EP4610179A1

EP4610179A1 - Machine for automated supply of cards with single-dose vial

Info

Publication number: EP4610179A1
Application number: EP25152760.2A
Authority: EP
Inventors: Blanca María Carmen GARCÍA CORONA
Original assignee: Ifc Team SL
Current assignee: Ifc Team SL
Priority date: 2024-01-25
Filing date: 2025-01-20
Publication date: 2025-09-03
Also published as: ES1311222U; ES1311222Y

Abstract

Machine for the automated supply of cards with single-dose vial comprising: a feeding station (4) of cards (2); a loading station (5) that picks up the cards (2) from the feeding station (4); a rotating disc (7), with housings (6) defining a shaping die, which rotates sequentially; a structure of various punches (8) associated with a lifting and lowering mechanism (10) configured with different ends (8a) for folding, marking fasteners or pushing the cards; and a vial (3) insertion unit (9) that inserts a vial (3) into the folded cards (2) inside the housing (6), all of them operated automatically and synchronously.

Description

OBJECT OF THE INVENTION

The invention, as expressed in the wording of the present specification, refers to a machine for the automated supply of cards with single-dose vial which brings, to the function for which it is intended, advantages and features described in detail below which represent an improvement of the current state of the art.
More particularly, the object of the invention focuses on a machine for supplying cards with single-dose vial, of the type normally used for distributing samples of liquid products, for example perfumes, which is specially designed for receiving and picking up the cards, for shaping them with the fold and die-cut required and with a variable format, for detecting and inserting the vial in the shaped card and for supplying the assembled set. All this is carried out in an automated way with a rotating disc system, with several housings that act as a lower die, and punches with a vertical displacement movement synchronized to the rotation of the disc to fit into the housings and shape the cards, insert the vial and eject the set, providing a fast and efficient means of assembling this kind of samples that improves the currently known systems, especially due to the flexibility offered by the machine to take in and work with different card models.

FIELD OF APPLICATION OF THE INVENTION

The field of application of the present invention is framed within the sector of the industry dedicated to the manufacture of automated installations for in-line assemblies, aimed particularly at the field of the assembly of cards.

BACKGROUND OF THE INVENTION

Cards with single-dose vial of the type described herein are widely known and are generally used for distributing samples of liquid products, usually perfumes, but also oils or other products. The single-dose vial in the form of a glass or plastic tube is incorporated in a small card shaped from a flat card, known in the sector as "card", which is specially folded and die-cut to secure the vial, either by simple die shaping or, in some cases, by the additional inclusion of a drop of glue, and which, in addition to serving as packaging and a protective support for the vial itself, also serves as a promotional leaflet for the product.
The problem is that, at present, although there are machines for die-cutting the cards and marking on them the folding and cutting lines that allow said securing of the vial, there is no known machine that performs, in an automated way, the task of assembling the cards with the corresponding vial, which involves at least the following steps:

picking up and shaping the card, i.e.:
- folding the card, usually in the center, to define at least three parts like a book, i.e., a front or front cover, a central part or spine and a back or back cover, between which the vial fits,
- raising the folds and cuts in the center area of the card to form an internal conduit where the vial will be held,
inserting a sample vial, which has been picked up from another container holding a plurality of vials, into the internal conduit formed by the folds and cuts of the shaped card,
placing the set formed by the folded card and incorporated vial in a grouping or collecting sample box or container for subsequent distribution.

Therefore, all this involves a practically handmade task that, when the product has to be assembled in large quantities, can involve high labor costs and time that would advantageously be reduced, the objective of the present invention being the development of a system to achieve its automation.
Additionally, and as a reference to the state of the art, it should be noted that, at least on the part of the applicant, the existence of any other machine or invention of a similar application for the assembly of cards with single-dose vial, which has the technical, structural and constitutive characteristics equal or similar to those of the one claimed here, is unknown.

EXPLANATION OF THE INVENTION

The machine proposed by the invention for the automated supply of cards with single-dose vial is a suitable solution for achieving the above-mentioned objectives which, at the same time, constitutes an improvement of what is currently known, with the characterizing details that make it possible and that distinguish it being set out in the final claims accompanying the present description.
Specifically, what the invention proposes, as mentioned above, is a machine for supplying cards with single-dose vial, of the kind normally used for distributing samples of liquid products, for example perfumes, which is specially designed to receive and pick up the cards, to shape them with the fold and die-cut required and with a variable format, to detect and insert the vial into the shaped card, and to supply the assembled set. All this is carried out in an automated way with a rotating disc system, with several housings that act as a lower die, and punches with a vertical displacement movement synchronized to the rotation of the disc to fit into the housings and shape the cards, insert the vial and eject the set, providing a fast and efficient means of assembling this kind of samples that improves the systems currently known.
More specifically, the machine for the automated supply of cards with single-dose vial essentially comprises the following elements:

A feeding station of flat cards, suitable for receiving cards of different sizes, where a certain number of cards to be used is manually introduced by an operator, acting as a manual feeder thereof.
A card loading station that picks up the cards from the feeding station, one at a time, and deposits them on a rotating disc on each of the disc's housings as the disc rotates.
A rotating disc with a plurality of radially distributed housings, each one defining a shaping die, which rotates in a synchronized motion with the loading station and with a punch system.
A structure of punches which, associated with a rising and lowering mechanism in common, preferably by means of a hydraulic piston, ascend and descend in coordination with the rotation of the disc in order to fit synchronously in several of the housings/die of the disc where the card has been deposited, Each of said punches is configured in a different way to define a station with a different function, namely, at least one for folding and shaping the card, another for die-cutting the card fasteners, and another for ejecting the card and vial set.
And a vial insertion unit which, preferably by means of a servo system located laterally to the disc, inserts a vial into the corresponding card inserted in the die and already shaped, through the lower part of the disc.

Preferably, the punch structure also comprises a punch associated with a vial presence detector configured as a station for ejecting and discarding invalid cards in which the vial has not been inserted or has not been inserted correctly.
Preferably, the machine comprises a sensor that detects the presence of a loaded vial in the vial insertion unit before it acts, such that, if there is no vial, the machine detects this and rejects as invalid the card ready to receive said vial, although this does not interrupt the functioning of the rest of the punches.
Preferably, the punch structure comprises a star-shaped support on the tips of which the punches suspended at the lower end of vertical rods are attached such that that they move in unison in a vertical direction thanks to a central piston that acts synchronously with the rotation of the disc which, in turn, moves by rotating sequentially in certain sections to make any of the housings with die coincide, each time, directly below each of the punches of the different stations.
And preferably, in turn, the loading station comprises a connecting rod-crank mechanism that moves in synchrony with the movement of said piston that moves the star of punches and said sequential rotation of the disc so that with it the different actions of each of the machine stations can be performed with absolute synchronism.
Preferably, each set of rods and punch, in turn, is detachable from the star, preferably by being fixed by means of a screwable part, allowing a variation of the configuration of said punches depending on the shaping characteristics of the card required in each case. In addition, preferably, the ends of the star to which said sets of rods and punch are fixed are extendable to be able to place the sets of rods with punch at the appropriate distance from the center.
Preferably, the card feeding station is designed in the form of a ramp and in such a way that it can be adjusted to receive cards of different sizes. In addition, preferably, it includes a sensor that detects when it is almost empty. Preferably, said feeding station is installed in such a way that reloading is done from the outside of the machine, so that the machine can continue operating during reloading and so that the operator in charge of reloading cannot be harmed by the operation of the machine.
Preferably, in each of the disc housings defining the shaping die of the cards, centering means are provided for the cards so that the loading station places the card in the correct position and perfectly centered on said housing. Said centering means are preferably defined by a series of hemispherical protrusions located around each housing. Preferably, since the cards can vary in size, the disc centering means are incorporated in a removable and interchangeable template which, in turn, is fixed on the surface of the disc.
Preferably, each of the housings that define the lower die of the disc are, in turn, also of variable dimensions to adapt the forming of the card to different needs in each case. For this purpose, said housings include a removable part with a hole of variable size that defines the die, such that said part is interchangeable to be able to replace it with an appropriate part of different dimensions, depending on the needs of each case.
Preferably, the cards with the correctly positioned vial, as well as the invalid cards, are ejected through the lower part of the disc into the respective collection containers, one for their disposal or reintroduction into the production line and another for their corresponding grouping and packaging.
Preferably, the main elements of the machine are incorporated inside a cabinet which, as a protective casing, defines a compact assembly.
With all this, and in particular owing to the interchangeability of most of the machine elements such as the punches or card feeder guides, etc., to adapt to different card measurements, the machine is particularly advantageous given its flexibility to take in and work with different card models.

DESCRIPTION OF THE DRAWINGS

To complement the description being made and in order to provide a better understanding of the characteristics of the invention, the present description is accompanied, as an integral part of the same, by drawings, in which the following has been represented for illustrative and non-limiting purposes:

Figures 1-A and 1-B show schematic top perspective views of the card with the single-dose vial for which the machine of the invention is intended, which has been represented respectively unassembled, with the card flat but already die-cut with the folding and cutting lines, and folded with the vial incorporated in the card.
Figure 2. shows a schematic top view of the main elements comprising the machine for the automated supply of cards with single-dose vial, showing their configuration and arrangement.
Figure 3. shows a schematic perspective view of the card feeding station, showing its configuration and essential parts.
Figure 4. shows a schematic perspective view of the card loading station from the feeding station to the rotating disc, showing the rod-crank mechanism.
Figure 5. shows a schematic perspective view of the punch structure and the rotating disc, in this case without including the loading station so as to show more clearly the different types of punches comprising the machine.
Figure 6. shows a perspective view of the disc with a die part in which there is a shaped card and one of the punches is acting on the card.
Figure 7. shows a schematic perspective view of an example of the vial insertion unit, showing the main parts of the unit.
Figure 8. shows a perspective view of the vial insertion unit inserting a vial into the folded card inside the die, where the arrangement of both elements can be seen.
Figure 9. shows a perspective view of one of the vertical rods with punch assemblies comprising the star structure at its ends.
Figure 10. shows a perspective view of a portion of the star structure on which the punches are secured, in this case in an example thereof with one of its extendable ends.
Figure 11. shows a schematic perspective view of the ensemble of the machine for the automated supply of cards with single-dose vial, which is the object of the invention, included inside the protective cabinet casing.

PREFERRED EMBODIMENT OF THE INVENTION

In view of the aforementioned Figures, it can be appreciated therein a non-limiting embodiment example of the machine of the invention for the automated supply of cards with single-dose vial, which comprises the parts and elements indicated and described in detail below, in accordance with the references associated therewith according to the following list:

1. machine
2. cards
2a. long fold lines
2b internal fasteners
2c short fold lines
2d cuts
3. vial
4. card feeding station
5. card loading station
6. disc housings
7. disc
8. punches
8'. side punch of the insertion unit
8a. punch end
9. vial insertion unit
9a. receptacle of the vial in the insertion unit
10. lifting and lowering mechanism of the punches
11. output of formed cards
11a. output of discarded cards
12. sensor for presence detection
13. piston for lifting and lowering of punches
14. star-shaped support
14a. distal end of the star-support tips
15. rods
16. anchoring piece of the rods with the punches
17. screws
18. connecting rod-crank mechanism
19. supporting column
20. stay
21. arm
22. securing assembly
23. centering means
24. removable disc template
25. interchangeable die part
25a. hole of the die part
26. tubular structure of the feeding station
27. top loading end of the feeding station
28. lower unloading output of the feeding station
29. protective casing of the feeding station
30. adjustable guides of the feeding station
31. anchors of the feeding station
32. cabinet
33. doors
34. access to the control system
35. cabinet wheels

Thus, as can be seen in said figures, the machine (1) of the invention is applicable for shaping and supplying cards (2) with a vial (3) secured inside, such that said cards (2) are folded from a flat rectangular card, with long fold lines (2a) at their center, and have internal fasteners (2b) for securing a vial (3) therein. These fasteners are preferably defined by the elevation of short fold lines (2c) and cuts (2d) perpendicular and adjacent to them, as shown in Figures 1-A and 1-B.
For this purpose, the machine (1) in question comprises, essentially:

a feeding station (4) of cards (2) in the form of a flat card, where an operator manually inserts a certain quantity of said cards (2), which are accessible from the lower part thereof, as shown in Figures 2 and 3;
a loading station (5) which, as shown in Figures 2 and 4, picks up the cards (2), one by one, from the lower part of the feeding station (4) and deposits them on each of the housings (6) of a rotating disc (7);
a rotating disc (7) shown in Figures 2 and 5, with a plurality of housings (6) radially distributed thereon, all of said housings (6) having an identical rectangular and elongated configuration, such as to define a shaping die of the cards (2), and wherein said disc (7) rotates sequentially to stop an instant at a housing (6) located to coincide with the loading station (4), with several housings (6) coinciding with several punches (8) located above, and with a housing (6) coinciding with an insertion unit (9) located laterally to the disc;
a structure of several punches (8) which, associated with a lifting and lowering mechanism (10) common to all of them, as shown in Figure 5, ascend and descend together, being arranged radially and perpendicularly on the disc (7) to fit, in the lower position of descent, in several of the housings (6) of the disc (7) each time the disc (7) stops, so that they act on the die of the housing (6) where the card (2) has been deposited, each of said punches (8) being configured with a differently formed end (8a) to act successively and with a different function on each card (2) located in each housing (6), to fold the card, mark the fastenings or push the card towards the lower part of the disc (7); and
a vial (3) insertion unit (9), shown in Figures 7 and 8, which, located laterally to the disc (7), inserts a vial (3) through the lower part of the disc into the card (2) in the housing (6) of the disc (7) each time it stops in front of said insertion unit (9),

Thus, as the disc (7) rotates and stops, each station of the machine applies its function to the corresponding card (2) of the housing (6) that is located to coincide with it until the card (2) with vial (3) is formed. Preferably, the control of the synchronization of the movement is carried out by a programmable electronic chip to which all the functional elements of the machine (1) are connected.
Thus, preferably, the punch structure (8) comprises, at least, a first punch (8) with a straight end (8a), modeled to fold the card (2) when inserted in the housing (6), another punch (8) with an end (8a) provided with blades for die-cutting the fasteners of the card (2), and another punch (8) with a long end (8a) for pushing and ejecting the card (2) plus vial (3) set through the lower part of the disc (7) towards an output (11) of formed cards.
Preferably, the punch structure (8) also comprises a punch associated with a sensor (12) that detects the presence of the vial (3) in the card (2) with the end (8a) configured to eject, below the disc (7), those cards (2) discarded as invalid if said vial (3) is not detected, towards an output (11a) of discarded cards.
Preferably, the vial (3) insertion unit (9), which is preferably driven by a servo system, also includes a sensor (12) that detects the presence of a vial (3) loaded therein before it acts. Figures 7 and 8 show an example of the vial (3) insertion unit (9), which comprises a receptacle (9a) where the vial (3) is housed and a side punch (8') that pushes the vial (3) towards the lower part of the housing (6) of the disc (7) placing it between the folded walls of the card (2).
Preferably, the punch structure (8) has, as a lifting and lowering mechanism, a piston (13) located in the central part of the disc (7).
Preferably, said punch structure (8) comprises an upper star-shaped support (14) on whose tips (14a) the punches (8) are attached, suspended by means of two vertical rods (15). Preferably, the set of rods (15) and punch (8) is attached to the end of each tip of the star-shaped support (14) in an easily removable way by means of a coupling piece (16) which is fixed with screws (17), allowing the interchange of said punches (8). In addition, preferably, the ends (14a) of said star-shaped support (14) to which the rods (15) with the punch (8) are fixed are extendable so that the assembly can be positioned at the suitable distance from the center.
In any case, preferably, the loading station (5) comprises, as a driving mechanism, a connecting rod-crank mechanism (18) that moves synchronously with the movement of the piston (13) that moves the punch structure (8) and synchronously with the sequential rotation of the disc (7).
More specifically, as shown in Figure 4, the loading station (5) comprises a support column (19) to which is attached a stay (20) from which the rod-crank mechanism (18) begins, comprising an arm (21) with a securing assembly (22), for example suction based, at the distal end thereof such that, in a first position of the mechanism, the arm (21) is positioned above and picks up the flat card forming the card (2) at the lower part of the feeding station (4), and in a second position, the arm (21) rotates and transfers and deposits the flat card (2) on the disc (7), just above the housing (6) which will be located to coincide with the loading station (5).
Preferably, so that the flat card forming the card (2) is well positioned and well centered on the housing (6), in each of the housings (6) of the disc (7) centering means (23) are provided which, preferably, are defined by a series of hemispherical protrusions located around each housing (6), as shown in Figures 2 and 4. Optionally, the centering means (23) of the disc (7) are incorporated in a removable and interchangeable template (24) which, in turn, is fixed on the surface of the disc (7), to be able to vary the position of the centering means according to the size of the card (2) to be used.
Additionally, the opening of the housings (6) that defines the shaping die of the cards (2) is preferably also variable in order to adapt to different card (2) sizes. For this purpose, optionally, the housings (6) incorporate a removable die part (25), such as the one shown in Figure 6, which fits inside the housing and has an elongated rectangular hole (25a) which can be of a variable size.
Preferably, the feeding station (4) of the cards (2), as shown in Figure 3, comprises a tubular structure (26) in the form of a ramp inside which the cards (2) are incorporated, having an upper loading end (27) and a lower unloading output (28) from where they are picked up by the loading station (5). Preferably, said tubular structure (26) has respective protective casings (29) as well as adjustable guides (30) to adapt to different card (2) dimensions. In addition, preferably, the feeding station includes a sensor (12) that detects when it is almost empty.
Preferably, said feeding station (4) is secured along with the rotating disc (7) of the machine by means of respective anchors (31) and such that the reloading of the cards (2) is carried out from the external part of the machine, allowing the machine to continue operating while loading and ensuring that loading is carried out safely.
Finally, with reference to Figure 11, it can be seen how preferably, several elements, the main elements of the machine (1), are incorporated and protected inside a cabinet (32) with access doors (33) which are optionally glazed to allow a view of the interior, and an access (34) to the control and electrical power supply system, which in turn defines it as a compact unit that can be moved by means of wheels (35) provided for this purpose and where only the loading end (27) of the feeding station (4) of the cards (2) and the insertion unit (9) of the vials (3) remain outside, which, for its part, can be of a variable configuration and design depending on the type of vial or product it is used for in each case.
Having sufficiently described the nature of the present invention, as well as the manner in which it is implemented, it is considered unnecessary to explain it further so that any person skilled in the art may understand its scope and the advantages derived therefrom, it being noted that, within its essentiality, it may be implemented in other embodiments which differ in detail from the one indicated by way of example, and to which the protection claimed will also apply provided that the fundamental principle thereof is not altered, changed or modified.

Claims

Machine for the automated supply of cards with single-dose vial, applicable for shaping and supplying cards (2) with a vial (3) secured inside, the cards (2) being folded from a flat rectangular card, with long fold lines (2a), in its center, and internal fasteners (2b) for securing a vial (3), is characterized in that it comprises:
- a feeding station (4) of cards (2) in the form of flat card, which are accessible from the lower part thereof;

- a loading station (5) that picks up the cards (2), one by one, from the lower part of the feeding station (4) and deposits them on the housings (6) of a rotating disc (7);

- a rotating disc (7) with a plurality of housings (6) distributed radially thereon, identical housings (6) defining a shaping die of the card (2), and wherein said disc (7) rotates sequentially to stop an instant at a housing (6) located to coincide with the loading station (4), with several housings (6) coinciding with several punches (8) located above them, and with a housing (6) coinciding with an insertion unit (9) located laterally to the disc;

- a structure of several punches (8) which, associated with a lifting and lowering mechanism (10) common to them all, ascend and descend together, being arranged radially and perpendicularly on the disc (7) to fit, in the lower position of descent, in several of the housings (6) of the disc (7) each time it stops, acting on the die of the housing (6) where the card (2) has been deposited, each of the punches (8) being configured with a different end (8a) to act successively on each card (2) with a different function to fold it, mark the fastenings or push it towards the lower part of the disc (7); and

- a vial (3) insertion unit (9) which, positioned laterally to the disc (7), inserts a vial (3) from the lower part thereof into the folded card (2) inside the housing (6) each time it stops in front of said insertion unit (9);
said loading station (5), said rotating disc (7), said punch structure (8) and said insertion unit (9) of vials (3) being driven automatically and in a synchronized manner such that, each time the disc (7) stops, it is positioned with a housing (6) coinciding with the loading station (4) and the latter places a card (2) on said housing (6), with several housings (6) coinciding with the various punches (8) and the latter descend and penetrate said housings (6), shaping the cards (2) and ejecting the formed set, and with a housing (6) coinciding with the insertion unit (9) and the latter inserts a vial (3) into the housing (6) below the disc (7).
Machine for the automated supply of cards with single-dose vial, according to claim 1, characterized in that the control of the synchronization of the movement is carried out by means of a programmable electronic chip to which all the functional elements of the machine (1) are connected.
Machine for the automated supply of cards with single-dose vial, according to claim 1 or 2, characterized in that the punch structure (8) comprises at least a first punch (8) with a straight end (8a), modeled to fold the card (2) when inserted in the housing (6), another punch (8) with an end (8a) provided with blades (8b) for die-cutting the fasteners of the card (2), and another punch (8) with a long end (8a) for pushing and ejecting the card (2) and vial (3) set through the lower part of the disc (7) towards an output (11) of formed cards.
Machine for the automated supply of cards with single-dose vial, according to claim 3, characterized in that the punch structure (8) also comprises a punch associated with a sensor (12) which detects the presence of the vial (3) in the card (2) with the end (8a) configured to eject, below the disc (7), cards (2) discarded as invalid if said vial (3) is not detected towards a discard output (11a).
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the vial (3) insertion unit (9) includes a sensor (12) that detects the presence of a vial (3) loaded therein before it acts.
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the punch structure (8) has, as a lifting and lowering mechanism, a piston (13) located in the central part of the disc (7).
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the punch structure (8) comprises an upper star-shaped support (14) on whose tips (14a) the punches (8) are attached suspended by means of two vertical rods (15); and in that the set of rods (15) and punch (8) is attached to the end of each tip of the star-shaped support (14) in an easily removable way, allowing an interchange of the punches (8).
Machine for the automated supply of cards with single-dose vial, according to claim 7, characterized in that the ends (14a) of the star-shaped support (14) to which the rods (15) are fixed with the punch (8) are extendable so that the assembly can be positioned at the appropriate distance from the center.
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the loading station (5) comprises a rod-crank mechanism (18).
Machine for the automated supply of cards with single-dose vial, according to claim 9, characterized in that the loading station (5) comprises a support column (19) to which a stay (20) is coupled from which the rod-crank mechanism (18) begins, comprising an arm (21) with a securing assembly (22) at its distal end and, in a first position of the mechanism, the arm (21) is positioned above and picks up the flat card forming the card (2) at the lower part of the feeding station (4), and in a second position, the arm (21) rotates and transfers and deposits the flat card (2) on the disc (7), on the housing (6) located to coincide with the loading station (5).
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the housings (6) of the disc (7) are provided with centering means (23) so that the flat card forming the card (2) is well positioned and well centered on the housing (6).
Machine for the automated supply of cards with single-dose vial, according to claim 11, characterized in that the centering means (23) of the disc (7) are incorporated in a removable and interchangeable template (24) which, in turn, is fixed on the surface of the disc (7), allowing to vary the position of the centering means according to the size of the card (2) to be used.
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the opening of the housings (6) defining the shaping die of the cards (2) is variable to adapt to different card (2) sizes.
Machine for the automated supply of cards with single-dose vial, according to claim 13, characterized in that the housings (6) incorporate a removable die part (25) that fits inside the housing and has an elongated rectangular hole (25a) of variable size.
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that the feeding station (4) of the cards (2) includes adjustable guides (30) to adapt to different card (2) dimensions and includes a sensor (12) that detects when it is almost empty.
Machine for the automated supply of cards with single-dose vial, according to any of the previous claims, characterized in that several elements of the machine (1) are incorporated and protected inside a cabinet (32) that defines it as a compact unit.