BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the detailed description given below, serve to explain the invention.
FIG. 1 is a perspective view of an exemplary bucket in accordance with the principles of the invention;
FIG. 2 is a side elevation view of an exemplary blister pack to be used in embodiments of the invention;
FIG. 2A is a top plan view of the blister pack shown in FIG. 2;
FIG. 3 is a left side elevation view of the bucket shown in FIG. 1, including a tamp being mounted on top of the bucket;
FIG. 4 is an illustrative front elevation view of a process for loading a stack of blister packs from a bucket, through a loading guide, and into a carton;
FIG. 5 is a perspective view of the bucket and loading guide illustrated in FIG. 4;
FIG. 6 is a perspective cross-sectional view of the bucket and loading guide shown in FIG. 5;
FIG. 7 is a front elevation view of an embodiment of a loading guide in accordance with the principles of the invention;
FIG. 7A is a left side view of the loading guide shown in FIG. 7;
FIG. 7B is a cross-sectional view of the loading guide shown in FIG. 7 taken generally along line 7B-7B thereof;
FIG. 7C is a cross-sectional view of the loading guide shown in FIG. 7 taken generally along line 7C-7C thereof;
FIG. 7D is a right side view of the loading guide shown in FIG. 7; and
FIG. 8 is a left side view of a carton with the blister packs positioned therein.
DETAILED DESCRIPTION
Various embodiments of the invention are directed to apparatus and methods of packaging items in a carton in a desired orientation that overcomes the drawbacks of current packaging machines. In particular, embodiments of the invention are directed to apparatus and methods of reorienting a stack of items such as blister packs for insertion into a carton at a desired orientation. As is known in the art, consumer products are provided to the consumer through an assembly line type of process including various stations that perform one or more functions in the overall process. For instance, one station may be a filling station that fills a receptacle (e.g., blister pack, pouch, etc.) with product; another station may seal the receptacle; another station may package the receptacle within a larger package (e.g., carton); and another station may seal the larger package. Each station may be associated with various apparatus for accomplishing the desired task.
The embodiments herein described are directed to apparatus and methods of packaging items within a carton, and more specifically, to packaging a stack of blister packs within a carton. Other apparatus that form no part of the present invention fill and seal the blister packs. These apparatus may provide a plurality of filled and sealed blister packs organized in a “shingle” to a conveyor system that delivers the blister packs to the packaging station on the assembly line. While embodiments of the invention are shown and described for packaging a stack of blister packs in a carton, these are merely illustrative and not intended to be limiting, as those of ordinary skill in the art will recognize that other items may benefit from the principles shown herein.
A handling apparatus in accordance with one embodiment includes a bucket conveyor having one or more buckets. Each of the buckets has a groove for receiving one or more blister packs such that a tab of a blister pack lies in the groove. The handling apparatus further includes one or more loading guides having a spirally-directed or helical groove for rotating the blister packs as they are pushed therethrough from the buckets and into cartons. The bucket conveyor comprises a plurality of individual buckets 10 movable in a machine direction (indicated by arrow 13). An exemplary embodiment of bucket 10 is shown in FIG. 1 and includes a front wall 12, a rear wall 14, sidewalls 16, 18, and a bottom wall 20. In one embodiment, a pair of carrying brackets 22, 24 are coupled to the bottom wall 20 and are provided with features for securing the buckets to parallel conveyor chains that further define the bucket conveyor (not shown). Alternatively, only a single bracket 26, as also shown in various figures, may be coupled to bottom wall 20 to secure the buckets 10 to a single conveyor chain on the bucket conveyor. Moreover, each of the buckets 10 is centered on the chain(s) at a desired pitch.
Each of the buckets 10 on the bucket conveyor includes a bucket channel 28 having an axis 28a and extending in a transverse direction substantially perpendicular to the machine direction. The channel 28 is configured to accommodate one or more blister packs 30 (FIG. 2), such as blister packs 30 arranged in a stacked configuration. FIGS. 2 and 2A illustrate an exemplary blister pack 30. As mentioned above, each blister pack 30 includes a generally cylindrical body 32 disposed about an axis 30a and defining a cavity 34 and an opening 36 for accessing the cavity 34. The opening 36 includes an upper flange 38 and a removable cover 39, such as a suitable foil, adhesively coupled to the upper flange 38 to retain product, such as tea, coffee and/or any of a wide variety of other products, in cavity 34. The upper flange 38 includes a projecting tab 40 that gives blister pack 30 a tear drop shape when viewed from above, as shown in FIG. 2A.
The usage of directional terms herein are for illustrative purposes and not intended to be limiting. More particularly, terms such as “upward,” “downward,” “lateral,” “vertical,” “horizontal,” “above,” “below,” “left,” “right,” “front,” and “back,” as well as terms derived from and/or related to these exemplary non-limiting terms may merely refer to orientations as shown in exemplary figures herein, such as to facilitate the description and understanding of details of depicted embodiments.
With reference to FIGS. 1 and 3, in order to confine the stack of blister packs 30 in buckets 10, the channel 28 has a lower portion 42 that conforms to the shape of the lower portion 44 of the blister pack 30 when the projecting tab 40 points downward (FIG. 2A). To this end, lower portion 42 includes a groove 43 adapted to closely receive the projecting tabs 40 of blister packs 30 therein. Channel 28 further includes an intermediate portion 46 above the lower portion 42 with substantially straight, vertical channel support walls 48, 50. Support walls 48, 50 are spaced apart by an amount substantially equal to the diameter D of the upper flange 38 of blister packs 30 (FIG. 2A). Channel 28 also includes an upper portion 52 with a pair of diverging channel support walls 54, 56. The upper portion 52 of the channel 28 is adapted to receive, as indicated by arrow 57, a tamp 58 having a pair of converging walls 60, 62 that respectively engage diverging support walls 54, 56 in upper portion 52, and a generally arcuate bottom wall 64 configured to engage an upper portion 66 (FIG. 2A) of the blister packs 30 to confine the stack of blister packs 30 from above. With this particular assembled configuration of bucket 10 and tamp 58 (shown in phantom in FIG. 3), the blister packs 30 are prevented from rotating about axis 28a of the channel 28 due to the asymmetry caused by projecting tab 40 and the manner in which projecting tab 40 is closely received in groove 43 of lower portion 42 of channel 28. Additionally, the tamp 58 prevents any movement of the blister packs 30 in a vertical direction by engagement of the upper portion 66 of the blister packs 30 with the bottom wall 64 of tamp 58.
In one exemplary aspect of this embodiment, all the blister packs 30 are deposited into the buckets 10 with the projecting tabs 40 in the downward facing direction and within groove 43, such that the stacked blister packs 30 are uniformly oriented within the buckets 10. Although the blister packs 30 may be deposited in the buckets 10 in any known manner, known seal apparatus may be configured to deliver the blister packs 30 to a next station in the assembly line with the projecting tabs 40 oriented in the downward position. Moreover, the downward projecting tab position may be desirable for other reasons, such as providing stability to the blister packs 30 during transportation thereof. Thus, fill and seal apparatus may be configured to drop a specific number of blister packs 30, for example, anywhere between about 5 and about 15 blister packs 30, into a bucket 10 with the projecting tabs 40 facing downward. Alternatively, however, the blister packs 30 may be deposited into the buckets 10 in any other orientation. Further, the number of blister packs 30 may also be greater or less than the illustrative range noted above, depending on the specific application.
While the blister packs 30 deposited in buckets 10 are prevented from rotation about axis 28a and from vertical movement by tamp 58, the blister packs 30 may slide along the channel 28 in the transverse direction (i.e., generally parallel to axis 28a). For instance, it may be desired that each of the blister packs 30 be substantially perpendicular to the channel 28 (e.g., where axis 28a is substantially coaxial and/or parallel with axis 30a). Unless constrained in the transverse direction, it may be possible for the blister packs 30 to slip along channel 28 such that the blister packs 30 are no longer perpendicular to the channel 28, but instead form an acute angle with respect to the channel 28 (i.e., axes 28a and 30a are no longer substantially parallel).
To prevent such transverse movement of the blister packs 30 in a bucket 10, sidewall 16 includes a lip 70 that projects into channel 28 by a relatively small amount. Lip 70 provides a bearing surface 71 adapted to engage the upper flange 38 of an end blister pack 30 adjacent lip 70. Accordingly, lip 70 prevents the blister packs 30 from falling out of channel 28 through sidewall 16 during normal operation or on the occasion that a transverse force is applied to the stack of blister packs 30 in bucket 10.
In another exemplary aspect of this embodiment, front and rear walls 12, 14 include notches 72, 74 extending from sidewall 18 toward opposed sidewall 16. Notches 72, 74 are configured to receive a stationary side guide 76 (shown in phantom in FIG. 1) associated with the bucket conveyor along which the buckets 10 travel. The side guide 76 may be adjustably positioned along the extending direction of notches 72, 74, as shown by arrow A in FIG. 1, so as to engage a blister pack 30 adjacent sidewall 18 and provide lateral support to the stack of blister packs 30 in bucket 10. The position of the side guide 76 may be determined by the number of blister packs 30 deposited in buckets 10. For instance, for a specific number of blister packs 30 (e.g., about 15) in buckets 10, side guide 76 may be positioned more adjacent sidewall 18. For fewer blister packs 30 (e.g., about 5), the side guide 76 is positioned in notches 72, 74 relatively closer to sidewall 16 so as to engage an end blister pack 30 closest sidewall 18. Those of ordinary skill in the art will recognize that the length of notches 72, 74 is sufficient to provide lateral support for the range of blister packs that may be accommodated in buckets 10. The lip 70 and side guide 76 effectively bound the stack of blister packs 30 therebetween to provide lateral support and prevent any undesired lateral movement of the stack of blister packs 30 (i.e., in the transverse direction). Those of ordinary skill in the art will further recognize that instead of using lip 70 to confine the blister packs 30 adjacent sidewall 16, a second side guide (not shown) could be alternatively used in a manner similar to side guide 76.
The blister packs 30 are conveyed in the buckets 10 to a cartoning apparatus for moving the stack of blister packs 30 from the buckets 10 on the bucket conveyor into respective cartons. This cartoner may include carton feeding and erecting apparatus, a carton conveyor, one or more loading guides, and downstream carton handling apparatus including dust flap closing, gluing, flap closing, compression and other conveying apparatus for finishing the carton and feeding it to a product discharge end of the cartoner, where the cartons are discharged for bulk packaging and shipment. The cartoner may further include a carton feeder for feeding cartons onto a carton conveyor which transports at least partially erected cartons in the machine direction. For example, in the illustrative embodiment of FIG. 4, the cartons 78 are generally rectangular with a major end panel open so as to receive the stack of blister packs 30 from buckets 10.
It will be appreciated that the cartoner also includes one or more loading guides 82 interposed between the bucket conveyor and the carton conveyor. In an exemplary embodiment, there may be six such loading guides 82 separated from one another in the machine direction so as to correspond to a pitch defined by the position of the buckets 10 on the bucket conveyor. Those of ordinary skill in the art will recognize, however, that more or fewer loading guides 82 may be used depending on the particular application. In the exemplary embodiment, the loading guides are stationary and therefore do not move in registration with either the bucket conveyor or the carton conveyor. Consequently, the cartoner is configured for an intermittent type of loading operation of the cartons. Those of ordinary skill in the art will recognize that, alternatively, the loading guides 82 may be associated with a guide conveyor that is adapted to move in registration with the bucket conveyor and/or carton conveyor so that a continuous type of loading operation of the cartons may be achieved.
The construction of an exemplary loading guide 82 is best illustrated in FIGS. 5-7D. The loading guide 82 includes a generally rectangular body 84 having a top wall 86, a bottom wall 88, spaced apart rear and front walls 90, 92, and a pair of spaced apart end walls 94, 96. Each of the loading guides 82 also includes a channel 98 having an axis 98a extending in the transverse direction, i.e., substantially perpendicular to the machine direction (arrow 13). As shown in FIGS. 5 and 6, the channel 98 is adapted to align with channel 28 in a respective bucket 10 (i.e., where axis 28a is coaxial and/or substantially parallel to axis 98a). In particular, the floor of the channel 28 in bucket 10 is substantially at the same level as the floor of channel 98 in loading guide 82. Additionally, in cross section, channel 98 is adapted to correspond to the shape of the blister packs 30 in bucket 10. Accordingly, the channel 98 has a cross-sectional shape similar to that shown in FIG. 2A and includes a generally cylindrical portion 100 and a groove portion 102 (FIGS. 7A-7D). The groove portion 102 of channel 98 is adapted to receive the projecting tab 40 therein.
In one aspect of this embodiment, the loading guide 82 is configured to reorient the stack of blister packs 30 in bucket 10 for insertion into a carton 78 in a desired orientation. As mentioned above, the blister packs 30 may be deposited into the buckets 10 with the projecting tabs 40 pointing or facing downward. As also mentioned above, in order to minimize the amount of packaging material required for the cartons 78, it may be desirable to size the cartons 78 to be just slightly larger than the diameter D (FIG. 2A) of the upper flange 38 of the blister packs 30 so that the projecting tabs 40 have to be oriented to lie within a corner region of the carton 78 in order for the blister packs 30 to fit therein (FIG. 8). Because the cartons 78 are supported on the carton conveyor by a major panel 104 of the carton 78 (FIG. 4) lying horizontally, the blister packs 30 must be reoriented in known systems by rotating the stack of blister packs 30 prior to insertion into the cartons 78. The loading guides 82 described herein accomplish this reorientation in an improved manner.
With reference to FIGS. 5-7D, an opening 94a in end wall 94 is shaped so that the groove portion 102 of channel 98 aligns with and is at the same height as the groove 43 in lower portion 42 of channel 28. In this way, the groove portion 102 may receive the projecting tab 40 as configured in the buckets 10, i.e., in the downward facing position, as each blister pack 30 is moved from a bucket 10 to the loading guide 82. The groove portion 102 of channel 98 (shown as the hatched portion in FIG. 6) is not parallel to axis 98a through the channel 98, but is rather configured as a helical or spirally-directed path 106 that winds around the channel wall 108, defining channel 98. As the blister packs 30 are moved through the channel 98, such as a result of a force exerted by a pusher discussed in more detail below, the projecting tabs 40 engage groove portion 102 so as to rotate the blister packs 30 about axis 98a as the projecting tabs 40 move along helical path 106. Accordingly, the groove portion 102 provides a track along which projecting tabs 40 ride as blister packs 30 move through channel 98. An exemplary progression of rotating blister packs 30 is illustrated by the successive side and cross-sectional views shown in FIGS. 7A-7D.
With reference to FIG. 7A, the groove portion 102 is located at the bottom of channel 98 so as to receive the downward pointing projecting tabs 40 of blister packs 30 as they are received from the buckets 10 through opening 94a. As shown in FIG. 7B, the groove portion 102 has been rotated an amount in the clockwise direction about axis 98a (as viewed in FIG. 7B relative to sidewall 94). FIG. 7C shows the groove portion 102 rotated further in the same clockwise direction. Lastly, FIG. 7D shows a right side view of loading guide 82 wherein the groove portion 102 is no longer pointing downward, but has been rotated through an angle α (wherein the right side view of FIG. 7D relative to the views in FIGS. 7A-7C is counterclockwise). In the exemplary embodiment, the angle α is about 45 degrees. Those of ordinary skill in the art will recognize, however, that the amount the items, such as blister packs 30, are rotated in loading guides 82 depends on the specific application and the exemplary amount of rotation herein described is only illustrative and not intended to be limiting. With reference to FIGS. 6-7D, when the blister packs 30 exit loading guide 82 through opening 96a in end wall 96, each blister pack 30 has been sequentially rotated for packaging in a carton 78 with the projecting tabs 40 oriented to lie in a corner region of carton 78.
With reference to FIGS. 4-6, an overall operation of an exemplary handling apparatus will now be described. The blister packs 30 are filled and sealed at filling/sealing stations of an assembly line or system using suitably chosen apparatus well known in the art. The filled blister packs 30 are delivered to the bucket conveyor and deposited into the buckets 10 in a horizontal stack of, for example and without limitation, anywhere between about 5 and about 15 blister packs 30. The stack of blister packs 30 is at least in part supported in the buckets 10 by side guide(s) 76, tamp 58, or both, and the blister packs 30 are positioned so that projecting tabs 40 are in the downward facing direction and in groove 43 of buckets 10. The filled buckets 10 are conveyed in the machine direction to a cartoner for loading the stack of blister packs 30 into a suitable carton 78. To this end, the cartoner includes one or more stationary loading guides 82 (e.g., about 6 loading guides 82). The cartoner also includes a carton conveyor for transporting cartons 78 in the machine direction in registration with the buckets 10 on the bucket conveyor.
As the buckets 10 approach the cartoner, a point in the process is reached where side guide 76 no longer supports the stack and the blister packs 30 may be retained within the buckets 10 by a second side guide 110 (FIG. 4) associated with the loading guides 82. The second side guide 110 operates in a manner similar to side guide 76 in that side guide 110 may be adjustably positioned within notches 72, 74 so as to engage the end blister pack adjacent sidewall 18 and prevent, with the cooperation of lip 70 (or opposing side guide), any lateral movement of the stack of blister packs 30 along channel 28. Again, the position of side guide 110 within notch 72, 74 depends on the number of blister packs 30 in the stack. Side guide 110, however, includes blade guides (not shown) that traverse the channel 28 in the buckets 10. The blade guides are of a telescoping construction and capable of retractable movement in the machine direction and out of the channel 28 so that the blister packs 30 may be moved in the transverse direction out of buckets 10 and into the loading guides 82. Those of ordinary skill in the art will recognize that instead of the side guides 110 traversing the channel 28 from the sides, as shown in FIG. 4, the guides may be configured to engage the blister packs 30 from above. For example and without limitation, tamps 58 may include an access opening adjacent sidewall 18 to allow a retractable member to engage the blister packs 30 from above.
With continued reference to FIGS. 4-6, to move the stack of blister packs 30 from the buckets 10 on the bucket conveyor to the cartons 78 on the carton conveyor and through the loading guides 82, the cartoner includes a pusher 114 on one side of the bucket conveyor and a pusher 116 on a relatively opposed side of the carton conveyor (FIG. 4). The pushers 114, 116 are operable so as to move the stack of blister packs 30 in the transverse direction from the buckets 10 to the cartons 78. When the buckets 10 are aligned with the loading guides 82 and cartons 78, as shown in FIG. 4, pusher 114 moves right in the transverse direction to engage the left-most blister pack 30 (as viewed in FIG. 4) and pusher 116 moves left in the transverse direction to engage the right-most blister pack 30. The pushers 114, 116 provide lateral support that keeps the blister packs 30 in a stacked configuration during the transition from bucket 10 to carton 78. Once the pushers 114, 116 are engaged with the stack of blister packs 30, the pushers 114, 116 move to the right in unison to move the stack of blister packs 30 out of the bucket 10. When the pushers 114, 116 engage the blister packs 30 to provide lateral support, the blade guides on second side guide 110 retract so as to clear the channel 28 and allow the transverse movement of the blister packs 30 with movement of pushers 114, 116.
The pushers 114, 116 are also operative to move the stack of blister packs 30 through the loading guides 82. As explained above, as the blister packs 30 move through channel 98, the blister packs 30 are rotated about axis 98a by movement of the projecting tabs 40 along groove portion 102 that defines helical path 106. While the pushers 114, 116 maintain the blister packs 30 in the stacked configuration, rotation of a blister pack 30 relative to a blister pack 30 adjacent thereto is facilitated such that individual blister packs 30 rotate relative to one another as they move through channel 98. More particularly, the stack of blister packs 30 is not rotated as a bulk unit, but instead each of the blister packs 30 in the stack is sequentially rotated as the stack moves through channel 98.
With continued reference to FIGS. 4-6, once the blister packs 30 have been moved through the loading guides 82, the blister packs 30 have been rotated by a desired amount (e.g. about 45 degrees) so as to reorient the projecting tabs 40 to a desired position. With the projecting tabs 40 reoriented, the pushers 114, 116 then move the stack of blister packs 30 into the carton 78. As shown in FIG. 4, the carton 78 includes an end panel 118 that is open so as to receive the blister packs 30 as they are moved from the loading guides 82. The carton 78 also includes an opposed end panel 120 that is at least partially open so as to allow pusher 116 to move therethrough. For instance, end panel 120 may include a first pair of flaps that are glued during an erecting stage and which provide an access opening to receive pusher 116 therethrough. After the stack of blister packs 30 is loaded into the carton 78, the pushers 114, 116 are retracted. The filled carton 78 may then be conveyed downstream (i.e., in the machine direction) for flap closing and gluing. As shown in FIG. 8, by rotating the blister packs 30 by a specified amount (e.g., about 45 degrees), the projecting tabs 40 are positioned in a corner region of carton 78.
With particular reference to FIG. 4, the cartoner may include a side guide 122 (FIG. 4) associated with the carton conveyor along which cartons 78 move after being loaded. The side guide 122 is positioned adjacent the opening in end panel 118 so as to prevent the blister packs 30 from falling out of the cartons 78 as they are conveyed downstream. The first pair of flaps in end panel 120 is adapted to prevent the blister packs 30 from falling out of this end of the carton as the cartons are conveyed downstream. Those of ordinary skill in the art will recognize, however, that alternatively another side guide (not shown) associated with the carton conveyor may be used to prevent the blister packs 30 from falling out of this end of the carton.
In another aspect of this exemplary embodiment, the various components may include one or more interlocking features that prevent the blister packs 30 from dropping into spaces or gaps between the components. For instance, and as best shown in FIG. 4, there may be a gap 123 between the buckets 10 and the loading guides 82. There may also be a gap 125 between the loading guides 82 and the cartons 78. As shown in FIGS. 5-7, to prevent any movement of the blister packs 30 into the gap 123 between the bucket 10 and the loading guide 82, the loading guide 82 includes a bottom lip 124 protruding from end wall 94. Additionally, the bottom wall 20 of bucket 10 adjacent sidewall 18 includes a bevel 126. When a bucket 10 is aligned with a loading guide 82, the bottom lip 124 protrudes under the opening in sidewall 18 and adjacent taper 126. In this way, blister packs 30 moving between the bucket 10 and loading guide 82 are prevented from dropping downward into the gap 123 therebetween. Furthermore, loading guide 82 may include a pair of tabs 128, 130 (FIGS. 4-5) protruding from sidewall 94 and adjacent the opening 94a therein. The tabs 128, 130 are received in the notches 72, 74 in buckets 10 as shown in FIGS. 5 and 6. The tabs 128, 130 prevent any movement of the blister packs 30 in the machine direction and into the gap 123 between the buckets 10 and the loading guides 82.
With reference to FIGS. 4-7, the loading guide 82 includes a downward bevel 132 in the top wall 86 and an upward bevel 134 in the bottom wall 88. As best shown in FIG. 4, an upper flap 136 in end panel 118 of carton 78 is configured to overlie bevel 132. In a similar manner, a lower flap 138 in end panel 118 of carton 78 is configured to underlie bevel 134. The respective cooperation between the flaps 136, 138 on the carton 78 and the bevels 132, 134 in loading guide 82 close the gap 125 therebetween.
While the present invention has been illustrated by a description of various preferred embodiments and while these embodiments have been described in some detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. For example, as noted above, while the above description of embodiments of the invention was directed to the packaging of blister packs in a carton, those of ordinary skill in the art will recognize that the same principles may be used in the packaging of other items that would benefit from the teachings herein. Accordingly, the principles taught herein may be utilized to package an item or stack of items for which reorientation of the item(s) is desired prior to insertion into a carton.
Moreover, while the embodiments of the invention have been shown and described as applicable to a tab on the item(s) cooperating with a groove in the loading guide to accomplish such reorientation of the item(s), these embodiments are not intended to be limiting. Those of ordinary skill in the art will recognize that items have or may be configured to have other features that may be utilized to accomplish reorientation of the item(s). For example, the item(s) may include a groove that cooperates with a helical ridge in the loading guide to rotate the item(s) by a desired amount. Thus, the invention is not limited to the tab/groove features described herein, but encompasses other features on the item and loading guide to accomplish rotation of the item(s) to achieve a desired orientation. Thus, additional advantages and modifications will readily appear to those skilled in the art. The various features herein described may be used alone or in numerous combinations depending on the needs and preferences of the user.