EP0817748B1

EP0817748B1 - Carrier feeder mechanism and apparatus for loading containers into open-bottomed carrier

Info

Publication number: EP0817748B1
Application number: EP96911779A
Authority: EP
Inventors: Glenn Robinson; Will L. Culpepper; John Madigan
Original assignee: Mead Corp
Current assignee: WestRock Packaging Systems LLC
Priority date: 1995-04-13
Filing date: 1996-04-15
Publication date: 2000-02-16
Anticipated expiration: 2016-04-15
Also published as: IL117897A; KR100454353B1; WO1996032324A1; TW307730B; DE69622549T2; KR100454352B1; MY123046A; KR19980703754A; EP0820403B1; CA2218065C; AR001627A1; ATE221488T1; TR199701089T1; EP0820403A4; DE69622388T2; CA2218046C; WO1996032320A1; BR9604964A; CN1082005C; EP0817745A4

Description

The invention relates to bottom-loading basket-style carriers for articles such as beverage bottles.

Previous methods and apparatus for loading bottles into basket-style carriers from the bottom are disclosed in US patent number 2,276,129 to Wesselman, US patent number 2,603,924 to Currie et al., US patent number 3,521,427 to Masch, US patent number 3,627,193 to Helms, US patent number 3,698,151 to Arneson, US patent number 3,751,872 to Helms, US patent number 3,747,294 to Calvert et al., US patent number 3,805,484 to Rossi, US patent number 3,842,571 to Focke et al., US patent number 3,848,519 to Ganz, US patent number 3,924,385 to Walter, US patent number 3,940,907 to Ganz, US patent number 4,915,218 to Crouch et 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.

EP 590 568, Senzani, discloses a feeder mechanism according to the preamble of claim 1. The feeder mechanism comprises at least one carrier engaging station. The carrier is withdrawn from a hopper and retained by the feeder in a substantially vertical orientation and is rotated to the desired release position where the carrier is released to be moved downstream.

The present invention provides a mechanism and apparatus for the continuous opening and loading of basket-style bottom-loading carriers and seeks to overcome or at least mitigate problems of the prior art.

One aspect of the invention provides a feeder mechanism for an apparatus for loading carriers comprising at least one carrier engaging station disposed for drawing and retaining a carrier thereto in a substantially vertical orientation at a first rotatable position and releasing the carrier therefrom at a second rotatable position characterised in that said carrier engaging station further comprises a carrier stop guide member disposed thereon for abutting an upwardly oriented face of the carrier drawn thereto.

According to an optional feature of this aspect of the invention said upwardly oriented face may be a handle panel of a carrier, including a hand aperture region thereof, wherein said stop guide member abuts said handle panel proximate the hand aperture.

According to another optional feature of this aspect of the invention said stop guide member may comprise a channel-shaped member disposed proximate a top region of said carrier engaging station.

A second aspect of the invention provided an apparatus for feeding carriers in to a packaging machine and for transferring said carriers down stream to a loading station, the apparatus comprising a feeder mechanism and a carrier timer transport assembly disposed in operative communication with said feeder mechanism, which timer transport assembly is adapted for receiving said carriers from said feeder mechanism and initiating transport of the carriers in a planar motion down stream to said loading station. Preferably, the carrier timer transport assembly may comprise a pair of endless timing chains adapted to stagger the carriers at a pre-determined distance apart and a belt assembly adapted to transport said carriers at the pre-determined spacing initiated by said timing chains to the loading station. More preferably, the carrier timer transport assembly may further comprise insert means adapted to cooperate with said stop guide member such that said insert means is placed within the handle aperture of the carrier to transport said carrier downstream.

According to an optional feature of this aspect of the invention a second stop guide member of said carrier timer transport assembly being adapted to cooperate with said insert means to provide a steadying counterforce as said insert means transports the carriers downstream. Preferably, said second stop guide member is channel shaped.

Optionally, said stop guide member may comprise a channel shaped member proximate a top region of said carrier engaging station.

According to another optional feature of this aspect of the invention there may comprise a pair of guide rails connected in substantially parrallel arrangement disposed, to provide a steadying counterforce as said insert means transports the carrier downstream.

Other advantages and features of the present invention will be apparent from the following description, the accompanying drawings, and the appended claims.

Brief Description 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.

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.

Fig. 15 is a side elevational view of declination and seating assemblies of the apparatus of Fig. 5.

Fig. 16 is an isometric illustration of a second alternate embodiment of a timing and transport segment of the apparatus of Fig. 5.

Detailed Description 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 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. 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. 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. The blank 906 is essentially symmetric about a perforated fold line 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.

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. 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.

Other features of the carton will be apparent from the drawings and in particular Figures 1, 2 and 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 articles or 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.

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 constructed upon an elongate 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. When the carriers 3 are in the hopper 30, they are in collapsed condition with the

bottom wall panels

910, 912 pivoted up and lying flat against the sides of the carrier 3. Upon removal from the hopper 30, the

bottom wall panels

910, 912 of the carrier 3 fall away from their position flat against the sides of the carrier 3. As a carrier 3 moves through the timing section the

bottom wall panels

910, 912 are engaged and pulled outward to open the carrier 3 for loading. As the carriers 3 are being pulled open along the carrier path of the apparatus 10, bottles are moved along in a path beneath the carriers. In the lower path (the bottle path) a star wheel 105 on either side of the apparatus 10 meters a row of bottles 3 into distinct groups for loading. For example, groups of three or four bottles in each row. An endless chain with lugs is one of the means for transporting bottles after they have been metered by the 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 gripping and

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.. As the carriers 3 move from the pusher wheel assembly 120 a package conveyor 130 such as side lugs 134 mounted upon respective opposing endless chains 132 engage the trailing end panel of the carriers 3/packages 7 and push them further along the apparatus 10. As the carriers 3 are moved along by the package conveyor 130, a bottom panel locking section 140 folds

carrier support tabs

961, 963, 971, 973 and

bottom wall panels

910, 912 into position for attachment of the

support tabs

961, 963, 971, 973 to the

bottom wall panels

910, 912 and for closure of the bottom of the carrier 3. The

bottle panels

910, 912 are drawn together for proper alignment and held in that position while closure of the bottom of the carrier 3 is completed by a rotating punch lock mechanism. The loaded, fully closed carrier is then ejected from the apparatus 10.

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 10 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.

Hopper 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 10. In the hopper assembly a pair of opposing

side walls

31, 32 form 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 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.

Carrier 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 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. These patents are hereby incorporated by reference. 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.

Timing-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-Transport 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 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 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 Figures 7 and 9, 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 U-shaped flap 984 foldably extending from its upper portion. 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 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. 10, 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 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.

-Timing-Transport Section: Second Alternate Embodiment

Referring now to Fig. 16, 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.

Bottom-Panel Grippers

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 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. 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.) The grippers 82 continue to hold the respective

bottom panels

910, 912 outward during movement.

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 ad a bottle-gripper conveyor 112 which engages the sides of the bottles.

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 15, 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 declinatin assembly where the

extended bottom panel

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 15, 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 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. 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. 15. The unit 7 is now ready for closure.

In Fig. 15 the bottles 1 are shown in groupings 5 of two by three arrays, a total of six bottles per group. However, as previously mentioned, it is noted that the system of the invention works well with various multiples of bottles to be packaged. To reinforce this point, the description and illustrations of the preferred embodiment utilize both six- and eight-bottle configurations. For example, the bottle grippers 114 illustrated in the isometric schematic of Fig. 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.

Closure of the Carrier

Closure of the bottom of the carrier 3 may be achieved by several means. For example, adherence of the

bottom panels

910, 912 to one another by an adhesive. Another effective means for closure is the use of a locking mechanism known as a "punch lock" in the packaging field wherein the outermost of the two bottom panels has male locking members that are superimposed over corresponding female apertures and members formed in the inside bottom panel.

Other modifications may be made in the foregoing without departing from the scope and spirit of the claimed invention. In particular the feeder mechanism is not limited to incorporation into the packaging machine hereinbefore described and can be supplied as a modular unit for other types of packaging machine or supplied on a retrofit basis.

Claims

A feeder mechanism (50) for an apparatus for loading carriers (3) comprising at least one carrier engaging station (52) disposed for drawing and retaining a carrier (3) thereto in a substantially vertical orientation at a first rotatable position and releasing the carrier (3) therefrom at a second rotatable position characterised in that said carrier engaging station further comprising a carrier stop guide member (56) disposed thereon for abutting an upwardly oriented face of the carrier (3) drawn thereto.
A mechanism of claim 1 wherein said upwardly oriented face is a handle panel (980, 990) of a carrier, including a hand aperture region thereof, wherein said stop guide member abuts said handle panel proximate the hand aperture.
The mechanism of claim 1 or claim 2, said stop guide member (56) comprising a channel-shaped member disposed proximate a top region of said carrier engaging station.
An apparatus for feeding carriers in to a packaging machine and for transferring said carriers down stream to a loading station, the apparatus comprising a feeder mechanism (50) according to any of claims 1 to 3 and a carrier timer transport assembly disposed in operative communication with said feeder mechanism, which timer transport assembly is adapted for receiving said carriers from said feeder mechanism and initiating transport of the carriers in a planar motion down stream to said loading station.
An apparatus of claim 4 wherein the carrier timer transport assembly comprises a pair of endless timing chains (60) adapted to stagger the carriers at a pre-determined distance apart and a belt assembly (61, 63) adapted to transport said carriers at the pre-determined spacing initiated by said timing chains (60) to the loading station (100).
The apparatus of claim 4 wherein the carrier timer transport assembly comprises insert means (262) adapted to cooperate with said stop guide member (56) such that said insert means is placed within the handle aperture of the carrier to transport said carrier downstream.
The apparatus of claim 6 further comprising a second stop guide member (278) of said carrier timer transport assembly being adapted to cooperate with said insert means to provide a steadying counterforce as said insert means transports the carriers downstream.
The apparatus of claim 7 wherein said second stop guide member is (278) channel shaped.
The apparatus of claim 6 to 8 further comprising a pair of guide rails (280) connected in substantially parallel arrangement disposed between the first and said second stop guide members, to provide a steadying counterforce as said insert means (262) transports the carrier downstream.