WO1994020369A1 - Stacked article packaging method - Google Patents

Abstract

A method for continuously forming stacked article groups, comprising the steps of supplying at least two streams of articles, each at a predetermined vertically distinct level; forming and longitudinally transporting a stream of first article groups having at least one article, at a first level; placing a support base on a top surface of each first article group; and forming a second article group, having at least one article, at a second level on top of the support base of each longitudinally moving first article group, whereby stacked article groups are formed. The stacked article groups are subsequently processed for packaging.

Description

STACKED ARTICLE PACKAGING METHOD

SPECIFICATION

BACKGROUND OF THE INVENTION

This invention relates to packaging methods and apparatus. Particularly,

this invention relates to a continuous method of forming stacked or multiple

layer article groups. The packaging method of the present invention is

useable to package different types, styles and sizes of articles, in a wide range of stacked article group patterns, and into a variety of packaging

media, into cartons in a fast and reliable manner.

In the past, various machines and processes have been proposed and

utilized to package selected article groups into packages. Each prior art

machine and process, however, accomplishes the packaging of the article

groups in a distinct manner and utilizes particular machinery. Moreover,

prior art cartoners have limited adjustability, limited output capability, and

have been difficult to construct and maintain due to their respective designs. And finally, no method or apparatus, insofar as is known provides

continuous motion packaging of stacked or layered product groups.

Prior art packaging assemblies include U.S. Patent 4,802,324 to

applicants' assignee for a Vertical Cartoning Assembly and Method which discloses the placement and assembly of cartons over preselected article groups being moved on a conveyor. U.S. Patent 5,036,644, also to applicants' assignee, discloses a Packaging Sleever Assembly which

transfers flat packaging sleeves directly onto preselected article groups and

subsequently wraps and closes the cartons. Various end loading packagmg

machines have also been proposed in the art. For example, U.S. Patent 3,778,959 to Langen et al. discloses an end loader which utilizes a plurality of transversely extending spaced apart fences or flights mounted on a

conveyor to rake or capture a predetermined number of containers from

infeed container slips. U.S. Patent 4,237,673 to Calvert et al. discloses a

machine also for loading container sleeves through their open ends. U.S. Patent 4,936,077 to Langen et al. discloses a carton loading machine which utilizes pusher mechanisms with spring loaded pusher heads to stagger

adjacent product group rows during transfer into the carton.

In view of the limitations and shortcomings of prior art methods and

apparatus, it is an object of this invention to provide a method of continuously and reliably forming stacked product groups at high speed.

Another object of this invention is to provide a packaging method which is

useable with a variety of package types, articles and stacked article group

types and sizes. A particular object of the invention is to provide a method

which forms stacked or multiple layer article groups via a base member disposed between a lower article sub-group and an upper article sub-group. SUMMARY OF THE INVENTION

The present invention provides a method for continuously forming

stacked article groups, comprising the steps of: supplying at least two

streams of articles, each at a predetermined vertically distinct level; forming

and longitudinally transporting a stream of first article groups having at least

one article, at a first level; placing a support base on a top surface of each

the first article group; forming a second article group, having at least one

article, at a second level at or above the support base of each longitudinally

moving first article group, whereby stacked article groups are formed. The

support base is preferably constructed of paperboard and has a thin,

substantially flat, rectilinear configuration with a surface area substantially coextensive with that of the top surface of the first article group. The

support base may have a flap member disposed along one base edge and

defined by a scoreline, the flap member being foldable over one edge of the

top surface of the first article group.

In a preferred embodiment, the invention provides a continuous cartoning method for loading stacked article groups into packages or cartons

of a type having an outer structure and an inner divider structure,

comprising the steps of: supplying at least one stream of articles at a first

predetermined location and a first vertical level along a longitudinally oriented axis; forming and longitudinally transporting a stream of lower article sub-groups at the first location; depositing the inner divider structure

at a second predetermined location along the axis, downstream from the first

location; supplying at least one stream of articles at a third location

downstream from the second location, and at a second vertical level higher

than the first vertical level; slidably forming, at the third location, an upper

article group on each the divider structure of each the lower article sub¬

group, whereby stacked article groups are formed; transporting the stacked

article groups along the longitudinal axis; providing a longitudinal stream of

cartons, with open ends facing and synchronized with the stacked article

groups, adjacent to and parallel with the article groups; and laterally moving

the stacked article groups into the synchronized cartons.

These and other benefits of this invention will become clear from the

following description by reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the packaging or cartoning assembly of the present invention;

FIG. 2 is a top plan view of the cartoner assembly;

FIG. 3 is a perspective view of a carton assembled by the cartoner

assembly; FIG. 4 is a crossectional view of the carton taken along line 4-4 of FIG.

3;

FIG. 5 is a detailed side view of the cartoner assembly;

FIG. 6 is a detailed top plan view of the cartoner assembly;

FIG. 7 is a top plan view of a portion of the cartoner assembly;

FIG. 8 is a side view of selected portions of the article group selection

and transport mechanism;

FIG. 9 is a top view of a portion of the carton supply and transport

mechanism;

FIG. 10 is a side view of a portion of the carton supply and transport

mechanism;

FIG. 11 is a top view of the discharge end of the carton supply and

transport mechanism;

FIG. 12 is a side view of the discharge end of the carton supply and

transport mechanism;

FIG. 13 is a side view of the infeed guides of the article supply mechanisms;

FIG. 14 is a side view of the carton support assembly of the carton supply and transport mechanism;

FIG. 15 is a top view of the carton support assembly of FIG. 14;

FIG. 16 is a left end view of the carton support assembly of FIG. 14;

FIG. 17 is a right end view of the carton support assembly of FIG. 14; FIG. 18 is a top view of the crossloading mechanism;

FIG. 19 is a crossectional view of the cartoner apparatus taken

approximately along line 19-19 of FIG. 5;

FIG. 20 is a crossectional view of the cartoner apparatus taken

approximately along line 20-20 of FIG. 5;

FIG. 21 is a crossectional view of the cartoner apparatus showing details

of the article group selection and transport mechanism;

FIG. 22 is a crossectional view of the cartoner apparatus taken along line

22-22 of FIG. 7; FIG. 23 is a crossectional view of the cartoner apparatus taken

approximately along line 23-23 of FIG. 5;

FIG. 24 is a crossectional view of the cartoner apparams taken approximately along line 24-24 of FIG. 5;

FIG. 25 is a crossectional view of the cartoner apparams taken approximately along line 25-25 of FIG. 5;

FIG. 26 is a top view of a loader arm assembly;

FIG. 27 is a combined side and end view of a pushing face;

FIG. 28 is an end view of the loader arm assembly taken along line 28-

28 of FIG. 26; FIG. 29 is an end view of a loader arm guide;

FIG. 30 is a crossectional view of a loader arm assembly operatively

extended across the article group selection and transport mechanism; FIG. 31 is a detailed side view of the flight bar structures of the article

group selection and transport mechanism.

FIG. 32 is a top view of the loading zone of an alternative embodiment

of the present invention; and

FIG. 33 is a side view of the embodiment shown in FIG. 32

DESCRIPTION OF THE PREFERRED EMBODIMENT

The methods and apparams of the present invention are for forming

stacked article groups in a continuous, high speed process. As shown in the

drawings, the method of this invention is implemented via a continuous

motion, high-speed packaging apparams 10. The apparams 10 is adjustable

to provide reliable, continuous and high speed packaging of articles or

products of varying types, sizes and quantities into packages of varying

types and sizes. For example, the apparams 10 is useable to load standard

twelve ounce beverage cans into 24(12/12), 30(15/15) and 36(18/18) pack

stacked combinations. Moreover, the process of loading beverage containers into paperboard cartons, for example, is accomplished quickly and reliably,

under typical industry tolerances for both container and carton construction.

The resultant filled cartons output by the apparams 10 are of high quality

and consistency, having maximized squareness and tautness for improved storage qualities and transportability. Although the embodiments disclosed load stacked article groups into paperboard cartons, its within the purview of

this invention to process the stacked article groups in a variety of ways

subsequent their formation, including side loading, shrink wrapping,

banding or having paperboard or other material formed around them.

Referring to FIGS. 1 and 2, the continuous motion cartoner assembly 10 generally comprises a carton supply and transport mechanism or stream 11,

an article group selection and transport mechanism or stream 12, a pair of

article supply mechanisms or streams 13 and 14, a divider placement

mechanism 15, and an article group transfer or cross loading mechanism 16. These mechanisms are shown to be supported by a unitary frame strucmre 17, although if aligned properly, separate support structures may be utilized

consistent with the teachings of this invention.

The carton supply mechanism 11 is shown to be disposed proximate an

input end 18 of the assembly 10. Carton sleeves or blanks 25 are subsequently transported in a linear fashion to an output end 21 of the

apparams 10. The article supply mechanisms 13 and 14 are also shown to

be disposed at the input end 20 of the apparatus 10. A first portion of each

article supply mechanism 13 and 14 is disposed spacially parallel to the article group selection and transport mechanism 12, and a second portion

merges, at a predetermined angle, with the article group selection transport

mechanism 12 to supply streams of product or articles 20 to two separate

positions along the article group selection and transport mechanism 12. These merging mechanisms 12-14 are further constructed and arranged to

meter individual articles 20, via a fixed flight bar arrangement, into

predetermined stacked article groups 21 and 22 on the mechanism 12.

The stacking function of the device 10 is accomplished by forming a first

group 21 at a low level, placing a separator or divider sheet 24 on the lower

group 21 via the divider sheet placement mechanism 15, and then

simultaneously forming a second group 22 downstream at a higher level and

allowing the upper group 22 to slide across the divider sheet 24 by the action

of the flight bars of the article group selecting mechanism 12. In an

alternative embodiment, the second group is formed on an upper dead plate and dropped or otherwise deposited onto the divider sheet.

The article group selection and transport mechanism 12 is disposed

adjacent and parallel to the carton supply and transport mechanism 11 and

extends downstream, in a linear orientation. Merged or combined article

groups 23 are transported downstream thereon in a spaced and metered

fashion, each group 23 being aligned with a carton 25 traveling on the carton

supply and transport mechanism 11. The crossloading mechanism 16 is

disposed adjacent to and parallel with the second portion of the article group

selection and transport mechanism 12, extending and traveling longitudinally with respect to the apparams 10. The crossloading mechanism 16 has a plurality of loading arms which extend transversely or perpendicularly with respect to the transport mechanisms 11, 13 and 14, to move product groups 23 on the article group selection transport mechanism 12 into aligned cartons

25 traveling on the carton transport mechanism 11, thereby loading the

cartons 25 with product groups 23. Preferably, each of the aforementioned

mechanisms 11-14 and 16 has a conveyor type strucmre with an endless

chain or belt configured about rotatable drive and idler end means and

moving longitudinally with respect to the input (upstream) and output

downstream) ends 18 and 19 of the apparams 10. The movement of each

mechanism is further synchronized with one another, for example by a

common drive and/or gearing means.

Referring to FIGS. 3 and 4, the method of this invention is useable to construct carriers or cartons 26 containing cans 20 or other articles which

are disposed on top of one another or stacked. The paperboard carrier blank or sleeve 26 is comprised of leading and trailing side panels 40 and 41

foldably connected to top panel 42 and to a bottom panel 43. End panels 44

connect the top, bottom and side panels 40-43. As shown, the carrier 26 contains a bottom layer or sub-group 21 of articles, shown for purpose of illustration as beverage cans 20, and an upper layer or sub-group 22 of cans

in stacked relationship. The lower ends of the upper cans 22 are supported on a thin, paperboard divider sheet 24 (also referred to as a base or support

sheet) with the bottom cans 21 resting on the bottom panel 43. An extension

tab located on the medial edge of the sheet 24, and which folds down via a

perforation or scoreline is preferably provided to help stabilize the divider sheet 24. The extension tab provides a means for holding the sheet 24 stable

while the upper layer of cans 22 are pushed onto the separator sheet 24.

Once the cans 23 have been all properly positioned the sheet 24 is held in

place by guides on the apparams 10. The top panel 42 is disposed closely

adjacent, and preferably is in contact with, the top chimes 43 of the upper

level 22 of cans to provide for a tight fit between the cans 20 and the carrier

25. Although the apparams 10 shown in the drawings is utilized in a

beverage can cartoning operation with paperboard carrier sleeves,

modifications consistent with the teachings of this invention may be made to

package various other stacked containers or articles. In various carrier

configurations or to package the article groups via shrink wrapping, banding

or the like.

Referring also to FIGS. 5, 6, 20 and 22, the carton supply and transport mechanism 11 is preferably a rotary type carton placer 49, such as that

disclosed in U.S. Patent 4,530,686 owned by Applicants' assignee. The

carton erecting apparams 49 is supported above the input end of the carton

transport mechanism 11 by a vertically adjustable frame structure 50, and

basically transfers flat carton blanks or sleeves 25 from a power magazine 51 to the conveyance surface of the mechanism 11, simultaneously opening

the blank 25 so that it assumes a four-sided configuration with opposing

open ends bounded by at least one flap 44 each. Importantly, the partially erected carton 25 is placed in a transverse or lateral orientation so that its ends are open to the sides of the carton transport mechanism 11 for loading

purposes.

The carton transport conveyor 52 receives cartons or other carriers 25

from the carton supply placer 49 and transports them linearly downstream

with respect to the overall apparams 10. The downstream transport of

cartons 25 is synchronized with the article group selection and transport

mechanism 12 and with the crossloading mechanism 16, as described further

below, to effectuate carton 25 loading. Importantly, the carton transport

conveyor 52 is adjustable to accommodate cartons 25 of varying types and

sizes. Referring also to FIGS. 9, 10 and 22-25 in particular, the carton

transport conveyor 52 basically comprises a plurality of flight lugs 56 which

are connected to a pair of flight chains 181 and 182, the flight chains 181 and 182 being connected to and revolving about drive and idler ends 53 and 54. Although a pair of lugs 56 is shown, the number of lugs 56 per carton 25 may be varied for alternative carton configurations. The lugs 56 are

shown to serve a dual purpose in that they are disposed anterior with respect

to a particular carton 25 for control and stabilization purposes, while the pair

56 which is disposed posterior to the carton urges the carton 25 forward on

the conveyor mechanism 52. The lugs 56 are preferably constructed of nylon

or a similar material. The lugs 56 are attached to the flight chains 181 and 182 via lug bases. The flight chains 181 and 182 are supported at the top or forward run of the conveyor 52 by chain guides 183. The chain guides 183 are connected to the main frame 17 via guide supports 184. An elongated,

longitudinally extending return guide 185 is disposed along the bottom run

of the conveyor 52 and mates with a notch in each lug 56 to stabilize their

return during high speed operation. Additionally, a longitudinally oriented

slide rail (not shown) may be disposed between the flight chains 181 and

182, level with the horizontal plane of the chain guides 183, and with a low-

friction top surface to support the bottom of each carton 25 on the conveyor

52. The width-wise or transverse spacing between lugs 56 on the parallel,

side-by-side chains is preferably variable via a transverse lug adjustment

mechanism. Although a single pair of flight lugs 56 is shown, an alternative

structure may be constructed with phase adjustable leading and trailing flight

lugs, as is known in the art. This phase adjustment is desirable to permit the

apparams 10 to be used with various carton configurations to allow for

adjustment of carton spacing between, for example, 6 and 12 inch, on center arrangements to convert the apparams 10 from 6 to 36 pack processing.

Referring to FIGS. 5, 10 and 14-17, the apparams preferably includes a

carton stabilization strucmre 28 which supports the tops of the relatively tall, bi-level cartons 25 traveling on the carton supply and transport mechanism

11, particularly during the loading phase of operation. The carton

stabilization strucmre 28 basically comprises a pair of overhead rails 191 and 192 connected to vertical and horizontal support members 193 and 194 which are linked via adjustment mechamsm 195 supported by posts 196. A carton sleeve set up guide assembly 197 is also preferably disposed anterior

to the carton stabilizer 28 and immediately downstream of the point of initial

placement of the sleeve on the conveyor 52 by placer 49.

Referring to FIGS. 5, 6 and 13, the first or low article supply

mechanism 13 provides a plurality of input individual articles 20 to the apparams 10 at a first predetermined level or height and at a predetermined

point on the article group selection and transport mechanism 12. The

mechamsm 13 is shown to comprise a conveyor 60 disposed about a drive

sprocket/shaft assembly 61 and an idler sprocket/shaft assembly 62. The conveyor 60 preferably consists of a unitary, belt. Articles 20 transported

on the top, forward run of the conveyor 60 are separated into a plurality of

single file paths by lane separators 63. Each lane separator 63 is shown to

be an upstanding plate of a height sufficient to guide the flow of one or more containers 20 on the conveyor 60, and which is suspended above the conveyor 60. The lane separators 63 form product conveyance lanes which

angle towards the article group selection and conveyance mechanism 12. An approach angle of approximately 20-25 degrees with respect to the

longitudinal axis of the mechamsm 12 has been found to provide optimal

product group selection results. The conveyor 60 is disposed parallel with

and immediately proximate to the article group selection and transport

conveyor 12 to allow for article movement thereinbetween. A low friction, dead plate having angled lane grooves which correspond with the lane separators 63 is preferably interposed at the interface between the conveyor

60 and the transport mechanism 12. Each lane separator 63 has a terminal

portion 64 of a predetermined length, such that it extends into the path of the

article group selection and transport mechanism 12 a distance approximately

equal to one-third the width of the mechanism 12 conveyance path. Each terminal portion 64 is constructed such that it allows longitudinally

transported flight structures 74 (described further below) of the article group

selection and transport mechamsm 12 to pass through the angled conveyance

lanes. As the flight bars 74 mesh with and pass through the lane separator

end portions 64, they engage articles 20 disposed in lanes and rake them

onto the longitudinal conveyance path of the mechamsm 12 and between

adjacent flight bars 74.

The combination of forces exerted by the flight bars 74, lane ends 64,

and conveyors 60 and 12 serve to select and meter individual articles 20 into predetermined article groups 21 which are fully merged onto the article

group selection and transport mechanism 12. The size, orientation and

dimensions of the resultant product groups 21 is dependent upon the number

of infeed lanes, product dimensions, and the configuration and spacing of the flight bars 74. For example, in the instant embodiment, six (6) lanes of

product are active, and the flight bars 74 are spaced such that the resultant product group 21 is selected of eighteen (18) articles in three rows of six cans each. Lanes may be blocked off by closure means 67 to alter the group 21 size and/or orientation. The lane separators 63 and the flight bars 74 are

adjustable to provide full variability of product group parameters.

The low article supply mechanism 13 is shown to terminate at its infeed

end 18 for mating with a complementary external apparams, for example an

additional infeed conveyor or conveyors. Alternatively, such infeed conveyor may be integrated with the apparams 10. Further, although this

embodiment utilizes conveyance lanes which are initially oriented parallel

with the remaining elements of the apparams 10 and subsequently angle

towards the article group selection transport mechanism 12, it is possible to provide an infeed conveyor that is entirely angled as such.

The article group selection and transport mechanism 12 selects article

groups 21 and 22 from the first or low article supply mechanism 13 as set

forth above and from the second or high article supply mechamsm 19

discussed below, and transports them linearly downstream with respect to

the overall apparams 10. The downstream transport of article groups 21 and

22 is synchronized with the carton supply and transport mechanism 11 and with the crossloading mechamsm 16, as described further below, to

effectuate carton 25 loading. Referring also to FIGS. 7, 21 and 22, the

article group selection and transport mechanism 12 generally comprises a

conveyor 73, a plurality of flight bar assemblies 74 fixed to and

longitudinally transported on the conveyor 73, and a plurality of slide plates 75, which are disposed on the conveyor 73 between the spaced flight bars

74.

The conveyor 73 runs at a predetermined speed and includes a drive

sprocket shaft assembly 76 and an idler sprocket shaft assembly 77, a pair of

parallel endless conveyor chains 78 which are connected to and revolve

about the sprocket/shaft assemblies 76 and 77, forming a longitudinally

extending forward or top run 79 and a return or bottom run 80. Idler

assembly 77 is disposed just anterior to the area where the first or low

article supply mechamsm 13 merges with the article group selection and

transport mechanism 12, and marks the beginning of the conveyor 73. The drive sprocket shaft assembly 76 is disposed adjacent the end of the

crossloading mechanism 16 and marks the end of the conveyor 73. The

conveyor chains 78 are each supported by top and bottom longitudinally

extending chain guides 81, which in turn are connected to the main frame 17

via upstanding conveyor supports 82.

Referring also to FIG. 31, the flight bar assemblies 74 are each shown to

include a top rail member 83 and a bottom rail member 84 which are

connected to one another by vertical spacers 85. The top and bottom members 83 and 84 are shown disposed parallel to one another and spacially

separated by the spacers 85. Each top and bottom member 83 and 84 further

has an angled front end 150 and an elongated, rectilinear body 151 terminating in a flat back end. The front end 150 slants or angles inwardly from its leading edge to its trailing edge to enable the flight bars 74 to select

individual articles 20 disposed in the article infeed lanes and to separate

them from the closely spaced nearest upstream article 20. As is best shown

in FIG. 7, a pair of fixed slide plates 152 and 153 are connected to each

flight bar 74 assembly. Both the flight bars 74 and the slide plates 152 and 153 are connected to the flight chains 78 via connection brackets 86. The

slide plates 152 and 153 are thin, flat structures with a low friction top

surface which support the lower article groups 21 and further permit sliding

movement thereon. Additionally, slotted slide plates 154 are disposed between adjacent flight bar assemblies 74, each plate 154 including a

laterally oriented slot 155.

The height of the flight bar 74 (i.e., the separation distance between the

top and bottom members 83 and 84) is a function of the container and

container group size and configuration. For example, taller cans (12 oz.)

require greater flight bar 74 height than a short can (10 oz.), for proper selection and transport. The width of the top and bottom members 83 and 84 is a function of the desired dimensions of the product groups 21 and 22

formed. It is within the purview of this invention that the flight bar 74

height and width be fully adjustable to accommodate various container and group parameters.

As is best shown in FIGS. 7, 8 and 21, a group stabilization strucmre

161 including a pair of longitudinally oriented upper and lower guide rails 162 and 163, and lateral adjustment structures 163 is disposed on the outer

or lateral side of the article group selection and transport mechanism 12.

The lower guide rail 162 extends from the upstream end of the mechamsm

12 to a point anterior to a point on the mechamsm 12 at which the upper

group 22 is formed. The upper guide rail 162 extends throughout the region

on the article group selection and transport mechanism 12 at which the upper

group 22 is formed. The upper and lower rails 162 and 163 are disposed at

predetermined vertical levels, between the upper and lower members 83 and

84 of the flight bars 74, to contact the base and upper article sub-groups 21

and 22 respectively. The lateral extension distance of the rails 162 and 163

is adjustable by means of the lateral adjustment structures 164 for varying

article group 23 sizes.

Referring to FIGS. 5 and 19 the divider placement mechanism 15 deposits a divider sheet 24 on the top surface of lower or base article group

21 formed and traveling on the article group selection and transport

mechanism 12. The divider placement mechanism 15 is shown to be

disposed above the article group selection and transport mechanism 12 at a

predetermined point downstream from where the base article group 21 is first fully formed. The divider placement mechanism 15 preferably

comprises a rotary placer mechamsm 92 of the type manufacmred and sold

by Applicants' assignee and having a pair of apex positions with vacuum control members 94. A power magazine 93 is shown operatively connected to the placer 92 to provide a continuous supply of divider sheets 24 thereto.

Although a rotary-type placer is preferred for divider sheet placement, other

placement means may be substituted to practice the basic method of this

invention. Referring again to FIGS. 7, 8 and 21, a divider hold down assembly 168

including a pair of medial and lateral rails 169 and 170 and adjustment

structures 171 is disposed above a segment of the article group selection and

transport mechanism 12, extending downstream from a point immediately

posterior to the point of placement of the divider sheet 24 by the placer 92. The medial rail 169 has a anterior segment which includes a top member 169 with an upturned forward lip 174 and a side member 173 with a plow

configuration, and a rail shaped posterior segment 175. This configuration is

designed to engage and fold down the medial flap on the divider sheet 24,

formed by a perforation or scoreline, and to hold the flap down over the medial edge of the lower article sub-group 21 to stabilize the position of the

divider sheet 24 during downstream transport and lateral movement of the

upper article sub-group 22 across the divider sheet 24 top surface. The

lateral rail 170 extends a predetermined distance downstream to stabilize the lateral edge region of the divider sheet 24 prior to lateral merging of the

upper group 22 across the divider sheet 24. The strucmre of the divider

hold down assembly 168 has been shown to yield a substantially flat divider sheet 24 for improved article group 22 merging thereacross, especially in paperboard divider sheets 24 constructed with recycled materials which tend

not to lay flat when unstabilized.

Referring again to FIGS. 5, 6 and 13, the second or high article supply

mechanism 14 provides a plurality of input individual articles 20 to the

apparams 10 at a second predetermined level or height and at a

predetermined point downstream from the low article supply mechanism 13.

The mechamsm 14 is also shown to comprise a pair of conveyors 100 and

101, each being disposed about a drive sprocket shaft assembly and an idler

sprocket shaft assembly. The conveyors 100 and 101 may consist of a

plurality of individual tracks or paths or alternatively a unitary, wider path

or belt. Articles 20 transported on the top, forward run of the conveyors

100 and 101 are separated into a plurality of single file paths by lane

separators 102. Each lane separator 102 is shown to be an upstanding wall

of a height sufficient to guide the flow of one or more containers 20 on the conveyors 100 and 101, and which is suspended above the conveyors 100

and 101. The lane separators 102 form product conveyance lanes which

angle towards the article group selection and conveyance mechanism 12 at an approach angle of approximately 20-25 degrees with respect to the longitudinal axis of the mechanism 12. The conveyors 100 and 101 are

disposed parallel with the article group selection and transport conveyor 12.

Conveyor 101 is further disposed immediately adjacent the article group selection and transport conveyor 12 to allow for article 20 movement thereinbetween. A dead plate region is also preferably utilized. Each lane

separator 102 has a terminal portion 103 of a predetermined length, such

that it extends into the path of the article group selection and transport

mechanism 12 a predetermined distance. Each terminal portion 103 is

constructed such that it allows the longitudinally transported flight strucmres

74 of the article group selection and transport mechamsm 12 to pass through

the angled conveyance lanes. As the flight strucmres 74 mesh with and pass

through the lane separator end portions 103, they engage articles 20 disposed

in lanes and rake them onto the longitudinal conveyance path of the

mechanism 12.

The combination of forces exerted by the flight bars 74, lane ends 103, and conveyors 100, 101 and 73 serve to select and meter individual articles

20 into predetermined upper article groups 22 which are merged onto the

divider sheet 24 on top of the lower or base article group 21 traveling on the

article group selection and transport mechanism 12. The size, orientation

and peripheral dimensions of the resultant upper product groups 22 is

dependent upon the number of infeed lanes, product dimensions, and the configuration and spacing of the flight bars 74. The divider sheet 24

provides a low friction base surface upon which the upper group 22 is

transversely, slidably moved to form a stacked group 23. Lanes may be

blocked off by closure means 104 to alter the group 22 size and/or orientation. The lane separators 103 and the flight bars 74 are adjustable to

provide full variability of product group parameters.

Referring to FIGS. 32 and 33, a portion of an alternative embodiment of

the stacked article cartoning apparams 205 is shown wherein upper article

sub-groups 206 are deposited on the top surface of divider sheet 207 on

lower article sub-group 200 to form a stacked article group 209. In this

embodiment, an upper stream 210 of article sub-groups 206 is disposed

above and in longitudinal alignment with a lower stream 211 of article sub¬

groups 208. The upper stream 210 is shown to include a dead plate 212

across which the upper article sub-groups 206 are moved by the action of

upper pusher bars 213. The lower stream 211 includes a conveyor 214 and flight bars 215. As shown, the upper article sub-groups 206 are dropped

directly, vertically on top of the divider sheet 207 as they move over the

terminal edge 216 of the dead plate. Longitudinal movement of the upper

and lower article sub-groups 206 and 208 is synchronized.

The article group lateral transfer or crossloading mechanism 16 is synchronized with the aforementioned apparams 10 elements to move completed, stacked article groups 23 traveling on the article group selection

and transport conveyor 12 into aligned cartons 25 traveling on the carton

supply and ttansport conveyor 11. Referring to FIGS. 7, 18, 22 and 26-30,

the crossloading mechanism 16 basically comprises a plurality of loader arm

assemblies 110, a flight chain and guide tube assembly 111 to which the loader arm assemblies 110 are attached at predetermined intervals, and

which provides a longitudinal movement component thereto, and a control

cam assembly 112 which provides a predetermined transverse motion

component to the loader arm assemblies 110. The flight chain and guide tube assembly 110 has a forward or top run

113 and a return or bottom run 114 and comprises drive and idler

sprocket shaft assemblies 115 and 116 and a pair of spacially parallel flight

chains 117 and 118 which are connected to and revolve about the sprocket shaft assemblies 115 and 116. The flight chains 117 and 118 are

maintained in a rectilinear configuration on both the top and bottom runs 113 and 114 by chain guides 119 and 120, which are linked to the frame 17 via vertical support members 121.

Pairs of elongated guide bes 122 are disposed at predetermined

intervals along the flight chains 117 and 118, each guide tube 122 being

directly connected at one end to the outer flight chain 118, and at its

opposite end to the inner flight chain 117 so that they are oriented

transversely with respect to the axis of the apparatus 10 and to the downstream or forward run of the crossloader 16. The guide mbes 122 have

a low friction exterior surface to provide slidable support of the loader arm

assemblies 110. The pairs of closely spaced mbes 122 increase the stability

of transverse movement of the arm assemblies 110. Further stability is attained by the guide blocks 123 (connected to the inner ends of the guide mbes 122 via set screws) traveling in a longitudinally oriented guide rail 124

which is linked to the frame 17 via a support 125. As best shown in FIG.

29, lateral retainers 126 are mounted on the top of each guide block 123 to

guide the transversely moving arm assemblies 110. The spacing between

successive sets (pairs) of mbes 122 corresponds to the spacing between the

flight bars 74 of the article group selection and transport conveyor 12 and of

the flight lugs 56 of the carton transport conveyor 11 so that the arm

assemblies 110 are aligned to push product groups 23 from between the

flight bars 74 into the cartons 25.

The loader arm assemblies 110 are movably mounted on the guide mbes

122, and in a transverse orientation with respect to the axis of the apparams

10. The arm assemblies 110 are conveyed in a downstream, longitudinal

direction while they simultaneously reciprocate in a transverse direction

under the control of a cam mechanism 112 described below. Each loader

arm assembly 110 basically comprises an elongated, rectilinear base plate

127 and a loading head 128 located at one end of the base plate 127. The

base plate 127 is shown to have a rigid, flat, elongated strucmre which is

oriented horizontally. A rigid stiffing bar 129 is connected to the top surface of the base plate 127, vertically oriented, to increase the rigidity and sttength of the arm assembly 110. Preferably, a plurality of bores are

disposed in the stiffing bar 129 to reduce its weight. The inwardly disposed

end of the base plate 127 is slidably supported by the lateral retainers 126 of

Strøl E SHEET (RULE 26) the guide block 123. A first or outer bushing block 130 is connected to the

bottom of the base plate 127 at its opposite end. The first bushing block 130

has a pair of apertures, including bushings, through which the guide mbes

122 are slidably extended. A second or inner bushing block 131 is similarly

connected to the base plate 127 and interfaces with the guide mbes 122 a

short distance from the first bushing block 130. The bushing blocks 130 and

131 are further connected by a spreader bar 132 which is oriented and rides

in the space between the guide tubes 122. A rotatable cam follower 133 is

connected to the bottom of the spreader bar 132. The longitudinally traveling

cam follower 133 cooperates with the cam guide assembly 112 to cause the arm assembly 110 elements to transversely reciprocate on the guide mbes 122 and through the lateral retainers 126 of the guide block 123.

The loading head 128 is shown to have two fixed, flat face members 134 and 135. As the arm assemblies 110 move forward, the face members 134

and 135 push the article groups forward from the article group selection transport conveyor 12 into the cartons 25. A support roller 144 is disposed

on the bottom of the head 128 to provide support when the head 128 is

extended across the article group selection and ttansport mechanism 12.

Additionally, a t-shaped guide pin 145 is disposed on the bottom of the base

plate 127 of the arm assembly 110 to mate with the slot 155 in slide plate

154 to laterally stabilize the arm member 110 during high speed operation.

The loading head 128 configuration is variable to interface with a wide range of product group 23 configurations. Although in the instant embodiment the

head 128 is configured for use with a stacked configuration, the head 128

can be modified for cartoning various other product and product group

arrangements, including non-stacked configurations. Head 128 modification

is accomplished by changes in the configuration of the face members 134

and 135. A transition conveyor 29, shown in FIGS. 2 and 22, is disposed

between the crossloading mechanism 16 and the carton ttansport mechanism

12 to provide a moving base for the movement of the article groups 23 into

the longitudinally conveyed cartons 25. A fixed dead plate may alternatively

be used. The bottom member 84 of the flight bars 74 is elongated to extend across the top run of the transition conveyor 29 to guide or funnel article groups 23 across the conveyor 29 and into the cartons 25, between the

carton end panels 44.

The loader control cam assembly 112 controls the transverse, reciprocal

motion of the arm assemblies 110. The loader conttol cam assembly 112 is generally oriented longitudinally with respect to the overall crossloading mechanism 16, and has a top or forward run 136 and a bottom or return run

137 corresponding to the revolving arm assemblies 110. The top run 136

basically comprises an inwardly sloping approach segment 137, an apex 138,

and an outwardly sloping return segment 139. In the approach segment 137, the cam follower 133 is urged inwardly, and drives each arm assembly 110

into moving engagement with a product group 23 until it is loaded in a carton 25. A lag segment 146 of decreased slope is disposed at a predetermined point where the loading head 128 first contacts the article

group 23 to provide gentle, even pressure at this initial contact point. In the

return segment 139, the face 128 is retracted from the carton 25 prior to its

being reset in the return run 137 of the cam assembly 112. The forward run

136 of the cam assembly 112 comprises an outer rail 140 and an inner rail 141 which is spaced from the inner rail 140 a distance equivalent to the

diameter of the cam follower 133. The follower 133 is disposed in a cam

pathway formed between the outer and inner rails 140 and 141 to effectuate

ttansverse, inward motion to the arm assemblies 110. Preferably, the outer rail 140 is connected to a pivot point 142 at one end and to a release

mechanism, such as a pressure release cylinder and piston 143 proximate its opposite end. The release mechanism 143 is controlled by a sensing mechanism, for example, a photoeye or capacitive proximity sensor, such

that if an excessive force is placed on the outer rail 140, for example due to

a jamming of the arm assembly 110, the release mechanism 143 will be

actuated releasing the outer rail 140 which pivots about point 142.

The bottom or return run 136 of the cam assembly 112 includes circular

guide plates 148 and 149, and a bottom cam rail 147 which contacts the cam

follower 133 to further rettact and reset the loader arms 110 for further

loading cycles. Since the loader arms 110 are substantially extended when they revolve around sprocket/shaft assembly 115, it is critical that they be stabilized by the guide pin 145 in slide plate 154 groove 155 during high

speed operation.

As shown in FIGS. 2, 6, 7, 9 and 23, lateral and medial flap tuckers 30

and 31 are disposed adjacent each side of the carton transport mechanism 11,

one anterior to the loading region to provide a closed carton backside against

which the loaded containers may nest, and one posterior to the loading

region to allow article group 23 ingress to the carton 25 through its open,

unglued end flaps 44.

Referring to FIGS. 1 and 12, an overhead carton squaring station 33 is

shown disposed immediately downstteam of glue stations 37, immediately

above the carton supply and ttansport mechanism 12, and extending a

predetermining longitudinal distance downstteam. The overhead station 33

assists in maintaining the squareness of the loaded cartons. The overhead

compression station preferably comprises an endless chain 201 with a

plurality of vertical lugs 202 having a bottom downstteam run of a predetermined longitudinal distance and being disposed a predetermined

vertical distance above the article ttansport conveyor 12. The vertically disposed lugs 202 have a predetermined configuration such that they aid in

maintaining the squareness of the cartons 26. One or more compression

belts (not shown) may additionally be added for package conttol purposes.

As shown in FIGS. 1, 6, 24 and 25, gluing, side compression and

discharge mechanisms 32 and 37, 34 and 35 are disposed consecutively, further downstream and adjacent the carton supply and transport mechanism

11 to complete the carton flap securement process.

As many changes are possible to the embodiments of this invention

utilizing the teachings thereof, the descriptions above, and the accompanying

drawings should be interpreted in the illustrative and not the limited sense.

Claims

THAT WHICH IS CLAIMED IS:

1. A method for forming stacked article groups, comprising the steps

of:

a) supplying at least two streams of articles, each at a predetermined

vertically distinct level;

b) forming and longimdinally ttansporting a stteam of first article

groups having at least one article, at a first level;

c) placing a support base on a top surface of each the first article group;

and

d) forming a second article group, having at least one article, at a second level on top of said support base of each said longimdinally moving first article group, whereby stacked article groups are formed.

2. A continuous method for forming stacked article groups having upper

and lower sub-groups of at least one article, comprising the steps of:

a) inputting a stream of articles at a first location along a longitudinally

oriented axis and at a first vertical level to form a stream of longimdinally moving lower article sub-groups;

b) placing a divider strucmre on each said lower article sub-group; and

inputting a stteam of articles at a second location along said axis and at a

second vertical level to form the upper article sub-group on the top surface of each said divider strucmre whereby longimdinally moving stacked article groups are formed.

3. The method of Claim 1, wherein two article streams are supplied, a

first said article stteam being supplied at a first longimdinal position, and a

second article stteam being supplied at a second, distinct longimdinal

position, said first article group being formed at said first position, said

second article group being formed at said second position, and said support

base being placed at a position between said first and said second positions.

4. The method of Claim 3, wherein said second article group is

slidingly moved across said support base to form said stacked article group.

5. The method of Claim 3, wherein said second article group is

deposited onto said support base to form said stacked article group.

6. The method of Claim 3, wherein said support base has a thin,

substantially flat, rectilinear configuration with a surface area substantially

coextensive with that of the top surface of said first article group.

7. The method of Claim 6, wherein said support base further has a flap

member disposed along one base edge and defined by a scoreline, said flap

member being foldable over one edge of die top surface of said first article

group.

8. The method of Claim 6, wherein said support base is constructed of

paperboard.

9. The method of Claim 4, further comprising the step of stabilizing

said support base on its operative top position on said first article group.

10. The method of Claim 1, wherein said infeed articles are further

segregated into at least two rectilinear article lanes.

SUBSlHUTE SHEET (RULE 26)

11. The method of Claim 10, wherein said article lanes intersect said

longimdinal stream at a predetermined angle and wherein said first and

second article groups are formed by being raked from said article lanes.

12. The method of Claim 1, further comprising the step of placing said

stacked article groups in cartons.

13. The method of Claim 12, wherein said cartons are provided in a

longimdinally oriented stteam, synchronized with said stacked article

groups, and further have open ends facing said stacked article groups.

14. The method of Claim 13, wherein said stacked article groups are placed

into cartons by laterally loading them into open sides of the cartons.

15. The method of Claim 14, wherein the carton is constructed of

paperboard and includes an outer strucmre with top, bottom, front and rear

sides, and open ends bounded by end flaps, and wherein the articles are

beverage cans.

16. A continuous method for forming stacked article groups, comprising

the steps of:

a) supplying at least one stream of articles at a first predetermined

location and a first vertical level along a longimdinally oriented axis;

b) forming and longimdinally transporting a stteam of lower article sub¬

groups at said first location;

c) depositing a divider strucmre at a second predetermined location

along said axis, downstream from said first location;

d) supplying at least one stream of articles at a third location

downstteam from said second location, and at a second vertical level higher

than said first vertical level;

e) forming, at said third location, an upper article group on each said divider strucmre of each said lower article sub-group, whereby stacked article groups are formed; and

f) ttansporting said stacked article groups along said longimdinal axis

17. A method of continuously loading cartons with stacked article

groups having upper and lower sub-groups of at least one article, comprising

the steps of: a) supplying an input stream of articles at a first location;

b) selecting articles at said first location to form a lower article sub¬

group;

c) ttansporting the lower article sub-group longimdinally to a second

location;

d) depositing a base strucmre on said lower article sub-group prior to its

arrival at said second location;

e) supplying an input stteam of articles at said second location;

f) selecting articles at said second location to form an upper article sub¬ group on top of the lower article sub-group, which is slidably moved across

said base strucmre, to thereby form a stacked article group;

g) longimdinally ttansporting said stacked article group;

h) supplying and longimdinally ttansporting a carton in spacial

synchronization with the stacked article group; and

i) laterally transferring the stacked article group into the longimdinally transported carton