Note: Descriptions are shown in the official language in which they were submitted.
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METHOD AND APPARATUS FOR LOADING CONTAINERS INTO OPEN-BOTTOMED BASKET-STYLE
CARRIER
Technical Field of the Invention
The invention relates to bottom-loading basket-style
carriers for articles such as beverage bottles.
~ackaround of the Invention
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 al., 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.
Summary of the Invention
The present invention provides a method and apparatus
for the continuous opening and loading of basket-style
bottom-loading carriers.
In accordance with a preferred embodiment of the
invention an apparatus for loading containers into basket
style bottom-loading carriers has a first container infeed
conveyor; a divider disposed proximate the first container
infeed conveyor for segregating the containers into columns;
a container meterer for metering each of the columns of
containers into groupings of a predetermined number of
containers; a second container conveyor having members
attached thereto for engaging a last container in each
grouping of containers; container gripper conveyors having
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container grippers for maintaining the container groupings;
a carrier infeed supplier; a carrier feeder for removing
carriers from the carrier infeed supplier; a carrier timer-
transport assembly for receiving carriers from the carrier
feeder and initiating transport of the carriers in
synchronous parallel motion above the containers; a gripper
assembly for opening the carriers by grasping and pulling
outwardly with respect to a centerline of the carriers the
bottom panels of the carriers; a declination belt assembly
l0 having a downwardly-declining pair of opposing elongated
endless belt pairs in face contacting relationship forming
a pathway for receiving transversely extending bottom panels
of the carriers and transporting the carriers downwardly
over the groupings of containers; a seating assembling
having a plurality of members having a groove for engaging
tops of handles of carriers, the members in rotatable
cooperative disposition with respect to the carriers which
have been placed over the groupings of containers such that
as said members rotate a bottommost member engages the
respective tops of the handles of the carriers; and a two-
part lug assembly for placing the bottom panels together in
locking relationship with respect to one another.
Other advantages and features of the present invention
will be apparent from the following description, the
accompanying drawings, and the appended claims.
Brief Descrit~tion of the Drawings
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.
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Fig. 4 is an illustration of a container for the
carriers of Fig. 1 in the collapsed condition of Fig. 3.
Fig. 4A is an illustration of a container for the
carriers of Fig. 1 in the collapsed condition of Fig. 3,
configured for use with an automatic carrier loading feature
of the hopper of the apparatus of Fig. 5.
Fig. 5 is a schematic illustration of an apparatus for
loading bottom-loading basket-style carriers according to a
preferred embodiment of the invention.
Fig. 6 is an isometric illustration of a hopper for the
apparatus of Fig. 5.
Fig. 7 is an elevational view of the hopper of Fig. 6
loaded with at least one carrier.
Fig. 8 is an isometric illustration of a carton feeder
of the apparatus of Fig. 5.
Fig. 9 is a plan illustration of a portion of a nip
belt assembly of the apparatus of Fig. 5 engaging a carrier.
Fig. 10 is an isometric illustration of a handhold
aperture insert assembly of a timing-transport section for
use with the apparatus of Fig. 5.
Fig. 11 is an isometric illustration of a handhold-
aperture insert for the assembly of Fig. 10.
Fig. 12 is an illustration of a modified handle portion
of the carrier of Fig. 1.
Fig. 13 is side view through a section of the handhold
aperture insert assembly of Fig. 10 with the insert seated
in the handhold aperture of a carrier and with a stop-guide
rail
of the apparatus facilitating seating of the insert with the
carrier.
Fig. 14 is a partial front end view of the features of
the handhold-aperture insert assembly illustrated in Fig.
13.
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Figs. 15 and 16 are schematic representations of the
panel-gripper assembly of the apparatus of Fig. 5 in
operation.
Fig. 17 is an end elevational illustration of the nip
belt assembly and panel-gripper assembly of the apparatus of
Fig. 5 engaging a carrier.
Fig. 18 is a plan layout of the panel-gripper assembly
of the apparatus of Fig. 5.
Fig. 19 is a side elevational illustration of a panel
gripper in engagement with a caroming track of the of the
apparatus of Fig. 5.
Fig. 19A is an illustration of a modified version of
the gripper of Fig. 19.
Fig. 19B is a schematic illustration of a carrier with
indications of points of engagement of grippers and band
hooks.
Figs. 20, 21 and 22 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. 23 is an isometric illustration of the bottle
transport conveyor of the apparatus of Fig. 5.
Fig. 24 is a rear elevational illustration of a bottle
gripper of the bottle-apparatus of Fig. 5.
Fig. 25 is a top plan illustration of a bottle-gripper
conveyor of the apparatus of Fig. 5.
Fig. 26 is a side elevational view of declination and
seating assemblies of the apparatus of Fig. 5.
Figs. 27 and 28 are end elevational views from the
declination belt section of the apparatus of Fig. 5.
Fig. 29 is an isometric illustration of an alternate
version of a declination block of the apparatus of Fig. 5.
Fig. 30 is an elevational illustration of a planetary
gear version of the carrier seating assembly of the
apparatus of Fig. 5.
Fig. 31 is an isometric illustration of a folder-gluey
assembly of the apparatus of Fig. 5.
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Fig. 32 is a top plan view of the folding block of the
folder-gluey assembly of Fig. 31.
Fig. 33 is a side elevational view of the folding block
of the folder-gluey assembly of Fig. 31.
Fig. 34 is a side elevational view of the folding block
of the folder-gluey assembly of Fig. 31.
Fig. 35 is a side elevational view of the folding block
and sealing block of the folder-Bluer assembly of Fig. 31.
Fig. 36 is a top plan view of the bottom-panel
alignment assembly.
Fig. 37 is an isometric illustration of a bottle
stabilizer assembly for the apparatus of Fig. 5.
Fig. 38 is an end view of the bottle stabilizer
assembly of Fig. 37 in engagement with a carrier package.
Fig. 39 is an isometric illustration of a second
alternate embodiment of a timing and transport segment of
the apparatus of Fig. 5.
detailed Descrit~tion of the Preferred Embodiment
The Carrier
The method and apparatus 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
- application serial number 08/326,987. That application 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
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simultaneously. The carrier 3 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 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, corner tabs 926, 936 foldably connected
to the cell bands and a central cell portion 927, 937
integrally formed with the side wall 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
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Fig. 2 and collapsed carrier 3 shown in Fig. 3. The blank
906 is essentially symmetric about a perforated fold line
S
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 side wall 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 961, 963,
971, 973 for attachment to the bottom wall panels 910, 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, 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
corner tabs 926, 936 from respective handle panels terminate
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
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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 carrier 3 enable it to
be formed 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, such as the box shown in Fig. 4, 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
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extend above the exposed, protruding support tabs 961, 963,
971, 973 and thereby protect the tabs 961, 963, 971, 973
from damage during shipping to the loading site. The
container 5 may be placed in proximity to the hopper 30 of
the apparatus and upended to place the carriers 3 into the
hopper 30 chute bottom-down, ready for manipulation by the
apparatus. Referring now to Fig. 4A, in an alternate
version of a container 205 for the collapsed carriers 3, the
end walls 202 and side walls 204 again extend'above the
protruding tabs of the carrier but in addition, each end
wall 202 has a slot 208 extending between the upwardly
protruding tabs. The slotted container 205 is utilized in
conjunction with the automatic loading feature of the hopper
described below. Referring now also to Fig. 4B, the
container 205 of Fig. 4A has an aperture 203 in each end
wall, each aperture in alignment with the other. The
aperture 203 is used as a means for inspecting a container
of carriers to assure that the carriers have been properly
constructed to the extent that openings in properly
constructed carriers will provide an unobstructed line of
travel or sight between apertures 203 aligned over the
openings in the carriers. For example, by referring to
Figs. 2 and 3 it is noted that there is a portion of the
carrier between sets of opposing bands 921 & 923, 931 & 933
that is open when the carrier is properly constructed. The
carrier and blank may also be designed so that other
portions may be made to remain unobstructed when the
collapsed carrier is properly formed. Thus, when the
apertures 203 are aligned with these unobstructed openings
either a probe or sensor may be utilized to verify that the
pathway is unobstructed and thus the collapsed carriers are
properly formed and the container of carriers is suitable
- for use.
Overview of Apparatus and Method
Referring first to the schematic illustration in Fig.
5 of the overview of the apparatus 10 according to a
preferred embodiment of the invention, the apparatus 10 is
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constructed upon an elongated frame. In the illustration
the direction of 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 cam-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
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against the sides of the carrier 3. As a carrier 3 moves
through the timing section the bottom 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 l0
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
starwheel 105. 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 1 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
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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
l0 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.
bottle Infeed Conveyor
Referring to Fig. 5, bottles 1 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 l0
for loading into carriers 3. Different endless chains or
belts and a combination of different endless chains or belts
is used to The carriers 3 and bottles 1 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 1. Then, as will be described
further below, the two paths become one when the carriers 3
are moved downwardly over groups of bottles 1.
HQ~ber Assembly
Referring now to Figs. 5, 6, and 7, suitable means for
making cartons available for loading is provided by a hopper
assembly 30. The hopper assembly 30 of the preferred
embodiment is essentially a conveyor-driven chute. In Figs.
6 and 7 the hopper assembly 30 is shown from its "loader"
end, that is, the end into which cartons are placed for
conveyance to the next assembly of the apparatus lo. In the
hopper assembly a pair of opposing side walls 31, 32 form
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the chute. A pair of opposing belts 37, 38 provide the
conveying means for the cartons 3. The belts 37, 38 are
moveable by known drive means upon rollers mounted upon a
support rod 41, 42, or similar structure. The roller rods
41, 42 are in turn mounted upon trucks 43, 44 or similar
structures which, like the side wall trucks 33, 34, are in
turn permanently or movably mounted upon a support rod 36.
Trucks 33, 34, 43, 44 are attached along the length of the
side walls 31, 32 and roller rods 41, 42. Referring now
particularly to the elevational view of Fig. 7, therein can
be seen the manner in which a collapsed bottle carrier 3
suitable for manipulation by the apparatus 10 and hopper
assembly 30 is loaded in the hopper where it is engaged by
the side walls 31, 32 and belts 37, 38 of the hopper 30.
The hopper 30 is adjustable to accommodate varying sizes of
carriers 3 , for example, six-pack or eight-pack. The hopper
30 is adjusted by changing the location of the trucks 33,
34, 43, 44 along the support rod 36. The direction arrows
denoted 45, 47 illustrate the directions in which the trucks
may be moved, inwardly or outwardly, depending upon the size
of the carrier 3 to be accommodated. For example, a six-
bottle version would be a shorter carrier 3 than an eight-
bottle version. The trucks and associated side walls and
belts would be placed in closer proximity for the six-bottle
carrier than for an eight-bottle carrier. Although it would
be possible to move both sides of the walls and roller rods
it is simpler to maintain one wall-and-belt set stationary
while moving the other set, for instance, the set with which
the direction arrows 45, 47 are associated. As can be seen
in Fig. 7 the belts are positioned to engage each carrier 3
adjacent the protruding tabs 961, 963, 971, 973. Once the
carriers 3 are loaded into the hopper 30 the conveyor belts
37, 38 move the upright collapsed carriers along the hopper
side walls 31, 32 to the "exit" end of the hopper 30.
Operation of Hopper
Carriers 3 are loaded into the "loading" end of the
hopper with the bottoms of the carriers 3 oriented
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downwardly. Referring now briefly to Fig. 4, as a means to
facilitate loading of multiple carriers 3 into the hopper 30
simultaneously, carriers 3 may be loaded °'top-down" into a
container 5 so that the container may be simply up-ended to
dump the carriers 3 "bottom-first" into the hopper 30. '
Packing the collapsed carriers 3 for shipment in this up
side down manner also enables the container 5 to help
protect the tabs 961, 963, 971, 973 from damage during
transport. When packaged up-side down in this manner the
carriers 3 are able to be conveniently shipped without
damage to the support tabs and then easily loaded into the
hopper 30.
In order to provide the greatest hopper length but
still conserve the amount of floor space consumed by the
apparatus the hopper chute is angularly aligned with respect
to the main portion of the elongated apparatus 10.
harrier Feeder
Referring momentarily to Fig. 5, as previously noted,
the layout of the apparatus is generally linear with bottles
1 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 Figs. 5 and 8, 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. The carrier feeder 50 is a rotary type
assembly having three spaced-apart suction-cup support
stations 52. Each cup support station 52 supports suction
cups 54 for adherence to and removal of a collapsed carrier
3 from the exit end of the hopper 30. The stations 52
rotate as indicated by the rotational direction arrow 57
about an axis 59. For example, the stations 52 may be made '
to rotate about the axis 57 slidably by means of a support
tie rod 53. In a suitable arrangement, each tie rod 53 has
one end affixed to a member at the axis 59 and the other end
attached to the respective support station 52. Station 52
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rotation may be accomplished by means known in the machine
arts. For example, through use of an orbital cam mechanism
which utilizes drive shafts, cam rods, curvilinear shallow
and deep cam tracks, and cam rollers as described in U.S.
patents numbers 4,625,575; 5,019,029; 5,102,385 and
5,104,369.
The preferred embodiment contains three cup
support stations 52, however, as few as one and more than
three may be used. Three stations effectively move the
carriers 3 in a horizontal path to the timing section 60 or
260 of the apparatus 10. The actual suction cups 54 are not
shown~in Fig. 8 in order to more clearly illustrate other
features. However, nozzles 55 upon which cups 54 are
positioned are shown. The suction cups 54 are spaced apart
so as to engage the carrier 3 at strategic peripheral points
for handling. Suction, or a vacuum, for operation of the
suction cups 52 is provided by typical pneumatic components.
The guide 56 relates to a timing feature used to remove
carriers 3 from the suction cup support stations 52, and
will be explained in greater detail below.
Timincr-Transport Section
Alternate versions of the timing-transport section are
described. The first version is described referring to Fig.
5. 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 1 as the carriers 3 and bottles 1 move downstream.
-Timing'-TransQort Section: First Embodiment
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
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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 engages 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
Figs. 5 and 9, 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
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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. 17, as the top portion of
the handles of carriers 3 are pinched and translated along
by the belts 72, the support tabs 961, 971, 963, 973 travel
along through the lower belt assembly guide 78.
-Timing-Transport Section: Alternate Embodiment
The alternate embodiment employs several features
distinct from the immediately preceding described embodiment
of a timing-transport assembly to achieve interval spacing
and initiate timed transport of the carriers. As in the
previously-described embodiment, the alternate embodiment
engages the carriers 3 in the collapsed condition shown in
Fig. 3. Referring now to Fig. 10, the alternate embodiment
utilizes an assembly of chain-mounted insert members 260 to
both define separation between carriers 3 and to transport
the carriers in synchronous timing with the down-stream
elements of the apparatus. Referring now to Fig. 11 and
Fig. 12, therein are respectively illustrated a handhold-
aperture insert 264 and one side (the other side being
identical) of handhold aperture 983 of the handle portion of
a carrier 3. The handhold aperture 983 is U-shaped with a
1T-char~cA fl an C~ftd fnl right v csti-nnrl i nrr frntn i f-C lITTCY r~nYf-i
nn
.. .....,.,~..~.,. ~~..t. ~..~ a..~...~...~j ....~..........~..7 «....., ~~...
..t.t..-.i Zrva.a.iv...
The insert 264 has a tapered U-shaped projection that
corresponds to the shape of the handhold aperture 983 and
flap 984. In the upper corners of the apertures 983 the
spacing between the handhold flap 984 and the sides of the
aperture 983 may be slightly elongated to provide a more
stable point of engagement. The corresponding portion in
the upper corners of the U-shaped projection of the insert
262 have matching dimensions. The front portion 266 of the
inner bottom surface of the insert 262 is bevelled to more
easily accommodate the handhold flap 984. Referring now
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again to Fig. 10, the inserts 262 are mounted upon endless
chains 276 that travel in the direction indicated by the
direction arrows 277. The rods 270 upon which the inserts
262 are mounted are in turn mounted within rollers 269 upon -
trucks 268 that travel the closed cyclical path of the
endless chains 276. During the bottom of the cycle of the
run of the endless chains 276, the rods 270 with mounted
inserts 262 translate outwardly (transversely) of the chains
276 toward stop-guides 56 and 278. A suitable mechanism for
causing transverse translation of the rods 270 is the use of
a cam follower (shown in Fig. 13) on the rod 270 which
interacts in known manner with a camming bar or rail to
achieve motion at predetermined points along the rail. v-
shaped rollers 269 cooperate with a roller-engagement member
having a corresponding V-shaped edge enable the rods 270 to
be reciprocally translatable as denoted by the direction
arrows 275 shown in Fig. 13. Referring now also momentarily
to Fig. 8, the insert 262 first engages a carrier 3 that has
been engaged by the carrier feeder 50 and rotated so that
its station 52 faces the insert 262 that translates
outwardly first. The stop-guide 56 mounted upon each
station 52 of the feeder provides support for the handle
portion of the carriers 3 when the insert 262 attempts to
seat itself. The insert 262 and the stop-guide 56 of the
feeder cooperate to promote full seating of the insert
within the handhold aperture of the carrier to provide a
steadying counter force as the chain-mounted inserts 262
transport carriers 3 down stream. Fig. 13 is an
illustration of the insert 262 engaging the handle of a
carrier 3 as the insert 262 is guided and the carrier 3 is
urged toward the insert 262 by the stop-guide rail 278. The
cooperation and interaction between the insert 262, carrier
3 and stop-guide 56 of the feeder would appear the same.
Referring now again to Fig. l0, once the carrier 3 has been
engaged by the insert 262 at the feeder 50, the insert 262
translates downstream into the channel of the stop-guide
rail. For further clarity in understanding the features
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discussed reference may be made to the elevational view of
Fig. 14 which looks into the projection, or nose, 264 at the
front of the insert 262.
Timinct-Transport Section: Second Alternate Embodiment
Referring now to Fig. 39, in a second alternate
embodiment of timing transport elements, an intermediate
stop-guide 280 is located between the support stations 52
and the channel guide-stop 278. In the preferred embodiment
illustrated the intermediate stop guide 280 consists of two
spaced apart bars that form a channel which facilitates
nesting between the support stations 52 and the intermediate
guide and between the support stations 52 and the channel
guide, as illustrated. The intermediate stop-guide 280
combines the functions of the station stop-guide 56 and the
channel guide-stop 278 in providing a resistance surface for
the handle area of the carrier as the handhole of the
carrier is engaged by the handhole-aperture insert 262 as
previously described above. Also shown in Fig. 39 is a
feature of the invention which is applicable to all of the
embodiments of the invention. That is, a tab guide 282
which receives and guides the support tabs 961, 963, 971,
973 as the carriers are transported downstream. On either
side of the tab guide 282 the apparatus may also have panel
fold-down guides such as curved bars which are typically
used in the cartoning field to engage and fold a panel or
flap to a desired position. In this present invention such
guides fold the bottom panels 910, 912 of the carrier
downward from their essentially upright positions as shown
in Fig. 3 to a substantially horizontal position where they
may be engaged by the grippers of the panel gripper assembly
80 as described in greater detail below.
Eottom-Panel Gripoers
Referring to Fig. 5, in a panel-gripper assembly 80,
panel-grippers open the collapsed carrier 3 in preparation
for loading. As the carriers 3 move through either of the
alternate versions of a timing-transport section (Which are
described above) carrier-panel grippers 82 moving on
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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 _
also to Figs. 9 and 13, a carrier 3 is shown in a condition
to be grasped by grippers 82. Referring now again
particularly to Fig. 5, 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. 15 and 16 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 of Figs. 9 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. 15, 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
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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 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. 16 and 17. 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. 16 and 17 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. 17 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.
A plan layout of the grippers 82, chains 84, 86, 88 and
lugs 89 is illustrated in Fig. 18. In the preferred
embodiment of the invention, as the grippers 82 travel the
closed circuit defined by the gripper chains 84, 86 they are
caused to translate outwardly toward the opposing set of
grippers and then inwardly away from the opposing set of
grippers (and thus outwardly of the centerline 901 of the
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carriers) through utilization of a cam follower mounted upon
each gripper 82 which travels in a caroming groove, or track,
292.
Referring now also to Fig. 19, 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 caroming groove (or track) 292 that defines the
translational movement of the arms 284, 286.
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. 20, 21
and 22. 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
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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 jaws 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. 15, 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.
' 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. Referring now to Fig. 19A, therein is
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illustrated a band hook 302 extending from the top of a
gripper 80. Referring now also to Fig. 19B, the band hook
302 engages a respective top band 923, 933 of the carrier at
the positions indicated by arrows 310, 312 as the bottom _
panels are respectively grasped by the grippers at locations
indicated by an "x°' 306, 308 as shown. The hooks 302 on
opposing pairs of grippers 80 in the first gripper section
are offset (as illustrated by their engagement positions) to
avoid interference with one another.
An additional guide structure may be used in the
gripper assembly to help maintain the carriers in their
°'squared-up" condition and to help maintain the bottom
panels in their horizontal position. Though not shown, a
suitable guide is an L-shaped elongated member extending
forwardly with respect to the apparatus wherein the right
angle formed at the intersection of a vertical side wall and
a horizontal bottom panel abuts the right-angled corner of
the L-shaped guide. A guide is aligned along each side of
the carrier and apparatus. Each guide flares slightly
outwardly of the center of the apparatus at the second set
of grippers to allow for the additional width of the carrier
which is created when the grippers pull further outwardly to
form the bevelled corners of the carriers as described
above.
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. 23, 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
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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.
Referring now to Figs. 5, 24 and 25, bottles are
maintained in the groupings and spacings metered out by the
starwheel 105 by means of a pair of bottle-gripper conveyors
112. The bottle-gripper conveyors 112 work in conjunction
with the bottom-engaging bottle conveyor described
immediately above to transport bottles. Each bottle-
gripper conveyor 112 has bottle grippers 113 mounted upon an
endless chain 111. Each bottle gripper 113 is a block-like
member with a series of adjacent C-shaped cavities for
receiving bottles 1. The number of C-shaped cavities
corresponds to the number of bottles to be contained in each
column of the carrier 3. For example, a carrier for six
bottles would have three bottles per column and a carrier
for eight bottles would have four bottles per row. The
invention employs a single chain 111 to circulate the bottle
grippers 113 while maintaining the grippers 113 in a
constant orientation facing the center of the apparatus 10.
Referring now particularly to Fig. 24, from a rear
elevational view of a gripper 113, each gripper 113 has a
cam follower 114 mounted on its upper surface at an end of
the gripper 113 opposite an end which is pivotally attached
to the bottle-gripper chain 116. Referring now particularly
to Fig. 25, the lower portion of each gripper 113 is
pivotally attached to the gripper chain 111. Each bottle-
gripper cam follower 114 rides in a caroming track (or
groove) that maintains the inward-facing orientation of the
bottle-grippers 113 as the grippers 113 travel the closed
path defined by the chain 111. A sprocket wheel 116 guides
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the cam follower 114 as the chain 111 rotates the gripper
113 around the chain wheel 117. The sprocket wheel's 116
engagement of the cam follower 114 together with the pivotal
connection 118 of the follower 113 to the chain 111 maintain
the gripper's 113 orientation as the gripper chain 111
carries the grippers around the chain wheel 117.
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. 5 and 26, 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. 5 and 26 but more particularly to Figs.
27 and 28, the pairs of belts 92, 94 and 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
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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 (as is
illustrated in Fig. 9 with reference to the rollers 74 in
the nip belt assembly 70) . 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. 26, 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. 26) 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. 27, 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.
Referring momentarily to Fig. 28, to further ensure
stable movement of carriers 3 an alternate version of the
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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. 26. 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.
30, 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
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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. 26. A more
precise means of maintaining alignment is illustrated in
Fig. 30. Fig. 30 illustrates the use of a planetary gear
system to maintain the downward orientation of the seating
blocks. In Fig. 30, 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. 5 and not visible in Fig. 26, 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.
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In Figs. 26 and 27 the bottles 1 are shown in groupings
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
5 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. 5 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.
Referring now briefly to Fig. 29, in an alternate
version of the overhead declination block 102a bevelled
bottom walls lOla lead to the groove, or slot 103a for
receiving the carrier handle.
Folder and Gluey
Referring now again particularly to Fig. 5, 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. 31, therein is
illustrated a folder-gluey 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
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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. In addition to the illustration
of Fig. 31, reference may now also simultaneously be made to
Figs. 32, 33, 34 and 35 which contain additional views of
the folder-Bluer feature and any of the previously described
figures which illustrate the panels 910, 912 and support
tabs 961, 963, 971, 973. 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 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
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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). From a point of view
facing the front portion of the support block 141, as in
Fig. 34 in particular, the right side of the block 141 is
configured to engage and accommodate the longer tabs 961,
971 while the left side is configured to engage and
accommodate the longer tabs 963, 973. The block 141 first
separates each long tab 961, 963 from its accompanying short
tab 971, 973. A horizontal facet 142 and a vertical facet
143 form a wedge-like cove 159 for the longer, or major, tab
961, 963. A recess 154 for the minor tab is formed by an
inclined facet 152 and a vertical facet 153. A short
upwardly-inclined edge 155 at the intersection of facet 143
and 152 engages the major support tab 961, 963. As the
carrier advances, the major support tab 961, 963 moves
divergingly away from the minor support tab 971, 973 along
the edge 155. The leading major tab folding edge 155
intersects and is continued by a trailing major tab folding
edge 144. The trailing major tab folding edge 144 is formed
at the intersection of the major tab vertical facet 143 and
the upwardly-inclined major tab ramp 145. As the carrier 3
continues its travel the major support tab 961, 971
continues its diverging ascent along trailing major tab
folding edge 144. Because the major tab ramp 145 and the
trailing major tab folding edge 144 also diverge outwardly
as well as upwardly, the major support tab 961, 971
ultimately is placed in and travels in face contacting
relationship with the major tab ramp 145. As the carrier
continues to travel, the major support tab 961, 971
subsequently comes into face contacting relationship with
the horizontal surface 156 of the folding block. As the
major support tab 961, 963 is folded to the right side of
the folding block 141 as described, the minor support tab
971, 973 is folded to the left. The minor tab recess 154 of
the block 141 provides space for the minor tab 971, 973 of
the carrier 3 to be initially separated from the major tab
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961, 963. The minor tab 971, 973 is initially engaged by
. the leading minor tab folding edge 160. The leading minor
tab folding edge 160 is formed at the intersection of the
planes of the minor tab vertical facet 147 and the major tab
ramp 145, and intersects the trailing minor tab folding edge
148. The trailing minor tab folding edge 148 is formed at
the intersection of the minor tab vertical facet 147 and the
minor tab ramp 149. The minor tab 971, 973 is moved
outwardly and upwardly with respect to the carrier 3 by the
outwardly and upwardly diverging edge 148. Further
downstream movement of the carrier 3 causes the minor tab
971, 973 to come into face-contacting relation with the
minor tab ramp. As the carrier 3 begins its travel upon the
folding block 141 the bottles 3 in the carrier are supported
on their undersides by the support ledges 158. When the
carrier package 7 reaches the horizontal surface 156 of the
folding block the major 961, 963 and minor 971, 973 tabs
have been folded outwardly and into flat face relationship
with the underside of bottles 3 of each package 7. As the
conveyor continues to transport a package 7 downstream, glue
is applied by conventional means such as a glue gun to the
downwardly-extending greater bottom wall panel 912 as
mentioned above. Glue is applied to the central portion of
the panel 912 in a position suitable for the support tabs
961, 963, 971, 973 to be adhered thereto when the greater
panel is folded up into flat face relation with the bottom
of the package 7. Glue is applied at a convenient location
such as the gluey recess 157 provided.
Referring particularly now to Figs. 31 and 35, after
glue has been applied to the bottom panel 912 the bottom of
the carrier 3 is closed and locked in successive stages.
The dead plate 161 following the folding block 141 provides
a suitable static surface upon which the package 7, and
bottles 3 in the package in particular, may glide during
further transport. The second vertical panel folding wedge
164 engages and folds the lesser bottom wall panel 910
downward in the same manner as the first vertical panel-
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folding wedge 162 folds the greater panel 912 as described
above. The greater 912 and lesser 910 bottom panels are
sandwiched between respective first 162 and second 164
panel-folding wedges and the dead plate 161. The first
horizontal panel-folding wedge 166 and second horizontal
panel-folding wedge 168 fold the respective bottom panels
912, 910 into their closing position of flat face
relationship with one another. As can be more clearly seen
in Fig. 35, the first horizontal panel-folding wedge 166 is
longer and engages and folds the glue-containing greater
panel 912 under before the lesser bottom panel is
manipulated. The lesser bottom panel 910 thus becomes the
outer-most of the two bottom panels.
The bottom wall sealing plate 170 follows the dead
plate 161 and provides a surface 174 upon which the support
tabs 961, 963, 971, 973 and glue-containing greater bottom
panel 912 are caused to be pressed together thereby adhering
the support tabs 961, 963, 971, 973 to the greater bottom
panel 912. The bevelled lip 172 at the front of the sealing
plate 170 helps the package 7 enter the sealing plate 170
without becoming easily snagged. To ensure a smooth
transition from the deadplate 161 to the sealing plate 170,
the bevelled lip 172 of the sealing plate 170 is positioned
lower than the deadplate 161 and horizontal folding wedges
166, 168 and the plate 170 itself is positioned sufficiently
close to the deadplate 161 to permit the bottom the bottom
panels 910, 912 to engage the bevelled lip 172 without
snagging. The side walls 176 of the sealing plate 170 urge
the side walls of the carrier 3 inwardly to a desired
position and help keep the transported packages 7 properly
aligned during transport. The front portion of each
sidewall 176 is inwardly bevelled to also help guide the
package onto the sealing plate 170 between the walls 176.
Closure of the Carrier
Closure of the bottom of the carrier 3 may be achieved
by several means. For example, adherence of the bottom
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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. Referring now to Fig. 36, the bottom
panels 910, 912 are urged into predetermined face-to-face
alignment with one another by means of conveyor-mounted lug
sets 182 in the bottom-panel alignment assembly. The lug
sets 182 engage pull holes (also known as alignment
apertures or tightening apertures) 914 (which can be seen in
Fig. 3) in the bottom panels 910, 912 of the carriers 3.
Each lug set 182 has an outwardly-biased moveable lug member
184 and a stationary lug member 186. Outward biasing may be
accomplished by the spring 196 shown or other suitable
biasing mechanism. A pair of opposing lug sets 182 is
mounted upon a pair of support rods 190. The pairs of lug
sets 182 are mounted upon conveyors such as endless chains
188. The moveable lug member 184 of each set is spring-
biased outwardly and is moved inwardly along the support
rods 190 through moving contact with the cam rail 192. The
moveable lug members 184 of the lug sets 182 are in a
retracted position prior to translating inwardly upon the
' ramp 194. The tightening apertures 914 of the carriers 3
are initially engaged by the lug sets 182 when the moveable
lug members 184 are retracted (that is, prior to riding up
the ramp 194). Each moveable lug member 184 has an angular-
shaped protruding portion 185 that is configured to
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correspond to and be closely received by the apex of the
triangular-shaped tightening apertures 914. Each stationary
lug member 186 has a lip-like linear protruding portion 187
that is configured to correspond to and be closely received
by the base of the triangular-shaped tightening apertures
914. As previously discussed, the bottom panels 910, 912 of
carriers 3 are in face-to-face partially overlapping
relationship when the packages 7 leave the folding and
gluing area 140 of the apparatus l0. As the moveable lug
members 184 travel the leading ramp 194 they pull the bottom
panels 910, 912 inwardly to a predetermined position. The
stationary lug members 186 help prevent the bottom panels
910, 912 from being drawn too far inwardly. The leading
ramp 194 may be stepped in known manner to provide two tiers
of ramps for the moveable lugs 184 so that leading and
trailing moveable lug members may move inwardly essentially
simultaneously to prevent a "scissoring" effect when the
bottom panels 910, 912 are drawn together. In this
arrangement cam followers of the leading moveable lug
members engage only the upper-tiered ramp. The upper-tiered
ramp is more steeply inclined than the lowered-tiered ramp.
The less steep lower-tiered ramp is contacted only by the
cam followers of the trailing moveable lug members. Because
of the difference in pitches of the two ramps the leading
lug members are delayed in their inward movement until the
trailing lug members are also moving inwardly. After the
bottom panels 910, 912 have been tightened a predetermined
amount and held in place by the lug sets, 182 punch lock
features may be engaged by means of conventional rotating
fingers 200 which synchronously protrude upwardly through
the alignment assembly 180. The moveable lug members 184
are allowed to retract to their outwardmost position by a
ramp 195 at the trailing (or exit) end of the cam rail 192. '
The fully-closed packages 7 may then exit the apparatus by
conventional means.
Referring now to Figs. 37 and 38, as the bottom panels
910, 912 of the carrier 3 are drawn together the tops of
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bottles are engaged by belts 402 of a bottle stabilizer
assembly 400. The belts 402 rotate in the same direction as
the direction of carrier travel and at the same speed. The
bottle stabilizer 400 prevents bottles from rising upwardly
out of the carrier as the bottom panels 910, 912 are drawn
together as described above.
other modifications may be made in the foregoing
without departing from the scope and spirit of the claimed
invention.
