Closure stacking and packaging apparatus.

Abstract

A closure stacking and packaging apparatus is disclosed for automatically stacking and then packaging closures. The apparatus includes a framework for supporting the stacking and packaging apparatus. A stacking station is supported by the framework for receiving and stacking a plurality of the closures. Also, a movable transporter is movably supported by the framework, the transporter being movable from a location thereof adjacent to the plurality of closures stacked by the stacking station, to a further location disposed downstream relative to the location. A packaging station is supported by the framework, the packaging station being disposed in a vicinity of the further location for receiving and packaging the plurality of closures transported to the packaging station by the transporter.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a closure stacking and packaging apparatus.

More particularly, the present invention relates to a closure stacking and packaging apparatus for automatically stacking and then packaging closures.

Background Information

Bottle and container caps and closures are manufactured in very large quantities. Such container closures usually include a round disc shaped base with an upstanding peripheral wall which often defines an internal thread for subsequently attaching the closure to a correspondingly threaded neck of a container. Most container closures are mass produced by an injection molding technique and are shipped in large cartons or containers.

Automated machines can produce container closures at the rate of 700 to 800 per minute. Packaging of such large quantities of container closures into shipping containers for distribution to container manufactures presents many problems. In view of the huge supply of such container closures at 700-800 per minute, it is clearly desirable that these container closures be stacked automatically and that the stacked container closures be rapidly and reliably inserted and packed within suitable shipping containers.

The present invention solves this problem and provides an automated apparatus for rapidly stacking columns of superimposed container closures. These stacked container closures are then automatically transported several columns at a time by a fully automated transporter connected to a source of partial vacuum. A suitable open-ended packaging container is automatically moved along a conveyor to a packing station. A polyethylene liner bag is automatically inserted into the container and an alignment mechanism is inserted into the open end of the liner and container. The alignment mechanism includes four sets of arms which move outwardly when inserted within the container for urging the liner bag outwardly to conform to the internal shape of the container. The alignment mechanism also automatically assures that the container is accurately aligned for the reception therein of the transporter and columns of container closures attached thereto by vacuum. After insertion of the transporter and closures into the plastic liner, the vacuum is automatically cut off so that the closures are accurately packed one layer of columns at a time within the container for subsequent shipping.

The present invention also provides an arrangement in which four containers supported by the conveyor are oriented such that one corner of each container is disposed adjacent to one corner of an adjacent container so that all four corners are disposed adjacent to each other. The transporter is then moved laterally after one of the containers has been filled so that an adjacent container can then be filled. In this way, using a two-container wide arrangement rather than a single row of containers, the number of containers that can be filled is doubled while the speed of the conveyor is halved.

Accordingly, the present invention provides a unique closure stacking and packaging apparatus for automatically stacking and subsequently packaging container closures.

The present invention also provides a relatively simple arrangement in which the caps or container closures are automatically stacked and then packaged within a container.

Therefore, it is a main feature of the present invention to provide a closure stacking and packaging apparatus for controllably and automatically stacking and packaging closures.

Yet another feature of the present invention is the provision of a closure stacking and packaging apparatus for mechanically and reliably controlling movement of container caps from a stacking station to a packing station.

Other features and advantages of the present invention will be readily apparent to those skilled in the art by a consideration of the detailed description of a preferred embodiment of the present invention contained herein.

SUMMARY OF THE INVENTION

The present invention relates to a closure stacking and packaging apparatus for automatically stacking and then packaging closures. The apparatus includes a framework for supporting the stacking and packaging apparatus. A stacking station is supported by the framework for receiving and stacking a plurality of the closures. Also, a movable transporter is movably supported by the framework, the transporter being movable from a location thereof adjacent to the plurality of closures stacked by the stacking station, to a further location disposed downstream relative to the location. A packaging station is supported by the framework, the packaging station being disposed in a vicinity of the further location for receiving and packaging the plurality of closures transported to the packaging station by the transporter.

In a more specific embodiment of the present invention, the framework rigidly supports the stacking station and the packaging station.

Also, the framework movably supports the transporter such that movement of the transporter in a vertical and a horizontal direction is permitted.

Furthermore, the stacking station includes an input arrangement for receiving a stream of the closures and a stacking arrangement disposed downstream relative to the input arrangement for stacking the closures.

Moreover, the stacking arrangement includes a plurality of guides, each guide of the plurality of guides being disposed parallel to and spaced relative to an adjacent guide. The arrangement is such that adjacent guides define therebetween a rack for supporting a column of stacked closures formed by the stream of closures arriving from the input arrangement.

The rack permits stacking of the closures in a column such that the stacking arrangement generates a plurality of columns, each column including a stack of superimposed closures.

Additionally, the movable transporter includes a frame movably connected to the framework.

A receiver is pivotally secured to the frame for selectively receiving the plurality of closures from the location and subsequently transporting the plurality of closures to the packaging station at the further location.

Furthermore, the receiver is controllably pivoted such that the receiver is aligned with the plurality of closures disposed at the stacking station.

More specifically, the receiver includes a vacuum device which, in use of the apparatus, is connected to a source of partial vacuum. The arrangement is such that when the vacuum device is selectively connected to the source of partial vacuum, the closures are drawn towards and are supported relative to the receiver at the location for subsequent transportation thereof to the packaging station.

The packaging station includes a conveyor which extends through the framework. The conveyor, in use of the apparatus, is capable of supporting and sequentially moving a plurality of packaging containers past the packaging station.

Also, a control mechanism is provided for selectively moving the containers along the conveyor.

Additionally, the packaging station includes a container alignment mechanism which cooperates with a container supported by the conveyor for aligning the container thereby permitting movement of the movable transporter and closures supported thereon into the container.

The container alignment mechanism includes a plurality of arms which cooperate with the container when the container is disposed at the further location. The arms enter the container and subsequently move away relative to each other for both locating the container and aligning the container for subsequent insertion therein of the movable transporter and closures supported thereon into the container.

Additionally, the control mechanism controls movement of each container towards and away from the further location, movement of the arms relative to each other for positioning and aligning each container at the further location and for moving the movable transporter from the location to the further location.

A drive mechanism is provided for driving the movable transporter. The drive mechanism is selectively controlled by the control mechanism.

Many modifications and variations of the present invention will be readily apparent to those skilled in the art by a consideration of the detailed description contained hereinafter taken in conjunction with the annexed drawings which show a preferred embodiment of the present invention. However, such modifications and variations fall within the spirit and scope of the present invention as defined by the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side elevational view of a closure stacking and packaging apparatus according to the present invention for automatically stacking and then packaging closures;

FIG. 2 is a similar view to that shown in FIG. 1 but shows a transporter disposed downstream relative to the location shown in FIG. 1;

FIG. 3 is a similar view to that shown in FIG. 2 but shows the transporter above a packaging station;

FIG. 3a is an enlarged view taken on the line 3a-3a shown in FIG. 3;

FIG. 3b is a view taken on the line 3b-3b of FIG. 3a;

FIG. 3c is a view taken on the line 3c-3c shown in FIG. 3;

FIG. 3d is a similar view to that shown in FIG. 3c but shows arms having aligned a liner within the container;

FIG. 4 is a similar view to that shown in FIGS. 1 to 3 but shows the transporter moved downwardly into the packaging station;

FIG. 4a is a view taken on the line 4a-4a shown in FIG. 4 and shows how the receiver cooperates with the closures;

FIG. 5 is a similar view to that shown in FIG. 1 but shows the transporter with the vacuum released so that the closures are deposited on the base of the container;

FIG. 6 is a similar view to that shown in FIG. 1 but shows the receiver removed from the container;

FIG. 7 is a similar view to that shown in FIG. 1 but shows the receiver moving back towards the stacker;

FIG. 8 is a similar view to that shown in FIG. 1 but shows the receiver pivoted back to cooperate with the next batch of closures stacked on the stacker; and

FIG. 9 is a similar view to that shown in FIG. 1 but shows the receiver depositing the next batch of closures in the container.

Similar reference characters refer to similar parts throughout the various views of the drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of a closure stacking and packaging apparatus generally designated 10 according to the present invention for automatically stacking and then packaging closures C. As shown in FIG. 1, the apparatus 10 includes a framework 12 for supporting the stacking and packaging apparatus 10. A stacking station generally designated 14 is supported by the framework 12 for receiving and stacking a plurality of the closures C. Also, a movable transporter generally designated 16 is movably supported by the framework 12, the transporter 16 being movable from a first location generally designated L1 (location) adjacent to the plurality of closures C stacked at the stacking station 14.

FIG. 2 is a similar view to that shown in FIG. 1 but shows the transporter 16 in a second location generally designated L2 disposed downstream relative to the first location L1 shown in FIG. 1.

FIG. 3 is a similar view to that shown in FIG. 2 but shows the transporter 16 at a third location L3 above a packaging station generally designated 22. The packaging station 22 is supported by the framework 12 and is disposed in a vicinity of the third location L3 for receiving and packaging the plurality of closures C transported to the packaging station 22 by the transporter 16.

In a more specific embodiment of the present invention, the framework 12 rigidly supports the stacking station 14 and the packaging station 22.

Also, as shown in FIG. 1, the framework 12 movably supports the transporter 16 such that movement of the transporter 16 in a vertical direction is permitted as indicated by the arrow 24. FIG. 2 shows how the transporter 16 is also selectively permitted to move in a horizontal direction as indicated by the arrow 26.

Furthermore, as shown in FIGS. 1 to 3, the stacking station 14 includes an input arrangement generally designated 28 for receiving a stream S of the closures C and a stacking arrangement generally designated 30 disposed downstream relative to the input arrangement 28 for stacking the closures C.

FIG. 3a is an enlarged view taken on the line 3a-3a shown in FIG. 3. As shown in FIG. 3a, the stacking arrangement 30 includes a plurality of guides 31, 32, 33, 34, 35 and 36. Each guide such as guide 31 of the plurality of guides 31 to 36 is disposed parallel to and spaced relative to an adjacent guide such as guide 32. The arrangement is such that adjacent guides 31 and 32 define therebetween a rack 38 for supporting a column 40 of stacked closures C formed by the stream S of closures C arriving from the input arrangement 28.

FIG. 3b is a view taken on the line 3b-3b of FIG. 3a. As shown in FIG. 3b, the rack 38 permits stacking of the closures C in a column 40 such that the stacking arrangement 30 generates a plurality of columns 40, 41, 42, 43 and 44, each column such as column 40 including a stack 45 of superimposed closures C.

FIG. 4 is a similar view to that shown in FIGS. 1 to 3 but shows the transporter moved downwardly into the packaging station 22. As shown in FIG. 4, the movable transporter 16 includes a frame generally designated 46 movably connected to the framework 12.

A receiver 48 is pivotally secured to the frame 46 for selectively receiving the plurality of closures C from the first location L1 (location) and subsequently transporting the plurality of closures C to the packaging station 22 at a fourth location L4 (further location).

Furthermore, the receiver 48 is controllably pivoted about a pivotal axis 50 such that the receiver 48 may be aligned with the plurality of closures C disposed at the stacking station 14 as shown in FIG. 1 at the location L1.

More specifically, as shown in FIG. 1, the receiver 48 includes a vacuum device 52 which, in use of the apparatus 10, is connected by a flexible conduit to a source of partial vacuum 54. The arrangement is such that when the vacuum device 52 is selectively connected to the source of partial vacuum 54, the closures C are drawn towards and are supported relative to the receiver 48 for subsequent transportation thereof through various locations including locations L1 to L3 to location L4 at the packaging station 22 as shown progressively in FIGS. 1 to 4.

As shown in FIGS. 1 to 4, the packaging station 22 includes a conveyor 56 which extends through the framework 12. The conveyor 56, in use of the apparatus 10, is capable of supporting and sequentially moving a plurality of packaging containers 58 past the packaging station 22.

FIG. 4a is a view taken on the line 4a-4a of FIG. 4. As shown in FIG. 4a, a control mechanism 62 is provided for selectively moving the containers 58 along the conveyor 56 as indicated by the arrow 60.

FIG. 3c is a view taken on the line 3c-3c shown in FIG. 3. As shown in FIG. 3c, the packaging station 22 includes a container alignment mechanism generally designated 64 which cooperates with a container 58 supported on the conveyor 56 for aligning a plastic liner or the like L within the container 58 thereby permitting movement of the movable transporter 16 and closures C supported thereon into the container 58.

The container alignment mechanism 64 includes a plurality of arms 66, 67, 68 and 69 which cooperate with the container 58 when the container 58 is disposed at the second location 20. The arms 66 to 69 which are of Y shaped configuration enter downwardly into the container 58 and subsequently move away relative to each other as indicated by the arrows 70, 71, 72 and 73 for both locating the liner L within the container 58 and aligning the container 58 for subsequent insertion therein of the movable transporter 16 and closures C supported thereon into the container 58.

FIG. 3d is a similar view to that shown in FIG. 3c but shows the arms 66 to 69 having aligned the liner L within the container 58 and having aligned the container for insertion of the transporter 16.

Additionally, the control mechanism 62 controls movement of each container 58 towards and away from the further location L4, movement of the arms 66 to 69 relative to each other for positioning and aligning each container 58 at the further location L4 and for moving the movable transporter 16 from the location L1 to the fourth location L4.

Drive mechanisms 74, 75 and 76 as shown in FIG. 1 are provided for driving the movable transporter 16. The drive mechanisms 74 to 76 are selectively controlled by the control mechanism 62.

FIG. 5 is a similar view to that shown in FIG. 1 but shows the transporter 16 in a location L5 with the vacuum released so that the closures C are deposited on the base of the container 58.

FIG. 6 is a similar view to that shown in FIG. 1 but shows the transporter 16 in a location L6 with the receiver 48 removed from the container 58.

FIG. 7 is a similar view to that shown in FIG. 1 but shows the transporter 16 in a location L7 with the receiver 48 moving back towards the stacker 14.

FIG. 8 is a similar view to that shown in FIG. 1 but shows the receiver 48 in the location L1 with the receiver 48 pivoted back to cooperate with the next batch of closures stacked on the stacker 14.

FIG. 9 is a similar view to that shown in FIG. 1 but shows the receiver 48 in a location L9 with the receiver 48 depositing the next batch of closures in the container 58.

In operation of the apparatus 10 according to the present invention, caps or closures C are fed into the input arrangement 28 and are guided by the guides 31 to 36 as shown in FIG. 3a to form five columns 40 to 44. When the stacked closures fill each of the five racks 38, the control mechanism 62 activates the drive mechanisms 74 to 76 for moving the frame 46 towards the columns 40 to 44. The control mechanism 62 then causes the receiver 48 to tilt as indicated by the arrow A shown in FIG. 1 until the receiver 48 is disposed substantially parallel to the slightly tilted columns 40 to 44. Next, the vacuum device 52 is connected to the source of partial vacuum 54 so that all the columns 40 to 44 of stacked superimposed caps or closures C are drawn toward and held against the receiver 48 which has five corresponding grooves defined by the surface of the receiver 48 as shown in FIG. 4a so that alignment of the columns 40 to 44 is maintained because the vacuum is applied to the columns 40 to 44 through a plurality of orifices defined by the surface of the receiver 48. The receiver 48 controlled by the control mechanism 62 is pivoted while the receiver 48 is moved from the first location L1 to the second location L2. At the second location L2, the arms 66 to 69 align and position the container 58 such that insertion of the correctly oriented receiver 48 lies in a plane substantially parallel to the base of the container 58 and the conveyor 56. In this disposition of the receiver 48, the receiver 48 and closures C attached thereto by vacuum are inserted into the open top of the container 58. On release of the closures C by cutting off the vacuum, the columns 40 to 44 are released from the receiver 48. This process is repeated until the container 58 is filled with the required number of layers of columns 40 to 44 of the caps C.

In a modification of the present invention, the container is replaced by a further container having four compartments. When the first compartment has been filled, the process is then repeated but with the receiver 16 reaching further across the conveyor 56 for filling a second compartment of the further container (not shown) which is disposed on the conveyor 56. After the first and second compartments have been filled with closures, the conveyor is programmed to move the further carton downstream so that the third compartment is filled. The receiver 48 is then retracted for filling the fourth compartment. When the further container has been filled, the control mechanism 62 activates the drive mechanism 74 for advancing the further container and so that the process can be repeated for sequentially filling subsequent containers.

Therefore, the present invention provides a unique fully automated apparatus for stacking and packaging closures at high speeds of approximately 720 caps per minute.

Claims

1. A closure stacking and packaging apparatus for automatically stacking and then packaging closures, said apparatus comprising: a framework for supporting the stacking and packaging apparatus;a stacking station supported by said framework for receiving and stacking a plurality of the closures;a movable transporter movably supported by said framework, said transporter being movable from a location thereof adjacent to said plurality of closures stacked by said stacking station, to a further location disposed downstream relative to said location; anda packaging station supported by said framework, said packaging station being disposed in a vicinity of said further location for receiving and packaging said plurality of closures transported to said packaging station by said transporter.

2. A closure stacking and packaging apparatus as set forth in claim 1 wherein said framework rigidly supports said stacking station and said packaging station.

3. A closure stacking and packaging apparatus as set forth in claim 1 wherein said framework movably supports said transporter such that movement of said transporter in a vertical and a horizontal direction is permitted.

4. A closure stacking and packaging apparatus as set forth in claim 1 wherein said stacking station includes: an input arrangement for receiving a stream of the closures;a stacking arrangement disposed downstream relative to said input arrangement for stacking the closures.

5. A closure stacking and packaging apparatus as set forth in claim 4 wherein said stacking arrangement includes: a plurality of guides, each guide of said plurality of guides being disposed parallel and spaced relative to an adjacent guide such that adjacent guides define therebetween a rack for supporting a column of stacked closures formed by said stream of closures arriving from said input arrangement.

6. A closure stacking and packaging apparatus as set forth in claim 5 wherein said rack permits stacking of said closures in a column such that said stacking arrangement generates a plurality of columns, each column including a stack of superimposed closures.

7. A closure stacking and packaging apparatus as set forth in claim 1 wherein said movable transporter includes: a frame movably connected to said framework;a receiver pivotally secured to said frame for selectively receiving said plurality of closures from said location and subsequently transporting said plurality of closures to said packaging station at said further location.

8. A closure stacking and packaging apparatus as set forth in claim 7 wherein said receiver is controllably pivoted such that said receiver is aligned with said plurality of closures disposed at said stacking station.

9. A closure stacking and packaging apparatus as set forth in claim 8 wherein said receiver includes: a vacuum device which in use of the apparatus is connected to a source of partial vacuum such that when said vacuum device is selectively connected to the source of partial vacuum, the closures are drawn towards and are supported relative to said receiver for subsequent transportation thereof to said packaging station.

10. A closure stacking and packaging apparatus as set forth in claim 1 wherein said packaging station includes: a conveyor extending through said framework, said conveyor in use of the apparatus being capable of supporting and sequentially moving a plurality of packaging containers past said packaging station;a control mechanism for selectively moving said containers along said conveyor.

11. A closure stacking and packaging apparatus as set forth in claim 10 wherein said packaging station includes: a container alignment mechanism cooperating with a container supported by said conveyor for aligning the container thereby permitting movement of said movable transporter and closures supported thereon into the container.

12. A closure stacking and packaging apparatus as set forth in claim 11 wherein said container alignment mechanism includes: a plurality of arms which cooperate with the container when the container is disposed at said second location, said arms entering the container and subsequently moving away relative to each other for both locating the container and aligning the container for subsequent insertion therein of said movable transporter and closures supported thereon into the container.

13. A closure stacking and packaging apparatus as set forth in claim 12 wherein said control mechanism controls movement of each container towards and away from said further location, movement of said arms relative to each other for positioning and aligning each container at said further location and for moving said movable transporter from said location to said further location.

14. A closure stacking and packaging apparatus as set forth in claim 13 further including: a drive mechanism for driving said movable transporter, said drive mechanism being selectively controlled by said control mechanism.

15. A closure stacking and packaging apparatus for automatically stacking and then packaging closures, said apparatus comprising: a framework for supporting the stacking and packaging apparatus;a stacking station supported by said framework for receiving and stacking a plurality of the closures;a movable transporter movably supported by said framework, said transporter being movable from a location thereof adjacent to said plurality of closures stacked by said stacking station, to a further location disposed downstream relative to said location;a packaging station supported by said framework, said packaging station being disposed in a vicinity of said further location for receiving and packaging said plurality of closures transported to said packaging station by said transporter;said movable transporter including:a frame movably connected to said framework; anda receiver pivotally secured to said frame for selectively receiving said plurality of the closures from said location and subsequently transporting said plurality of the closures to said packaging station at said further location.

16. A closure stacking and packaging apparatus for automatically stacking and then packaging closures, said apparatus comprising: a framework for supporting the stacking and packaging apparatus;a stacking station supported by said framework for receiving and stacking a plurality of the closures;a movable transporter movably supported by said framework, said transporter being movable from a location thereof adjacent to said plurality of closures stacked by said stacking station, to a further location disposed downstream relative to said location;a packaging station supported by said framework, said packaging station being disposed in a vicinity of said further location for receiving and packaging said plurality of closures transported to said packaging station by said transporter;said framework rigidly supports said stacking station and said packaging station;said framework movably supporting said transporter such that movement of said transporter in a vertical and a horizontal direction is permitted;said stacking station including:an input arrangement for receiving a stream of the closures;a stacking arrangement disposed downstream relative to said input arrangement for stacking the closures;said stacking arrangement including:a plurality of guides, each guide of said plurality of guides being disposed parallel and spaced relative to an adjacent guide such that adjacent guides define therebetween a rack for supporting a column of stacked closures formed by said stream of closures arriving from said input arrangement;said rack permitting stacking of said closures in a column such that said stacking arrangement generates a plurality of columns, each column including a stack of superimposed closures;said movable transporter including:a frame movably connected to said framework;a receiver pivotally secured to said frame for selectively receiving said plurality of closures from said location and subsequently transporting said plurality of closures to said packaging station at said further location;said receiver being controllably pivoted such that said receiver is aligned with said plurality of closures disposed at said stacking station;said receiver including:a vacuum device which in use of the apparatus is connected to a source of partial vacuum such that when said vacuum device is selectively connected to the source of partial vacuum, the closures are drawn towards and are supported relative to said receiver for subsequent transportation thereof to said packaging station;said packaging station including:a conveyor extending through said framework, said conveyor in use of the apparatus being capable of supporting and sequentially moving a plurality of packaging containers past said packaging station;a control mechanism for selectively moving said containers along said conveyor;said packaging station including:a container alignment mechanism cooperating with a container supported by said conveyor for aligning the container thereby permitting movement of said movable transporter and closures supported thereon into the container;said container alignment mechanism including:a plurality of arms which cooperate with the container when the container is disposed at said further location, said arms entering the container and subsequently moving away relative to each other for both locating the container and aligning the container for subsequent insertion therein of said movable transporter and closures supported thereon into the container;said control mechanism controlling movement of each container towards and away from said further location, movement of said arms relative to each other for positioning and aligning each container at said further location and for moving said movable transporter from said location to said further location; anda drive mechanism for driving said movable transporter, said drive mechanism being selectively controlled by said control mechanism.