Note: Descriptions are shown in the official language in which they were submitted.
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Method for Storing, Transporting and Dispensing Cartons
Cross-reference to Related Applications
(Not applicable)
Statement regarding Federally-sponsored Research and Development
(Not applicable)
Technical Field of the Invention
The invention relates to cartons used in packaging, and more specifically to a
method for storing, transporting and dispensing cartons utilizing a coil, or
spiral roll, of
imbricated cartons.
Background of the Invention
Cartons of various configurations are useful for packaging multiples of
articles
such as beverage cans and bottles. Such cartons, which may also be referred to
as
carriers, are typically stored in multiple quantities in collapsed condition
and are erected
just prior to being loaded. Collapsed cartons are generally stored in some
rectangular
configuration such as a rectangular box or simply a stack of the cartons
themselves. In
turn, boxes or stacks of cartons are often palletized into a larger
rectangular
configuration.
Although collapsed cartons are typically stored in some sort of rectangular
configuration, often it would be useful to have an alternate storage
configuration.
Alternate configurations are useful when the cartons have to be stored in an
area that
does not easily accommodate a rectangular pallet of cartons.
In order to load cartons in a packaging machine it is necessary to transfer
the
cartons from their storage medium to a carton input apparatus of the packaging
machine. Because packaging machines optimally operate at high rates of
throughput,
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cartons fed into the machine from a hopper, magazine or similar apparatus are
quickly
consumed and must be frequently replenished. Thus, the smaller the storage
configuration for cartons, the more frequently the carton infeed apparatus
must be
replenished.
The need for frequent carton replenishment places a demand upon the machine
operator that increases the cost and diminishes the efficiency of a packaging
operation.
However, although larger boxes or stacks can reduce the replenishment
requirements, it
will be more difficult for an individual operator to handle extremely large
boxes or
stacks. The cost and efficiency of the packaging operation would again be
negatively
impacted if the machine operator has to handle extremely large boxes or
stacks.
It can be appreciated that it would be useful to have a means for storing and
transporting cartons that reduces the need to frequently replenish the carton
infeed
apparatus and that is able to be easily managed by an operator.
Brief Summary of the Invention
In accordance with a preferred embodiment of the invention, cartons are stored
in imbricated fashion on a coil, or spiral roll.
In accordance with another aspect of a preferred embodiment of the invention,
an imbricated roll or coil of cartons is wound around a disk utilizing a
length of a tape
member.
In accordance with a further aspect of a preferred embodiment of the invention
a
de-curler mechanism removes a curl that is imparted to cartons stored on a
roll so as to
restore the cartons to a substantially flat condition.
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In accordance with still another aspect of the invention, a de-curler
mechanism
is comprised of a series of interacting rollers that impart a convex curvature
to the
cartons.
In accordance with yet a further aspect of the invention, a de-curler is
comprised
of a variable-radius mechanism
In accordance with an even further aspect of the invention, the de-curler is
comprised of a cylindrical or corkscrew framework.
In accordance with a final preferred embodiment of the invention, cartons are
fed directly from the coil, or spiral roll, to a carton feeder having a series
of carton
engaging wheels. Each wheel revolves in a direction counter to its adjacent
wheel.
Other advantages and objects of the present invention will be apparent from
the
following description, the accompanying drawings, and the appended claims.
Brief Description of the Several Views of the Drawings
Fig. 1 is a perspective illustration of a carton that is suitable for use in
accordance with the teachings of a preferred embodiment of the invention;
Fig. 2 is an illustration of the carton of Fig. 1 in collapsed condition;
Fig. 3 is a perspective illustration of a partially rolled coil of imbricated
cartons
in accordance with the teachings of the present invention;
Fig. 4 is a perspective illustration of a fully rolled coil of imbricated
cartons
shown in a horizontal disposition;
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Fig. 5 is an end elevation view of the collapsed carton of Fig. 2;
Fig. 6 is an end elevation view of a collapsed carton after it has been
removed
from storage on the coil shown in Figs. 3 and 4;
Fig. 7 is a schematic representation of a coil being unrolled, the stream of
curled
cartons de-curled through a de-curling mechanism and the stream of cartons
forwarded
to a carton hopper in a packaging machine, in accordance with a preferred
embodiment
of the invention;
Fig. 8 is a schematic representation of a carton de-curling mechanism in
accordance with an alternate preferred embodiment of the invention;
Fig. 9 is a schematic representation of a carton de-curling mechanism in
accordance with another alternate preferred embodiment of the invention; and
Fig. 10 is a schematic representation of a coil being unrolled, the cartons
forwarded to a carton hopper in curled condition, the cartons being withdrawn
from the
hopper by a mufti-wheeled feeder in accordance with a further preferred
embodiment of
the invention.
Detailed Description Preferred Embodiments of the Invention
Throughout the drawings, the same reference numerals are used to denote the
same or like features of the invention.
The invention teaches a methodology for storing collapsed cartons such as
cartons for articles such as beverage cans or bottles in a spiral roll, or
coil, of imbricated
cartons. The term "imbricated" refers to the manner in which collapsed cartons
are
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disposed in a continuous column in flat-face, overlapping fashion like fish
scales or
roof shingles.
Referring first to Fig. 1, therein is illustrated an end-loadable type carton
10 that
is suitable for practicing a method for storing and transporting cartons in
accordance
with a preferred embodiment of the invention. Referring now to Fig. 2, therein
is
depicted the carton 10 of Fig. 1 in collapsed condition.
Referring now to Fig. 3 therein is shown a partially rolled coil 20 of
imbricated
collapsed cartons 10. The collapsed cartons 10 are wound around a spool 22
(which
may also be considered a hub, disk or other suitable cylindrical foundation
member).
The cartons 10 to be wound are placed in a continuous, overlapping column with
a band
or belt 24 running longitudinally along the length of the column to facilitate
winding
and stability. In accordance with a preferred embodiment of the invention,
flat,
collapsed cartons 10 are treated like magazines or newspaper sections that are
similarly
rolled in imbricated coils. In the preferred embodiment illustrated, the
continuous
spiral is wound with the rotational axis of the spool disposed horizontally,
producing a
vertically oriented roll. ~nce the roll 20 is completed, it may be transported
andlor
stored in the same vertical disposition or in a horizontal disposition as
shown in Fig. 4
wherein the axis of the spool is oriented vertically.
The roll 20 is unwound to make the cartons 10 available for use in a packaging
machine. Cartons are typically fed into a packaging machine for loading in
substantially flat collapsed condition as shown in Fig. 2 and the end
elevation view of
Fig. 5. Cartons generally must be flat and uncurled because they must be
manipulated
by the machine and tightly loaded with articles within close tolerances. A
carton 10
that has been stored on a roll 20 as described above typically is not flat but
has a curved
configuration as shown in the end elevation view of Fig. 6. The invention
teaches "de-
curling" (or "flattening") the curled carton prior to carton loading.
Referring now to the schematic illustration of Fig. 7, one method of de-
curling
the cartons is to pass them through a de-curling assembly 30 consisting of a
series of
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rollers 32 that in effect impart a reverse curl. The rollers 32 apply a convex
curvature to
the cartons 10 that counteracts the concavity applied by the roll 20 thereby
in effect
producing a relatively flat carton 10. Stated differently, the reverse-curl de-
curling
process imparts a convex curvature that cancels, or negates, the concave
curvature
imparted by the roll 20.
In Fig. 7, the de-curling mechanism 30 is shown schematically preceded by a
stream of curled cartons 12, which in turn is preceded by the roll 20 of
cartons 10. The
stream of de-curled cartons 13 is forwarded to a carton infeed assembly such
as a carton
hopper 14 as shown.
Figs. 8 and 9 schematically depict alternative de-curling mechanisms.
Referring
now to Fig. 8, a variable-radius de-curler 40 provides a convex surface for a
simple
reversal of the concavity imparted by the roll 20. The infeed stream 41 of
cartons is
drawn across the convex surface of the variable-radius device to produce an
outfeed
(with respect to the de-curler) carton stream 43 of substantially flat cartons
ready for
further processing in the packaging machine.
Referring now to Fig. 9, therein is depicted a cylindrical or corkscrew-like
de-
curling framework 50 in schematic representation. The infeed stream 51 of
concavely-
curled cartons from the roll 20 is run through the cylindrical framework 50 in
the
clockwise direction indicated by the arrow 55 to produce an outfeed stream 53
of
substantially flat cartons.
Referring now to Fig. 10, therein is illustrated an alternate de-curling
method in
accordance with another preferred embodiment of the invention. In this
embodiment,
cartons 10 from the roll 20 are fed directly to a carton magazine or hopper
61. The
cartons 10 in the hopper axe still in a curled state at this point. The
cartons 10 are
withdrawn from the hopper 61 and placed in at least a partially-erected
condition
between flight bars or lugs 72 on an erected-carton conveyor 70 by a mufti-
wheeled
carton-feeder mechanism 60 that is known in the packaging art.
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The carton feeder 60 consists of multiple wheels 62 64, 66 that rotate in
opposite directions (as shown by rotational direction arrows 63, 65, 67). Each
wheel 62
64, 66 has suction cups 69 disposed at predetermined locations. Vacuum
pressure is
selectively applied to the suction cups 69 at predetermined intervals. In the
first wheel
62 the suction cups 69 are attached to articulating members 68 that are
propelled
outwardly of the center of the wheel 62 at predetermined locations so as to
engage a
carton 10 in the hopper and extract the carton as the wheel 62 travels in its
counter-
clockwise motion 63. The selective application of vacuum together with
synchronized
rotation of the wheels causes the extracted carton to be transferred from the
first wheel
62 to the second wheel 64, then transferred from the second wheel 64 to the
third wheel
66, and ultimately deposited upon the conveyor 70 between its flight bars or
lugs 72.
The curvature of the cartons 10 that has been caused by the roll is reversed
and the
carton 10 is substantially flattened by the alternating rotational motions of
the wheels
62, 64, 66.
The invention provides an alternative to storing cartons in rectangular boxes
or
stacks. As described above, the de-curled, or flattened, cartons are fed
directly into a
hopper, carton feeder assembly or other carton-receiving assembly such as a
carton
conveyor of a packaging machine in accordance with a preferred embodiment of
the
invention. The cartons are unwound, uncurled and ultimately de-imbricated in a
continuous stream. In this manner, a continuous supply of cartons greater than
a supply
from a box or stack of cartons is fed into the machine.
