Patent Application
20190233143
The present disclosure relates to packaging systems and, more particularly, a lid applicator system for containers.
A lid is often necessary to secure contents within a container. However, manually placing a lid onto each container can be tedious and time-consuming. Where the contents are foodstuff, hygienic application of the lid is also a concern. To solve these problems, automatic lid applicators have been used. Generally, when loaded into automatic lid applicators, the lids are arranged in a nested manner to be dispensed onto the containers.
Known automatic lid applicators have had difficulty with the rapid automatic placement of lids onto containers. Specifically, this problem arises when separating the nested lids for their subsequent placement onto the containers. This is especially true of lids with flanges, which have recesses on one side into which an adjacent lid will nest with a lid, and become loosely held in a stacked arrangement by friction, until the lid is separated from the adjacent lid to be placed onto the container.
One known method of separating these lids from each other is to manually separate the lids prior to providing the lids to the automated lid applicator. However, this minimizes the usefulness of the automated lid applicator. In cases where the containers have perishables such as foodstuff, minimizing human interaction with both the containers and the associated lids is also desirable so as to package the perishables in a hygienic manner.
Accordingly, there is a continuing need for a high-speed lid dispensing and applicator system. Desirably, the lid dispensing and applicator system effectively separates individual lids from nested stacks of lids in a continuous manner, for the lids to be individually secured to containers by the applicator system.
In concordance with the instant disclosure, a high-speed lid dispensing and applicator system that effectively separates individual lids from nested stacks of lids in a continuous manner, for the lids to be individually secured to containers by the applicator system, has been surprisingly discovered.
In one embodiment, a lid applicator system includes a main body and a conveyor. The main body has a front side, a rear side, a top side, a bottom side, a left side, and a right side. The main body includes a chute, a plurality of worm screws, and a lid compression element. The chute is disposed between the front side and the rear side of the main body, and extends upwardly from the top side of the main body. The chute is configured to hold a nested stack of lids. The worm screws are disposed between the top side and the bottom side of the main body. The worm screws are configured to advance the nested stack of lids toward the bottom side of the main body. The worm screws are also configured to separate an individual lid from the nested stack of lids, particularly where the individual lid is bottommost in the nested stack of lids. The worm screws are further configured to deposit the individual lid onto a container. The lid compression element is disposed on the bottom side of the main body, adjacent to the rear side of the main body. The lid compression element is configured to press the individual lid onto the container as the container is moved adjacent to the lid compression element. The conveyor is disposed beneath the bottom side of the main body, and spaced apart from the chute and the lid compression element of the main body. The conveyor, together with the bottom side of the main body, defines a passage through the main body for receiving the container. The conveyor is configured to move the container through the passage from the front side of the main body to the rear side of the main body, beneath the chute, and to the lid compression element to cause the individual lid to be sealed with the container.
In another embodiment, the main body of the lid applicator system has at least one sensor and at least one motor. The at least one sensor is configured to detect the presence of the container on the conveyor as it is moved through the passage by the conveyor. The at least one motor is configured to selectively rotate the plurality of worm screws to deposit the individual lid onto the container. Each of the worm screws has a cylinder body with an upper end and a lower end. A spiral thread is disposed on an outer surface of the cylinder body between the upper end and the lower end of the cylinder body. An upper portion of the spiral thread is disposed adjacent the upper end of the cylinder body and has a first distribution density or frequency of rotation. A lower portion of the spiral thread is disposed adjacent the lower end of the cylinder body and has a second distribution density or frequency of rotation. The second distribution density of the spiral thread is greater than the first distribution density of the spiral thread. The lid compression element has a lid compression surface with a leading edge and a trailing edge. The lid compression surface is oriented at an angle relative to the conveyor such that the leading edge of the lid compression surface is spaced apart farther from the conveyor than the trailing edge of the lid compression surface.
In a further embodiment, a method for applying the individual lid to the container includes the steps of placing the nested stack of lids within the chute and moving, by the conveyor, the container through the passage from the front side of the main body toward the rear side of the main body. The method further includes a detecting of the presence of the container on the conveyor and a rotating, in response to the detecting of the presence of the conveyor, each of the plurality of worm screws. The rotating of the worm screws causes a separation of the individual lid from the nested stack of lids at a position adjacent the chute, which in turn causes a deposition of the individual lid onto the container. The individual lid is thereby loosely disposed on the container. The method next includes a moving, by the conveyor, the individual lid and container beneath the lid compression element. This causes a pressing of the individual lid onto the container by the lid compression element. The individual lid is thereby press fit and sealed with the container.
The above, as well as other advantages of the present disclosure, will become readily apparent to those skilled in the art from the following detailed description, particularly when considered in the light of the drawings described herein.
The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.
The lid applicator system 2 has a main body 8 and a conveyor 10. As shown in
In particular embodiments, the main body 8 further includes a chute 28 (shown in
As shown in
Referring to
With reference to
As shown in
Referring to
In particular embodiments, the at least one sensor 44, 46 includes a laser sensor that is configured to engage the motor 48 when the container 6 passes a predetermined location on the conveyor 10, for example, underneath the lid compression element 38. The at least one sensor 44, 46 then causes the motor 48 to rotate the worm screws 30, 32, 34, 36, dispensing another one of the lids 40 for the next container 6 on the conveyor 10.
In certain embodiments, the main body 4 may have the at least one sensor 44, 46 for monitoring a position of the nested stack of lids 40 within the chute 28. These sensors 44, 46 can be employed to alert the user when the chute 6 is running low on lids 40, so that more may be loaded into the chute 28. The sensors 44, 46 may also inform the user when the chute 28 is empty, at which point the conveyor 10 may be stopped to thereby militate against containers 6 from being packaged without the lid 4. The at least one sensor 44, 46 to count the number of containers 6 on the conveyor 10. This allows the user to package a correct number of the containers 6 for a particular work order. Other suitable types and locations for the at least one sensor 44, 46 within the lid applicator system 2 may also be employed, as desired.
The at least one motor 48 is configured to selectively rotate the plurality of worm screws 30, 32, 34, 36 to deposit the individual lid 4 onto the container 6, for example, in accordance with the method 100 described herein. One of ordinary skill in the art may select any suitable type of the at least one motor 48 including electric, hydraulic, or pneumatic, as non-limiting examples.
With reference to
The at least one sensor 44, 46 may engage the at least one motor 48 directly, or relay information to a controller (not shown), which is configured to interpret the information from the at least one sensor 44, 46 and engage the at least one motor 48 to rotate the worm screws 30, 32, 34, 36 and selectively dispense the individual lid 4.
Where the controller is employed, each of the conveyor 10, the sensors 44, 46, and the at least one motor 48 may also be in electrical communication with the controller. The controller may be configured to cause the movement of the at least one motor 48, and likewise the worm screws 30, 32, 34, 36, based on at least one of a predetermined program and feedback from the sensors 44, 46 through which locations of the individual lid 4 and the container 6 within the lid applicator system 2 are determined in real-time. The controller may include at least one of a programmable logic controller (PLC) and a computer having a processor and a tangible, non-transitory memory on which processor-executable instructions may be stored. The instructions to be executed by the controller may be adjusted, for example, through a human interface such as a keyboard or touchscreen also in communication with the controller. Other means for controlling movement of the conveyor 10 and the worm screws 30, 32, 34, 36 via the at least one motor 48 may also be used within the scope of the present disclosure.
In a particular embodiment, as illustrated in
Furthermore, as shown in
Where the lid applicator system 2 is provided with the aforementioned combination of first, second, third, and fourth worm screws 30, 32, 34, 36, and where the chute 28 is defined by the plurality of guide bars 54, it should be appreciated that the each of the worm screws 30, 32, 34, 36 may be generally aligned with individual ones of the guide bars 54 of the chute 28. For example, as shown in
In particular, and referring to
With specific reference to
In another example, the second set of the worm screws 34, 36, including the third worm screw 34 and the fourth worm screw 36, may have an additional spiral rib 70 that is not present on the first set of the worm screws 30, 32. The spiral rib 70 may be both disposed on the outer surface 68 of the cylinder body 60, and also adjacent to the lower end 64 of the cylinder body 60. The size and shape of the spiral rib may be selected by a skilled artisan, as desired.
In particular, the spiral rib 70 is configured to cause the separation of the individual lid 4 from the nested stack of lids 40 where the bottommost, individual lid 4 of the nested stack of lids 40 has been advanced through the chute 28 to locations of the spiral rib 70 of each of the third worm screw 34 and the fourth worm screw 36. The spiral rib 70 may also be configured to militate against the individual lid 4 inadvertently falling out of the chute 28 and onto the conveyor 10 prior to the container 6 being at the required location beneath the chute 28.
As shown in
The flanges 72 of the lids 4, 40 are also configured to be contacted by the spiral threads 66 adjacent the lower ends 64 of the cylinder bodies 60 of the worm screws 30, 32, 34, 36, in conjunction with a contacting of the flanges 72 by the spiral ribs 70, to separate the individual lid 4 from the nested stack of lids 40 to deposit the individual lid 4 onto the container 40. One of ordinary skill in the art may select suitable dimensions for the spiral thread 66 and the spiral rib 70, for example, based on the associated dimensions of the lids 4, 40 and the container 6, within the scope of the present disclosure.
It should be further appreciated that the flanges 72 of the lids 4, 40 are further configured to form a friction fit with an associated container 6 upon the individual lid 4 being press fit into place and sealed with the container 6 by the lid compression element 38 as described herein.
In another embodiment, the spiral thread 66 may gradually become wider along the length of the cylinder body 60. The wider orientation of the spiral thread 66 may assist in separating the lids 4, 40. This may be especially effective where the lids 4, 40 have the flanges 72, which may otherwise become frictionally attached to each other where the lids 4, 40 are nested together in the stack 40. Additionally, the worm screws 30, 32, 34, 36 may be covered with a material that facilitates grip, such as rubber, silicone, or any other gripping material. Suitable coating materials may be selected by a skilled artisan, as desired.
As shown in
It should be understood that this particular orientation of the individual lid 4 during the initial deposition by the worm screws 30, 32, 34, 36 may be accomplished by at least one of the difference in the densities (D2) of the spiral threads 66 of the second set of the worm screws 34, 36 compared to the first set of the worm screws 30, 32, and the presence of the spiral ribs 70 on the second set of the worm screws 34, 36. This orientation of the lid 4 at the lid separation angle (α) is believed to dispose the individual lid 4 in an optimum placement for the final sealing of the individual lid 4 to the container 6 by the lid compression element 38 in operation.
Referring now to
Although the lid compression surface 78 of the lid compression element 38 may be oriented substantially parallel to the conveyor 10, it should be appreciated that the lid compression element 38 may also be oriented at a sealing angle (β), for example, as shown in
In operation, and as shown in
Upon placement of the nested stack of lids 40 within the chute 28, and the container 6 onto the conveyor 10, the method 100 further includes a fourth step 108 of moving, by the conveyor 10, the container 6 through the passage 42 from the front side 12 of the main body 8 toward the rear side 14 of the main body 8. In a fifth step 110, at least one of the presence and the position of the container 6 on the conveyor 10 is then detected, for example, with the at least one sensor 44, 46. In a sixth step 112, and in response to the detecting of the presence of the container 6 on the conveyor 10, each of the plurality of worm screws 30, 32, 34, 36 is moved to cause a separation of the individual lid 4 from the nested stack of lids 40 at a position adjacent the chute 28. This movement also causes a deposition of the individual lid 4 onto the container 6 in a seventh step 114, whereby the individual lid 4 is loosely disposed on the container 6.
In certain embodiments, the individual lid 4 is separated from the nested stack of lids 40 in the sixth step 112 at the angle (α) relative to the conveyor 10, with the leading edge of the individual lid 4 being disposed closer to the conveyor 10 than the trailing edge of the individual lid 4. It should be appreciated that this orientation of the individual lid 4 permits it to be pulled away from the nested stack of lids 40 upon being contacted with a leading edge of the container 6 as it is moved through the passage 42 by the conveyor 10 in the seventh step 114.
In an eighth step 116, the loose combination of the individual lid 4 and the container is then moved, by the conveyor 10, beneath the lid compression element 38. This causes a pressing of the individual lid 4 onto the container 6 by the lid compression element 38, whereby the individual lid 4 is fully sealed with the container 6. As established hereinabove, the lid compression surface 78 may also be provided with the sealing angle (β) to facilitate the complete sealing of the individual lid 4 with the container 6 in the eighth step 116. Other suitable steps for depositing and sealing the individual 4 with the container 6 may also be employed within the scope of the disclosure.
In further embodiments, the lid applicator 2 of the present disclosure may be mounted on a track (not shown), which in turn may be secured to the conveyor 10. The containers 6 are placed on the conveyor 10, and the nested stack of lids 40 is loaded into the chute 28. As the containers 6 move toward the main body 8, the at least one sensor 44, 46 on the main body 8 counts each approaching container 14 and relays that number to the controller. The container 6 then travels through the passage 42 of the lid applicator 2 until it is directly below the chute 28. Once below the chute 28, the rim of the container 14 contacts the lip of the individual lid 4 which is being advanced downwardly at an angle by the worm screws 30, 32, 34, 36. The forward momentum of the container 6 on the conveyor 10 carries the individual lid 4 away from the worm screws 30, 32, 34, 36, and the individual lid 4 forms a loose seal with the container 6. The container 14 and lid 8 then pass under the platform having the flat surface 25, which presses the lid 8 onto the container 14, forming a complete seal. After the container 14 passes under the flat surface 25, the sensor 38 on the main body 4 may send a signal to the motor 26, causing the worm screws 20 to rotate and dispense another lid 8 at an angle to receive the next container 14.
It should be understood that multiple units of the lid applicator system 2 can be placed adjacent a single conveyor 10. The main bodies 8 of the lid applicator systems 2 may be provided with actuators, such as electrical, mechanical, hydraulic or pneumatic actuators, which may be used to raise an individual one of the main bodies 8 above the conveyer system 10 where that particular lid applicator system 2 is not intended to be in use. There can be any number of lid applicator systems 2 placed on a single conveyor 10. A skilled artisan will appreciate that, having multiple lid applicator systems 2 disposed in series allows for the use of lids 4, 40 and containers 6 of different sizes and shapes to be used on a single line conveyor 10, is more efficient, and minimizes change over time between different products to be packaged.
Advantageously, the lid applicator system 2 of the present disclosure is high-speed, and has been found effective in separating individual lids 4 from nested stacks of lids 40 in a continuous manner, for the lids 4 to be individually secured to containers 6 by the lid applicator system 2.
Other variations and embodiments of the invention are contemplated. Those skilled in the art will readily appreciate such variations upon carefully reviewing the above disclosure. Therefore, the present invention is not to be limited by the above description, but is to be determined in the scope of the claims which follow.
This application claims the benefit of U.S. Provisional Application Ser. No. 62/623,693, filed on Jan. 30, 2018. The entire disclosure of the above application is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62623693 | Jan 2018 | US |
