WO2002042162A1

WO2002042162A1 - Log packaging apparatus and method

Info

Publication number: WO2002042162A1
Application number: PCT/US2001/043233
Authority: WO
Inventors: Dennis P. Couturier
Original assignee: C.G. Bretting Manufacturing Company, Inc.
Priority date: 2000-11-20
Filing date: 2001-11-20
Publication date: 2002-05-30
Also published as: AU2002225644A1

Abstract

A packaging apparatus (10) for packaging compressed logs (L) using a compression system (12) in conjunction with a turret system (14) for moving logs (L) to different positions in the apparatus (10). The turret system (14) has a turret (38) that is rotatable to bring the turret clamps (40) into the different positions in the packaging apparatus (10). In one position, a turret clamp (40) receives a compressed log (L) ejected from a compression station (22). Wrap material (36) is fed to a position between and immediately beside the compression station (22) and a turret clamp (40). A compressed log (L) ejected from the compression station (22) is pressed through the wrap material (36) and into the turret clamp (40). The turret clamp (40) is movable to a wrap sealing station (62) in which wrap material (36) about the log (L) in the turret clamp (40) is sealed and a discharge station (70) in which logs (L) are ejected from the turret clamp (40) to a discharge system (66). The wrap sealing system (54) preferably has one or more adhesive applicators (56) for applying a bonding material or element (e.g., glue, tape, etc.) to unsecured wrap material (36) about the log (L) in the turret clamp (40), and at least one tucker (60) for manuipulating the unsecured wrap material (36) in bonding oprations.

Description

LOG PACKAGING APPARATUS AND METHOD

Field of the Invention

The present invention relates to packaging equipment and methods, and more particularly to apparatuses and methods for packaging compressed product.

Background of the Invention

Numerous systems and devices exist for packaging product in a variety of ways, including without limitation banders, wrapping machines, sleeve wrap machines, and the like. However, certain applications in which the product packaged is compressed prior to or during packaging can present machine design problems unique to those applications. Also, many applications require packaging speeds demanding fast and efficient machine operation. Packaging systems and devices capable of performing packaging operations at high speed and which handle, manipulate, and package compressed product typically are quite complex and difficult to manufacture and repair. Such machine design problems are typical, for example, in packaging systems and devices for paper products. Accordingly, the following description and appended claims directed to the present invention is with reference to the packaging of folded and stacked paper products such as napkins, paper towels, and the like. Because these products are often found in long stacks of product units conveyed to a packaging system, such product is referred to herein and in the appended claims as being in the form of "logs". It should be noted that the present invention is equally applicable to packaging of non-paper products such as cellophane and other synthetic materials, fabric, woven and non-woven textiles and cloth, foil, etc., regardless of product porosity, density, and dimensions. Also, the present invention is equally applicable to packaging of products in other than stacked form, including without limitation rolled or wound product, fiber product, bundled product, and the like. Such product forms are also referred to hereinafter (and in the appended claims) as "logs". However, the term "log" does not indicate or imply any particular shape of product or number of individual units making up such product, and includes product which is defined by one or more units (e.g., napkins, towels, and the like) collectively taking virtually any shape, length, width, and depth. Due to their complexity, conventional stacked product systems are typically very compact and crowded, and therefore do not permit easy access to different components therein for repair and maintenance. Such systems are also therefore difficult to clear when product jams or misfeeds occur or when system adjustments must be made.

The increased speeds at which existing stacked product packaging systems are called to operate presents another problem. For example, interfolding and stacking equipment speed (upstream of packaging systems) is continually increasing with advancements in paper handling and processing technology. Therefore, many conventional stacked product packaging systems simply cannot be used at the very high product speeds becoming more common in connected paper processing and handling equipment.

In light of the problems and limitations of the prior art described above, a need exists for a log packaging apparatus and method having a simple design which permits easy access for jam removal and for maintenance, assembly and repair, and which is capable of high operational speeds. Each preferred embodiment of the present invention achieves one or more of these results.

Summary of the Invention

The present invention employs a turret system in conjunction with a log compression system to produce a log packaging apparatus having a simple design and capable of a higher packaged log output rate than prior art log packaging devices. The turret system has a turret with at least one turret clamp thereon. The turret is rotatable to bring the turret clamps into different positions in the log packaging apparatus. In one position, a turret clamp is located adjacent to the log compression system and receives compressed logs ejected from a log compression station therein. The log compression system preferably has a log compressor for compressing logs and a log ejector for ejecting logs from the log compression station. Preferably, the turret clamp is movable to a wrap sealing station in which wrap material about the log in the turret clamp is sealed and a log discharge station in which logs are ejected from the turret clamp to a log discharge system for transport to downstream operations. As used herein and in the appended claims, the term "sealing" means that at least some portion of the wrap material is affixed by a bonding material or element to some other portion of the wrap material (or in less preferred embodiments, also or instead to the log), and does not indicate or imply that any particular amount of wrap material is used, to what extent the wrap material covers or encloses the log, or that the log is necessarily entirely enclosed in the wrap material.

The wrap system preferably has one or more adhesive applicators for applying a bonding material or element (e.g., glue, tape, etc.) to unsecured wrap material about the log in the turret clamp, and at least one tucker for manipulating the unsecured wrap material in bonding operations. The log discharge system is preferably capable of maintaining log compression upon compressed logs received from the turret clamp.

The log compression system preferably receives logs of material from upstream operations via a log conveyor. The log conveyor conveys each log to the log compression station in which a log compressor is moved to compress the log to a desired size. Upon reaching the desired size, the compressed log is preferably ejected from the log compression station (such as by a piston driven wall). Wrap material is fed into the log packaging apparatus to a position preferably between and immediately adjacent the log compression station and the turret clamp. Therefore, a compressed log ejected from the log compression station is pressed through the wrap material (which wraps at least partly about the log in so doing) and into the turret clamp. Because the turret clamp is preferably the same width as or only slightly wider than the compressed log, significant log decompression does not occur.

The log in the turret clamp is then rotated by the turret to the wrap sealing station in which a tucker preferably folds unsecured wrap material in the turret clamp into place upon the log in the turret clamp. A bonding material is preferably then applied to the unsecured wrap material, after which time another tucker folds another portion of unsecured wrap material in the turret clamp upon the bonding material to seal the log. Preferably, the turret clamp is then rotated by the turret to the log discharge station, within which an actuator of the turret clamp moves to eject the sealed log to the log discharge system.

Highly preferred embodiments of the present invention have multiple turret clamps for significantly increasing the output of packaged logs from the apparatus. Also, highly preferred embodiments have extendible and retractable turret clamps for improved turret clamp positioning with respect to the various systems in the apparatus. Because the turret and turret clamps move logs to different stations and systems in the apparatus, the various systems in the apparatus are much more accessible for assembly, maintenance, repair, and jam removal. Further objects and advantages of the present invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the drawings.

Brief Description of the Drawings

The present invention is further described with reference to the accompanying drawings, which show a preferred embodiment of the present invention. However, it should be noted that the invention as disclosed in the accompanying drawings is illustrated by way of example only. The various elements and combinations of elements described below and illustrated in the drawings can be arranged and organized differently to result in embodiments which are still within the spirit and scope of the present invention.

In the drawings, wherein like reference numerals indicate like parts:

FIG. 1 is a plan view of the log packaging apparatus according to a preferred embodiment of the present invention; and

FIGS 2-11 are plan views of the log packaging apparatus illustrated in FIG. 1, showing the apparatus in progressive steps of apparatus operation packaging a log.

Detailed Description of the Preferred Embodiments

With reference first to FIG. 1, the log packaging apparatus 10 of the present invention has a log compression system 12 and a turret system 14 which operate together to package bundles, rolls, stacks, or other groups of product in a wrap material. By way of illustration only, the following description and accompanying figures show packaging operations of a stack of paper towels in a sleeve wrapper.

The log compression system preferably includes a log conveyor 16 and a log compressor 18. The log conveyor 16 is preferably a conventional chain conveyor having a series of paddles 20 thereon for moving logs from upstream equipment (such as a product stacker, interfolder, etc.) to a log compression station 22 adjacent to the log compressor 18. The paddles 20 are connected to chains of the log conveyor 16 in a conventional manner. Other well known types of log conveyors 16 can instead be used to convey product to the log compressor 18, including without limitation belt conveyors, cable and pulley or tabletop conveyor systems, slide or turret conveyor systems, and the like.

The log compressor 18 most preferably comprises a piston connected to or having a pressure surface 24 facing the log compression station 22. The log compressor 18 is preferably hydraulically actuated in a conventional manner to move into and out of the log compression station 22, although pneumatic or other actuators can instead be used. Because the product being compressed in the preferred embodiment of the present invention shown in the figures is a log of stacked paper towels, the pressure surface 24 is preferably a flat plate 26 connected to the end of a piston rod 28. Preferably, the pressure surface 24 is substantially parallel to the surface of the log conveyor 16 in order to generate proper compression forces upon a log in the log compression station. Specifically, each log placed in the log compression station 22 is compressed between the log compressor 18 and the surface of the log conveyor 16 when the log compressor 18 is moved toward and into the log compression station 22.

Although the flat plate 26 and piston rod 28 arrangement is preferred as described above and illustrated in the figures, many other well known pressure surfaces and pressure transmitting devices can be used if desired. Such surfaces can be defined by a plate, grate, rows of bars or rods, piston surface, and the like, and preferably is of a shape adapted for the type and form of product being compressed. For example, a concave grate can be used for compressing logs of material in roll form, while a solid flat plate can be used to compress particulate material in the log compression station 22. It should be noted that the surface of the log conveyor 16 in highly preferred embodiments is shaped and takes a form similar to the pressure surface 24 of the log compressor 18 (e.g., concave if rolled products are compressed, flat and solid if particulate matter is compressed, and the like).

It will be recognized by one having ordinary skill in the art that many other types of compressing devices and assemblies can be used to compress logs in the log compression station 22. Such compression devices and assemblies need not be hydraulically movable, and can operate under pneumatic, mechanical, or other power to compress logs. For example, a pressure plate can be movable by a screw drive into and out of the log compression station 22, can be moved by a rack and pinion gear set, can be pressed against a log in the log compression station 22 by cams rotated to press against the rear of the pressure plate 26, can be pressed by a conventional air, hydraulic, or magnetic ram, and the like. These alternative compression devices and assemblies are well known to those skilled in the art and fall within the spirit and scope of the present invention.

Although not required to practice the present invention, it is desirable to guide a log into the log compression station 22 and to contain the log therein during compression operations. For this purpose, a first wall 30 preferably runs alongside the log compression station 22 in facing relationship with a second wall 32 on an opposite side of the log compression station 22. The first wall 30 is preferably movable (e.g., slidable, rotatable, and the like in any conventional manner) to permit a log in the log compression station 22 to be ejected therefrom to downstream equipment as discussed in more detail below. In the preferred embodiment of the present invention shown in the figures, the first wall 30 is slidable in an upward direction by a rack and pinion gear set (not shown) mounted to the top of the first wall 30 and powered by a motor (e.g., a stepper motor or other conventional motor capable of positioning operations). Many other wall movement devices well known to those skilled in the art can instead be used as desired.

The second wall 32 is preferably laterally movable across the log compression station 22 by one or more hydraulic pistons 34. Like the pressure surface 24 discussed above, numerous alternative devices and assemblies can be used to push the second wall 32 in such a manner, including without limitation pneumatic rams, rack and pinion gears, screw drives, and the like. Such alternative devices and assemblies are well known to those skilled in the art and fall within the spirit and scope of the present invention. When in a retracted state, the second wall 32 defines a side of the log compression station 22 and helps to contain a log therein during compression operations. When the first wall 30 has been moved from beside the log compression station 22, the second wall 32 can be pushed by the piston 34 across the log compression station 22 to clear the log compression station 22 and to eject a compressed log located therein. Both walls 30, 32 can take almost any shape desired, but most preferably take shapes matching the shape of the log within the log compression station 22. Also, both walls 30, 32 can be replaced by structure or elements performing the same containing and guiding functions of walls 30, 32 and the ejecting function of wall 32. For example, either or both walls 30, 32 can be replaced by bars running alongside the log compression station 22, by a series of bars, poles, rods, tubes or the like arranged to form gates beside the log compression station, etc.

Located preferably beside the log compression system 12 is a sleeve feed path through which sleeve packaging material 36 passes into the log packaging apparatus 10. Specifically, sleeve packaging material 36 is preferably fed into the log packaging apparatus 10 horizontally (i.e., into the plane of the page of FIGS. 1-11) in a manner well known to those skilled in the art by a conventional sleeve feed apparatus (not shown). The feed path of the sleeve packaging material 36 is located with respect to logs ejected from the log compression station 22 so that the logs are pressed into the sleeve packaging material 36. Preferably, sleeve packaging material 36 is fed into the log packaging apparatus 10 in long strips which are substantially the same length of the logs being packaged. As discussed in more detail below, other types of packaging material can be used in the apparatus 10 for packaging logs in different manners, such as by banding logs, bagging logs, or the like. Packaging material feed apparatuses for each such packaging material are well known to those skilled in the art and are not therefore described further herein. However, each such apparatus preferably feeds the packaging material to a location immediately adjacent the log compression station 22 for receiving logs as will be described below.

With continued reference to FIG. 1, the log packaging apparatus of the present invention also has a turret system 14 which includes a turret 38 upon which is mounted at least one turret clamp 40. In a highly preferred embodiment shown in the figures, the turret 38 has two turret clamps 40 located on opposite sides of the turret 38. The turret 38 is mounted in a conventional fashion to preferably rotate about a horizontal axis 42 in a controlled manner via a motor (not shown). The motor (e.g., a stepper motor or other conventional motor capable of performing positioning operations) is controllable to position the turret clamps 40 on the turret 38 in different circumferential positions about the axis 42. Such turrets 38 are well known in the art and are not therefore described further herein.

Each of the turret clamps 40 has a log receptacle 46 which is of sufficient size to receive a log therein. More preferably, each of the turret clamps 40 is shaped to match the shape of compressed logs from the log compression station 22. Because the turret clamps 40 of the illustrated preferred embodiments receive long logs having a rectangular cross section (i.e., long logs of stacked paper towels), the turret clamps 40 preferably each have a box-shaped log receptacle 46 as shown. In other embodiments of the log packaging apparatus 10 where logs of a different shape are packaged, the log receptacles 46 are preferably shaped differently, such as a log receptacle 46 having a square cross sectional shape for square logs, a U-shaped log receptacle for round logs, and the like. The log receptacle 46 is preferably defined at least in part by two opposing surfaces between which compressed logs are received. The opposing surfaces can take a number of different forms capable of receiving and retaining a compressed log therebetween, including without limitation plates, fingers, posts, and the like. In the preferred embodiment shown in the figures, two opposing plates 48 are attached to a frame 44 consisting of a series of connected arms extending from the plates 48 as shown. Although not required, the log receptacle 46 of each turret clamp 40 preferably is also defined by a back surface 50. The back surface 50 can be one or more plates, bars, rails, and the like located between the opposing surfaces (i.e., between the opposing plates 48) of the turret clamp 40, and can even be part of the turret clamp frame 44. The back surface 50 preferably functions to properly locate logs in the log receptacle 46 of each turret clamp 40 and to support logs in position in the log receptacle 46 of each turret clamp 40. In the preferred embodiment shown in the figures, the back surface 50 is an elongated flat plate running substantially the entire length of the turret clamp 40 for retaining and supporting a rectangular log of product in the turret clamp 40. However, like the plates 48, the back surface 50 can be in any desired shape and more preferably is shaped to match the shape of a log in the log receptacle 46.

Each turret clamp 40 is preferably extendable and retractable in its position on the turret 38 as shown in FIG. 1. Turret clamp extension and retraction can be accomplished in a number of well known ways, such as by an actuator, (electrical solenoids, hydraulic or pneumatic pistons, and the like) track or rail assemblies upon which the turret clamps 40 are mounted to slide by conventional actuation devices, cable and pulley assemblies or gear assemblies, etc. In the preferred embodiment shown in FIG. 1, each turret clamp 40 is mounted to an electrical solenoid 52 which is itself mounted to the turret 38. Specifically, an electrical solenoid 52 is connected to the frame 44 of each turret clamp 40 in a conventional manner. Each solenoid 52 pushes its respective turret clamp 40 away from the turret 38 when actuated in one direction and pulls the turret clamp 40 back to the turret 38 when actuated in an opposite direction. Rather than employ an actuator which can be actuated in two directions, the turret clamp 40 can be biased in one position by a bias element such as an extension spring, magnets, and the like, and can be forced out of the position by actuation of a one-directional solenoid or other actuation device.

In order to eject logs from the log receptacle 46 of the turret clamps 40, each turret clamp 40 preferably has a log ejector mechanism. The log ejector mechanism preferably functions to push a log from the log receptacle 46, and most preferably does so by moving the back surface 50 of the turret clamp 40. As shown in FIG. 1, the illustrated preferred embodiment of the present invention has an actuator 64 mounted between the frame 44 and the back surface 50 (e.g., a surface of a rear plate of the turret clamp 40). Like the electrical solenoid 52 actuatable to extend and retract the turret clamp 40, the actuator 64 is most preferably an electrical actuator, but can take any of the forms mentioned above to push and pull the back surface 50 of the turret clamp 40. In addition, other conventional assemblies and devices capable of ejecting an object from a receptacle can instead be used in place of the movable back surface 50 and actuator 64 of the preferred embodiment described above. For example, one or more piston rods defining the back surface 50 or movable through apertures in the back surface 50 can be actuated to eject logs from the turret clamp 40, one or more apertures through the back surface 50 can be connected to an air source to exert air pressure behind a log in the turret clamp 40 and to thereby push the log out of the turret clamp 40, etc. Such other ejection assemblies and devices and their manner of connection and operation are well known to those skilled in the art and fall within the spirit and scope of the present invention.

Highly preferred embodiments of the present invention include a wrap sealing system 54 located adjacent a wrap sealing station 62 and the turret 38 as shown in FIG. 1. Preferably, the wrap sealing system 54 has an adhesive applicator 56 connected in a conventional manner to a source of adhesive 58, and at least one tucker 60. The adhesive applicator 56 preferably is one or more adhesive spray nozzles (only one which is visible in the figures, with others extending into the plane of the page behind the adhesive applicator shown) connected under pressure to a source of liquid glue 58. The adhesive applicator 56 is oriented toward the wrap sealing station 62 to apply adhesive to a log in a turret clamp 40 when positioned adjacent the wrap sealing system 54 by rotation of the turret 38. Although spray nozzles are preferred, numerous alternative glue application devices exist, including without limitation a drip nozzle guiding flowing glue to a line, series of dots, or other pattern of glue to wrap material of a log in the wrap sealing station 62, a sponge, felt, brush, or roll applicator fed by one or more adhesive lines (preferably under pressure), a dip wire movable or pivotable between a dip tank of adhesive to wrap material of a log in the wrap sealing station 62, and the like. Similarly, other wrap bonding material can be employed in the present invention, including without limitation cohesive material (in which case the material is preferably applied to two areas of wrap material which are then brought together for bonding), tape applied by a conventional tape applicating device adjacent to the wrap sealing station 62, staples driven by a conventional stapling device, and the like. Depending at least in part upon the type of wrap material used, it is even possible to perform wrap sealing operations without adhesive, cohesive, fasteners, or other sealing materials applied at the wrap sealing station 62. Specifically, shrink wrap material and thermally bonding wrap material can be heated or otherwise bonded in a conventional manner to seal the wrap material. Wrap material can even be pre-treated or have bonding material already placed thereon so that sealing operations only require wrap material placement and/or folding in the wrap sealing station 62. Such other adhesive material, glue application devices, and manners of wrap sealing are well known to those skilled in the art and fall within the spirit and scope of the present invention.

As mentioned above, the wrap sealing system 54 preferably has at least one tucker 60. Most preferred embodiments of the present invention have a tucker 60 on each side of the wrap sealing station 62. Each tucker 60 is a series of fingers, a plate, or other member movable adjacent to the wrap sealing station 62 to fold over or fold down wrap material as will be described in more detail below. In the preferred embodiment of the present invention illustrated in the figures, each tucker 60 is a series of fingers (only one of which is shown for each tucker 60 in the figures, the remaining fingers in each series extending into the plane of the figures) slidable adjacent to the wrap sealing station 62 in a conventional manner. Specifically, the fingers of each tucker 60 preferably face one another over the wrap sealing station 62 and are actuatable by one or more actuators (not shown) to slide to and from respective positions beside the wrap sealing station 62. The actuators moving the tuckers 60 are preferably electrical solenoids, but can be any device or assembly capable of extending and retracting the tuckers 60 adjacent to the wrap sealing station 62. It should be noted that the tuckers 60 need not necessarily slide as described above and illustrated in the figures, but can instead pivot or swing into their positions beside the wrap sealing station 62, simultaneously slide and pivot, etc. Fold over or fold down devices (such as fingers, plates, swing arms and like devices), their manner of connection, motion, and operation, and the actuators used to actuate such devices are well known to those skilled in the art and are therefore not described further herein. Such devices and their manner of connection, motion, actuation, and operation fall within the spirit and scope of the present invention.

The present invention also preferably includes a log discharge system 66 located adjacent to the turret 38. The log discharge system 66 functions to receive logs from the turret system 14 and to transport logs to downstream equipment. Although not required in many cases, the log discharge system 66 is preferably capable of retaining compression upon logs received from the turret system 14. Therefore, preferred embodiments of the present invention have a log discharge system 66 with two facing conveyor assemblies 68 between which logs are received from the turret system 14. The conveyor assemblies 68 are preferably conventional conveyor belts extending away from the turret system 14 to downstream equipment. However, other well known conveyor devices and assemblies can instead be employed to receive and move logs from the turret system 14.

In operation of the preferred log packaging apparatus described above and illustrated in the figures, a log L of a desired length (extending into the page of the figures) is fed into the log compression system via the log conveyor 16 as shown in FIG. 2. At this stage, the wall 30 is in its position beside the log compression station 22 and the piston rod 28 and the pressure surface 24 are retracted as shown in FIG. 2. Next, the piston rod 28 is extended to press the pressure surface 24 against the log L in the log compression station 22. Once a desired compression is reached or during log compression, the wall 30 is preferably moved as shown in FIG. 3 in preparation for log ejection from the log compression station 22.

The piston 34 and wall 32 are then extended to push the log L out of the log compression station 22, into the wrap material 36 and into the turret clamp 40 aligned with the log compression station 22 as shown in FIG. 4. Preferably, the log L is not significantly decompressed by being ejected from the log compression station 22. However, to help ensure smooth insertion of the log L into the turret clamp 40, the log receptacle 46 in the turret clamp 40 is preferably the same width or slightly wider than the compressed log L so that the compressed log L easily fits within the turret clamp 40. For example, the plates 48 of the turret clamp 40 can be approximately 0.125 in. wider than the compressed log L. Because the compressed log L (e.g., of compressed stacked material) is pressed first into the wrap material 36 prior to or at the same time as being pressed into the turret clamp 40, the compressed log is already partially wrapped when it enters the turret clamp 40, thereby also facilitating smooth insertion into the turret clamp 40. Specifically, the log L preferably presses into and draws the wrap material 36 around itself as the log L enters the turret clamp 40. To this end, the wrap material 36 is preferably fed into the log packaging apparatus 10 closely beside the log compression station 22 to avoid significant log decompression prior to log entry into the turret clamp 40. For a similar reason, the turret clamp 40 (and more particularly, the plates 48 of the turret clamp 40 in the preferred embodiment) is preferably rotated by the turret 38 to a station immediately adjacent the log compression station 22 and the wrap material 36. A log L being ejected from the log compression station 22 is therefore preferably immediately pressed into and through the wrap material 36 and between the plates 48 of the turret clamp 40.

It should be noted that in alternative embodiments of the present invention, the wrap material 36 can move toward and/or away from the log compression station 22 while or before a log L is ejected from the log compression station 22 into the turret clamp 40. Specifically, an alternative embodiment of the present invention can draw the wrap material 36 into the log receptacle 46 prior to or during log ejection from the log compression station 22. The wrap material 36 can be sucked into the log receptacle 46 by vacuum from vacuum apertures in the turret clamp 40 in fluid communication with a vacuum or suction source, one or more fluid jets (not shown) can be positioned adjacent to the log compression station 22 to blow the wrap material 36 into the log receptacle 46, and the like. Alternatively, many conventional systems move wrap material toward a stationary or moving object to be wrapped therein. After the wall 30 has been moved to permit log ejection as described above, such a system can be employed to move the wrap material 36 toward the log L in the log compression station 22 prior to or during log ejection. However, because the illustrated embodiment of the present invention requires only wrap material feed and movement in one direction (e.g., closely adjacent to the log compression station 22), the above-described log ejection and log wrap operations are most highly preferred.

In highly preferred embodiments of the present invention, the opposing surfaces of the turret clamps 40 (e.g., the turret clamp plates 48 in the illustrated embodiment) are adjustable to increase or decrease the width of the log receptacle 46 for receiving logs L of different sizes. Adjustment can even be performed automatically based upon the size of a compressed log L measured in the log compression station 22 in any conventional manner, such as by one or more optical sensors, one or more sensor monitoring the amount of piston rod movement, and the like. Manual and automatic adjustment of the opposing surfaces is comparable to adjustment of robotic jaws, can be performed in numerous manners well known to those skilled in the art, and is therefore not discussed further herein.

After pushing the log L and wrapping material 36 into the turret clamp 40 as just described, the piston 34 and wall 32 are preferably retracted to their original positions shown in FIGS. 1-4, and the tunet clamp actuator 52 preferably retracts the turret clamp 40 away from the log compression station 22 as shown in FIG. 5.

With the turret clamp 40 retracted, the wall 30 is now preferably moved back to its position beside the log compression station 22 in preparation for guiding and containing the next log L fed into the log compression station 22. Also, fresh wrap material 36' is also fed into the log packaging apparatus 10 for the same purpose. With reference to FIG. 6, the turret 38 preferably rotates to bring the log L and the turret clamp 40 into the wrap sealing station 62. The wrap material 36 is preferably wrapped about a majority of the log L in the turret clamp 40, with the unwrapped material unsecured to the log L as also shown in FIG. 6. To seal this unwrapped material about the still-compressed log L, the turret clamp actuator 52 preferably extends the tunet clamp 40 and log L in the wrap sealing station 62 to the position shown in FIG. 7. One of the tuckers 60 flanking the turret clamp 40 in the wrap sealing station 62 is then extended as also shown in FIG. 7 to fold a portion or flap of the unwrapped wrap material over the log L. The adhesive applicator 56 preferably then applies an amount of adhesive (or other bonding material as described above) to the portion or flap folded by the tucker 60. A second tucker 60 is then preferably extended as shown in FIG. 8 to fold another portion or flap of the unwrapped wrap material over the log L and over the adhesive material applied by the adhesive applicator 56. In this preferred manner, the wrap material 36 is sealed about the log L in the turret clamp 40.

In the next step of log packaging apparatus operation, the turret clamp 40 is preferably retracted in the wrap sealing station 62 as shown in FIG. 9 in preparation for tunet rotation. As shown in FIG 10, the tunet 38 is then rotated until the tunet clamp 40 and log L therein is positioned in a log discharge station 70. As with the ejection of logs from the log compression station 22, the log L is preferably not significantly decompressed by being ejected from the tunet clamp 40. Therefore, the width between conveyor assemblies 68 in the log discharge system 66 is preferably the same or slightly larger (e.g., 0.125 in. larger) than the width of the log L in the turret clamp 40. Also, the distance between the tunet clamp 40 and the log discharge system 66 (and more specifically, between the plates 48 of the tunet clamp 40 and the log discharge system 66) is preferably as small as possible. The tunet clamp 40 is therefore preferably extended in the log discharge station 70 to a position immediately adjacent to the log discharge system 66 for log discharge. After or during extension of the tunet clamp 40 to the log discharge system 66, the back surface 50 of the tunet clamp 40 is preferably moved by its actuator 64 to eject the log L from the log receptacle 46 of the turret clamp 40 (see FIG. 10). Preferably, by the time the log L begins to exit the tunet clamp 40, the turret clamp 40 is immediately adjacent to the log discharge system 66 so that the compressed log L is smoothly transfened to the log discharge system 66. The log discharge system 66 preferably then transports the compressed log L to downstream operations. After the log L has been ejected from the turret clamp 40, the turret clamp 40 is preferably retracted by its actuator 52 to the position shown in FIG. 11 and is then rotated by the tunet 38 to the position shown in FIG. 2 for receiving another log L' in another cycle of log packaging apparatus operation.

Like the turret clamps 40, the log discharge system 66 is preferably at least manually adjustable to accommodate logs L of different sizes and to exert different compressive forces upon logs therein. For example, and with reference to the prefened embodiment of the present invention illustrated in the figures, numerous systems and devices exist for moving one or both conveyor assemblies 68 of the log discharge system 66 toward and away from one another. These systems and devices can be manually operated or can operate automatically upon receiving width information about the logs being processed (e.g., either by direct measurement signals received from one or more sensors or conventional measurement devices on the tunet clamps 40, log width information received from one or more sensors or conventional measurement devices on the log compression station 22, and the like). Such systems and devices and their manner of connection and operation are well known to those skilled in the art and are therefore not described further herein.

It should be noted that log packaging apparatus operation can be affected by the type of bonding material used as described above. For example, if tape is used to bond flaps of wrap material together in the wrap sealing station 62, later operations can be performed at any desired apparatus speed. However, where liquid adhesive is instead used, a setting time may be needed before the bond is exposed to significant stresses. The logs L packaged in the apparatus of the present invention are preferably compressed prior to being wrapped. Therefore, it is desirable to maintain log compression in packaging operations downstream of the wrap sealing station 62 for sufficient time to allow certain bonding materials to set. This can be achieved in a number of different ways, such as by pausing the tunet clamp 40 at the wrap sealing station 62 for a time sufficient to allow such bonding material to set, slowing the speed at which the above-described steps following adhesive application are performed, maintaining compression in the log discharge system 66 for sufficient time to set the bonding material, or a combination of such operations. In this regard, if the wrap material 36 does not require setting or has already been set by the time the log L reaches the log discharge station 70, the log discharge system 66 need not be of a type maintaining compressive force upon logs L received from the tunet clamp 40.

The log packaging apparatus operations above have been described with reference only to one tunet clamp 40. However, highly prefened embodiments of the present invention have multiple tunet clamps 40 permitting multiple logs L to be wrapped in the log packaging apparatus 10 at once, thereby significantly increasing the output of packaged logs with respect to a one tunet system and with respect to prior art packaging devices. Multiple logs L in the apparatus would preferably therefore be in different stages of wrapping at any given time. In the prefened embodiment illustrated in the figures, the tunet 38 has two turret clamps 40 on opposite sides of the turret 38. Therefore, after the tunet clamp 40 and the log compressor 18 have been retracted in the step illustrated in FIG. 5, the log packaging apparatus 10 is ready to receive another log L' in the log compression station 22 (see FIG. 6). At any time thereafter, compression operations upon the log L' can take place (i.e., while the first log L is in the wrap sealing station 62 and/or when the first log L is being discharged to the log discharge system 66). Likewise, while the first log L is being discharged to the log discharge system 66, the next log L' can be ejected from the log compression station 22 to the second tunet clamp 40 as shown in FIG. 10. It will be appreciated that three, four, or even more tunet clamps 40 can be mounted upon the tunet 38 to receive and move multiple logs L in a similar manner. The relative positions of the log compressor 18, the wrap sealing system 54, and the log discharge system 66 is preferably determined by the relative positions and number of the tunet clamps 40 upon the tunet 38 so that an optimal number of tunet clamps 40 are aligned with the most apparatus stations to enable operations to be performed simultaneously on different logs. Still other embodiments of the present invention have more than one log compression system 12, wrap sealing system 54, and/or log discharge system 66 to further increase the number of logs L that can be wrapped simultaneously by the log packaging apparatus 10.

With reference to FIGS. 1-11, it can be seen that the various systems of the present invention can be spaced from one another about the tunet 38 in a large number of anangements. Unlike prior art log packaging devices which often locate two or more such systems close together while keeping the log stationary during many packaging operations, the spaced anangement provided by the present invention permits much easier access to the various systems for quicker and more convenient manufacture, assembly, maintenance, repair, and jam removal. The flexibility of system location as described above is another advantage that does not exist in conventional log packaging devices.

The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and anangement are possible without departing from the spirit and scope of the present invention as set forth in the appended claims. For example, and noted above, the present invention can be used to package product found in other than stacked form, such as in rolled form (e.g., toilet paper, paper towels, etc.), bundled form (e.g., banded or unhanded stacks of newspaper, folded boxes, bags, etc.), or even fiber or particulate form (e.g., food product, wood chips, etc.). The shape and design of various portions of the log packaging apparatus 10 can therefore take forms better suited for the product being packaged. For example, the log conveyor 16 can have multiple-sided compartments that are conveyed along the wall 30 and in which loose or particulate matter is transported for packaging. Upon compression of such matter by the log compressor 18, the wall 30 preferably moves and the wall 32 is moved by the piston 34 to push the compressed matter into packaging material 36 between the log compression station 22 and a tunet clamp 40. Also, the packaging material used need not necessarily be a sleeve as described above. Instead, the packaging material in which each stack of product is placed can be sheeting, film or other type of wrap, one or more bands, straps, or other elongated members, a bag, tube, sock, or other substantially enclosed packaging element (particularly useful for packaging the loose or particulate matter discussed in the example application above), and the like. Packaging material feed systems for continuously or intermittently supplying such packaging material, members or elements to a particular packaging location (i.e., to a position between the log compressing station 22 and the tunet 38) are well known in the art and are not therefore described further herein.

One having ordinary skill in the art will also recognize that a number of the operations in the prefened embodiments described can be performed in different manners while still falling within the spirit and scope of the present invention. For example, alternative embodiments of the present invention need not necessarily have tunet clamps 40 that are retractable and extendable. The log compression system 12, wrap sealing system 54, and log discharge system 66 can be positioned within the apparatus so that the tunet clamps 40 rotate upon the turret 38 into the above-described stations before these systems with minimal clearance and without requiring turret clamp extension or retraction. Also, the turret clamps 40 need not necessarily have an actuator 52 for pushing out logs L from the tunet clamps 40. Logs L compressed within the tunet clamps 40 can be pulled therefrom via suction devices, jaws, and other conventional package manipulation devices. Especially where package compression is not required for the log discharge system 66, the tunet clamps 40 can even be adjustable to widen the plates 48 and to permit logs L to slide or fall out of the tunet clamps 40 to the log discharge system 66. In this regard, it should also be noted that the particular orientation of the tunet 38 and the tunet clamps 40 shown in the figures is not required in the present invention. The tunet 38 can rotate about an axis placed in virtually any orientation (vertical, horizontal, or diagonally with respect to either such orientation).

In addition, any one or more of the various operations of the present invention can be performed manually, if desired. However, most prefened embodiments of the present invention employ a system controller for automated operation of the conveyor 16, log compressor 18, piston and wall 34, 32, wall 30, wrap material feed, tunet 38, turret clamp extension and retraction, and conveyor assemblies 68. The system controller (not shown) is preferably connected to and controls the timing and speed of each of these elements in a manner well known to those skilled in the art.

Claims

I claim:

1. A log packaging apparatus for packaging a log in a wrap, comprising: a log compression station; a sealing station; a log compressor movable to compress logs in the log compression station; a tunet clamp having a log receptacle dimensioned to receive logs from the log compression station; a tunet upon which the tunet clamp is located, the tunet being rotatable between a loading station in which the turret clamp is positioned to receive logs from the log compression station and the sealing station for substantially sealing wrapping material about at least a portion of a log in the log receptacle.

2. The log packaging apparatus as claimed in claim 1, wherein the material is a sleeve, the sleeve having a feed path into the log packaging apparatus between the log compression station and the tunet.

3. The log packaging apparatus as claimed in claim 1, further comprising a gate defining at least one side of the log compression station, the gate being retractable to permit discharge of logs from the log compression station.

4. The log packaging apparatus as claimed in claim 1, wherein the turret clamp has at least two substantially opposing surfaces at least partially defining the log receptacle, the at least two substantially opposing surfaces being located a distance from one another sufficient to maintain compression of logs received from the log compression station.

5. The log clamp as claimed in claim 1, further comprising a log ejector movable toward the log compression station for ejecting logs therefrom into the tunet clamp.

6. The log clamp as claimed in claim 1, further comprising at least one tucker located adjacent the sealing station, the at least one tucker movable past the log receptacle for wrapping at least a portion of the material about a log in the log receptacle.

7. The log clamp as claimed in claim 1, further comprising a glue applicator adjacent the sealing station, the glue applicator positioned to apply glue upon the material in the tunet clamp in the sealing station.

8. The log clamp as claimed in claim 1, further comprising a discharge station, the tunet being rotatable to the discharge station in which the tunet clamp is positioned to discharge logs to a the log discharge station.

9. The log clamp as claimed in claim 1, wherein the tunet clamp has a log ejector actuatable to eject a log from the log receptacle in the tunet clamp.

10. The log clamp as claimed in claim 1, wherein the tunet clamp is extendable from the turret in at least one of the loading station and the sealing station.

11. A log packaging apparatus for packaging a log within a wrapping material, the apparatus comprising: a tunet having a tunet clamp mounted thereon for rotation with the tunet, the turret rotatable between a first station and a second station; a log compressor located adjacent to the first station; a gluing device located adjacent to the second station; a first log path from the log compressor through the wrapping material and into the turret clamp in the first station; and a second log path from the first station to the second station, the second log path at least partially defined by turret rotation.

12. The log packaging apparatus as claimed in claim 11, wherein the tunet clamp is extendable from the turret in at least one of the first station and the second station.

13. The log packaging apparatus as claimed in claim 11, further comprising a log ejector movable toward the tunet clamp in the first station for ejecting logs from the log compressor into the turret clamp.

14. The log packaging apparatus as claimed in claim 11, further comprising a gate movable between a first position in which the gate at least partially separates the turret from a log compressed by the compressor and a second position in which the gate does not separate the tunet from the log compressed by the compressor.

15. The log packaging apparatus as claimed in claim 11 , further comprising a tucker located adjacent to the second station, the tucker being movable past the tunet clamp in the second station for wrapping at least a portion of the wrapping material about at least a portion of the log in the tunet clamp.

16. The log packaging apparatus as claimed in claim 11, wherein the wrapping material is sleeve material fed into the log packaging apparatus adjacent the first station.

17. The log packaging apparatus as claimed in claim 16, further comprising a log compression station in which logs are compressed by the log compressor, the log packaging apparatus further comprising a log ejector movable through the log compression station to eject logs therefrom through the sleeve material and into the tunet clamp in the first station.

18. The log packaging apparatus as claimed in claim 11, wherein the turret is rotatable to a third station, the log packaging apparatus having a log discharge mechanism located adjacent to the third station for receiving logs from the tunet clamp.

19. The log packaging apparatus as claimed in claim 18, wherein the log discharge has at least two substantially opposing surfaces capable of maintaining compressive force upon a log therebetween received from the log compressor.

20. The log packaging apparatus as claimed in claim 18, wherein the turret clamp is extendable from the tunet from the third station.

21. The log packaging apparatus as claimed in claim 11, further comprising a log ejector positioned to eject logs from the compressor into the tunet clamp in the first station.

22. A method for packaging compressed logs of product, comprising the steps of: compressing a log in a first log station; moving the log with respect to a wrap material to at least partially wrap the log in the wrap material; inserting the log in a second log station within a tunet clamp, the tunet clamp being coupled to a tunet; rotating the tunet to move the tunet clamp and the log to a third log station; and at least partially sealing the wrap material about the log in the third log station.

23. The method as claimed in claim 22, further comprising the step of guiding the log into the first log station via a gate.

24. The method as claimed in claim 23, wherein the gate is located in a first position between the first log station and the second log station, the gate being movable to a second position permitting log ejection from the first log station to the second log station.

25. The method as claimed in claim 22, wherein the step of moving the log includes pushing the log toward the wrap material via a pusher element.

26. The method as claimed in claim 25, wherein the pusher element pushes the log into the wrap material and then into the tunet clamp, the log being at least partially wrapped in the wrap material after insertion into the tunet clamp.

27. The method as claimed in claim 22, further comprising the step of extending the tunet clamp toward the first log station prior to the step of inserting the log in the second log station.

28. The method as claimed in claim 22, further comprising the step of retracting the tunet clamp away from the first log station after the step of inserting the log in the second log station.

29. The method as claimed in claim 28, further comprising the step of feeding fresh wrap material between the tunet and the first log station after the step of retracting the tunet clamp.

30. The method as claimed in claim 22, wherein the step of sealing the wrap material includes the step of positioning a first portion of the wrap material over the log in the third log station.

31. The method as claimed in claim 30, wherein the step of sealing the wrap material further comprises the steps of: applying adhesive to the first portion of the wrap material; and positioning a second portion of the wrap material over the adhesive after the step of positioning the first portion of the wrap material.

32. The method as claimed in claim 22, further comprising the steps of: rotating the tunet to move the tunet clamp and the log to a fourth log station after the step of substantially sealing the wrap material; and discharging the log from the tunet clamp.

33. The method as claimed in claim 32, further comprising the step of maintaining compression upon the log in the fourth log station and after the step of discharging the log from the tunet clamp.