Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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FOLDING UPPER RETENTION WINGS
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure relates to packaging, and more particularly to systems
and
methods for packaging multiple product units, such as cans or bottles,
together.
2. Description of Related Art
One way of packaging multiple bottles or cans together utilizes a paperboard
wrapper
which is wrapped around four of the six sides of a grouping of cans or
bottles. For example,
a paperboard wrapper or carton can be wrapped around the top, left, bottom,
and right sides
of a two-by-two group of four cans. A similar paperboard carton can be used
with the same
technique to package a two-by-three six pack of cans.
The conventional techniques have been considered satisfactory for their
intended
purpose. However, there is an ever present need for improved systems and
methods for
packaging. This disclosure provides a solution for this need.
SUMMARY OF THE INVENTION
A system includes a pair of guide rails extending in a longitudinal direction,
spaced
apart from one another by a gap configured to receive a series of carton
blanks therein, and to
retain in a folded position a leading upper flap and a trailing upper flap of
each carton as the
carton is conveyed along the pair of guide rails. A rotary conveyance mounted
stationary
with respect to the longitudinal direction. The rotary conveyance has a
rotation axis oriented
perpendicular to the longitudinal direction and being mounted for rotation
about the rotation
axis. At least one pair of tines extends radially outward from the rotary
conveyance. Each
pair of the at least one pair of tines includes a leading tine and a trailing
tine. The leading
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tine is positioned to contact and fold the leading upper flap of a passing
carton blank in the
series of carton blanks as the rotary conveyance rotates so the leading upper
flap is folded
prior to the leading upper flap passing into the gap between the pair of guide
rails. The
trailing tine is configured to contact and fold a trailing upper flap of the
passing carton as the
rotary conveyance rotates so the trailing upper flap is folded prior to the
trailing upper flap
passing into the gap between the pair of guide rails.
A second pair of guide rails can be laterally offset from the first pair of
guide rails
relative to the longitudinal direction. A second rotary conveyance can be
mounted stationary
with respect to the longitudinal direction, laterally offset from the first
rotary conveyance and
aligned with the second pair of guide rails. The second rotary conveyance can
be mounted
for rotation about the rotation axis. The first and second rotary conveyances
can be
configured to fold two leading upper flaps and two trailing upper flaps of
each carton blank in
the series of carton blanks.
The rotary conveyance can include a main wheel mounted stationary with respect
to
the longitudinal direction. The trailing tines can follow a cam path to
articulate relative to the
main wheel. The leading tines can be fixed so as not to articulate relative to
the rotary
conveyance.
A secondary wheel can be mounted across from the rotary conveyance stationary
with
respect to the longitudinal direction. The secondary wheel can have a rotation
axis offset
from and parallel to the rotary axis of the rotary conveyance. The secondary
wheel can
include a wheel contour configured to maintain folded position of the leading
and trailing end
flaps after folding by the pair of tines and before the leading and trailing
flaps enter the gap
between the pair of guide rails. The leading and trailing tines of the rotary
conveyance can be
fixed so as not to articulate relative to the rotary conveyance.
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The rotary conveyance can include a chain drive forming a cycling path
elongated to
extend in the longitudinal direction. The leading and trailing tines can
follow a cam path to
articulate relative to the chain drive.
A pack conveyor can be aligned with the longitudinal direction. The pack
conveyor
can be positioned to align a series of packs of product with respective carton
blanks, wherein
each pack is aligned with a respective carton blank as the carton blank is
folded by the rotary
conveyance.
A pack conveyor can be positioned to introduce a series of packs of product
from a
lateral direction into alignment with the longitudinal direction, wherein the
pack conveyor is
positioned to align the packs with respective carton blanks at a position
downstream of where
the carton blanks enter the gap between the guide rails.
A method includes folding leading upper flap of a carton blank, folding a
trailing
upper flap of a carton blank, and passing the leading and trailing upper flaps
in a folded
condition into a gap between a pair of guide rails. The method includes
interlocking the
leading upper flap into a leading can in a pack of product, interlocking the
trailing upper flap
into a trailing can in a pack of product, and wrapping the carton blank around
the pack of
product to package the pack of product together.
Folding the leading upper flap of a craton blank can include folding two
leading upper
flaps of the carton black at the same time, wherein folding the trailing upper
flap includes
folding two trailing upper flaps of the carton blank at the same time, and
wherein interlocking
the leading and trailing upper flaps includes interlocking the two leading
upper flaps into two
side by side leading units in the pack of product and interlocking the two
trailing upper flaps
into two side by side trailing units in the pack of product. The pack of
product can be a two-
by-three six pack of cans.
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Folding the leading and trailing upper flaps can be performed with access only
from
above the carton blank as the pack of product is below the blank. It is also
contemplated that
folding the leading and trailing upper flaps can be performed by accessing the
carton blank
from above and from below, wherein the pack of product is aligned with the
carton blank
downstream after the leading and trailing upper flaps are folded. Folding can
include initially
folding with access from only from above the carton blank and maintaining
folding after
initially folding, wherein maintaining folding includes accessing only from
below the carton
blank after accessing only from above and before passing the leading and
trailing flaps into
the gap between the guide rails.
Folding the leading upper flap can occur prior to folding the trailing upper
flap.
Interlocking the leading and trailing upper flaps can include lowering the
carton down a ramp
into engagement with the pack of product. Passing the leading and trailing
upper flaps into
the gap between the guide rails can include first passing the carton blank
under an upper one
of the guide rails then passing the carton blank over a lower one of the guide
rails while still
keeping the carton blank below the upper guide rail. Folding at least one of
the leading and
trailing upper flaps can include articulating a tine to effect folding
thereof.
These and other features of the systems and methods of the subject disclosure
will
become more readily apparent to those skilled in the art from the following
detailed
description of the preferred embodiments taken in conjunction with the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that those skilled in the art to which the subject disclosure appertains
will readily
understand how to make and use the devices and methods of the subject
disclosure without
undue experimentation, preferred embodiments thereof will be described in
detail herein
below with reference to certain figures, wherein:
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Fig. 1 is a schematic perspective view of an embodiment of a system
constructed in
accordance with the present disclosure, showing the main wheel from a view
point above the
carton blanks;
Fig. 2 is a schematic perspective view of the system of Fig. 1, showing
folding of a
leading upper flap of one of the cartons from a view point below the carton
blanks;
Fig. 3 is a schematic perspective view of the system of Fig. 1, showing the
leading
upper flap entering the gap between the guide rails from a view point below
the carton
blanks;
Fig. 4 is a schematic perspective view of the system of Fig. 1, showing
folding of a
trailing upper flap from a view point below the carton blanks;
Fig. 5 is a schematic perspective view of a portion of the system of Fig. 1,
showing
the cam path for articulating the trailing tines;
Fig. 6 is a schematic perspective view of a portion of the system of Fig. 1,
showing
one of the main wheels;
Fig. 7 is a schematic end view of the portion of the system of Fig. 6, showing
both of
the main wheels;
Fig. 8 is a schematic perspective view of a portion of the system of Fig. 1,
showing
chain drives in lieu of the main wheels;
Fig. 9 is a schematic plan view of a portion of the chain drives of Fig. 8,
showing the
tines and a carton blank;
Fig. 10 is a schematic perspective view of a portion of the chain drives of
Fig. 8,
showing the cam paths for articulating the lugs;
Fig. 11 is a schematic perspective view of the system of Fig. 1, showing
another
rotary conveyance that accesses the carton blanks from above and below;
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Fig. 12 is a schematic perspective view of the rotary conveyance of Fig. 11,
as viewed
from a position above the carton blanks;
Fig. 13 is a schematic perspective view of the rotary conveyance of Fig. 11,
showing a
secondary wheel with a different wheel contour from that shown in Fig. 11;
Fig. 14 is a schematic view of a process of packaging products in accordance
with the
present disclosure, showing a carton blank being wrapped around a pack of cans
wherein the
upper flaps are engaged with respective cans;
Fig. 15 is a schematic view of the process of Fig. 14, as viewed from a point
below
the carton blanks;
Fig. 16 is a perspective view of a portion of the system of Fig. 1, showing
the rotary
conveyance of Fig. 11 installed, and a pack conveyer that introduces product
packs
downstream of the rotary conveyance; and
Fig. 17 is a side elevation view of the system of Fig. 16, showing the main
and
secondary wheels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to the drawings wherein like reference numerals
identify
similar structural features or aspects of the subject disclosure. For purposes
of explanation
and illustration, and not limitation, a partial view of an embodiment of a
system in
accordance with the disclosure is shown in Fig. 1 and is designated generally
by reference
character 100. Other embodiments of systems in accordance with the disclosure,
or aspects
thereof, are provided in Figs. 2-17, as will be described. The systems and
methods described
herein can be used to fold upper flaps of carton blanks for engagement with
product units,
such as beverage cans, to lock the product units in the carton after wrapping
the carton
around a pack of the product units.
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The system 100 includes a pair of guide rails 102, 104 extending in a
longitudinal
direction D. The upper guide rail 102 is spaced apart from the lower guide
rail 104
(identified in Fig. 2) by a gap G configured to receive a series of carton
blanks 106 therein,
and to retain in a folded position a trailing upper flap 108 and a leading
upper flap 110 of
each carton 106 as the carton 106 is conveyed along the pair of guide rails
102, 104. A rotary
conveyance 112 is mounted stationary with respect to the longitudinal
direction D. The
rotary conveyance 112 has a rotation axis A oriented perpendicular to the
longitudinal
direction D. The rotary conveyance 112 is mounted for rotation about the
rotation axis A.
A second pair of guide rails 114, 116 is laterally offset from the first pair
of guide
rails 102, 104 relative to the longitudinal direction D. A second rotary
conveyance 118 is
mounted stationary with respect to the longitudinal direction D, laterally
offset from the first
rotary conveyance 112 and aligned with the second pair of guide rails 114,
116. The second
rotary conveyance 118 is mounted for rotation about the rotation axis A at the
same speed as
the first rotary conveyance 112. For purposes of clarity, this disclosure
discusses the
operation of the first rotary conveyance 112 and the first and second guide
rails 102 and 104,
however those skilled in the art will readily appreciate that the description
of the structure
and operation of the first rotary conveyance 112 and the rails 102, 104 can
readily be applied
to the second rotary conveyance 118 and its corresponding rails 114, 116. The
first and
second rotary conveyances 112, 118 are configured to fold two trailing upper
flaps 108, 120
and two leading upper flaps 110, 122 of each carton blank 106 in the series of
carton blanks
106.
Multiple pairs of tines 124, 126 extend radially outward from the rotary
conveyance
112. Each pair of tines 124, 126 includes a trailing tine 124 and a leading
tine 126. The
leading tine 126 is positioned to contact and fold the leading upper flap 110
of a passing
carton blank 106 in the series of carton blanks 106 as the rotary conveyance
112 rotates so
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the leading upper flap 110 is folded prior to the leading upper flap 110
passing into the gap G
between the pair of guide rails 102, 106. Fig. 2 shows a leading upper flap
110 being folded
by one of the leading tines 122 at position Pl. Fig. 3 shows the same upper
flap 110 entering
the gap G at position P2. Fig. 4 shows the same upper flap 110 at position P3
being captured
in gap G and being conveyed along the guide rails 102, 104. Passing the
leading and trailing
upper flaps 110, 108 into the gap G includes first passing the carton blank
106 under an upper
one of the guide rails 102 then passing the carton blank 106 over a lower one
of the guide
rails 104 while still keeping the carton blank 106 below the upper guide rail
102 because
guide rail 102 starts upstream, i.e. further to the left in Fig. 1, than guide
rail 104.
Each trailing tine 124 is configured to contact and fold a trailing upper flap
108 of the
passing carton 106 as the rotary conveyance 112 rotates so the trailing upper
flap 108 is
folded prior to the trailing upper flap 108 passing into the gap G between the
pair of guide
rails 102, 104. Fig. 4 shows the trailing upper flap 108 (of the same carton
for which the
folding of the leading upper flap 110 was explained above) being folded by the
tine 124 at
position P4, and at position P5 a trailing upper flap 108 of preceding carton
blank 106 is
shown captured between the guide rails 102, 104. After folding the trailing
upper flap 108,
the trailing tine 124 articulates away from the trailing upper flap 108 to
clear carton blank
106 as the carton blank 106 passes beyond the rotary conveyance 112.
The rotary conveyance 112 includes a main wheel 128 (identified in Figs. 5 and
7)
that is mounted stationary with respect to the longitudinal direction D. The
trailing tines 124
follow a cam path 130 defined in sidewall 134 to articulate the trailing tines
124 relative to
the main wheel 128 as indicated by the curved arrow in Fig. 5. Each trailing
tine 124 rotates
about a respective tine axis T relative to the main wheel 128 as a result of a
respective cam
follower 132 of the trailing tine 124 following the cam path 130, which cam
path 130 remains
stationary relative to the rotation of the main wheel 128. The leading tines
126 (not shown in
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Fig. 5, but see Fig. 1) are fixed so as not to articulate relative to the
rotary conveyance 112.
The corresponding sidewall 134 for the second rotary conveyance 118 is shown
in Figs. 6-7.
With reference now to Fig. 8, another device 200 for use in system 100, e.g.,
in lieu of
the rotary conveyances 112 and 118 with their respective main wheels 128, uses
rotary
conveyances 212, 218 each of which includes a respective chain drive 228. Each
chain drive
228 defines a rotary path that rotates around the axis A, but is elongated
along the
longitudinal direction D. Fig. 9 shows that each chain drive 228 includes
leading tine 226
and a trailing tine 224, and those skilled in the art will readily appreciate
that any suitable
number of pairs of tines 224, 226 can be included on each chain drive 228. The
elongated
shape of the chain drives shown in Fig. 8 allows the tines 224, 226 to have
prolonged contact
with the cartons 106 (labeled in Figs. 1 and 9) for applications where
prolonged contact is
advantageous. The prolonged contact is prolonged in terms of distance, but
those skilled in
the art will appreciate that the chain drives 228 can facilitate high speed
throughput, so the
prolonged contact is not necessarily prolonged in terms of time. With
reference to Fig. 10,
the prolonged contact is facilitated by articulation of both of the tines 224,
226. The leading
tine 226 articulates about pivot 236 and its articulation is driven by cam
follower 238 in cam
track 240 of the cam wall 234. The trailing tine 224 articulates about pivot
242 and its
articulation is driven by cam follower 244 in cam track 246 in the cam wall
234. The
articulation of the tines 224, 226 is similar to that described above with
respect to trailing tine
124.
The rotary conveyances described above with respect to Figs. 1-10 provide for
folding
the upper flaps 108, 110 without requiring access from below the cartons 106.
This provides
for folding the upper flaps 108, 110 in settings where the products, e.g.,
packs 148 of cans
150 are conveyed directly beneath where the rotary conveyances are folding the
upper flaps
108, 110, as shown for example in Fig. 1. In Fig. 1, a pack conveyor 152 is
aligned with the
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longitudinal direction D. The pack conveyor 152 is positioned to align a
series of packs 148
of product with respective carton blanks 106, wherein each pack 148 is aligned
with a
respective carton blank 106 as the carton blank is folded by the rotary
conveyance 112, 118.
With reference to Fig. 16, in other applications pack conveyor 352 is
positioned to
introduce a series of packs (not shown in Fig. 16, but see packs 148 of Fig.
1) of product from
a lateral direction I into alignment with the longitudinal direction D. The
pack conveyor 352
is positioned to align the packs 148 with respective carton blanks 106 (not
shown in Fig. 16,
but see Fig. 1) at a position downstream of where the carton blanks 106 enter
the gap G (see
Fig. 1) between the guide rails 102, 104 and 114, 116. In other words, in Fig.
16, the carton
blanks 106 can enter from the left along the direction D, the packs 148 can
enter along
direction I from a lateral position, and the packs 148 meet the cartons
downstream of the
beginning of the rails 102, 104, 114, 116, and together the packs 148 and
cartons leave the
area as indicated by the output arrow 0 in Fig. 16. This allows introduction
of the packs 148
downstream of the rotary conveyances 312, 318 (shown from the side in Fig.
17), which
means that the cartons can be accessed from below while folding the upper
flaps 108, 110.
With reference now to Fig. 11, system 100 is shown wherein the folding is done
by
accessing the cartons 106 from both above and below. A respective secondary
wheel 360,
362 is mounted across from each of the main wheels 328 of rotary conveyances
312, 318
stationary with respect to the longitudinal direction D. Each secondary wheel
360, 362 has a
rotation axis R offset from and parallel to the rotary axis A of the rotary
conveyances 312,
318. Each secondary wheel 360, 362 includes a wheel contour 364 configured to
maintain
folded position of the leading and trailing end flaps 110, 108 after folding
by the pair of tines
326, 324 and before the leading and trailing flaps 110, 108 enter the gap G
between the pair
of guide rails 102, 104. The leading and trailing tines 326, 324
(respectively) of the rotary
conveyances 312, 318 are fixed on their respective main wheels 328 so as not
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relative thereto. Figs. 11 and 12 show two of the leading tines 326 folding
two of the leading
upper flaps 110 from points of view below and above the cartons 106,
respectively. Folding
the upper flaps 108, 110 can include initially folding with access from only
from above the
carton blank 106 and secondary wheels 360, 362 maintain the folding after
initially folding as
described above, wherein maintaining folding includes accessing only from
below the carton
blank 106 before passing the leading and trailing flaps 110, 108 into the gap
G between the
guide rails 102, 104.
The number of tines 324, 326 can be varied as needed for a given application,
as can
the wheel contour 364. Fig. 13 shows a modified version of the main wheels 428
with fewer
tines 424, 426, and secondary wheels 460, 462 with a different wheel contour
464. These
modifications can be made, e.g., to accommodate systems with different speeds.
The wheel
contour 464 can move at twice the speed of the cartons 106, for example,
whereas the wheel
contour 364 in Fig. 11 moves at the same speed as the cartons 106.
With reference now to Figs. 14 and 15, which schematically show the system 100
from a view point above and below the cartons 106, respectively, stages of
packaging packs
148 in cartons blanks 106 are shown. On the left in Figs. 14 and 15, cartons
106 approach the
main and secondary wheels 428, 460, 462, which fold the leading and trailing
upper flaps 110,
108. After folding the upper flaps 110, 108, the blank 106 is passed into the
gap G, identified
in Fig. 3, with the upper flaps 108, 110 in a folded condition. Then the pack
148 is
introduced below the carton 106, and the guide rails 102, 104, 114, 116 (shown
in Figs. 1-3)
ramp the cartons 106 downward into contact with the pack 148. In the case
where the packs
148 are initially introduced below the cartons 106 as in Figs. 1-4, there are
no wheels 460,
462 accessing the blanks 106 from below. As the carton blanks 106 come into
contact with
the packs, the two side-by-side leading upper flaps 110 are interlocked into
the upper rims
170 of the two side-by-side leading cans 150, and the side-by-side trailing
upper flaps 108 are
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interlocked into the side-by-side upper rims 170 trailing cans 150. Then the
carton blank 106
is wrapped around the pack 148 of product to package the pack 148 of product
together, as
shown on the far right of Fig. 14. Those skilled in the art will readily
appreciate that while
shown in the context of a two-by-three six pack of cans 150, other products or
pack
configurations (such as four packs) can be used without departing from the
scope of this
disclosure.
The methods and systems of the present disclosure, as described above and
shown in
the drawings, provide for packaging product units such a beverage cans within
cartons with
superior properties including ease us use and reliability. While the apparatus
and methods of
the subject disclosure have been shown and described with reference to
preferred
embodiments, those skilled in the art will readily appreciate that changes
and/or
modifications may be made thereto without departing from the scope of the
subject disclosure.
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