US2842911A - Machine for forming and feeding coupons - Google Patents

Description

July 15, 195s W. H. HARLAN MACHINE FOR FORMING AND FEEDING COUPONS 4 Sheets-Sheet 1 Filed Aug. 28, 1953 IN1/Imran. (EN /lf d1un/4 ATTORNEYS.

July 15, 1958 w. H. HARLAN 2,842,911

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iinited States aten-t AVV MACHHNE FOR FRMNG AND FEEDING CUFNS Warren H. Harlan, Greenhilis, Ohio, assigner to The Procter & Gamble Company, Cincinnati, hio, a corporation oi @hin Application August Z3, i953, Serial No. 377,1@`

12 Qlaims. (Cl. ESQ-S7) My invention relates to means for forming and feeding coupons, two-page leaflets, or other types oi' merchandising literature into packages, cartons or other containers which are iilled on high speed packaging machinery. The coupons7 or the like, may be formed from paper or other suitable sheet material. For the purpose of simplifying the following description, the papers or other articles to be inserted will be referred to as coupons, and the packages into which they are to be inserted will be referred to as cartons, it being understood that neither of these terms is to be taken in a limiting sense.

The coupons will ordinarily be inserted into cartons which contain granules, powders or material. in ake form, for example, soaps, other detergents, starch, breakfast foods, cake mixes, and the like. These materials are conventionally packaged on high speed packaging machinery which sets up the cartons, closes one end of them, fills them with ameasured or weighed quantity of the contents, and then closes and seals the opposite end. Devices have previously been suggested for inserting coupons into cartons, but so far as i am aware these have been successful in operation only up to a speed of Vabout 120 cartons per minute. Modern high speed packaging machinery, however, lls cartons up to 270 per minute consistently, and up to 300 per minute for short runs.

A principle object of this invention is the` provision of means for forming and feeding coupons accurately, and at such speeds as to be consonant with the packaging speeds of modern packaging machinery as just outlined. it is an object of 'my invention to provide a mechanism which will form and feed, or insert coupons at speeds which are adjustableV to the. speeds of they packaging machinery.

It is an object of my invention to provide a mechanism which will insure the presenceoi'a coupon in each package or cartonof the product being'handled, and which Will operate to stop, the packaging mechanism if, forV any reason, the supply of coupons fails.

These and other objects of my invention which will be set forth hereinafter, or will be apparent to one skilled in the art upon reading these specifications, l accomplish by that organizationA and assembly of parts andbythat method of operation of which ishall now describe an exemplary embodiment. Reference. is made to the accompanying drawings wherein:

Figure l is a topplan View of my apparatus forfforming and feeding coupons. p

Figure 2 is an -elevational'view thereof. Y

Figure 3 is'- a' partial sectional viewtaken alongfthe section line'-"l of Figure-2.

Figure 4' is a partial sectional View taken along'ithe section lined-tof FigureZ. p

Figurev 5"isapartial sectional view taken along the seetion'line 5 5 of Figure 4.

Figure 6 is av partialsectionalfview ofthe cut-'ofi mechanism-taken along the section line 6-6 of Figure 5.

Zii i Patented July 15, 1958 Figure 7 is a transverse sectional `view related toV Figure 6, and taken along the section line 7-7 of that figure.

Figure 8 is a partial sectional view of a rapid feeding or insertion mechanism taken along the section line S- of Figure 5.

Figure 9 is an elevational view of the mechanism illustrated in section in Figure 8. y

Figure 10 is a plan View of the actuating finger of the mechanism of Figure 9.

Figure 1l is a partial elevational view of the bearing mechanism for' the larger feeding roll.

Figure 12 is a partial plan view of the main clutch and clutch actuating mechanism.

Figure 13 is a partial sectional View taken through the clutch and attendant partsalong thetsection line. 13--13 of Figure 12.

Figure 14 is a partial sectional view takenalong the section line 14-14 of Figure l2.

Figure 15 is a perspective View of a completed coupon in the Vform in which it is inserted into the carton.

Figure 16 is a partial sectional view through the roll supply and mandrel showing means effective to stopV the mechanism ifV the supply of coupon material fails.

Referring first to Figures l andvZ which show the generalV layout of my coupon forming and inserting mechanism, the index numeral 1 indicates the frame of a packaging machine which may be of any suitable type, and need. not here be described. At the` point of use of myk coupon mechanism, the packaging machine presents a series of cartons 5, 5a, etc., moving along in filled or unlled` but unclosed condition on a conveyor 5 which forms a part of the packaging machine. The open, upwardly extending tops or bottoms of the cartons are indicated at lil, 10a. My coupon forming and inserting mechanism comprises a frame 11 adapted to be attached'to the frame 1 of 'the packaging machine. in the frame i1 there is journaled aV shaft i2, bearing at one end an expansble mandrel 15 to accept a roll of preprinted coupon stock. Such a roll of stock is indicated at 16. The expansible mandrel may be operated by a handle element i7 to permit the installation of the roll. The opposite end of'the shaft 12, on the other side of the frame 11, is fitted with a suitable tension brake such as one comprising a brake drum 1S and a brake band. Since the roll 16 is afxed toV 19 which is adjustable. the shaft through the expansible mandrel, it will be evident that the tension on the strip of coupon material 2t). being withdrawn from the roll can be set at any value desired.

The strip,k Zii'passes first over an idler 2li on an arm ZZand'nextover an idler 23 on an arm 24. Between the idler sheaves 21 and 23, an idler roll or sheave 25 on an, arm 26 rests by gravity on the strip. The arm 2d is fastened by means of'a clamps` i to a shaft Edicurnaled on the frame. The opposite end of this shaft carries a lever 29 upon which a counterweight 3d is adjustably mounted for` the purpose of regulating the pressure of the idler 25 against the. strip.

it is desirable to provide a meansfor stopping the entire rriechanism,includingtheV packaging machine ifvthe supplyofcoupon material runs out or Vfails atthe roll 16. To this end a `limit switch 31 is mountedv on bracket; 32 on the frame 11; As. shown in Figure 16, there' is a plateV .il-fi? mounted'on a sleeve 143 ar'iixed to theshaft' i2; The expansible mandrel 15`ts over thel sleeve; and the roll of coupon-forming material lies against'the'platc. The plate is perforated 'as vat 149and is provided with a bracket' 59 on'which a spring pressed nger ispivoted as shown. arranged to contact the roll of'coupon-forming` material,

One'end ofthis linger is.

whereby the finger is held in the position shown against the tension of the spring. When the supply of couponforming material is exhausted, the finger swings in a counterclockwise direction in Figure 16, the other end Vof the finger coming into position to contact and actuate the trigger of the limit switch 31. YThe limit switch 31 will be effectively in the circuit of the main motor of the packaging machine, and the arrangement is such that if the supply of coupon material fails at the source, the motor will be deenergized.

The strip 26 next passes beneath an idler 33 on a bracket 34 mounted on the frame, and next over arlarge timing wheel 35, which will presently be described in detail. Y

The strip is provided with perforations or notches accurately related to the printing on the strip. The timing wheel 35 is provided withV sets of pins 36 for engaging in the perforations or notches. This enables the timing wheel to maintain a xed relationship with the strip 20 and the printed material thereon, so as to feed the strip in exact timed relationship to cutting means later set forth.

I find it convenient to provide a splicing station in the space between idlers 23 and 33 as illustrated in Figure 2. This splicing station consists of a platform 37 held by a bracket 38 to the frame 11. The platform bears spaced pins 39 properly related to the spacing of the holes or notches in the strip. Thus, it becomes possible to locate the trailing end of a supply of the strip material on the platform 37 by means of the pins, and then locate with respect to it the leading end of a fresh supply of strip material in the same fashion, interposing a suitable adhesive between the lapping ends. By splicing a fresh supply of the strip material to the end of a preceding supply, it becomes possible to operate the machine without rethreading.

The circumference of the timing wheel 35 is accurately proportioned to the length of the printed coupons in the strip material 20. Preferably the size of the wheel 35 is such that it can accept a plurality of coupon lengths about its circumference. In the illustrated embodiment the wheel 35 has six sets of the pins 36, its circumference, therefore being equivalent to six coupon lengths.

The manner in which the timing wheel 35 is driven will be best appreciated from the showing of Figure 3. Here a main drive shaft 40 is journaled at one end in a prolongation of the frame 11 and, near its other end, in a supplementary frame element 41. Beyond this supplementary frame element, the main drive shaft 40 bears a sprocket and is connected by a chain 42 to a sprocket (not shown) aixed to the main drive of the packaging machine. Other drives, e. g. shafts and gears, may be employed to connect my coupon forming an inserting device with the drive of the packaging machine; but it is essential that the two mechanisms be connected together in such a way that the coupon forming and inserting mechanism will be driven in exact timed relationship with the packaging machine.

Between the housing or frame elements 11 and 41 the main drive shaft 40 bears a clutch plate 43 having a notch 44. ln the illustrated embodiment this clutch plate at one end, and a collar 45 at the other end serve to x the longitudinal position of the main drive shaft. R0- tatably mounted on the shaft 40 there is a wide gear element 46 carrying a Vsingle detent 47 adapted to enter the notch 44 of the clutch plate. The gear 46 has an integral sleeve 43 which is connected by means of a ball bearing to a clutch operating ring 50. It will be evident fromthis construction that the gear 46 may be moved toward and away from the clutch plate 43 byA means of the operating ring 50 so as to bring the detent into and out of engagement with the notch.

An adjacent shaft 51, again journaled in the frame Cir elements 11 and 41, carries an element 52 non-rotatably affixed to it, as by means of a key or a set screw 53. This element has a sleeve portion 52a on which a gear 54 is rotatably mounted. The upper face of this gear (as it is shown in Figure 3) has certain ball-receiving depressions 55 formed therein. One or several balls 56 are mounted in bores 57 in the element 52, and are urged toward the gear 54 by means of springs 58. When one or more of the balls engage the depressions in the gear 54, the gear is capable of rotating the element 52 and consequently the shaft 51 so as to transmit adequate power thereto. But the gear 54 and element 52, taken together, form a typel of clutch which will slip under suflicient resistance, and which will reengage for the transmission of power only in certain pre-arranged positions, as will be evident.

The sleeve 52a carries a gear 59 atiixed to it. This gear meshes with a very much larger gear 6i) on a shaft 61, journaled in the frame 11. The timing wheel 35 is mounted on the shaft 61 as shown.

In threading my mechanism it will be convenient to pass the strip of coupon material over and under the idlers heretofore described and engage it with the timing wheel 35. Thereafter the timing wheel may be rotated to feed the strip further for threading purposes. To this end I prefer to provide the shaft 61 of the timing wheel with a hand wheel 62, as shown in Figures i and 2.

The manner in which the main clutch of my apparatus is operated will be best appreciated from Figures 12, 13 and 14. A shaft 63 is journaled in ears on the frame member 41. A clutch operating lever 64 is aflixed to this shaft. Also affixed to the shaft are a pair of arms 65 and 66, arranged to lie at opposite sides of the clutch operating ring 50. This ring is provided with a pair of studs 67 and 68. The arms 65 and 66 are notched to engage these studs. Springs 69 and 7) urge the clutch operating ring 50 to clutch-closing position. It will be evident that when the lower end of the clutch operating lever 64 is moved to the right in Figure l2 the clutch will be positively disengaged. When the lever is moved in the opposite direction, the clutch operating ring 5) will be released; but the clutch will not actually engage until that position is reached in which the detent 47 can enter the notch 44.

I aix a block 71 to the clutch operating lever 64. This block moves over a plate 72 (see Figure 14) aixed to the frame 11. The plate is provided with recesses indicated at 73 and 74; and a spring pressed plunger 75 having a nose adapted to enter either of these recesses is mounted in a bore in the block 71. Thus, the clutch operating lever is provided with a definite clutch-open and clutch-closed position. One end of the spring 69 may be attached to a pin 76 on the block 71 or to a pin on the frame 11. By locating a limit switch 77 in the position shown in Figures 1, 2 and 12, arrangement can be made so that this switch will =be actuated when the clutch operating lever 64 is in the clutch-open positioru If, then, the'switch is arranged to be open circuited when the clutch lever is in the clutch-open position, and if the switch is effectively located in the circuit of the main motor of the packaging machine, it will be evident that the packaging machine cannot operate so long as the coupon forming and inserting mechanism is not operating.

Tracing the path of the coupon strip 20 as it leaves the timing wheel 35 (this is most conveniently done in Figure 2) it will be seen that the strip passes over an idler 78 on an arm 79 aixed to the frame 11, and then under a folding wheel or disc 80 on an arm 81, and into a pair of pinch rolls one of which is shown at 82. These pinch rolls feed the now doubled or folded strip to a cutting mechanism located beneath the platform or bracket 83 in Figure 2, where the folded strip is severed into individual coupons. assures the timing of the strip as fed, it is advantageous Since the timing wheel hereinabove describedto drive the pinch roll at a speed slightly faster than the speed of the strip so as to maintain tension thereon. As soon as a coupon has thus been severed from the strip, it is engaged by a rapidly operating pair of feed rolls, one of which is shown at 84, and is projected yat a substantially higher rate of speed into the open end of the carton 5.

The form, mounting, and drives for this mechanism will best be appreciated by considering Figures 3'to 7 inclusive. A supplementary frame member or bracket 85 is aihxed to the frame 11 at rightangles thereto. An assembly consisting of a bevel gear 87, a relatively large gear 33, and a relatively small gear 89 is journaled by means of ball bearings on a stub shafttl (see VFigure 52). This assembly is driven by a bevel gear 86 .on the end of the shaft 51 (Figure 3) which meshes with the bevel gear 87.

The smaller gear 89 meshes with a gear 91 on a shaft 92. The gear 91 in turn meshes with a gear 93.]ournaled on a stub shaft 94. The gear 93 meshes with a gear 95 on a shaft 96. This shaft'is journaled in the frame member 85, and on its opposite end bears the roll 82 of the pinch roll combination mentioned above. The mating roll of this pinch roll combination is not illustrated in any of the iigures, but it will be understood as being a roll mounted on a shaft 97, bearing'a gear 98 `meshing with the gear 95. The shaft 97 is not journaled directly in' the bracket or frame member 85 but instead is journaled in a block 99 which is pivoted tothe frame member as at ldd in Figure 4. An operatinghandle 101 is aixed to this block, and is connected by aspring'102 to a stud 1113 on the frame 11. The spring insures that the upper and lower pinch rolls will be pressed together under sufcient force for positive, timed feeding; but 'by operating the handle 101 the rolls may berdrawn apart for threading purposes.

The pinch roll combination feeds the `folded strip to a severing means next to be described. The shaft 92 is journaled at one end in a ball bearing 11M in the frame member 85, and at the other end .in aball bearing 105 in the angularly related end 83aof thesupplementary frame member or platform 83. Theshaft 92 carries fa roll 106 to which a ily-knife 107 is aixed. In order to obviate any lost motion, misalignment, or change of position of the shaft 92, it is provided with Va pair of extra `ball bearings 108 and 1%19. Ringsfsurrounding'theserbearings (as most clearly shown in Figure 6) are provided with headed studs 110 and 11'1 which, passingthrough holes in the frame member 11, are Vresili'ently urged in o-ne direction by springs 112 and 113 engagedbetween the frame member and `their respective heads. It may be noted that the forces generated by gears 89 and V931 meshing with gear 91 also tend to move gear 91 and its shaft 92 in the direction of the urge of the springs 112 and 113.

The fly-knife 107 Von the 'roll 106 coacts witha stationary knife `11d (Figure 7) affixed to a ,block 115 which is slidable'on the members 83and 85 and is aixed thereto by bolts 116 and 117 Voperating in oval or laterally elongated holes in the members 85 and 83. The position of the block 115 can be very accurately adjusted by means of set screws 118 and 119, and the block then rmly fastened in position by means of the bolts. Thus, the stationary knife 114 can be made to coact properly with the ily-knife 107. It will be understood that the gearing arrangement causes the knife to cut the strip, which is being fed to it in timed relationship, in such manner as to sever each coupon from the next succeeding one. Ordinarily the mechanism is timed so that the cuts are made at the positions of the holes or notches in the strip, giving the folded coupon in the form illustrated at 120 in Figure l5.

There remains the mechanism for feeding the severed coupons into the cartons as they move along the conveyor 9. Referring again to Figure 4, it will be seen that the 6 gear 88 meshes with a gear 121 on a shaft 122. This shaft is` journaled, as lshown in Figure 5, in the bracket or frame element 85, and bears on its outer end a feed roll 123. This feed Vroll is grooved centrally as at 123a for a purpose vhereinafter described.

The shaft 122 kalso bears a gear 124 whichmeshes with a vgear 125 on a shaft 12'6. The shaft 126 on its outer endcarries afsomewhat thinner roller but of larger diameter, 127 (see Figures 8 and 9). This roller is also grooved as at 128.

The shaft 126 is not journaled in the frame element 85, but rather in a block 129 which is pivoted to the member S5 as at 130. The block 129 bears a stud 131 which is connected by a spring 132 to another stud 133 on 'the frame element 85 as shown in Figure 4. The purpose of this construction is to permit a very iine adjustment of therelative positions of the shafts 122 and 126. To this end, the block 129 may be provided with a set screw adjusting means 134 adapted to engage against the member '85. A supplementary flocking screw 135 maybe pro vided if desired (Figure ll).

A lever 136, shaped as shown best in Figure l0, is pivotedas at -13'7 soasto -lie partly within the groove of the roll 127. This-leverhaspins 138 and 'operating through slots 140 and 141 in one of the cheeks of the roller 127 (see Figure 9). The pin 138 is connected by a spring 142 to alpin 145 on the roller 127 in such fashion as to urge the lever yto the position shown in Figure 9, in which the lower end of the lever projects beyond the periphery of thevroll 127. The pin 139 on the lever projects far enough beyond the face of the roller 127 to engage the operating arm 144 of a limit switch 145 on a bracket 146.'

The roller 123 is grooved as at 123e to permit the lever 136 to assume the -position shown in Figure 9.

The roller 127 is provided with a pad 146 of such circumferential length and thickness as to coact with the roller 123 in feeding-a severed coupon. The adjustment of the positions of the shafts 122 and 126 is such that a coupon will not be ygripped'between the rollers 123 and 127 excepting when the pad 146 also lies in the bite between these two rollers. But it will now also be evident that if a coupon is engaged between the roller 123 and the pad 146 onftheroller 127, the `lever 136 cannot assume the position shown in Figure 9; instead, its outer end will be depressedwithinthe groove `of the roller 127", and its other end willztbefraised within the notch 141. This brings thepin 139out of position to actuate the lever 14d of the limit switch V145. opencircuited .whentactuated and is located effectively in the circuit of themainmotor of the-packaging machine, it will be evident that theV motor may run so long as severed .coupons .aresuccessively and properly fed by the rolls 123 and 127.` Shouldiacoupon fail 'to be engaged between these rollersat thelproper time, however, thc

switch will be actuated, andthe entire mechanism will be stopped. v

The rollers 123,:and 127 are timed .so as to feed the coupons at a very much greater rate/of speed than the speed of travel of the coupon strip before severance. Consequently the introduction or insertion of the severed coupons into the cartons 5, 5a, etc. is extremely rapid and positive. The cartons, passing on from the position shown in Figure 2, are lled and/ or closed and sealed, by the standard mechanism of the packaging machine.

Modifications may be made in my invention without departing from the spirit of it. Having thus described may invention in an exemplary embodiment, what I claim as new and desire to secure by Letters Patent is:

1. In a machine for forming and feeding coupons into cartons, the improvement which comprises in combination a feeding mandrel with constant tension braking means, said mandrel adapted to hold a supply of coupon-forming material in rolled strip form, said strip being perforated or notched in index with printing thereon, a timing roll If this switch is arranged to be having projections to engage the holes or notches'in the strip, pinch rolls adapted to feed the strip by withdrawing it from the timing roll, a cut-off knife adapted to cut the strip into separate coupons while said strip is moving, a pair of impelling rolls to grip the severed coupons and feed them into cartons, means for continuously driving said timing roll, pinch rolls, cut-off knife and impelling rolls in timed relationship with each other, said means adapted to synchronize the relative motion of said timing roll to said cut-off knife so that said coupons are cut from said strip in index with the printing thereon.

2. Apparatus -claimed in claim 1 including folding means operative between the said timing roll and the said cut-oif knife.

3. In a machine of the character described, in sequence, means for supplying coupon material in the form of a lstrip of indenite length, said strip having perforations or notches registering with printing thereon, a timing wheel having projections to engage in said perfcrations or notches, a pair of pinch rolls, and a rotary cut-off knife, said cut-off knife adapted to cut said strip in registry with the printing thereon while said strip is moving, continuous means for driving said timing wheel, pinch rolls and cuto knife in timed relationship, and means permitting the rotation of said timing wheel for threading purposes, said means comprising a dsengageable clutch in the drive of said timing roll, said clutch having predetermined positions of engagement such that said coupon material will at all times be fed in registry to said cut-off knife when said timing roll and said cut-off knife are being driven.

4. Apparatus claimed in claim 3 including folding means located between said timing roll and said pinch rolls.

5. Apparatus claimed in claim 4 including a pair of impelling rolls adapted to receive severed coupons from said cut-oi knife and deliver them at a linear speed in excess of the speed of travel of said strip, and driving means for said impelling rolls.

6. In a packaging machine in which unclosed cartons are moved at a rate of about 270 a minute or more in sequence past a point, a continuously revolving drive and motor for said packaging machine, an apparatus for forming and feeding coupons into said cartons, said apparatus being located at said point and comprising a supply of coupon material in strip form, said strip having perforations or notches registering with printing thereon, a timing roll having projections for entering said perforations or notches, a pair of feeding rolls, a rotary cut-off knife and a pair of impelling rolls for receiving coupons severed from said strip by said cutot knife and impelling them at enhanced speed into said cartons, drive mechanism for said timing roll, said pinch rolls, said cut-01T knife and said impelling rolls, and aV timed connection between said drive mechanism and the said drive for said packaging machine.

7. Apparatus claimed in claim 6 including means whereby said timing roll may be rotated for threading purposes without detiming the timed mechanism, said means comprising a dsengageable clutch connected to said timing roll, said clutch being engageable only in predetermined timed positions.

'8. Apparatus claimed in claim 6 including means whereby said timing roll may be rotated for threading purposes without detiming the timed mechanism, said means comprising a dsengageable clutch connected to said timing roll, said clutch being engageable only in predetermined timed positions, and a hand wheel connected to said timing roll.

9. The structure claimed in claim 8 in which a clutch is interposed between said driving mechanism and the drive for said packaging machine, said clutch having an operating lever, a limit switch in the circuit of said motor and means for actuating said switch when said last mentioned clutch is open whereby to deenergize said motor.

10. The structure claimed in claim 9 in which one of said impelling rolls carries a coupon-actuated nger, a limit switch arranged to be actuated by said finger upon operation of said impelling rolls in the absence of a coupon, said limit switch being located in the circuit of said motor whereby to stop said packaging machine and the coupon forming and feeding machine in the event of coupon failure.

l1. Apparatus claimed in claim 10 including a means contacting said supply of coupon material, and a third limit switch located in the circuit of said motor and adapted to be actuated by said contacting means whereby the packaging machine and coupon forming and feeding machine will be stopped in the event of strip failure.

12. In a coupon forming and feeding device, a pair of slotted impelling rolls, a linger pivoted in the slot of one roll and having an end adapted to enter the slot of the other roll under the inuence of a biasing spring, a limit switch having an actuating member, a pin on the other end of said finger for striking said actuating member when said finger is in the aforesaid position, the arrangement being such that the presence of a coupon between said rolls will move the end of said lever out of the slot in said second mentioned roll, and said pin into a position in which it cannot contact said actuating member.

References Cited in the le of this patent UNITED STATES PATENTS 1,247,364 Bracy Nov. 20, 1917 2,100,776 Fulk Nov. 30, 1937 2,109,505 Rue Mar. 1, 1938 2,208,345 Rosebush July 16, 1940 2,361,421 Sherman Oct. 31, 1944 2,456,449 Rouan Dec. 14, 1948 2,470,557 Herrmann May 17, 1949 2,518,011 Hoppe Aug. 8, 1950 2,521,435 Wockenfuss Sept. 5, 1950 2,586,055 Kanick Feb. 19, 1952 2,632,545 Schubert Mar. 24, 1953

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