Pouch containment and carton loading

Abstract

A stack of products such as pouches are formed in a product bucket, pushed into a stack guide bucket and from there into a carton. A stack tamp descends over the stack, engages and confines it downwardly during stack pushing from product bucket and through stack guide bucket into a carton. Multiple product buckets, stack guide buckets and cartons move downstream during cartoning, and are respectively aligned in a cartoning station. Reciprocal containment blades hold the stack in respective cartons prior to flap closing.

Claims

1. An apparatus for loading stacks of product into cartons, comprising: a product bucket having a discharge end; an elongated static stack guide having a terminal end; a product stack guide bucket; said static stack guide being operably disposed between said discharge end of said product bucket and said stack guide bucket upstream from the terminal end of said static stack guide; a reciprocally and vertically operable tamp foot oriented to tamp down a product stack in said product bucket and said product stack guide bucket; a stack pusher oriented to push a product stack from said product bucket into said stack guide bucket, past said terminal end of said static stack guide and into a carton; a reciprocally and vertically operable stack containment blade extending in a vertical direction of a reciprocal motion of the stack containment blade and being configured to directly confront and confine a rearward end of said pushed stack within said carton; and at least one flap closer configured to close at least one flap of said carton against a loaded product stack.

2. The apparatus as in claim 1 wherein said product bucket, said stack guide bucket, said tamp foot, said containment blade and said stack pusher are driven in parallel machine directions, and further comprising a first cam operably oriented to reciprocate said tamp foot, and a second cam operably oriented to reciprocate said stack containment blade.

3. The apparatus as in claim 1 further comprising a plurality of product buckets moveable in a machine direction; a plurality of stack guide buckets moveable in said machine direction; and a plurality of stack pushers moveable in said machine direction and perpendicular thereto; a plurality of tamp feet moveable in said machine direction and perpendicularly thereto; and a plurality of stack containment blades moveable in said machine direction and perpendicularly thereto.

4. The apparatus as in claim 1 wherein said apparatus includes a carton loading station, wherein said terminal end of said elongated static stack guide is positioned in said machine direction upstream from said carton loading station.

5. The apparatus as in claim 4 wherein said elongated static stack guide has an upper edge tapering downwardly upstream of said elongated static stack guide terminal end.

6. The apparatus as in claim 5 further comprising respective cams for respectively reciprocating said tamp foot and said stack containment blade at positions downstream from the taper of said upper edge of said elongated static stack guide.

7. The apparatus as in claim 1 wherein said product bucket includes partial spaced apart side walls opposite said discharge end, said stack pusher being extendible into said product bucket between said partial side walls.

8. The apparatus as in claim 1 further comprising an extended minor flap guide extending in a machine direction through and beyond a carton loading station.

9. The apparatus as in claim 1 wherein the at least one flap closer comprises a plurality of flap closers configured to close flaps of said carton against the loaded product stack.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other objectives and advantages are further described in the following written description and in the drawings wherein:

(2) FIG. 1 is an isometric view of one embodiment of the invention;

(3) FIG. 2A is an isometric view of a product bucket as in FIG. 1 illustrating a stack of product or pouches therein;

(4) FIG. 2B is an isometric view of an unfilled product bucket as in FIGS. 1 and 2A;

(5) FIG. 3 is an enlarged isometric view of the left end portion of FIG. 1 for clarity.

(6) FIG. 4 is an enlarged isometric view as in FIG. 3 illustrating the stack pushing motion of the barrel loader;

(7) FIG. 5 is an enlarged isometric view as in FIG. 4 illustrating the vertical descent of the stack containment blade;

(8) FIG. 6 is an enlarged isometric view of the right end portion of FIG. 1 illustrating the descended stack containment blade and the rotary carton flap closure stars; and

(9) FIG. 7 is an enlarged isometric view of a portion of FIG. 6 as viewed from the back of a loaded carton and further illustrating the rotary carton flap closure stars and the product stack containment blade.

DETAILED DESCRIPTION OF THE INVENTION

(10) Turning now to the Figures, FIG. 1 illustrates apparatus 10 for cartoning a stack of products, such as individual, stacked, asymmetric pouches without disorientation of a formed stack in a product bucket through stack transfer into a carton.

(11) Several multiple flap cartons 12 (one shown) to be filled are conveyed in a machine direction MD on a suitable carton conveyor 13 shown only graphically in FIG. 1. A series of moving product guide buckets 14 are conveyed (in machine direction MD) on a suitable product guide conveyor 15, shown only graphically in FIG. 1. A series of product buckets 16 are conveyed in a machine direction MD on a suitable product bucket conveyor 17, shown only graphically in FIG. 1. See bucket attachment components of conveyor 17 in FIGS. 2A and 2B.

(12) A plurality of barrel loader slides 18 of any suitable barrel loader construction are mounted for movement in a machine direction MD on a barrel loader conveyor 19, shown only graphically in FIG. 1.

(13) A series of reciprocal stack tamps 20 are slidably mounted on carriages 22 (one shown) partially moveable in at least a machine direction MD and driven via carriage attachment components 25, 27 carried by respective chain runs 72, 74 (FIG. 6).

(14) A series of reciprocal stack containment blades 30 is also mounted on carriages 22 for motion at least partially in a machine direction by virtue of components 25, 27, (FIG. 6).

(15) A series of stack tamps 20 are vertically operated via cam 23, 23a while containment blades 30 are vertically operated via cam 24, 24a while both also move along in machine direction MD.

(16) It will then be appreciated that all components 12, 14, 16, 18, 20, 30 are all moveable in a machine direction MD through a stack cartoning station 36 indicated by cartoning station range bracket 36.

(17) In addition, it will be appreciated that tamps 20 and containment blades 30 are mounted for selective vertical motion perpendicularly to the machine direction MD, while all conveyors 13, 15, 17, 19, and chain runs 72, 74 are substantially parallel in operation in the downstream machine direction MD.

(18) It will also be appreciated that the carriage 22 is carried by the components 25, 27, respectively connected to chain runs 72, 74 which are graphically depicted by the so numbered dotted lines in FIG. 6. Preferably, chain run 72 is disposed between and parallel to cam members 23, 24, while chain run 74 is oriented outside cam member 23. As noted, chain runs 72, 74 are parallel to cam members 23, 24 and are directed in a machine direction MD parallel to conveyors 13, 15, 17 and 19.

(19) Thus carriage 22 is conveyed in machine direction MD, while carrying tamp feet 20 and containment blades 30.

(20) Moreover, it will be appreciated that the moving chain runs 72, 74 extend from upstream of a cartoning station 36, therethrough and beyond the position of the rotary flap closure 66 in the machine direction MD (FIG. 7), forming a loop with an operative path generally along a path of cams 23, 24.

(21) An elongated guide 38 is disposed along a path traversed by cartons 12 in the machine direction MD for holding minor carton flaps 12A, 12B inwardly, forming a stop in carton 12 for a stack of products, such as pouches, when loaded into cartons 12.

(22) An elongated static stack guide 40 is disposed along the machine direction MD from an upstream position where products are loaded into buckets 16, and terminating at an end 41. End 41 terminates at a position just short of cartoning station 36, so elongated static product guide 40 clears the moving stack guide bucket 14 in the machine direction MD just as guide bucket 14, and product bucket 16 pass downstream guide end 41 in cartoning station 36.

(23) As illustrated in FIG. 1, cartoning station 36 is located just downstream of end 41 of guide 40 in the machine direction MD. Bucket 16 in FIG. 1 has been filled but the product stack in product bucket 16, guide bucket 14 and carton 12 have not moved into station 36 in FIG. 1.

(24) Elongated static guide 40 has an upper edge tapered downwardly at 42 (FIG. 1) to allow clearance for descending tamp feet 20 as they come into alignment with product bucket 16, product guide bucket 14 and carton 12 as they move continuously downstream in machine direction MD and into alignment at cartoning station 36.

(25) Product bucket 16 (see FIGS. 2A, 2B) has three sides, including opposed sides 43, 45, open end side 47 and bottom 49. Bucket 16 also has an end 51, opposite open end 47, defined by two opposed partial sides 53, 55, defining a space therebetween for passage of stack pushers 57 conveyed by barrel loader slides 18.

(26) Operation and Further Detail

(27) In operation, a plurality of pouches P (FIG. 2A) are dropped into bucket 16 from any suitable loader such as by a direct drop knife at an upstream vacuum wheel (not shown). The pouches P form a pouch stack 60 in product bucket 16, the stack 60 formed and confined by bucket sides 43, 45, partial bucket sides 53 55, bottom 49, and the elongated static stack guide 40 while the bucket 16 moves downstream.

(28) When each bucket 16 and aligned stack guide bucket 14 clear the end 41 of elongated static guide 40 in cartoning station 36, barrel loader 18 is activated, causing sliding pusher 57 thereof to extend between partial stack confining product bucket sides 53, 55 and push the formed stack 60 from product bucket 16 into stack guide 14. Pusher 57 motion continues, pushing stack 60 into the open end of carton 12, until stack 60 engages closed minor carton flaps 12A, 12B, held by flap guide 38.

(29) Concurrently, tamp 20, moving in direction MD along with product bucket 16, stack guide bucket 14 and carton 12, descends onto the top of stack 60, confining and holding the stack 60 in its oriented form as the bucket 16 passes static guide edge 41.

(30) FIG. 3 illustrates the lowered tamps 20 just prior to pushing by pusher 57. Containment blades 30 remain in an upper, retracted position.

(31) FIG. 4 illustrates the yet incomplete pushing of stack 60 from product bucket 16 into stack guide bucket 14 with stack confining tamp 20 in descended lower position, confining stack 60.

(32) As the components continue downstream in the direction MD, pushing of stack 60 into carton 12, against carton flaps 12A, 12B is completed. FIG. 5 illustrates the beginning of downward motion of containment blades 30 across the rear end of the pushed stack 60 in carton 12 to confine stack 60 from slumping or falling backward when pusher 57 is withdrawn by barrel loader 57. Tamp 20 begins its ascent away from bucket 16 and guide bucket 14 (see FIG. 6).

(33) Downstream of cartoning station 36 an elongated static carton flap guide 76 is positioned in the machine direction MD to engage the leading minor flap 12C with a tapered end 77. Further downstream motion of carton 12 moves the carton and flap 12C to engage guide end 77. Thereafter, rotary flap closer or star 66 rotates to fold trailing minor carton flap 12D against the product stack 60 in carton 12 and containment blade 30.

(34) Carton end flaps 12E, 12F, 12G and 12H (FIG. 7) are then closed by appropriate carton flap guides (not shown).

(35) Containment blades 30 remain in place while minor flaps 12C, 12D are folded inwardly against product stack 6. Once flaps 12C, 12D are held in place by static guide 76, containment blades 30 ascend and return for another cycle.

(36) This confines the desired stack 60 form in carton 12.

(37) Thereafter, the stack-filled carton 12 proceeds downstream in direction MD for final closing gluing or the like by any suitable means.

(38) The tamps 20 have been raised and returned for another cycle.

(39) It will be appreciated that reciprocal movement of tamps 20 and containment blades 30 are each initiated and controlled by distinct separate cams 23, 24 as shown for coordinated operation.

(40) It will also be appreciated that while single elements or components 12, 14, 16, 18, 20, 22 and 30 are shown in the FIGS. for clarity, one preferred embodiment of the invention contemplates a plurality of each of these, driven continuously along from bucket loading to, through and beyond the cartoning station 36 with respective other like components for continuous cartoning operation, all while retaining control of the stacks and pouches as the stacks are formed, transported and loaded into cartons.

(41) Also, it will be appreciated that while feet 20 are referred to herein as tamp feet, they also serve to confine the product stacks from the top whether or not any tamping motion is applied.

(42) Finally, it will also be appreciated that the invention is useful not only in cartoning of asymmetric products or pouches but also in cartoning of stacks of a wide variety of uniform products.