The present invention is directed to the filed of article handling and more particularly to a system and method for extracting and polywrapping sorted articles. The articles are typically sorted by a delivery point packaging machine (DPP). Articles as used throughout the application is defined as at least one of mail, books, magazines and other such articles. DPP machines are used to sort large batches of articles. The articles are fed into the machine by feeders which also decode the destination address of the article as well as the article's thickness. The DPP includes a plurality of slots or pockets for receiving articles. The pockets are logically assigned a destination address and once the address is known (as will be the case when the article is fed into the DPP) the article is routed to its respective pocket. The pockets are stored in containers, themselves stored in a casting of a tower.
Once the batch of articles is appropriately sorted, it may become necessary, depending upon the application, to extract and polywrap the articles. Extracting the articles from the pockets entails the articles removal from the pockets with the sorting order of the articles within the pockets maintained. Polywrapping the articles entails wrapping at least one of the articles in a polywrap—a plastic like material—which facilitates article handling and the like.
Current systems for extracting and polywrapping articles are cumbersome, complicated, bulky and present engineering challenges. Additionally, extracting and polywrapping systems have not been effectively applied to DPP machines. Accordingly, a need exists in the art for effective and cost efficient article extraction and polywrapping. An additional need is that the aforementioned be applicable to DPP machines.
The present invention is directed to a method for performing article extraction and polywrapping. The invention is further directed to a system for carrying out the method. In the method: the casing are removed to an extraction zone or into an extraction position; a separator sheet present in the container is removed; the bottom of each pocket in the container is individually opened allowing the articles stored therein to fall through the opening; the downward motion of the article is assisted by an H-belt; the articles are received at a polywrapping station where the articles are sequentially polywrapped.
The present system comprises means for accomplishing the aforementioned method steps. In particular, the bottom of the pocket may include a plurality of tracks and the walls defining the pocket may include protrusions which interact with the tracks so as to facilitate lateral displacement of the pocket floor and prevent any articles from becoming caught between a pocket side wall and its base. The article contents remain within the pocket. The H-belt may comprise a top webbing running between the two walls and descendible to the floor. The polywrapping station my include a first and second crimping unit to crimp polywrap film at the beginning and end of the article descent, respectively so as to encase the articles in the film. Likewise, the top of a former set of polywrapped articles may form the bottom of a subsequent set of polywrapped articles, thereby making successive and more efficient use of the film. Additionally, the polywrapping station may include a pair of rollers as well as cutting means arranged to sequentially seal and separate the sets of now polywrapped articles.
These and other embodiments of the present invention will be set out below in more detail with respect to the specification and claims, wherein like reference numerals refer to like parts. In the figures:
a depicts a perspective schematic view of a pocket according to the present invention;
b depicts a second view of the pocket according to
a and 3b depict operation of the present method; and
Carrier 10 comprises a plurality of pockets 12a and 12b for accommodating at least one article 14 therein. The size and number of pockets per container and the number of articles accommodated therein are a matter of design. Pockets 12a include articles therein, while pocket 12b is empty. The pockets generally have at least one open side for article insertion. The pocket bottoms may be selectively opened as will be discussed herein. The pocket tops may be open or close as dependent upon design. As depicted in
Positioned below opening 20 is polywrapping means 21 comprising film 24, a pair of rollers 26, and a plurality of cross sealing bars 28a, 28b. The polywrapping means includes other components known to one skilled in the art and not discussed here for purposes of clarity. The film is introduced into the polywrapping means from two locations so as to run between the rollers and sealing bars in a downward direction away from the sheet bottom 16. Other film introducing schemes may be used as envisioned by the skilled person. As depicted in
b depicts the pocket 12 with base 100 removed and second sheet 50 descended. Prongs 52 abut protrusions 54. The descending motion of the second sheet will urge articles within the cavity through the now open pocket bottom. The combination of the first and second sheet comprise an H-belt.
The operation of the present invention will now be described with reference to
In section 4, the articles 14 accommodated within pocket 12 drop into opening 20 and rollers 26 and atop top cross sealer bars 28a (step 76).
In section 5, the cross section bars 28a descend in the direction of bottom cross bars 28b. This action pulls down the film with the articles creating the side walls which will seal in the articles with the film. Additionally, bottom cross section bars 28b now rise into position above top cross section bars 28a thereby getting ready for the next group of articles. The second sheet 50 is depicted partially descended and protrusions 42 partially elevated (step 78).
In section 6, with the tallest articles descending below the top cross sealer bars 28a, the top cross sealer bars 28a are brought together. The second sheet 50 is depicted fully descended and protrusions 42 fully elevated (step 80).
In section 7, with the pocket 12 now empty, the second sheet 50 is elevated back to a top position with the protrusions 42 descended into a bottom position (step 82).
In section 8, the separator sheet 56 is reinserted in cavity 102 (step 84). At this point, the now empty pocket may be reintroduced for receiving new mail and the method continues with the next pocket including articles therein. The method then ends (step 86).
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
The present application claims priority to provisional patent application No. 60/499,612, filed on Sep. 3, 2003, which is herein incorporated by reference.
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Number | Date | Country | |
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20050044817 A1 | Mar 2005 | US |
Number | Date | Country | |
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60499612 | Sep 2003 | US |