US3876083A

US3876083A - Machine for packaging flexible articles

Info

Publication number: US3876083A
Application number: US405366A
Authority: US
Inventors: Stephen F Evans; Eugene R Sorensen
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 1972-03-29
Filing date: 1973-10-11
Publication date: 1975-04-08
Anticipated expiration: 1992-04-08

Abstract

A machine for packaging flexible articles, e.g. disposable diapers, which includes mechanism for forming a stack containing a predetermined number of articles including devices for moving the stack and pushing it into a suitable container. The machine includes an infeed conveyor section used to convey and compress the articles whereupon they are ultimately delivered into successive slots of a pad wheel. The articles are stripped from the slots and simultaneously formed into stacks containing a predetermined number of articles. A pusher element and a stack controller arm are provided to convey each stack into the pocket of an intermittently rotating stack wheel. The stack wheel moves successive stacks into alignment with a support plate whereupon a transfer pusher moves each successive stack fully onto the support plate. A tamper plate is provided to exert a small amount of compressive force on the stack prior to lateral movement of the stack between the support plate and a ceiling plate which is adjacent the tamper plate. A reciprocating side pusher is used to move the stack laterally into position for ultimate movement into a container. A container wheel is intermittently rotated alongside the support plate. Container supporting nozzles project from one side of the container wheel, there being a container telescoped over each of the nozzles. When a nozzle containing an empty container is moved into contiguous relationship with the article stacks, a container load pusher is actuated to move the stacks into the container whereupon on further indexing of the container wheel, the filled container is removed by a full container pusher.

Description

United States Patent [191 Evans et a].

I MACHINE FOR PACKAGING FLEXIBLE ARTICLES [75] Inventors: Stephen F. Evans, St. Bernard;

Eugene R. Sorensen, Cincinnati, both of Ohio [73] Assignee: The Procter & Gamble Company, Cincinnati, Ohio [22] Filed: Oct. II, 1973 [2|] Appl. No.: 405,366

Related U.S. Application Data [62] Division of Ser. No. 239.!72. March 29. l972. Pat.

[52] U.S. Cl. 214/7; 27l/2l4; 93/930 P [51] Int. Cl. B66C 17/06 [58] Field of Search 214/7. 6 BA; 27l/2l3, 2l4. 27l/2l5; 93/93 C, 93 DP Primary E.t'aminerAllen N. Knowles Attorney, Agent. or FirmFredrick H. Braun; John V. Gorman; Richard C. Witte Apr. 8, 1975 [57] ABSTRACT A machine for packaging flexible articles, e.g. disposable diapers, which includes mechanism for forming a stack containing a predetermined number of articles including devices for moving the stack and pushing it into a suitable container. The machine includes an infeed conveyor section used to convey and compress the articles whereupon they are ultimately delivered into successive slots of a pad wheel. The articles are stripped from the slots and simultaneously formed into stacks containing a predetermined number of articles. A pusher element and a stack controller arm are provided to convey each stack into the pocket of an inter' mittently rotating stack wheel. The stack wheel moves successive stacks into alignment with a support plate whereupon a transfer pusher moves each successive stack fully onto the support plate. A tamper plate is provided to exert a small amount of compressive force on the stack prior to lateral movement of the stack between the support plate and a ceiling plate which is adjacent the tamper plate. A reciprocating side pusher is used to move the stack laterally into position for ultimate movement into a container. A container wheel is intermittently rotated alongside the support plate. Container supporting nozzles project from one side of the container wheel. there being a container telescoped over each of the nozzles. When a nozzle containing an empty container is moved into contiguous relationship with the article stacks. a container load pusher is actuated to move the stacks into the container whereupon on further indexing of the container wheel. the filled container is removed by a full container pusher.

14 Claims, 9 Drawing Figures FZJENT SHEET l 8f 7 Fig. 4

MACHINE FOR PACKAGING FLEXIBLE ARTICLES This is a division. of application Ser. No. 239.l72. now US. Pat. No. 3.8l0.344 filed Mar. 29. I972 BACKGROUND OF THE INVENTION The present invention relates broadly to the field of packaging machines. More particularly. it is directed to a machine for packaging articles. especially disposable diapers.

The high speed handling of flexible articles such as disposable diapers is a particularly difficult task because of the physical properties of the article being handled. Using disposable diapers as an example. it can be readily appreciated that they are flexible. compress ible and somewhat variable in dimension. These. of course. are desirable characteristics from the standpoint of the ultimate use of the article. but they are certainly undesirable characteristics when considering high speed handling and packaging by the use of automatic equipment.

Accordingly. one of the major obstacles for efficient high speed handling of articles of this character has been the provision of reliable equipment. There have been prior attempts at providing equipment that will function efficiently and effectively in commercial manufacturing operations but by and large it has been the experience that this phase of the operation has been a primary bottleneck. As an example of prior art techniques that have been employed to overcome some of the problems in the field. reference is made to US. Pat. No. 3.474.592 entitled MACHINE FOR PRODUCING AND PACKAGING DIAPERS which issued to Hans Hessncr on Oct. 28. I969; U.S. Pat. No. 2.224.606 entitled STACKING DEVICE which issued to Edmund N. Neckel on Dec. I0. 1940; and US. Pat. No. 3.557.972 entitled MECHANISM FOR THE STACK- ING OF ARTICLES which issued to Charles T. Banks on Jan. 26. l97l.

SUMMARY OF THE INVENTION The nature and substance of the invention will be more readily appreciated after giving consideration to its major aims and purposes. The principal objects of the invention are recited in the ensuing paragraphs in order to provide a better appreciation of its important aspects prior to describing the details of a preferred embodiment in later portions of this description.

A major object of the invention is the provision of a machine for packaging flexible articles.

Another object of the invention is the provision of a machine for receiving. stacking and accumulating a continuous or intermittent supply of individual articles such as disposable diapers and forming stacks containing a predetermined number of articles at very high speed.

Still another object of the invention is the provision ofa machine of the above character that is highly reliable and capable of operation at high speeds with virtually no damage to the article being handled.

A further object of the invention is the provision of a machine that will effectively handle articles such as disposable diapers and form them into individual groups which are then re-oriented and loaded into a container.

(ill

These and other objects are achieved by providing a machine which is capable of receiving individual articles into successive slots on the periphery of a continuously rotating pad wheel. The articles are removed from the slots of the wheel by a stripper plate as they contact the upper surface thereof. The articles are accumulated in a stack containing a predetermined number of articles. The formed stack is then pushed into a pocket ofa stack wheel. The stack wheel is indexed and moved intermittently such that successive stacks can be pushed from the stack wheel onto a support plate. A side pusher is provided to move the stack laterally on the support plate such that one or more stacks are in position for insertion into a container.

A container wheel is supported for intermittent rotation alongside the support plate. Erected and opened cartons or like containers are fed to the container wheel from a suitable source. The containers are placed in telescoping engagement with a receiving nozzle projected from one side of the container wheel. there being an opening in the container wheel in alignment with the nozzle. The container wheel is then indexed into position to receive the stack or stacks of articles which are inserted thereinto by means of a container load pusher. The filled container is subsequently removed from the container wheel by a full container pusher.

BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention. it is believed the invention will be better understood from the following description taken in connection with the accompanying drawings in which:

FIG. I is a side elevation illustrating the machine of the invention.

FIG. 2 is a plan view of the machine of FIG. 1 with the infeed conveyor portion removed to simplify and facilitate illustration in this view.

FIG. 3 is an enlarged fragmentary elevation taken on the line 3-3 of FIG. 2 illustrating the pad wheel. tunnel. and stack wheel.

FIG. 4 is an elevation in cross section taken on the line 4-4 of FIG. I illustrating the support plate and various pusher devices associated therewith including the container wheel.

FIG. 5 is a fragmentary side elevation taken on the line 55 of FIG. 4 provided primarily to illustrate the details of the tamper plate associated with the support plate for the purpose of compressing the completed stack.

FIG. 6 is another fragmentary side elevation taken on the line 66 of FIG. 4 which illustrates the pusher elements for moving the stacks into the containers and for thereafter removing the filled containers from the container wheel.

FIG. 7 is a fragmentary view taken on the line 77 of FIG. 3 illustrating the stripper plate. tunnel and spring loaded gate elements that are interposed be tween the pad wheel and the stack wheel.

FIG. 8 is a side elevation taken on the line 88 of FIG. 7 illustrating further details of the same portion of the device.

FIG. 9 is a perspective view of a disposable diaper that has been folded in half which is the preferred condition in which the machine of the invention acts on such articles.

In each of FIGS. 1 to 8 inclusive. some portions or elemcnts of the machine have been simplified or removed to provide for a clear understanding of underlying parts or elements. Those skilled in the art will be aware of these simplifications when considering the several views of the machine as a whole.

DESCRIPTION OF THE PREFERRED EMBODIMENT In order to achieve a thorough understanding of the invention. aa description of the preferred type of article for which it is designed seems desirable. It will be un derstood. however. that the machine is not limited. in a broad sense. to the handling of any particular type of article. In a preferred embodiment the machine is designed to form stacks of flexible articles and thereafter move them into a container or carton. The type of article for which the machine is adapted may be broadly characterized as a pad of the kind typified by any of several well known commercial products such as disposable diapers. paper napkins. paper towels. sanitary napkins or the like. In its preferred form. the machine has been developed to be used in the stacking and packaging of pads such as the disposable diapers of the type described and claimed in US. Pat. Re. 26,15l Duncan et al. issued Jan. 31. 1967, which is commonly owned by the assignee of the present invention. While the machine will be described in connection with the handling and packaging of disposable diapers. it will be understood that this does not form any limitation on the scope of the invention or is to imply that the machine is not capable of handling other kinds of articles having similar characteristics.

Referring initially to FIG. 9. there is illustrated a typical disposable diaper [0. this being the preferred form of paid handled by the machine. The diaper I is of the type having box pleats and will be familiar to persons of ordinary skill in the art who will be acquainted with the teachings ofthe aforesaid Duncan et al patent. The box pleats are formed and folded along the side edges of the diaper whereupon the diaper I0 is folded on itself in the middle portion thereof to form a nose ll after the diaper is folded into the configuration illustrated in FIG. 9. Diapers in the form of FIG. 9 are forwarded to the machine of the present invention from a final folding mechanism of a diaper converting machine. the movement of the diaper 10 being such that the nose II is foremost in its path of movement.

Referring now to FIG. I, the diapers 10 pass between the rolls l2 and I3 forming a portion ofthe final folding mechanism of the diaper converting machine whereupon they are delivered in single file order to an infeed conveyor illustrated generally at 14. The infeed conveyor 14 consists of a first section 15 and second section 16. there being a diverter plate 17 interposed between the

sections

15 and 16. The infeed conveyor 14 is supported by the frame 18 which is used as a rigid support for the several mechanisms of the entire machine.

The first section lS of the infeed conveyor 14 comprises a pair of opposed forwarding belts l9 and suitably supported and driven to receive the diapers 10 with their nose It foremost and move them forward at a speed matched with the speed at which they are received from the rolls l2 and 13. The forwarding belts l9 and 20 are backed by the compression rolls 19a and 20a spaced apart such that the belts l9 and 20 also impart a desired amount of compression to the folded diaper l0. Diapers l0 slide over the diverter plate 17 whereupon the nose ll of each diaper is engaged by the entrance nip between the forwarding

belts

21 and 22 mounted in the second section 16. The

belts

21 and 22 forward the individual diapers 10 for the purpose of feeding them individually to the pad wheel 23 as will be hereinafter more fully described.

The belts l9 and 20 are directly driven from the pad cycle shaft 24 which is turned at an angular speed of one revolution per diaper. The source of motive power for rotating the pad cycle shaft 24 may be provided by an independent power unit or it can be directly coupled to the diaper converting machine. The shaft 24 drives the belts l9 and 20 by the use of a conventional chain and sprocket drive mechanism including the right angle gear box 25. The forwarding

belts

21 and 22 may be driven at matched speed with the belts l9 and 20. However. they are preferably driven at a slightly slower speed, about 15 per cent slower. so that they can prop erly insert the individual diapers into the pad wheel 23.

The forwarding

belts

21 and 22 are also driven from the pad cycle shaft 24 by the use of a conventional chain and sprocket drive mechanism which includes a variable speed drive 26 and a right angle gear box 27. The variable speed drive 26 may be used for fine adjustment of the speed of the belts 2] and 22 to permit variation of the insertion speed of successive diapers into the slots 28 in the pad wheel 23. While the forwarding belts of the second section 16 are preferably driven at a somewhat slower speed than those of the first section 15, this presents no problem of buckling or puckering of the diapers 10 as they are transferred across the diverter plate 17 from the first to the second section since the distance between the exit nip of the first section 15 and the entrance nip of the second section 16 is equal to or slightly less than the length dimension of the thick absorbent core portion of the diaper 10. Thus during transfer. the diaper I0 is fully supported by the diverter plate 17 as it moves from the first section 15 to the second section 16 without any substantial effect on the diaper itself.

The machine includes means for forming a plurality of diapers 10 into a stack containing a predetermined number of diapers. This will now be described in reference to FIGS. 1, 2 and 3. As previously indicated, the function of the pad wheel 23 is to receive successive diapers ll) delivered in spaced single file order from the infeed conveyor 14. The pad wheel 23 is mounted for rotation on the frame [8 and is provided with a plurality of equally spaced arcuate slots 28. The pad wheel 23 is turned continuously by means to be described such that the slots 28 are sequentially aligned with the exit nip of the forwarding

belts

21 and 22. Thus, successive slots 28 are moved into diaper receiving position such that diapers 10 can be inserted therein. As illustrated in FIG. 2, the pad wheel 23 may comprise a pair of spaced similarly configured wheel elements 2323 mounted on a common shaft 29 and driven continuously by the pad cycle shaft 24 through a conventional chain and sprocket driven mechanism includ ing the gear box 30.

Means are provided to remove each individual diaper 10 from the successive slots 28 in the pad wheel 23 and thereby form a stack 3] containing a predetermined number of diapers standing on their noses ll. Referring to FIGS. 1, 2, 3, 7 and 8, it will be noted that an obliquely mounted stripper plate 32 is provided such that it intercepts the path of movement of the slots 28 in the pad wheel 23 (FIG. 7). As a consequence. the nose ll of each diaper It) strikes the stripper plate 32 causing it to slide from the slot 28 as the pad wheel 23 is rotated. The diapers 10 are thereby placed in essentially vertical orientation on the stripper plate 32 (FIG. 3). As each successive diaper it) is deposited on the stripper plate 32, the previously deposited diaper or diapers l0 ofa given stack 31 are moved slightly forward by the trailing edges 33 (FIG. 3) of the pad wheel 23.

Means are provided to hold the diapers in their upright position and prevent twisting thereof as they are removed from the pad wheel 23 to form a stack 31 on the stripper plate 32. Mounted along opposite sides of the stripper plate 32 in substantially vertical orientation are guide plates 34 and 35 (FIG. 7). A plurality offlexible fingers 36 (FIGS. 7 and 8) which may be formed of rubber or like material are mounted such that one row is above and another row below the

guide plates

34 and 35. The flexible fingers 36 assist in maintaining the individual diapers l0 upright until a stack 31 consisting of a predetermined number of diapers has been completed whereupon it is moved forward by a pusher element to be hereinafter described. The

guide plates

34 and 35. together with the flexible fingers 36, combine to form a tunnel 37 which functions as a support and guide for the individual stack 31 of diapers 10 as they are moved to the right as viewed in FIGS. 7 and 8. The flexible fingers 36 on opposite sides of the tunnel 37 are spaced apart such that they engage the side edges of the diapers forming the stacks 31. This maintains the diapers upright during their insertion in the tunnel 37 regardless of whether the diaper supply is continuous or interrupted.

Means are provided for conveying and moving the stack onto a support plate. As best illustrated in H68. 1 and 3, means for moving the stacks 3l is supported by the frame l8 and includes a chain 38 running over the several illustrated sprockets (FIG. 3). A plurality of pushing elements 39 project outwardly from and are secured to the chain 38. The chain 38 is intermittently moved when a completed stack 31 has been formed to move the stack from the stacking station adjacent the pad wheel 23 by sliding it through the tunnel 37 for the purpose of delivering the completed stack to a second station at a pocket of the stack wheel 45.

In examining FIGS. 3 and 7, it will be noted that the individual pusher elements 39 are relatively narrow permitting their movement between the spaced elements 23-23 forming the pad wheel. In addition, a central slot 46 is formed in the stripper plate 32 to permit movement of the pushing elements 39 to the stack wheel and beyond. As illustrated in FIG. 3. the stack wheel 45 is mounted for intermittent rotation on the frame [8 and contains a plurality of pockets 47, each being designed to receive and retain a stack 31 of diapers 10.

An additional mechanism is provided for controlling the completed stack 3] and to prevent dislodgement of the leading diaper in the stack when it is moved from the stacking station to the second station in the pocket 47. This mechanism is illustrated in FIGS. 1 and 3. it comprises a superstructure 41 supported above the frame 18. A chain 40 is assembled to run over the illustrated sprockets which are journalled and supported on the superstructure 41. A plurality of stack controller arms 42 are sttached to the chain 40 for intermittent movement in a circuitous path. The arms 42 can be pivoted at the pin 43 such that they can be retracted from and extended into their operative positions during each cycle of their movement by the use of conventional cams and cam followers as will be appreciated by those skilled in the art. The arm 42 is pivoted into its extended position after movement of the chain 40 such that the pad 44 on the arm 42 will be stopped in posi tion to contact the foremost diaper in the completed stack 31. The arm 42 is pivoted to its retracted or inactive position after the stack 31 is delivered to the pocket 47.

The chain 40 moves intermittently in unison with the chain 38. The movement of the

chains

38 and 40 is timed so that a completed stack 31 is formed between a pushing element 39 and a stack controller arm 42. Thereupon. the

chains

38 and 40 are put in motion so that a cohesive stack 3] is moved and delivered from the stacking station to a second station at the pocket 47 without any of the diapers 10 becoming dislodged on otherwise disoriented in the stack.

Referring again to FIGS. 7 and 8. it will be noted that a pair of spring loaded

side members

48 and 49 are provided at opposite sides of the pocket 47 of the stack Wheel 45. These

side members

48 and 49 are provided to prevent lateral movement of the stack and thereby retain it in the pocket 47. in the inlet portion of the pocket 47 are mounted a plurality of flexible fingers 50 provided to permit entrance of the stack 3] into the pocket 47 with relative ease. The fingers 50 tend to preclude reverse travel and retain the stack in the pocket. Each pocket 47 in the stack wheel 45 is provided with a similar pair of spring loaded

side members

48 and 49 as well as a plurality of flexible fingers 50.

The pad wheel 23 is rotated continuously whereas the pushing elements 39. the stack controller arms 42 and the stack wheel 45 are moved and/or rotated intermittently inasmuch as their movement is dependent upon the formation of a completed stack 3l before they can move the stack and be in position to receive the next succeeding stack. Referring now to FIGS. 1 and 2, the drive for these various elements will now be described. Basically. the pushing elements 39, the stack controller arms 42 and the stack wheel 45 are driven by the stack cycle shaft Sl which receives its power input from the pad cycle shaft 24. Whereas the pad cycle shaft 24 makes one revolution per diaper, the stack cycle shaft 51 makes one revolution per stack. in order to achieve such synchronization and make allowance for missing diapers. the drive from the pad cycle shaft 24 to the stack cycle shaft 51 includes a differential drive element 52 that has two inputs. The first is a direct input to the shaft 53 by means of the chain 54 driven by the pad cycle shaft 24. The second input to the differential drive 52 is from the one revolution clutch 55.

The output from the differential drive 52 is directly coupled to the stack cycle shaft Si by means ofthe gear box 56. Ordinarily the pad cycle shaft 24 will thereby directly drive the stack cycle shaft 51 at the proper reduction through the intermediary of the differential drive 52. However, in the event of a missing diaper. the one revolution clutch 55 is energized by a suitable control (not shown) which is designed for detecting any missing diapers. The one revolution clutch 55 then exactly cancels the input from the shaft 53 for one revolution and this then precludes movement of the stack in formation for an additional revolution of the pad cycle shaft 24 so that the predetermined number of diapers is deposited in the stack 21. In other words. the differential drive 52 is used to provide a variable control whereby each stack formed on the stripper plate 32 will have the same number of diapers therein (usually either twelve or fifteen depending on diaper size).

The chain 38 for moving the pushing elements 39 is driven intermittently from the stack cycle shaft 51. The drive includes a conventional chain and sprocket drive mechanism from the shaft 51 to a conventional indexing mechanism 56a (FIG. 2). The output from the indexing mechanism 56a is transmitted to a gear box 57 (FIG. 3). The output from the gear box 57 provides an intermittent drive to the chain 38 through a conventional chain and sprocket drive mechanism as illustrated. The chain 38 is timed so that it moves a stack 31 through the tunnel 37 upon completion of the stack 31.

The chain 40 for moving the stack controller arms 42 is driven intermittently from the stack cycle shaft 51 so that it moves synchronously with the chain 38. The drive for the chain 40 is not illustrated because it is identical to that used for the chain 38. That is. it includes a conventional chain and sprocket drive mechanism from the shaft 51 to a conventional indexing mechanism (not shown). the output of which is transmitted to a gear box (not shown). The output from the latter gear box is used to intermittently drive the chain 40 through the medium of another conventional chain and sprocket drive.

The stack wheel 45 is intermittently indexed and rotated through a predetermined are upon entry of a stack 31 in a pocket 47. The drive for the stack wheel 45 includes a conventional indexing mechanism 57a driven from the stack cycle shaft 51 by means ofa conventional chain and sprocket drive.

The machine includes mechanism and means for removing the stack 31 from the stack wheel 45 and moving it on a support plate 58 whereupon it is moved into position for insertion into a carton or similar packaging receptacle. After the pocket 47 containing a stack 31 has been indexed through two cycles. it is in position to have the stack 31 removed. A transfer pusher is provided for this purpose which moves the stack 31 onto the support plate 58. Spaced over the support plate 58 and essentially parallel therewith are the stationary ceiling plate 59 and the oscillating tamper plate 60 (see FIGS. 4 and As seen in FIG. 3. the transfer pusher includes a pusher head 61 secured to a crosshead 62 which is mounted for sliding movement on the rods 63. Movement is imparted to the pusher head 61 by means of the rocker arm 64. the connecting rod 65 and the crank 66 (FIG. 5). The crank 66 is driven through the gear box 67 by a conventional indexing mechanism 68, the latter being driven by a conventional chain and sprocket drive from the stack cycle shaft 51 (FIGS. 2, 4 and 5). It will be apparent. then. that at the appropriate time in the cycle. i.e.. when the pocket 47 of the stack wheel 45 has reached the unload position alongside the support plate 58 (illustrated in FIGS. 1 and 3). that the pusher head 61 will be actuated to push the finished stack 31 out of the pocket 47 and onto the support plate 58 as illustrated in FIGS. 1 and 4.

The machine also includes a means for compressing the stack 31 prior to and during the transfer of the stack from the stack wheel 45 by the pusher head 61. Referring again to FIG. 5, it will be noted that the tamper plate 60 is illustrated in its down position to which it is moved after the stack wheel 45 has been indexed such that a stack 31 is in position for removal from the stack wheel 45. The tamper plate 60 is moved to its uppermost position prior to indexing of the stack wheel 45 and after the stack 31 has been moved laterally from beneath the tamper plate 60 by means to be hereinafter described. The phantom outline 60' illustrates the uppermost position of the tamper plate 60 which is assumed during indexing of the stack wheel 45.

A four bar linkage mechanism is provided for moving the tamper plate 60. The four bar linkage mechanism includes the

links

69 and 70, the connecting rod 71 and the crank 72. The tamper plate 60 is moved in timed relation to the infeed of new stacks 31 by means of a conventional air driven rotary actuator 73 which is synchronously operated to achieve the purpose of compressing the new stack at the proper time in the cycle after delivery onto the support plate 58.

The machine includes means for moving the compressed staek into position for insertion into a carton. As best illustrated in FIG. 4, a side pusher device is provided to push each compressed stack of diapers from beneath the tamper plate 60 laterally between the sup port plate 58 and the ceiling plate 59. The lateral movement of the stack clears the infeed area beneath the tamper plate 60 so that another stack can be moved from the stack wheel 45 and deposited on the support plate 58. The side pusher device includes the pusher head 74 which is moved laterally by the crosshead 75 sliding on the rods 76. The pusher head 74 is actuated by the rocker arm 77 which is oscillated by the connecting rod 78, the latter being moved by the crank 79. The crank 79 is driven from the gear box 80 (FIG. 2) which in turn is driven from the indexing mechanism 81, the latter being connected through conventional chain and sprocket drive to the stack cycle shaft 51.

The drive mechanism for the pusher head 74 is thus designed to move each stack of diapers laterally at the appropriate time in the cycle in order to clear the infeed area of the support plate 58. Another stack is deposited in the infeed area of the support plate 58 on the next machine cycle. This stack is also pushed laterally clear of the infeed area as the machine moves through the same cycle used in imparting lateral movement to the first stack. As the second stack is pushed aside. it contacts and in turn pushes the first stack. The stacks accumulate as they are pushed laterally until the first stack contacts the wall 82 (FIG. 2) at the end of the support plate 58. In this position. the two stacks nearest the wall 82 are then ready for insertion into a container. A short wall 820 is provided (FIGS. 2 and 4) as a guide for the stacks such that movement of the stacks into the container is guided by the walls 82 and 820. In the preferred embodiment of the instant disclosure, the loading of two side-by-side stacks. i.e.. two stacks or a double stack. are described as being loaded into a container. However. it will be apparent to those skilled in the art that with relatively minor modification, the ma chine can be used to push a single stack into a container or three stacks or any number of stacks as desired. The machine can be used to load stacks into a bag, canon or any other kind of container or receptacle as will be understood by those skilled in the art.

Container wheel 83 is illustrated in FIGS. 1, 2, 4 and 6. The container wheel 83 functions as a preferred means for receiving and holding a container. carton or like receptacle in an article receiving attitude. It is supported alongside the support plate 58. The container wheel 83 is rotated intermittently. As seen in FIG. 4, the container wheel 83 is provided with a plurality of openings 84. The axis of the container wheel 83 is such that when one of the openings 84 is in its lowermost position, i.e., the 6:00 oclock position in FIG. 4, it is aligned with the opening formed by the ceiling plate 59, the wall 82, the support plate 58 and the guide wall 82a. In this position. the double stack of diapers can be pushed laterally through the opening 84.

A container receiving nozzle 85 is mounted extend ing from each of the openings 84 (FIGS. 1, 2 and 6). The outer ends of the nozzles 85 are provided with spring leaf members to facilitate loading and feeding of containers such as cartons. The nozzles 85 receive and support individual containers or cartons 86 which are held in telescoping engagement thereover by the engagement of the carton flaps with spring clips 85a. The cartons 86 are fed to the machine with their bottom flaps adhered shut prior to their engagement over the nozzles 85. Cartons 86 may be automatically or manually loaded onto each nozzle 85 when the opening 84 is in the 9:00 oclock position as viewed in FIG. 4.

A suitable mechanism is provided for indexing the container wheel 83 such that it serves as a preferred means for aligning each container or carton 86 with successive stacks 31 that have been moved into position for insertion into a container. The container wheel 83 is driven from the stack cycle shaft 51 by conventional chain and sprocket drive mechanisms through an electric clutch brake 87 (see FIGS. 1 and 2). A container cycle shaft 88 is driven from the electric clutch brake 87 and imparts the drive to the container wheel 83 by means of the conventional indexing mechanism 89 and the right angle gear box 90, the latter being directly connected to and supporting the container wheel 83. The drive mechanism just described properly indexes and cycles the container wheel 83 as each container or carton is filled and removed from the nozzles.

Suitable mechanism and means are provided for pushing the stacks 31 on the support plate 58 into the containers or cartons 86 and simultaneously removing a full container from the container wheel 83 (FIG. 6). The mechanism for moving the stacks of diapers into the containers includes a container load pusher 91 movable laterally by the crosshead 92 which slides on the rods 93. The crosshead 92 is actuated by the rocker arm 94 which is oscillated by the connecting rod 95, the latter being moved by the crank 96, the power input to the crank 96 being received from the gear box 97.

A similar mechanism is provided to remove a filled container 86 from the container wheel 83 when it is in the uppermost position or the 12:00 oclock position as viewed in FIG. 4. Referring to FIG. 6, this mechanism includes a full container pusher 98, moved laterally by the cross head 99 sliding on the rods 100. Crosshead 99 is moved by the rocker arm 10! which is oscillated by a mechanism including the connecting rod 102 and the crank I03. Container load pusher 91 and the full container pusher 98 are driven from the container cycle shaft 88 through a conventional chain and sprocket drive from the gear box 104 (FIG. 2), the right angle gear box 105, the indexing mechanism 106 which in turn drives the gear box 97 which is illustrated in each of FIGS. 2, 4 and 6. The drive from the gear box 97 to the full container pusher 98 is by means of a conventional chain and sprocket drive.

While not illustrated in the drawings, the apparatus preferably includes mechanism and means for maintaining a low pressure air cushion between the contacting surfaces of the diapers and the corresponding surfaces of the tamper plate 60, ceiling plate 59 and the support plate 58. This is preferably provided to minimize sticking and thereby prevent diaper damage and distortion which could occur as the diapers are moved in several directions while going through the cycle. This is achieved by providing the surfaces in question with a series of holes which are supplied with low pressure air to produce the desired air cushion effect thereby reducing the frictional forces between the pad surfaces and the support and ceiling plate surfaces.

It will be apparent to persons skilled in the art that many variations can be made within the scope of the invention. For example. pad wheel size, slot size. slot length and the extent the pads are driven into the slots can be varied. The pushing elements 39 and the stack controller arms 42 which coact to move stacks 3] from the pad wheel 23 to the stack wheel 45 can be actuated by a linkage. air cylinder or other means in lieu of the chains described heretofore. The stack wheel 45 can be made by any reasonable number of pockets. A variety of different pocket designs could be used to contain stacks. The container wheel 83 can be made with more or less than four nozzles. With minor adjustments in size change parts. the double stack operation can be eliminated and a single stack can be formed and moved into the containers.

While particular embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention and it is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

What is claimed is:

l. A mechanism for stacking and moving flexible articles comprising the combination of:

a. means for forming a plurality of articles into a stack containing predetermined number of superposed articles.

b. means for holding the articles along their side edges to maintain them in their upright position and to prevent twisting of the articles as they are being formed into a stack while simultaneously being removed from said stack forming means.

c. means for conveying and moving said stack from a stacking station to a second station. and

d. means for controlling the completed stack during movement by said conveying and moving means to prevent dislodgement and misalignment of any articles in said stack during movement. said control ling means being actuated synchronously with said conveying and moving means.

2. A mechanism for stacking and moving flexible articles as claimed in claim 1 wherein said stack forming means comprises a pad wheel having a plurality of spaced arcuate slots on its periphery, means for depositing articles into the slots thereof and a stripper plate for intercepting a leading edge of each article while supported in a slot to remove the articles from said slots and form a stack of superposed articles on said stripper plate.

3. A mechanism for stacking and moving flexible articles as claimed in claim 1 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

4. A mechanism for stacking and moving flexible arti cles as claimed in claim 2 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

5. A mechanism for stacking and moving flexible articles as claimed in claim 1 wherein said means for holding the articles along their side edges comprises a plurality of flexible fingers directed inwardly toward and engaging both side edges of the articles forming the stacks.

6. A mechanism for stacking and moving flexible articles comprising the combination of:

a. means for continuously conveying articles in single file order.

b. means for receiving successive articles from said conveying means and forming said articles into a stack of superposed articles at a stacking station.

c. means for holding the articles along their side edges to maintain them in their upright position and to prevent twisting of the articles as they are being formed into a stack while simultaneously being removed from said stack forming means.

d. means for removing said stack from said stacking station after the stack contains a predetermined number of articles.

e. said removing means including means for conveying and moving said stack of articles from the stacking station to a second station.

7. A mechanism for stacking and moving flexible articles as claimed in claim 6 wherein said means for receiving successive articles and forming said articles into a stack comprises a pad wheel having a plurality of spaced arcuate slots on its periphery. means for depositing articles into the slots thereof and a stripper plate for intercepting a leading edge of each article while supported in a slot to remove the articles from said slots and form a stack of superposed articles on said stripper plate.

8. A mechanism for stacking and moving flexible articles as claimed in claim 6 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

9. A mechanism for stacking and moving flexible articles as claimed in claim 7 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

10. A mechanism for stacking and moving flexible articles as claimed in claim 6 wherein said means for holding the articles along their side edges comprises a plurality of flexible fingers directed inwardly toward and engaging both side edges of the articles forming the stacks.

11. A mechanism for stacking and moving flexible articles comprising the combination of:

a. means for forming a plurality of articles into a stack containing a predetermined number of superposed articles,

b. means for conveying and moving said stack from a stacking station to a second station, and

c. means for controlling the completed stack during movement by said conveying and moving means to prevent dislodgement and misalignment of any articles in said stack during movement. said controlling means being actuated synchronously with said conveying and moving means. said controlling means comprising an intermittently moving stack controller arm having a forwardly projecting pad for engaging the foremost article in the stack during movement thereof to said second station thereby preventing dislodgement and misalighment of any articles in said stack during movement thereof.

12. A mechanism for stacking and moving flexible articles as claimed in claim 11 wherein said stack forming means comprises a pad wheel having a plurality of spaced arcuate slots on its periphery. means for depositing articles into the slots thereof and a stripper plate for intercepting a leading edge of each article while supported in a slot to remove the articles from said slots and form a stack of superposed articles on said stripper plate.

13. A mechanism for stacking and moving flexible articles as claimed in claim 11 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

14. A mechanism for stacking and moving flexible articles as claimed in claim l2 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

Claims

1. A mechanism for stacking and moving flexible articles comprising the combination of: a. means for forming a plurality of articles into a stack containing predetermined number of superposed articles, b. means for holding the articles along their side edges to maintain them in their upright position and to prevent twisting of the articles as they are being formed into a stack while simultaneously being removed from said stack forming means, c. means for conveying and moving said stack from a stacking station to a second station, and d. means for controlling the completed stack during movement by said conveying and moving means to prevent dislodgement and misalignment of any articles in said stack during movement, said controlling means being actuated synchronously with said conveying and moving means.

4. A mechanism for stacking and moving flexible articles as claimed in claim 2 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.

6. A mechanism for stacking and moving flexible articles comprising the combination of: a. means for continuously conveying articles in single file order, b. means for receiving successive articles from said conveying means and forming said articles into a stack of superposed articles at a stacking station, c. means for holding the articles along their side edges to maintain them in their upright position and to prevent twisting of the articles as they are being formed into a stack while simultaneously being removed from said stack forming means, d. means for removing said stack from said stacking station after the stack contains a predetermined number of articles, e. said removing means including means for conveying and moving said stack of articles from the stacking station to a second station.

7. A mechanism for stacking and moving flexible articles as claimed in claim 6 wherein said means for receiving successive articles and forming said articles into a stack comprises a pad wheel having a plurality of spaced arcuate slots on its periphery, means for depositing articles into the slots thereof and a stripper plate for intercepting a leading edge of each article while supported in a slot to remove the articles from said slots and form a stack of superposed articles on said stripper plate.

11. A mechanism for stacking and moving flexible articles comprising the combination of: a. means for forming a plurality of articles into a stack containing a predetermined number of superposed articles, b. means for conveying and moving said stack from a stacking station to a second station, and c. means for controlling the completed stack during movement by said conveying and moving means to prevent dislodgement and misalignment of any articles in said stack during movement, said controlling means being actuated synchronously with said conveying and moving means, said controlling means comprising an intermittently moving stack controller arm having a forwardly projecting pad for engaging the foremost article in the stack during movement thereof to said second station thereby preventing dislodgement and misalighment of any articles in said stack during movement thereof.

12. A mechanism for stacking and moving flexible articles as claimed in claim 11 wherein said stack forming means comprises a pad wheel having a plurality of spaced arcuate slots on its periphery, means for depositing articles into the slots thereof and a stripper plate for intercepting a leading edge of each article while supported in a slot to remove the articles from said slots and form a stack of superposed articles on said stripper plate.

14. A mechanism for stacking and moving flexible articles as claimed in claim 12 wherein said means for conveying and moving said stack comprises an intermittently moving pushing element for moving a newly formed stack to said second station.