Patent Application
20190002148
The present invention relates to a glove stacking apparatus for preparing a stack of folded gloves prior to packing into a box, and to a method of stacking and folding gloves, particularly ambidextrous disposable hygienic gloves.
The control of infection of patients in hospitals, clinics, and doctors' surgeries has become an ever more pressing concern with the rise of infectious bacteria resistant to multiple antibiotics, in particular methicillin-resistant staphylococcus aureus (MRSA) and Clostridium difficile (C. difficile). In the United Kingdom alone there are thought to be about 5,000 deaths a year from infections caught in hospitals but some experts believe the number could be as high as 20,000.
Disposable medical gloves can help prevent cross-contamination, but a problem arises if external parts of the glove touch the same areas of a dispensing container as have previously been touched by hands which are contaminated with harmful micro-organisms. Such external parts of the gloves can then become contaminated prior to contact with a patient, if these external parts are the fingers or palm area of the glove the likelihood of a patient being contaminated is dramatically increased. To control contamination the cuffs of gloves should therefore be presented to the user from a glove dispenser, so that the user can don one glove at a time while avoiding skin contact with the external glove surfaces at the finger portions, and even the palm portions, of each glove.
In this specification, the term “finger portion” includes the portion of the gloves having glove thumbs, and the term “cuff portion” includes the portion of the glove having the cuff end. A transverse fold in a disposable medical inspection glove will be close to the point when the base of the thumb digit meets the base of the second (i.e. index) finger digit and so the base portion of the glove thumb may be on either side of this transverse folding line, depending on the exact length of the glove and the proportions of the moulded thumb and finger digits. The transverse fold will, in general, cut across a palm portion of the glove. As inspection gloves are most commonly ambidextrous, the “palm portion” may equivalently be termed a “dorsal portion” or “palm and dorsal portion” of the glove. The terms “finger portion” and “cuff portion” as used herein are therefore to be construed purposively, for example as the being, respectively the portion of the glove nearest the tips of the five digits and the portion of the glove nearest the cuff end and neither term excludes the palm and dorsal portion or the possibility that a base part of a digit may end up on the cuff side of a transverse fold line.
Therefore, because of the need to enhance infection Control, the preferred method of dispensing these gloves is by the cuff, so that the user can only remove the gloves from the container by the cuffs rather than by the glove fingers. One example of cuff first glove dispensing systems is disclosed in GB 2454753 A, which shows a cuff-first system in which cuffs are individually folded in half along a transverse axis approximately mid-way along the length of each glove, such that a finger portion of each glove is folded underneath a cuff portion of the same glove. Gloves are then dispensed from an edge of the stack which is held inside a box container having a dispensing aperture in one side face. An advantage of this glove dispensing system is that gloves are packed in an inexpensive box, made from card material and having a removable cover over an opening, with each glove folded over on itself so that the box may have an approximately cubic shape. A disadvantage of this arrangement is that all the cuffs are at one side of the stack, and as the cuff of inspection gloves typically have a rolled end and are therefore thicker, this side of the stack will end up being thicker, which limits how many gloves may fit inside a dispenser of any given size. Therefore it is preferable if the cuffs alternate on opposite sides of the stack. In this case, for there to be a single dispensing aperture, the aperture would have to extend across the top of the stack of gloves rather than across one side wall, and preferably the stack of gloves would be biased towards the dispensing aperture so that it was not necessary to reach into the dispensing aperture for a user to grasp the cuff of the next glove to be dispensed.
Another type of glove dispensing system is disclosed in GB 2510428 A, in which gloves are interfolded inside a stack of gloves for cuff-first dispensing from a dispensing aperture. The stack is packaged inside an inexpensive disposable plastic bag which is itself held inside a re-usable plastic box outer dispenser, which has a dispensing aperture, aligned with a dispensing aperture of the bag. In this specification, the term “interfolded relates to this type of glove folding arrangement, in which gloves are folded transversely proximate a mid-point along the length of the glove. The cuff portion of the next glove to be dispensed is accessible at one end of the stack and the finger portion of the same glove wraps behind the cuff portion of the subsequent glove to be dispensed, such that as each cuff-portion is pulled Out from the dispensing aperture, the finger portion of that glove being dispensed pulls the next cuff portion partially clear of the stack so that this preferably protrudes from the dispensing aperture, for easier manual access when that subsequent glove is to be dispensed. In this arrangement, within the stack (i.e. with the exception of the top-most and bottom-Most gloves of the stack) each glove is folded around portions of the two adjacent gloves, with each cuff-portion being sandwiched between the finger portions of the two adjacent gloves. Similarly, each finger portion is sandwiched between the cuff portions of the two adjacent gloves.
There are two ways in which gloves can be added to a stack and then interfolded with each other. In one way, the finger portion of each glove is deposited at the glove stacking area and a cuff portion is deposited over a folding flap; gloves can then be dispensed cuff-first from the top of the stack. In other way, this orientation is reversed; gloves can then be dispensed from the bottom of the stack.
Most gloves used in hospitals and clinics are examination gloves, and these are used in large numbers. Such gloves are supplied not in individual sterile packages, but in relatively inexpensive cardboard dispensing boxes. The size of boxed gloves is an issue owing to the need to minimise the space needed to store gloves, or the size of dispensing apparatus holding boxed gloves. It is therefore desirable to pack as many gloves as possible into the stack of gloves held within a glove dispenser. As there is a limit to reducing material thickness, the need is therefore to stack gloves as evenly as possible with a minimum of trapped air within the stack of gloves.
Examples of equipment suitable for forming a stack of folded gloves, whether interfolded or not, is disclosed in patent documents WO 2010/020782 A2, WO 2011/048414 A1 and WO 2014/037701 A1. Gloves are transversely folded and held within a packing recess that has a floor with a supporting surface that is relatively movable away from an entrance to the recess such that as a stack of gloves inside the recess grows the top of the stack remains substantially at the same level as the top of the recess. The top of the stack therefore presents a glove stacking area on which subsequent folded gloves may be added to the stack.
To automate the process, glove folding flaps are provided, disposed at opposite sides of the glove stacking area. A packing plate may be provided between the recess floor and the bottom of the growing stack, and a sheet-like packing insert may be provided atop the packing plate and folded upwards a short distance where the packing plate meets recess wall surfaces to prevent portions of gloves from falling into a clearance gap between the packing plate or recess floor and the adjacent wall surfaces of the recess. The packing plate is useful in removing the completed stack from the recess. The completed stack is compressed in the direction of the height of the stack, i.e. along a stacking axis drive, by placing the open mouth of an inverted, rigid packing box over the glove stacking area at the top of the recess, and then driving the recess floor upwards to compress the stack between the packing plate and the opposing, downwardly facing, inside base surface of the inverted box, until the packing plate comes into contact with the open mouth of the box when all the gloves are compressed into the packing box. The packing plate and packing box are provided with interengaging magnets when these meet so that the compressed stack can be easily removed from the packing recess for final packing of the stack of gloves into a dispensing container. The dispensing container may be a card dispenser or a bag dispenser, and in each case it is advantageous if the dispenser lines the inside of packing box. The packing plate can then be removed from the packing box opening, and the dispenser closed where this was left open to allow insertion of the glove stack into the lined packing box.
It is an object of the present invention to provide an apparatus and method for stacking gloves prior to packing in a dispensing box. It is also an object of the present invention to reduce the packing volume of a given number of stacked gloves or to increase the number of gloves contained within a stack having a given packing volume.
According to the invention, there is provided a glove stacking apparatus for forming a stack of folded gloves, comprising:
a supporting surface for supporting said stack as folded gloves are added to the stack along a stacking axis;
a first flap pivotable about a first pivot axis and a second flap pivotable about a second pivot axis, said first and second axes being disposed on corresponding opposite first and second sides of a glove stacking area within which gloves folded by said flaps are, in use, added to the stack, the supporting surface being relatively movable along a stacking axis away from said glove stacking area as said folded gloves are added to the stack;
a cyclic flap actuation system configured to drive a folding action of each flap in which said flaps alternately pivot about the corresponding pivot axis from a first orientation in which said flap is positioned on its corresponding side of the glove stacking area to a second orientation in which said flap extends over the glove stacking area, whereby each flap when in the first orientation is configured to fold a first portion of a deposited glove overlapping said flap towards a second portion of said glove deposited at the glove stacking area as said flap pivots to the second orientation, the folding action of said flaps alternating as gloves are added to the stack;
and wherein
each flap in addition to being pivotable about the corresponding axis is also laterally movable both towards and away from the glove stacking area and comprises a plurality of fingers for folding said first portions, said fingers extending in a lengthwise direction and being separated by gaps;
following the folding action said flap actuation system is configured to drive a withdrawing action of each flap in which said flaps are alternately withdrawn from the glove stacking area, said flap to be withdrawn being maintained in the second orientation while being laterally moved away from the glove stacking area along said lengthwise direction until said fingers are withdrawn from the glove stacking area;
following the withdrawing action said flap actuation system is configured to drive a returning action of each flap in which said withdrawn flap is pivoted about the pivot axis and laterally returned to the first orientation ready for the next folding action, whereby the flap actuation system completes a cycle; and
said apparatus further comprises a first supporting platform and a second supporting platform, said first and second platforms being disposed, respectively on said opposite first and second sides of the glove stacking area for supporting said first portion of a deposited glove prior to folding of said first portion by the fingers of the corresponding flap, each supporting platform having a plurality of slots therein, the slots of each platform being aligned with the fingers of the corresponding flap to accommodate movement of said fingers during said cycle of the flap actuation system.
Also according to the invention, there is provided a method of forming a stack of folded gloves using a glove stacking apparatus for forming a stack of folded gloves, the apparatus comprising: a supporting surface for supporting said stack as folded gloves are added to the stack along a stacking axis; a first flap pivotable about a first pivot axis and a second flap pivotable about a second pivot axis, said axes also being laterally movable with respect to a glove stacking area within which gloves folded by said flaps are, in use, added to said stack, said first and second axes being disposed on corresponding opposite first and second sides of a glove stacking area and the flap comprising a plurality of fingers that extend away from the corresponding pivot axis; a cyclic flap actuation system configured to drive a folding action of each flap in which said flaps alternately pivot about the corresponding pivot axis; and a first supporting platform and a second supporting platform, said first and second platforms being disposed, respectively on said opposite first and second sides of the glove stacking area, the first supporting platform be configured to be used in conjunction with the first flap and the second supporting platform being configured to be used in conjunction with the second flap, each supporting platform having a plurality of slots therein, wherein the method comprises:
depositing a sequence of gloves to be folded into a stack by said apparatus, each glove having a first portion and a second portion, one of said portions being a finger portion and the other of said portions being a cuff portion, the first portion of each glove being deposited, alternately, at one or the other of said platforms and the second portion of each glove being deposited at the glove stacking area;
when a glove is deposited with the first portion at the first platform, using the first platform to support said glove and using the flap actuation system to pivot the fingers of the first flap about the first pivot axis in a folding action of said flap to lift said first portion off the first platform and to fold said first portion towards the glove stacking area until the fingers of the first flap extend over the glove stacking area, said folded glove thereby being added at the top of the stack of folded gloves;
when a glove is deposited with the first portion at the second platform, using the second platform to support said glove and using the flap actuation system to pivot the fingers of the second flap about the second pivot axis in a folding action of said flap to lift said first portion off the second platform and fold said first portion towards the glove stacking area until the fingers of the second flap extend over the glove stacking area, said folded glove thereby being added at the top of the stack of folded gloves;
as said alternately folded gloves are added to the stack of folded gloves, using the supporting surface to support said stack whilst relatively moving the supporting surface away from the glove stacking area so that the top of said stack remains substantially level with said pivot axes so that said flaps may continue to alternately fold and add to said stack subsequently deposited gloves;
after each folding action using the flap actuation system to drive a withdrawing action of the corresponding flap in which said fingers are laterally withdrawn towards a side of the glove stacking area, said fingers thereby being withdrawn from said stack;
after each withdrawing action, using said flap actuation system to pivot and laterally move said flap in a returning action of the corresponding flap to return said flap to a position ready for a subsequent folding action; and
either during the folding action or during the returning action of each flap, passing the fingers of said flap through the slots in the corresponding supporting platform.
The slots may be apertures that allow passage of the fingers through the platform during the cycle of the flap actuation system. Alternatively, the slots may be grooves in a top surface of each platform, in which case the flaps in the returning action move the fingers into the grooves prior to the next folding action of said fingers.
The method may comprise an initial step of first moving the supporting surface proximate the level of the glove stacking area prior to deposition of the first glove.
If the recess has a movable floor that provides the supporting surface, then this floor may then be relatively lowered as required to keep the top of the stack of gloves in the recess substantially level with a desired level of the glove stacking area and the adjacent flaps and supporting platforms.
In a preferred embodiment of the invention, the apparatus comprises a glove packing recess, the recess having an opening through which folded gloves must pass as the stack grows, the opening therefore defining the glove stacking area. Preferably, the recess helps to contain and define the exterior shape of the stack of gloves as the stack is being formed.
The recess may simply be a frame that extends around the glove stacking area. Preferably, the recess has side rails or side walls that extend downwardly from the glove stacking area and that align the stack and help to define a substantially rectangular cross-section about the stacking axis of the growing stack, which may therefore be the same as an axis of the recess. At least some of the walls may be continuous and optionally be tapered outwards from the stacking axis in a downwards direction away from the glove stacking area, in order to minimise friction and binding with the external portions of stacked folded gloves, as the supporting surface moves away from the glove stacking area during the addition of folded gloves to the stack, or during a subsequent glove packing stage when excess air is compressed out of the completed stack by driving the supporting surface relatively upwards with respect to the glove stacking area prior to removal of the stack from the recess and packing into a bag, box or other container from which gloves will, in use, be dispensed.
The supporting surface may be provided, ultimately, by a floor that is relatively movable away from the glove stacking area. In this packing process, it is preferred if the lowermost glove in the stack of gloves rests directing in a thin packing insert or sheet that extends across the base of the recess and upwards around its periphery. A packing plate may also be provided above the floor and beneath the packing insert. The packing plate may be used to compress and contain the stack inside a rigid packing box after completion of the stack, prior to enclosing the stack inside a card material container or bag-like container having a dispensing aperture for cuff-first dispensing of the gloves. Examples of such packing recesses, packing plates, packing boxes and containers are known to those skilled in the art, for example as disclosed in patent documents WO 2010/020782 A2, WO 2011/048414 A1 and WO 2014/037701 A1 and as mentioned in the above introduction to this specification, and so will not be further described in detail.
The recess preferably has side walls or rails for aligning gloves stacked one on another inside the recess and a movable supporting surface which can be lowered as said stack of gloves grows so the topmost glove in the stack of gloves is substantially level with a top edge of the recess, which may be inset in a work surface. Although it is in principle possible that the supporting surface may be fixed and other components including the flaps may be upwardly movable. This is not preferred, however, as the stack, when completed, may be 600 mm, and so this may entail more mechanical complexity than having a downwardly movable supporting surface.
An actuator may be provided for moving the supporting surface downwardly so that the stack of gloves continues to be retained within the recess as gloves are added to the stack.
Preferably, the compression of the stack of gloves by the fingers of each flap provides a motive force for moving the supporting surface downwardly.
The movable flaps are preferably adjacent opposite edges of a recess which helps to define the edges of the stack as a portion of each deposited glove that initially overlaps one or the other of these edges folded towards the recess.
The, or each, flap may be hinged adjacent the corresponding side of the glove stacking area, the hinge then providing the corresponding pivot axis.
In a preferred embodiment of the invention, the recess is substantially square or rectangular and there is a pair of flaps on opposite side edges of the recess for folding alternately inwards to the recess portions of gloves overlapping alternately one or another of said opposite side edges of the recess. In this case, the glove stacking area is defined as the area within the topmost edges of the recess.
Preferably, the, or each, flap is arranged to fold towards the recess such that, in use, the fingers of each flap contact and continue to press against the stack of folded gloves formed in the recess in order to help compress the stack of gloves.
The flap actuation system will, in general, have a first and a second glove folding actuator for individually driving, respectively, the folding action of the first flap and the second flap. The flap actuation system will also, in general, have a first and a second flap movement actuator for individually driving, respectively, the lateral movement of the first flap and the second flap with respect to the glove stacking axis.
The operation of the first glove folding actuator and the first flap movement actuator are preferably synchronised during the returning action so that the flap can be both pivoted about the first axis while at the same time the first axis is moved laterally towards the glove stacking area as the first flap returns to aft orientation ready for the next folding action. The second glove folding actuator and the second flap Movement actuator are also preferably synchronised in the same way with relation to the second flap and second pivot axis.
The supporting surface is relatively movable along the stacking axis, which will normally be a vertical axis, with respect to the glove stacking area, which will, in use, be at the top of the stack of gloves that is being formed, so that the flaps may be used to alternately fold in towards the glove stacking area the portion of each deposited glove that overlaps one or the other of the flaps. This relative movement may most conveniently be provided if the support surface is movable away from the level of the glove stacking area. This relative movement may, however, alternatively be achieved by repositioning the flaps further away from a stationary supporting surface, or by a combination of movement of the supporting surface and the flaps.
The relative movement may be passive or automatic, for example driven by the increasing weight of the stack of gloves or by downward pressure exerted by the flaps as the flaps fold glove portions towards the glove stacking area and onto the top of the stack of glove being formed. Alternatively, an actuator may be provided to actively effect the relative movement of the supporting surface.
In either case, the apparatus may comprise an elevation adjustment mechanism configured to relatively move the supporting surface with respect to the first and second flaps along the stacking axis in order to keep the glove stacking area positioned substantially between the pivot axes as gloves are added to the stack.
The first and second flaps and the supporting surface are part of a glove folding and stacking station at which glove are to be deposited. Gloves may be moved towards the glove stacking area by means of a conveyor, the location and orientation of each glove being determined by a machine vision system, following which gloves are individually lifted from the conveyor and deposited partially over one or the other of the flaps and partially over the growing stack within the glove stacking area. The details of the conveyor and glove depositing apparatus are not central to the invention, which essentially concerns the glove folding and stacking apparatus and process after the deposition of gloves.
Each platform will, in general, have an upper surface and a lower surface. The upper surface is configured to provide support to the first portion of a deposited glove.
The withdrawing action of each flap may take place beneath the lower surface. Each withdrawn flap may therefore extend beneath the corresponding supporting platform lower surface.
The fingers of each flap pass through the slots of the corresponding platform preferably during the folding action of the flap.
in a preferred embodiment of the invention, each flap, during the returning action simultaneously pivots about the corresponding pivot axis and moves laterally such that the pivot axis moves towards the glove stacking area.
The withdrawing action of each flap preferably does not occur until after the folding action of the other flap. As a result of this, the fingers of both flaps are in contact with the stack for an interval until the withdrawing action has occurred.
Adjacent fingers of each flap are separated by a corresponding gap. So that the flaps do not interfere with each other when both are in contact with the folded stack of gloves, it is preferred if at least one finger of each flap is aligned with a corresponding gap between fingers of the other flap when the fingers of both flaps are in contact with the stack.
The width of each one of the gaps in each flap is preferably greater than the width of the finger in the other flap with which said gap is aligned.
Preferably, the width of the, or each, gap is between 2 and 10 times the width of the finger with which said gap is aligned. In a preferred embodiment of the invention, the fingers are aligned centrally with the corresponding gaps in the other flap.
The flap may be a fork-like flap, the fingers having the forms of tines that extend from a common base portion of each flap. In one embodiment, the base portion comprises a pivot shaft. In another embodiment, the base portion is a member that extends radially away from a pivot shaft. In either case, rotation of the pivot shaft defines the pivot axis.
The flap actuation system may be configured to maintain each flap in the second orientation after each folding action to apply a downward pressure to the stack until after the other flap has completed the subsequent folding action.
In a preferred embodiment of the invention, the flap actuation system is configured to apply a continuous pressure along the stacking axis to the stack through one or both of the flaps as gloves are added to the stack. Most preferably, at least one flap applies a compressive force to the stack at all times during the alternate folding of gloves as gloves are added to the stack.
The most common types of inspection glove are dip moulded on hand-shaped formers in latex or nitrile material. Gloves are then stripped from the formers, which inevitably results in air entering the glove interior. Gloves may be stripped either manually or in an automated process, and in either case each stripped glove has a unique configuration when laid flat, for example on a conveyor. These factors mean that there will, inevitably, be unwanted air pockets both inside gloves and between adjacent glove external surfaces once gloves have been folded into the stack. In principle, air can be squeezed out in a later processing step, however, it has been found in practice that this can take many minutes. The present invention greatly reduces the time needed to expel air from the stack, because the flaps remain in contact with the newly folded glove for a longer period of time as compared with the prior art in which a flap simply pivots away from the folded glove, retracing its path prior to the next folding action. The material of the most gloves is elastomeric and so will naturally tend to spring back, drawing in more air as soon as the flap is folded back. By moving the flap laterally away in the withdrawing step, this effect is reduced. Furthermore, there is no unwanted lifting effect due to air suction as the flap is removed. All these factors help stabilise the stack, particularly when at least one flap is always in contact with the stack and most particularly when One or both flaps are applying a compressive force prior to withdrawal.
In a preferred embodiment of the invention, each flap comprises a base portion proximate the pivot axis of the flap, with the fingers of the flap extending away from the base portion.
The pivot axis may be provided by at least one pivot shaft the, or each, shaft being rotatable about the corresponding pivot axis.
The base portion of each flap may comprise a shaft. The shaft may then extend laterally away from the flap towards a rotation and translation actuator for rotating the shaft about the corresponding pivot axis and for moving the shaft laterally both towards and away from the glove stacking area as required during the withdrawing and returning actions.
The flap actuation system may be configured during the withdrawing action to laterally move the flap such that the pivot axis of each flap moves away from the stack until the flap is fully withdrawn from the stack and then during the returning action to pivot the flap about the corresponding pivot axis while at the same time laterally moving the flap such that the pivot axis of each flap moves back towards the stack.
During the folding action each flap may rotate above a stacking plane passing through the stacking area.
During the returning action each flap may rotate below the stacking plane.
Each of the pivot axes may be provided by at least one pivot shaft rotatable about the corresponding pivot axis, each pivot shaft rotating and moving laterally beneath the corresponding supporting platform as the flap actuation system drives each flap throughout the cycle of the flap actuation system.
Preferably, each of the pivot axes is provided by at least One pivot shaft rotatable about the corresponding pivot axis, the pivot shaft carrying the corresponding fingers beneath the corresponding supporting platform as the flap actuation system drives each flap throughout the withdrawing action and returning action.
In a preferred embodiment of the invention, the slots in the platform separate adjacent platform strips. The platform may have a base portion, the strips extending in a lateral direction relative to the stacking axis towards the glove stacking area. Preferably, the strips are wider than the slots so that the supported glove does not sag significantly into the slots.
As the glove stack grows an elevation adjustment mechanism may be used to relatively move the supporting surface with respect to the flaps along the stacking axis in order to keep the glove stacking area positioned substantially between the pivot axes as gloves are added to the stack.
The glove stacking apparatus may be used as part of an apparatus for transporting and stacking folded gloves in a stack, comprising at least one conveyor for transporting the gloves to be stacked, a glove position sensor for sensing the presence and orientation of the transported gloves on the conveyor, a processor, the apparatus further comprising a glove depositing apparatus for moving the transported gloves from the glove conveyor and depositing the gloves one at a time over the glove stacking area and alternately one or the other of the supporting platforms, to form the folded stack supported by the supporting surface.
The glove depositing apparatus may include a lifting and depositing actuator for lifting each of the gloves to be moved from the conveyor and for depositing each of the lifted gloves over the glove stacking area and one or the other of the supporting platforms.
The processor is connected to the glove position sensor and to the glove depositing apparatus for controlling the deposition of gloves in accordance with the sensed presence and orientation on the conveyor so that, in use, the glove depositing apparatus lifts gloves from the conveyor and deposits the gloves on the glove stacking area and one or the other of the adjacent supporting platforms as described above.
The sensor may sense additionally the orientation of a cuff portion and/or thumb portion of each of the transported gloves on the conveyor, and the processor may be arranged to control the operation of the glove depositing apparatus in accordance with the sensed orientation so that, in use, a lifting and depositing portion of the glove depositing apparatus lifts gloves from the conveyor and deposits the gloves correctly oriented for alternate folding to form the stack with the cuff portion and finger portion of each deposited glove in a desired orientation with respect to other gloves in the glove stacking area and adjacent supporting platforms.
The lifting and depositing portion of the glove depositing apparatus may be connected to a pneumatic system for controlling a vacuum lift of the gloves, the vacuum lift being released prior to, or simultaneously with, depositing of the gloves. The lifting and depositing portion May include a lifting surface against which, in use, the gloves are held when moved and positioned by the glove depositing apparatus prior to depositing for stacking.
When the glove depositing apparatus includes a lifting and depositing portion, this may be used to lift each of the gloves to be moved from the conveyor and to deposit each of the lifted gloves at the stacking station.
The pneumatic system for applying a vacuum to a lifted glove in order to adhere the lifted glove to the glove depositing apparatus may act through a downwardly directed surface of a glove lifting and depositing head at the end of a robotic actuator arm.
The invention will now be further described, by way of example only, and with reference to the accompanying drawings, in which:
The apparatus 1 comprises a supporting base or surface 6 for supporting the stack 2 as folded gloves 10 are added to the stack along a stacking axis 8, which in this example is a vertically orientated axis. As shown in the schematic cross-sections starting with
The apparatus 1 comprises a first flap 18 pivotable about a first pivot axis 19 and a second flap 18′ pivotable about a second pivot axis 19′, these axes being parallel with each other and perpendicular with and laterally offset from the stacking axis 8. The first and second axes 19, 19′ are disposed on corresponding opposite first and second sides 21, 21′ of a glove stacking area 20 within which gloves 10 folded by the flaps are, in use, added to the stack 2. The glove stacking area is shown schematically with cross-hatching in
The apparatus comprises a cyclic flap actuation system 25, shown schematically in dashed outline in
In this example, each flap 18, 18′ always pivots in the same direction, the handedness of the pivoting movement always being opposite for the two flaps.
Each flap 18, 18′, when in the first orientation, is configured to fold a first portion 3 of a deposited glove 10 overlapping the flap towards a second portion 5 of the glove that has been deposited at the glove stacking area 20 as the flap pivots to the second orientation. This automatic folding action of the flaps alternates as gloves are added to the stack, such that glove folds are formed alternately, at the first and second sides 21, 21′ of the glove stacking area 20.
In this example, the glove first and second portions 3, 5 are, respectively, cuff and finger portions of each glove 10, and will therefore for the sake of clarity only be referred to as such in the following description. The stacking process described below forms an interfolded stack of gloves which, when packed into a box dispensing container or bag-like dispensing container having a dispensing aperture, will dispense gloves cuff-first from a dispensing end of the stack, which would, in this example, be the top end of the stack as oriented in
Each flap 18, 18′, in addition to being pivotable about the corresponding pivot axis 19, 19′, is also laterally movable by the flap actuation system 25 both towards 28, 28′ and away 29, 29′ from the stacking axis 8. The first and second flaps each also comprise a plurality of fingers 30, 30′ that extend away from corresponding first and second pivot shafts 31, 31′ that define the first and second pivot axes 19, 19′ of the flaps. The flap fingers are configured to lift and then fold over the glove cuff portions during each folding action.
The flap fingers preferably have a rounded cross-section. In this example the flap fingers have a circular cross-section which helps to minimise frictional drag between the flap fingers and adjacent glove layers during a withdrawing action, described below.
The apparatus further comprises first and second supporting platforms 24, 24′ that are disposed, respectively, on the opposite first and second sides 21, 21′ of the glove stacking area 20. These platforms provide support to the cuff portion 3 of a deposited glove 10 prior to folding of the cuff portion 3 towards and onto the growing stack 2 at the stacking area by the fingers 30, 30′ of the corresponding flap 18, 18′. As can be seen most clearly in
Part of the cyclic flap actuation system 25 may be combined within the overall control system 40. The flap actuation system 25 also comprises first and second hydraulically power rotation actuators 32, 32′ for pivoting 27, 27′ each of the flaps about the corresponding pivot axis 19, 19′, and first and second hydraulically powered linear actuators 34, 34′ for laterally moving 29, 29′ the corresponding pivot axes. Each rotation actuator comprises a hydraulic motor 33, 33′ and each linear actuator has a hydraulic motor 35, 35′. The rotation motors drive the pivot axes directly. Each rotation motor is mounted on a laterally movable carriage 36, 36′ that is laterally driven from a belt-driven drive chain 37, 37′ powered by the corresponding linear motor 35, 35′.
The control system 40 also controls the operation of another linear actuator 38 that controls the elevation of the recess floor 12. This vertical linear actuator 38 comprises a hydraulic motor 39 connected via a belt drive chain 41 to a vertical shaft worm gear 43 (see also
The operation of the apparatus 1 will now be more fully described, starting with
Gloves are transported to the glove stacking station 4 by a conveyor belt 50. The speed of the belt is set by a conveyor belt drive motor 51, which is controlled by the control system 40. A machine vision system 60 provides to the control system 40 an indication of the position and orientation of each glove 10. A robotic arm actuator 70, has a glove lifting and depositing head 71 with a vacuum lifting plate 72, which is controlled by the control system 40 to lift passing gloves 10 off the belt 50 and to deposit these, one at the time, at the glove stacking and folding station 4 with cuff portions 3 overlapping, alternately the first and second support platforms 24, 24′, as described above.
initially, as shown in
This folding action on the first deposited glove 10A is illustrated in
Then, as shown in
From this it can be seen that the apparatus is configured to deposit gloves with the finger portion of each deposited glove being disposed over the fingers of the same flap that will fold the cuff portion of the same glove in the subsequent folding action.
It should be noted that the pressure on the fingers of the flap about to be withdrawn, applied by the fingers of the other flap, is not such as to inhibit withdrawal of the flap, or cause the flap to pull folded or unfolded glove portions in contact with the fingers out of or away from the glove stacking area.
This downward pressure from the fingers 30, 30′ is a reaction force against an upwardly applied force from the recess floor 12. The rotation motors 32, 32′ do not actively control this force, but do include torque sensors 48, 48′ connected to the control system 40. The control system uses the vertical linear drive actuator 38 to adjust the elevation of the floor 12 up and down in order to maintain the pressure applied between the flap fingers and floor to within set limits. This also automatically results in the floor being lowered as gloves are added to the stack. The desired pressure will be different according to glove type, but is typically set to be between 1 and 5 Newtons, when the lateral folded dimensions of the stack of gloves is 118 mm by 125 mm.
After the folding of the second glove,
Once fully withdrawn,
As can be seen from
Meanwhile, as this is happening,
Then as shown in
Following this, pressure continues to be exerted on the stack between the fingers 30, 30′ of both flaps and the recess base surface 6.
At about the same time as this,
This embodiment also has first and second supporting platforms 124, 124′ that are disposed, respectively, on the opposite first and second sides 21, 21′ of the glove stacking area 20. These platforms may have the same thickness in the vertical direction of the platforms 24, 24′ These platforms provide support to the cuff portion 3 of a deposited glove 10 prior to folding of the cuff portion 3 towards and onto the growing stack 2 at the stacking area by the fingers 130, 130′ of the corresponding flap 118, 118′. Each supporting platform 124, 124′ has a plurality of slots 126, 126′ that are aligned with the fingers 130, 130′ of the corresponding flap when the flap is in the first orientation.
Between the slots 126, 126′ each platform has slats or projections 142, 142′. The flap fingers 130, 130′ are separated by gaps 144, 144′. The platform slats are aligned with corresponding finger gaps. As in the first embodiment, sufficient clearance, in practice about 1 mm on each side, is provided so that the slots in each platform allow passage of the fingers through the corresponding platform as the flap cyclically automatically moves through a repeating series of actions under the overall control of the control system 40.
As in the first embodiment the first flap 118 is pivotable 127 about the first pivot axis 119 and the second flap 118′ is pivotable 127′ about a second pivot axis 119′, these axes being parallel with each other and perpendicular with and laterally offset from the stacking axis 8. The first and second axes 119, 119′ are disposed on corresponding opposite first and second sides 21, 21′ of the glove stacking area 20 within which gloves 10 folded by the flaps are, in use, added to the stack 2.
In this embodiment, the pivot shafts 131, 131′ when retracted in the withdrawing action laterally move axially, along the pivot axes in a direction away 129 from the glove stacking area 20. As shown in
As in the first embodiment, each slot 126, 126′ extends through the corresponding platform 124, 124′, which optionally may have the same thickness in the vertical direction as in the first embodiment. The advantage of this is that during the returning action, the fingers may enter the slots, or be moved into position just below the level of the slots, and the glove supported on the platform, in different ways. For example, following completion of the rotation, by movement in the axial, horizontal direction; or, as in the first embodiment, by rotating into the slots from below. As shown schematically in.
Alternatively, the slots may be grooves in the top surface of the platform, which may therefore be thicker than that illustrated, the grooves being open at one end to receive the fingers in the axial, horizontal direction. The grooves would, however, have to be deep enough so that the fingers did not brush against or disturb the underside of the previously deposited glove. In this case, the slats or projections 142, 142′ would be lands between the grooves.
Whether the slots are apertures or grooves, the slots of each platform are aligned with the fingers of the corresponding flap when the flap is in the first orientation to accommodate movement of the fingers during the cycle of the flap actuation system.
Not shown in
the first portion of the third glove resting on the first platform is folded over the second portion of the fourth glove;
the fingers of the second flap are laterally withdrawn, and then rotated and moved back into alignment with the slots of the second supporting platform, thus completing full cycles of both flaps.
It will be appreciated that in the method described above, the control system 40 synchronises the deposition of gloves by the rest of the glove depositing apparatus and the folding of gloves by the flap actuation system, in such a way as to minimise the cycle time.
The recess 17 is about 600 mm deep when the floor is fully lowered. When stacking and folding nitrile medical inspection gloves of 3 g weight using prior art folding machinery as disclosed in WO 2010/020782 A2, WO 2011/048414 A1 and WO 2014/037701 A1 it has been possible to stack and fold about 180 gloves in this depth. Using the apparatus and method according to the invention described above, the number is increased to about 250 gloves. Because the glove layers are continuously compressed, it is easier and quicker to compress air out the completed stack when the floor is used to ram the stack up against the inside of a rigid packing box positioned above the top of the recess. The result is that 250 gloves can readily be packed in a standard size glove dispensing box, as opposed to between 125 and 180, as has possible in the prior art. As glove weight is expected to be reduced towards 2.5 g, it is expected that up to 500 gloves can be packed in a recess 600 mm long.
The increased packing density is achieved not just by helping to keep air from being drawn into the stack owing to the elastic rebound of the material in the folded gloves, but also by better control of the location of the fold line. Apart from the fold imparted to the first glove 10A, it can be seen from the above description that in each subsequent fold, the glove about to be folded is held down proximate the forthcoming fold line by at least some of the fingers of the other flap not doing the folding. The fold lines are therefore reliably and repeatedly positioned near the two opposite sides of the stack adjacent the first and second sides 21, 21′ of the glove stacking area 20. This helps to minimise wasted space within the glove stack as well as helping to keep the glove layers relatively flat between these sides.
It will also be appreciated that the invention completely avoids any pneumatic effects that could cause a lifting Or a shifting of the top folded layer, which can happen in the prior art when a glove folding flap simply retraces its path after the folding of a glove.
The production line will normally have two stacking stations 4 per robot 70, one recess being filled with folded gloves while the other is emptied of a completed stack. One control system 40 can also be used to control two stacking stations. When one recess is full, a worker will activate the control system 40 to compress the glove stack upwards out of the recess into a packing rigid packing box, as known in the prior art. While this is taking place, the robot starts to fill a previously emptied packing recess at the other stacking station. Gloves are placed and folded at a rate of about one per second and so it will take about 250 seconds to fill up the packing recess. Prior art glove folding apparatus would take about 180 seconds to place and fold 180 gloves in the same size packing recess. The increased time is an advantage on the production line because this gives enough time, nearly 4 minutes, for one worker to remove and pack the gloves before the packing station has to be ready to start receiving gloves. It is harder to achieve this within 3 minutes without using two workers or without periodically shutting down the belt conveyor.
The invention therefore affords greater convenience to the end user, and greater economy on the production line. The end user can store more gloves or store the same number of gloves in less space, and a glove dispenser will need refilling less often. In production, the labour requirement is reduced owing to the cycle time between changing over completed packing recesses being increased. During transportation, more gloves can be packed inside a standard 40 foot shipping container.
The invention therefore provides a convenient apparatus and method for stacking gloves prior to packing in a dispensing box.
It is to be recognized that various alterations, modifications, and/or additions may be introduced into the constructions and arrangements of parts described above without departing from the spirit or scope of the present invention, as defined by the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1522852.1 | Dec 2015 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2016/057947 | 12/22/2016 | WO | 00 |
