mounting chain 84 or 86. The view is from a vantage point
looking
at the front end of the gripper 82 toward the rear of the upper arm 284 where
the
opening roller 300 is attached. As the gripper is transported in the direction
indicated by the arrow 301 the rear of the upper arm 284 is pushed downward,
held
down for a period and subsequently allowed to return to its upwardmost
position
through interaction of the opening roller 300 with the opening ramp member
302.
The opening ramp member is a plate, bar or other structure having a cross-
sectional
configuration defining a leading downwardly-inclined ramp 303 and ending in an
upwardly-inclined trailing ramp 305. A flat portion 304 may be inserted
between the
two ramps 303, 305 to maintain the jaws (arms 284, 286) of the gripper 82 open
for
a short period. Fig. 20 illustrates the relative position of the opening
roller 300 and
opening ramp member 302 prior to contact between the roller 300 and leading
ramp
303. In Fig. 21, as gripper 82 travels in the direction 301 shown, the roller
300 is
engaged by the leading ramp 303 and rotates 306. The upper arm 284 is thus
pushed downward 307 opening the laws of the clamp. If the ramp 302 contains a
level portion 304 the jaws of the gripper 82 are held open during engagement
of the
roller 300 with the level portion. Travel of the roller 300 upon the trailing
ramp 305
closes the jaws of the gripper 82.
Referring now momentarily to Fig. 2 and the schematic illustration of Fig. 5,
it
is noted that the carrier 3 may contain nick members 929, 939 to promote
opening
of the collapsed carrier in a particular fashion. The nick members 929, 939
are
weak connecting members extending between respective center cell corner tabs
926,
936 and upper side wall bands 923, 933. The nick members 929, 939 cause
separation of the upper side wall bands 923, 933 from the center cell bands
925, 935
to be delayed. The delay causes the angles between the center cell bands 925,
935
and respective center cell corner tabs 926, 936 to more sharply form in the
erected
carrier.
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Each gripper 82 in the first set of grippers may also have a hook-like member
for engaging the top bands 923, 933 on either side of the collapsed carrier as
the
grippers engage the respective bottom panels 910, 912 to pull the carrier
open.
Bottle Metering and Transport
As previously mentioned, a starwheel 105 meters bottles from the bottle
infeed conveyor into groups for loading into the carriers. After metering,
timed,
spaced transport of the groups of bottles is achieved through use of a
conveyor 106
which travels under the bottles and a bottle-gripper conveyor 112 which
engages the
sides of the bottles. Referring now to Fig. 12, a bottle transport conveyor
106 has a
spaced-apart pair of endless chains 107 upon which bottle lugs 108 are mounted
and
each of which is flanked by a pair of bottle support rails 109. The rails 109
serve as
ledges which help support the outer periphery of the bottom of bottles. The
lugs
108 engage the rearmost bottle in each column of a bottle grouping. Although a
single lug may be used to engage the rearmost bottle in a column, paired sets
of lugs
108 allow more stable contact with bottles because two points on the bottle
are
contacted rather than one. The slot, or spacing 110, extending longitudinally
between the chain structures provides a travel path for the tabs 961, 971,
963, 973
when carriers are lowered onto groups of bottles. This aspect will be
explained in
greater detail below.
Carrier Lowering Section
After opening, carriers 3 are lowered onto groups of bottles 1 moving in a
parallel path beneath the path of the carriers 3. With reference now to Figs.
4 and
13, carrier lowering is accomplished through the combination of a declination
belt
assembly 90 and an overhead declination block assembly 100. When the erect
carrier 3 leaves the nip belt 70 and gripper 80 assemblies it is upright with
its bottom
panels 910, 912 extended outwardly of a center line 901 of the carrier 3. As
the
erect carrier 3 leaves the nip belt assembly 70 and the grippers 82 mounted
upon
the second gripper chain 86, it is directed toward the declination assembly
where the
extended bottom panels 910, 912 are respectively received by left and right
opposing pairs of declination belts 92, 94 and 93, 95. Referring now generally
to
Figs. 4 and 13 but more particularly to Figs. 14 and 15, the pairs of belts
92, 94 and
CA 02218035 2006-08-04
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93, 95 of the declination belt assembly 90 are spaced apart so that the
carriers 3
may pass between them. For reference, one pair of upper 92 and lower 94 belts
is
considered the "right" declination belts while the opposing upper 93 and lower
95
belts are considered the "left" pair. Each of the four belts 92, 93, 94, 95 is
an
endless belt. The spacing shown between the facing surfaces of each pair of
belts is
for illustration purposes. The facing surfaces of each pair of belts 92, 94
and 93, 95
belts are disposed closely enough so that the panels 910, 912 of the carrier 3
are
wedged between each pair of moving belts. The carriers 3 are thus translated
along
the apparatus 10 by the moving belts.
Although only the general structure of the belts assembly 90 is shown it can
be appreciated that means of endless belt movement commonly used by those
skilled in the art are employed. For example, the use of a circular roller
mechanism
91 disposed at the ends of the belt runs with additional rollers disposed
between the
ends of the runs to maintain opposing belts in surface-to-surface contact. The
belts
92, 94 and 93, 96 movements are in synchronization with the movement of the
bottle-group conveying mechanism (that is, the bottle-gripper conveyors 112).
Each
carrier 3 is received by the declination belts such that each carrier 3
overlies a group
of bottles 5. Referring now particularly to the side elevational view of Fig.
13, an
optimum angle of declination of the pairs of belts 92, 94 (and 93, 95 which
are
parallel to 92, 94 but not visible in Fig. 13) and the horizontal plane of the
groups of
bottles 5 is shown as an angle denoted "A" of 4 degrees. The angular
orientation of
the declination belts 92, 94 and 93, 96 causes the carriers 3 to gradually
descend
upon the groups of bottles 5. Lowering of the carriers 3 is aided by the
overhead
declination block assembly 100 in which a series of handle-engaging blocks 102
are
mounted upon an endless chain which in turn is in alignment and
synchronization
with the declination belts. Referring momentarily particularly to Fig. 14,
each block
102 has a groove or slot 103 for receiving the handle of a carrier 3. The
overhead
assembly is disposed with respect to the declination belts 92, 94 and 93, 96
such
that as carriers are moved by the belts 92, 94 and 93, 96 the apex of the
carrier 3,
that is, the top of the handle portion, is engaged by the groove/slot 103 and
helps
stabilize and reinforce the movement of the downward traveling carriers. The
blocks
may be spaced for synchronization but a simple means of utilization as
illustrated is
to have the blocks 102 abut one another so that essentially a continuous
groove or
slot is formed.
CA 02218035 2006-08-04
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Referring momentarily to Fig. 15, to further ensure stable movement of
carriers 3 an alternate version of the declination belt assembly 90 includes a
guide
98, 99 positioned to engage the fold line created between each bottom panel
910,
912 and an adjacent side wall of the carrier 3. The guide 98, 99 is parallel
and
coextensive with the length of the belts 92, 94 and 93, 96. The guides 98, 99
thus
further aid in lowering the carriers 3 and further stabilization of the
carriers 3 as they
are lowered.
To obtain optimum performance and reliability from the apparatus 10, rather
then being completely lowered over a group of bottles 5, each carrier is only
substantially lowered prior to the departure of the carrier panels 910, 912
from the
declination belts 92, 94 and 93, 96 and departure of the handle portion from
the
overhead declination blocks 102.
Completed lowering of each carrier 3 over a group of bottles 5 is achieved in
the seating wheel assembly 120 which follows the declination belt assembly 90
and
overhead declination block 100 assemblies. Carriers 3 and groups of bottles 5
exit
the declination belt 90 and overhead declination block 100 assemblies as a
unit
denoted by the number 6 in Fig. 13. The carrier-bottle unit 6 is a package in
which
the fully-erected carrier 3 is substantially but not completed lowered over
the bottle
grouping 5. The carrier 3 is either angularly disposed with respect to the
bottle-
grouping 5, due to the angular placement of the carrier 3 over the bottles 5,
or the
carrier 3 may be horizontally disposed as it exits the declination section due
to
contact of the rearmost end of the carrier handle by the last declination
block 102.
Referring now also to Fig. 17, the seating wheel assembly 120 is a ferris-
wheel-like
structure wherein seating blocks 122 are attached to a revolving wheel or drum
124
in a manner which maintains their downwardly-directed (that is, wherein the
handle-
receiving slot is downwardly directed) orientation. The seating blocks 122
maintain
the same orientation as they travel in the circular path of the wheel 124.
Suitable
means for preservation of the orientation of the seating blocks 122 as the
wheel 124
turns is to allow the seating blocks 122 to freely pivot with respect to the
wheel.
This arrangement is simply illustrated in Fig. 13. A more precise means of
maintaining alignment is illustrated in Fig. 17. Fig. 17 illustrates the use
of a
planetary gear system to maintain the downward orientation of the seating
blocks.
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In Fig. 17, the seating blocks 122 are mounted upon "planet" gears 127 that
revolve
around a centrally disposed "sun" gear 126 in known mechanical manner.
The seating blocks 122 have a handle-receiving groove or slot 123 like the
handle-receiving groove/slot 103 of the overhead declination blocks 102. Since
the
handle-receiving portion 123 of the seating block 122 is not fully visible in
the
illustration of Fig. 4 and not visible in Fig. 13, the blocks 102, 122 may be
considered
identical in this aspect. The rotation of the wheel 124 is synchronized with
the
movement of the carrier-bottle units 6 so that consecutive seating blocks 122
engage
the handles of consecutive carriers of the units 5. The movements of the wheel
124
and carrier-bottle unit conveyor are synchronized such that the handle of a
carrier-
bottle unit 6 intersects the angular path of the wheel 124 as the handle-
receiving
portion 123 of a seating block 122 reaches that same point. Thus, after the
seating
block 122 engages the handle of a carrier rotation of the wheel moves the
block 122
both downward and forward. Placement of the carrier 3 over a group of bottles
5 is
thus completed and the carrier is fully "seated" with respect to the group of
bottles 5.
The unit of a group of bottles 5 and a fully-seated carrier 3 is denoted by
the
reference numeral 7 in Fig. 26. The unit 7 is now ready for closure.
The seating blocks 122 may be spring-loaded such that if a bottle is engaged
rather than a carrier-handle the resistance will cause the seating block to be
pushed
backward toward its point of coupling. In this manner damage and jamming is
prevented if a misaligned bottle is engaged by a seating block 122.
In Figs. 13 and 14 the bottles 1 are shown in groupings 5 of two by three
arrays, a total of six bottles per group. However, as previously mentioned, it
is
noted that the system of the invention works well with various multiples of
bottles to
be packaged. To reinforce this point, the description and illustrations of the
preferred
embodiment utilize both six- and eight-bottle configurations. For example, the
bottle
grippers 114 illustrated in the isometric schematic of Fig. 4 is configured
for an eight-
bottle group while the carriers 3 and bottle groupings in other illustrations
depict a
six-bottle configuration. The principles of the invention are equally
applicable to both
six- and eight-bottle configurations as well as other arrayed configurations.
CA 02218035 2006-08-04
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Referring now briefly to Fig. 16, in an alternate version of the overhead
declination block 102a bevelled bottom walls 101 a lead to the groove, or slot
103a
for receiving the carrier handle.
Folder and Gluer
Referring now again particularly to Fig. 4, upon leaving the seating portion
120 of the apparatus 10 each package 7 is engaged and transported by a package
lug assembly 130. The package lug assembly 130 primarily consists of a pair of
opposing endless chains 132 upon which are mounted lugs 134 that engage each
package 7. Closure of the carton 3 of each package 7 is accomplished in the
folding
and gluing area 140 of the apparatus 10 as the packages are moved along by the
package lugs 134.
Referring now particularly to Fig. 18, therein is illustrated a folder-gluer
assembly 140 of the apparatus for loading bottom-loading basket-style carriers
10
according to a preferred embodiment of the invention. The gluing operation
will be
discussed later, however, for clarity of understanding it is now noted that
glue is
applied to the interior side (that is, the side which faces the inside of the
erected
carrier 3) of the so-called greater bottom wall panel 912 of the carrier 3.
Glue is
applied to adhere the riser panel support tabs 961, 963, 971, 973 to the
interior side
of the greater bottom wall panel 912. In a version of the carrier without
support tabs
961, 963, 971,973 folding and adherence of the support tabs would obviously
not be
necessary for such a carrier. The elements of the folder-gluer assembly 140
are
positioned to fold the elements of the carrier 3 in sequence. The folding
features of
the folder 140 are static elements that engage applicable panels and flaps of
carriers
3 as the packages 7 are moved by the package lugs 134 in the direction
indicated by
the direction arrow 71. As the packages approach the folding section the
bottom
panels flaps 910, 912 are generally more horizontally inclined rather than
downwardly vertically oriented. In the folding section, the bottom panels 910,
912
are first folded vertically downward, then under the carrier 3 into face-to-
face
relationship for later locking. The support tabs 961, 963, 971, 973 are folded
into a
horizontal position. The support tab folding elements are contained in what is
conveniently referred to as a tab folding block 141. Consistent with the
carrier
orientation discussed above, the greater bottom panel flap 912 is the first of
the two
CA 02218035 2006-08-04
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bottom panel flaps 190, 912 engaged. The greater panel flap 912 is engaged and
caused to be folded vertically downward by the inclined edge of the first
vertical
panel-folding wedge 162. The first vertical panel-folding wedge 162 folds the
greater
panel 912 to a vertically downward position wherein it is sandwiched between
the
wedge 162 and the folding block 141. The folding block 141 provides edges and
surfaces which separate and fold the support tabs into place and spaces which
accommodate the tabs as they are being manipulated. Each pair of a long and
short
support tab 961 & 971, 963 & 973, at opposing ends of the carrier is engaged
simultaneously by the block 141 (note Fig. 3, the end of the carrier with
support tabs
961, the longer tab, and 971, the shorter tab, is the leading end).
Closure of the Carrier
Closure of the bottom of the carrier 3 may be achieved by several means. For
example, adherence of the bottom panels 910, 912 to one another by an
adhesive.
Another effective means for closure is the use of a locking mechanism known as
a
"punch lock" in the packaging field wherein the outermost of the two bottom
panels
has male locking members that are superimposed over corresponding female
apertures and members formed in the inside bottom panel. To help effectively
close
the bottom of the carrier 3, particularly if the carrier will be closed
utilizing a punch
lock, the two bottom panels 910, 912 can be drawn inwardly to help align the
two
bottom panels 910, 912. This is particularly useful, and necessary, to engage
male
and female lock features and is also useful to generally ensure that the
carrier 3 is in
its optimum squared-up condition with the bottom panels 910, 910 overlapping
by a
predetermined amount.
Other modifications may be made in the foregoing without departing from the
scope and spirit of the claimed invention.
