EP0817746B1 - Method and apparatus for loading containers into open-bottomed basket-style carrier - Google Patents

Description

The invention relates to bottom-loading basket-style carriers for articles such as beverage bottles.

Previous methods and apparatus for loading bottles into basket-style carriers from the bottom are disclosed in US patent number 2,276,129 to Wesselman, US patent number 2,603,924 to Currie et al; US patent number 3,521,427 to Masch, US patent number 3,627,193 to Helms, US patent number 3,698,151 to Arneson, US patent number 3,751,872 to Helms, US patent number 3,747,294 to Calvert et al; US patent number 3,805,484 to Rossi, US patent number 3,842,571 to Focke et al; US patent number 3,848,519 to Ganz, US patent number 3,924,385 to Walter, US patent number 4,915,218 to Crouch et al; US patent number 4,919,261 to Lashyro et al; US patent number 5,234,103 to Schuster, and US patent number Re. 27,624.

US 3,940,907 to Ganz illustrates an apparatus for automatically opening and loading collapsed bottle carriers. The apparatus includes a conveyor mechanism for advancing successive collapsed cartons and slow members for opening the cartons. The erected cartons are lowered onto an advancing group of bottles and the top and bottom panels are closed. belt pairs in face-to-face relationship forming a pathway therebetween for receiving and gripping transversely extending bottom panels of the carriers.

According to another optional feature of this aspect of the invention there may further comprise a seating assembly having a plurality of seating members for engaging tops of handles of the carriers, said seating members in rotatable cooperative disposition with respect to the carriers which have been placed over said groupings of containers such that as said seating members rotate bottommost ones thereof engage the respective tops of handles of the carriers.

According to an optional feature of this aspect of the invention, said at least one column of a series of groupings of containers may comprise at least two columns.

A second aspect of the invention provides a packaging machine for loading containers into open-bottomed carriers, by carton loading apparatus referred to in any of the preceding few paragraphs, the packaging machine further comprising:

a container feeder assembly having conveyor mechanism for translating at least one column of a series of groupings of predetermined numbers of containers along a first level;

a carrier feeder for retrieving the carriers from a carrier infeed supplier;

A problem associated with the prior art is that it is difficult to accurately control the loading operation because the carton tends to collapse as it is being moved in a continuous forward direction.

The present invention seeks to overcome or at least mitigate the problems associated with the prior art.

The present invention provides a method and apparatus for the continuous opening and loading of basket-style bottom-loading carriers.

In accordance with a first aspect of the invention there is provided an apparatus for loading containers into open-bottomed carriers having transversely extendable panels extending from side walls the apparatus comprising carton lowering means to lower the carton onto said groupings of containers a carton gripper and lowering assembly for grasping and pulling the bottom panels of the carriers outwardly with respect to a centerline thereof such that the bottom panels are substantially transversely disposed with respect to side walls of the carriers as the carriers are transported in synchronous downwardly-declining linear motion over respective ones of said groupings of predetermined numbers of containers.

According to an optional feature of this aspect of the invention, the gripping and lowering assembly comprises a downwardly-declining pair of opposing elongated endless a carrier timer-transport assembly disposed in operative communication with said carrier feeder for receiving the carriers from said carrier feeder and initiating transport of the carriers in synchronous parallel motion with said at least one column of a series of groupings of predetermined numbers of containers at a second level above said first level such that the carriers are aligned over respective ones of said groupings of predetermined numbers of containers and a bottom panel closure mechanism for securing the bottom panels of each carrier together.

A third aspect of the invention provides a method for loading containers into bottom-loading carriers, the carriers having a pair of transversely extending panels extending from side walls thereof, the method comprising: translating the containers along a first level in at least one column of a series of groupings of predetermined numbers of the containers; retrieving the carriers from an infeed supply of the carriers and transporting the carriers in synchronous parallel motion with said at least one column of a series of groupings of predetermined numbers of containers at a second level above said first level such that the carriers are aligned over respective ones of said groupings of predetermined numbers of containers; as the carriers are translated, grasping and pulling the bottom panels of the carriers outwardly with respect to a longitudinal centerline thereof such that the bottom panels are substantial transversely disposed with respect to side walls of the carriers;engaging the bottom panels of the carriers and transporting the carriers in synchronous downwardly-declining linear motion over respective said groupings of predetermined numbers of containers; and securing the bottom panels of each carrier together to form a closure therewith.

According to an optional feature of the third aspect of the invention, the step of translating the containers along a first level in at least one column comprises translating the containers along a first level in at least two columns of a series of groupings of predetermined numbers of the containers.

Other advantages and features of the present invention will be apparent from the following description, the accompanying drawings, and the appended claims.

Fig. 1 is an isometric illustration of a carrier suitable for loading by an apparatus for loading bottom-loading basket-style carriers according to a preferred embodiment of the invention.

Fig. 2 is a plan view of a blank for forming the carrier of Fig. 1

Fig. 3 is an illustration of the carrier of Fig. 1 in collapsed condition.

Fig. 5 is a schematic illustration of an apparatus for loading bottom-loading basket-style carriers according to a preferred embodiment of the invention.

Fig. 6 is an isometric illustration of a hopper for the apparatus of Fig. 5.

Fig. 7 is an elevational view of the hopper of Fig. 6 loaded with at least one carrier.

Fig. 8 is an isometric illustration of a carton feeder of the apparatus of Fig. 5.

Fig. 9 is a plan illustration of a portion of a nip belt assembly of the apparatus of Fig. 5 engaging a carrier.

Figs. 15 and 16 are schematic representations of the panel-gripper assembly of the apparatus of Fig. 5 in operation.

Fig. 17 is an end elevational illustration of the nip belt assembly and panel-gripper assembly of the apparatus of Fig. 5 engaging a carrier.

Fig. 18 is a plan layout of the panel-gripper assembly of the apparatus of Fig. 5.

Fig. 26 is a side elevational view of declination and seating assemblies of the apparatus of Fig. 5.

Figs. 27 and 28 are end elevational views from the declination belt section of the apparatus of Fig. 5.

There are no Figures 4, 10-14, 19-25, 29-39.

Detailed Description of the Preferred Embodiment The Carrier

The method and apparatus 10 described herein as the preferred embodiment of the invention is particularly suitable for loading carriers such as the bottom-loading basket-style carrier 3 shown in Fig. 1. Although use of the method and apparatus 10 of the subject invention is not limited to the carrier 3 described below, the features of the invention are very clearly described by reference to the invention's handling and loading of the carrier 3 illustrated. A blank 906 for forming the carrier 3 is shown in Fig. 2. Fig. 3 is a plan view of the collapsed carrier 3 of Fig. 1.

The carrier 3 is of the nature described in US patent application serial number 08/326,987. That application is also owned by the owner of the present invention application. The carrier 3 and blank 906 for forming the carrier 3 are described below to facilitate understanding of the invention. First, reference is made to Figs. 1 and 2 simultaneously. The carrier 3 illustrated is generally designed to accommodate two rows of bottles. The examples of carriers 3 discussed herein describe use of the invention with carriers 3 that accommodate two rows of three bottles and two rows of four bottles, that is, a six-pack version and an eight-pack version. However, the invention may also be practiced to accommodate rows of other multiples of bottles. Both sides of the carrier are the same. Thus, the features described with respect to the side shown in Fig. 1 are equally applicable to the unseen side. The side wall 920, 930 has a cut-out portion that generally defines a lower side wall band 921, 931 and an upper side wall band 923, 933. Foldably connecting the lower 921, 931 and upper 923, 933 bands to respective end walls 940, 942, 950, 952 are respective corner tabs 922, 932, 924, 934. The corner tabs 922, 932, 924, 934 respectively form bevelled corners at the intersections of the side walls 920, 930 and end walls 940, 942, 950, 952.

A center cell is formed on each side of the carrier by cell bands 925, 935, corner tabs 926, 936 foldably connected to the cell bands and a central cell portion 927, 937 integrally formed with the side wall 920, 930.

A handhold flap 984 is also visible from the view shown. Cut lines between center cell portions of side walls 920, 930 and respective handle structure panels 980, 982, 990, 992 terminate in respective curved cut lines 986, 988, 996, 998. Cut lines between the upper bands 923, 933 of respective side walls 920, 930 and corresponding center cell portions terminate in respective curved cut lines 987, 989, 997, 999.

The blank 906 is essentially symmetric about a perforated fold line dividing the handle panels 980, 982, 990, 992, and halves, of the carrier 3 from one another. One of the two bottom wall panels 910, 912 is widthwise greater than the other and for convenience is designated the greater bottom wall 912. The other bottom wall panel is conveniently designated the lesser bottom wall panel 910.

Support tabs 961, 963, 971, 973 for attachment to the bottom wall panels 910, 912 are foldably connected to the lower edges of respective riser panels 960, 962, 970, 972. A suitable carrier for loading by the invention may also have the support tabs connected to the lower edges of respective end walls 940, 942, 950, 952 along fold lines without departing from the scope hereof. The center cell bands 925, 935 are connected along perforated fold lines to the lower portions of respective handle panels 980, 982, 990, 992. Handhold apertures 981, 983, 991, 993 are formed in the respective handle panels 980, 982, 990, 992.

Handhold flaps 984, 994 are connected along perforated fold lines to respective handle panels 980, 990 within the respective handhold apertures 981, 991 thereof. Curved cut lines 986, 987, 988, 989, 996, 997, 998, 999 help direct stress away from strategic termination points of cut lines in the carrier 3.

Other features of the carton will be apparent from the drawings and in particular Figures 1, 2 and 3.

As previously mentioned, the method and apparatus described herein are particularly suitable for loading carriers having the general characteristics of the type described above. The elements of the carrier 3 enable it to be formed in collapsed condition, shipped, loaded into the apparatus described herein, and then erected and loaded with bottles. Although several types of articles or bottles are suitable for handling and loading by the invention, the invention is particularly useful for loading so-called contoured PET bottles into the carrier 3 illustrated.

The carrier 3 is received by the apparatus of the invention in collapsed condition, as illustrated in Fig. 3, with the bottom wall panels 910, 912 pivoted upwardly into face contacting relationship with the side walls of the carrier 3.

Overview of Apparatus and Method

Referring first to the schematic illustration in Fig. 5 of the overview of the apparatus 10 according to a preferred embodiment of the invention, the apparatus 10 is constructed upon an elongate frame. In the illustration the direction of movement of bottles 1 and carriers 3 is from left to right. As a general overview, bottles move through the apparatus 10 in two rows along an essentially linear path. As the bottles move along their defined path, carriers (in collapsed condition with bottom wall panels folded upwardly flat against the sides of the collapsed carrier) are moved along the hopper 30 to a point of interface with the carrier feeder 50. The feeder 50 moves individual carriers 3 from the hopper 30 to a timing section 60. A timing-transport section meters out carriers at set intervals and a predetermined rate of speed. In one embodiment, the timing-transport section consists of two consecutive assemblies. The first segment of the two is a timing section 60 in which each carrier 3 is removed from suction cups 54 of the feeder 50 and conveyed at a predetermined stagger to the downstream components of the apparatus 10. In what may generally be referred to as the transport segment of the timing-transport section a path is defined between a pair of vertically oriented belts. More specifically, this segment is referred to as a nip belt assembly 70. The vertical nip belts 72 are a pair of opposing endless belts that pinch, or "nip," the handle area of each carrier (the carrier's topmost portion) and move the carriers in a defined linear path down the apparatus 10.

When the carriers 3 are in the hopper 30, they are in collapsed condition with the bottom wall panels 910, 912 pivoted up and lying flat against the sides of the carrier 3. Upon removal from the hopper 30, the bottom wall panels 910, 912 of the carrier 3 fall away from their position flat against the sides of the carrier 3. As a carrier 3 moves through the timing section the bottom wall panels 910, 912 are engaged and pulled outward to open the carrier 3 for loading. As the carriers 3 are being pulled open along the carrier path of the apparatus 10, bottles are moved along in a path beneath the carriers. In the lower path (the bottle path) a star wheel 105 on either side of the apparatus 10 meters a row of bottles 3 into distinct groups for loading. For example, groups of three or four bottles in each row. An endless chain with lugs is one of the means for transporting bottles after they have been metered by the starwheel 105. Bottle grippers 113 (moving in conveying fashion such as upon an endless chain) immediately follow the star wheels 114 and maintain the spacing and alignment of each bottle grouping. As the bottles 3 move further along the length of the apparatus 10 the bottle grippers 113 assure the spacing between bottles 1 and groups of bottles. At the same time, the carriers 3 move to a position whereby each bottom wall panel 910, 912 is received by a pair of downwardly-sloping gripping and declination belts 92, 94 & 93, 95. An overhead conveyor mechanism such as an endless overhead chain assembly 100 is aligned over the centrally located handles of the carriers 3 in parallel alignment with the declination belt assembly 90. Block members 102 mounted upon the overhead chain engage the tops of the handle portions of the carriers 3. The declination belt assembly 90 and overhead chain assembly 100 move the carriers 3 forward and downward over the dual-row groups of bottles. The lowering work of the declination belt assembly 90 and overhead chain assembly 100 is completed by the pusher wheel assembly 120. The pusher wheel assembly 120 has block members 122 mounted upon it to push downwardly upon the tops of the handles of the carriers 3, thereby fully lowering the carriers onto respective groups of bottles. As the carriers 3 move from the pusher wheel assembly 120 a package conveyor 130 such as side lugs 134 mounted upon respective opposing endless chains 132 engage the trailing end panel of the carriers 3/packages 7 and push them further along the apparatus 10. As the carriers 3 are moved along by the package conveyor 130, a bottom panel locking section 140 folds carrier support tabs 961, 963, 971, 973 and bottom wall panels 910, 912 into position for attachment of the support tabs 961, 963, 971, 973 to the bottom wall panels 910, 912 and for closure of the bottom of the carrier 3. The bottle panels 910, 912 are drawn together for proper alignment and held in that position while closure of the bottom of the carrier 3 is completed by a rotating punch lock mechanism. The loaded, fully closed carrier is then ejected from the apparatus 10.

Bottle Infeed Conveyor

Referring to Fig. 5, bottles 1 are brought into the apparatus 10 by an infeed conveyor assembly 20. Infeed conveyors typically used in the beverage packaging industry are suitable. In the preferred embodiment illustrated the conveyor assembly 20 has partitions 22 that segregate incoming bottles into two rows. Conveyor means such as an endless belt or chain move bottles through the apparatus 10 for loading into carriers 3. Different endless chains or belts and a combination of different endless chains or belts is used to The carriers 3 and bottles 1 are moved part of the way through the apparatus 10 simultaneously in separate paths, with the carriers 3 proceeding in a path disposed above the path of bottles 1. Then, as will be described further below, the two paths become one when the carriers 3 are moved downwardly over groups of bottles 1.

Hopper Assembly

Referring now to Figs. 5, 6, and 7, suitable means for making cartons available for loading is provided by a hopper assembly 30. The hopper assembly 30 of the preferred embodiment is essentially a conveyor-driven chute. In Figs. 6 and 7 the hopper assembly 30 is shown from its "loader" end, that is, the end into which cartons are placed for conveyance to the next assembly of the apparatus 10. In the hopper assembly a pair of opposing side walls 31, 32 form the chute. A pair of opposing belts 37, 38 provide the conveying means for the cartons 3. The belts 37, 38 are moveable by known drive means upon rollers mounted upon a support rod 41, 42, or similar structure. The roller rods 41, 42 are in turn mounted upon trucks 43, 44 or similar structures which, like the side wall trucks 33, 34, are in turn permanently or movably mounted upon a support rod 36. Trucks 33, 34, 43, 44 are attached along the length of the side walls 31, 32 and roller rods 41, 42. Referring now particularly to the elevational view of Fig. 7, therein can be seen the manner in which a collapsed bottle carrier 3 suitable for manipulation by the apparatus 10 and hopper assembly 30 is loaded in the hopper where it is engaged by the side walls 31, 32 and belts 37, 38 of the hopper 30. The hopper 30 is adjustable to accommodate varying sizes of carriers 3, for example, six-pack or eight-pack. The hopper 30 is adjusted by changing the location of the trucks 33, 34, 43, 44 along the support rod 36. The direction arrows denoted 45, 47 illustrate the directions in which the trucks may be moved, inwardly or outwardly, depending upon the size of the carrier 3 to be accommodated. For example, a six-bottle version would be a shorter carrier 3 than an eight-bottle version. The trucks and associated side walls and belts would be placed in closer proximity for the six-bottle carrier than for an eight-bottle carrier. Although it would be possible to move both sides of the walls and roller rods it is simpler to maintain one wall-and-belt set stationary while moving the other set, for instance, the set with which the direction arrows 45, 47 are associated. As can be seen in Fig. 7 the belts are positioned to engage each carrier 3 adjacent the protruding tabs 961, 963, 971, 973. Once the carriers 3 are loaded into the hopper 30 the conveyor belts 37, 38 move the upright collapsed carriers along the hopper side walls 31, 32 to the "exit" end of the hopper 30.

Operation of Hopper

Carriers 3 are loaded into the "loading" end of the hopper with the bottoms of the carriers 3 oriented downwardly.

In order to provide the greatest hopper length but still conserve the amount of floor space consumed by the apparatus the hopper chute is angularly aligned with respect to the main portion of the elongated apparatus 10.

Carrier Feeder

Referring momentarily to Fig. 5, as previously noted, the layout of the apparatus is generally linear with bottles 1 and carriers 3 being moved along separate linear paths, one over the other, part of the way through the apparatus 10, and then packages formed of the loaded carriers moving along a single path the rest of the way through the apparatus 10. Referring now to Figs. 5 and 8, the carrier feeder 50 removes carriers 3 from the hopper 30 and passes them on to elements in a linear carrier path disposed over the bottle path. The carrier feeder 50 is a rotary type assembly having three spaced-apart suction-cup support stations 52. Each cup support station 52 supports suction cups 54 for adherence to and removal of a collapsed carrier 3 from the exit end of the hopper 30. The stations 52 rotate as indicated by the rotational direction arrow 57 about an axis 59. For example, the stations 52 may be made to rotate about the axis 57 slidably by means of a support tie rod 53. In a suitable arrangement, each tie rod 53 has one end affixed to a member at the axis 59 and the other end attached to the respective support station 52. Station 52 rotation may be accomplished by means known in the machine arts. For example, through use of an orbital cam mechanism which utilizes drive shafts, cam rods, curvilinear shallow and deep cam tracks, and cam rollers as described in U.S. patents numbers 4,625,575; 5,019,029; 5,102,385 and 5,104,369. These patents are hereby incorporated by reference. The preferred embodiment contains three cup support stations 52, however, as few as one and more than three may be used. Three stations effectively move the carriers 3 in a horizontal path to the timing section 60 of the apparatus 10. The actual suction cups 54 are not shown in Fig. 8 in order to more clearly illustrate other features. However, nozzles 55 upon which cups 54 are positioned are shown. The suction cups 54 are spaced apart so as to engage the carrier 3 at strategic peripheral points for handling. Suction, or a vacuum, for operation of the suction cups 52 is provided by typical pneumatic components. The guide 56 relates to a timing feature used to remove carriers 3 from the suction cup support stations 52, and will be explained in greater detail below.

Timing-Transport Section

The embodiment of the timing transport section is described referring to Fig. 5. As previously mentioned, the timing-transport section moves carriers 3 from the feeder 50 to downstream components of the apparatus 10. The timing-transport section staggers the carriers 3 a predetermined distance apart and begins their travel at a predetermined rate of speed. This timed spacing of carriers 3 causes the carriers 3 to begin synchronized aligned movement with respective groups of bottles 1 as the carriers 3 and bottles 1 move downstream.

In this embodiment, the timing-transport section achieves timing and transport in two distinct segments, namely, a timing assembly 60 and a transport section for convenience herein referred to as a nip-belt assembly 70. The timing assembly 60 has conveyor-driven carrier support fingers for engaging and moving carriers 3 at predetermined intervals and inserting the carriers into nip belts at the predetermined intervals. The carrier support conveyor 60 is a pair of an upper 61 and a lower 63 endless timing chain. Each timing chain 61, 63 contains respective sets of lugs, or fingers, that engage portions of a collapsed carrier 3 as the carrier is released by the suction cups 54 of the feeder 50. The upper timing chain 61 has a series of upper engagement lugs 62 one of which engages the trailing edge of the handle portion of an engaged carrier 3. In the preferred embodiment illustrated an upper engagement lug 62 engages the carrier 3 at the intersection of the handle portion and the wall panels. The corner formed at the intersection provides a stable point of engagement. The lower timing chain 63 has a set of lower engagement lugs 64, 65, 66 that work in tandem with each upper engagement lug 62 of the upper chain 61 to hold the carrier 3 steady and guide it into the nip belt assembly 70. Although several combinations of lower engagement lugs in the set would be effective, in the preferred embodiment illustrated there are three lower engagement lugs 64, 65, 66 in each set. All three lugs 64, 65, 66 support the carrier from the bottom. The trailing lower engagement lug 66 is especially effective in helping push the collapsed carrier 3 forward. The nip belt assembly 70 receives collapsed carriers 3 from the feeder 50 and timing assembly 60. The nip belt assembly 70 moves carriers 3 along at the predetermined spacing initiated by the timing section 60 as the bottom panels 910, 912 of the carrier 3 are gripped and moved outwardly to open the bottom of the carrier 3 for loading. Referring now to Figs. 5 and 9, the nip belt assembly 70 has a pair of endless belts 72 mounted upon respective elongated rods of rollers 74. The belts 72 press together in an elongated vertical plane whose direction of movement 71 with respect to an engaged carrier 3 is downstream of the apparatus. The topmost portion of the handles of the carriers 3 are sandwiched between the belts 72 and translated along the path between the moving belts 72. An upper belt guide 76 directs the top portion of handles of carriers 3 into the pathway between the belts 72. The lower belt guide 78 extends along the length of the belts 72. The opening to the lower belt guide 78 directs the downwardly-extending support tabs 961, 971, 963, 973 of carriers 3 into the guide 78. Referring now also to Fig. 17, as the top portion of the handles of carriers 3 are pinched and translated along by the belts 72, the support tabs 961, 971, 963, 973 travel along through the lower belt assembly guide 78.

Bottom-Panel Grippers

Referring to Fig. 5, in a panel-gripper assembly 80, panel-grippers open the collapsed carrier 3 in preparation for loading. As the carriers 3 move through the timing-transport section (which is described above) carrier-panel grippers 82 moving on conveyors in a parallel path beneath the timing section grasp the bottom panels 910, 912 and pull them outward to open the carrier 3. Each carrier gripper 82 is a clamp that grasps a respective bottom panel 910, 912. Referring now also to Figs. 9 and 13, a carrier 3 is shown in a condition to be grasped by grippers 82. Referring now again particularly to Fig. 5, the grippers 82 are mounted upon two sets of conveyors (endless chains) 84, 86. Each set of chains 84, 86 is a pair of opposing endless chains that are respectively positioned on each side of the collapsed carriers 3 moving through the timing section. Referring now also to Figs. 15 and 16 the opening motions of the elements of the gripper assembly are schematically illustrated. The grippers 82 on both sets of gripper chains 84, 86 move outwardly of the centerline 901 of the carrier 3 in the direction indicated by the direction arrow denoted 81. At the same time, each chain 84, 86 rotates in the downstream direction indicated by direction arrow 83. The grippers 82 and chains of the first set of chains 84 open carriers 3 by pulling outwardly upon the bottom panels 910, 912 of the carriers. The first set of chains 84 and grippers 82 opens carriers 3 from the fully collapsed condition of Figs. 9 and 13 to an open condition. The chains 84 in the first set of chains 84 move at a greater speed than the relative speed of the carriers 3 as they are moved by the transport mechanisms of either the nip belts 72 or the inserts 262. (In turn, the movement of the carriers 3 by the timing-transport section of the apparatus is in timed sequence with the movement of the bottles in a parallel path below the carriers.) As can be seen in Fig. 15, the collapsed carrier 3 is folded in a collapsed condition in a manner resembling the bellows of an accordion wherein the front portion of the collapsed carrier projects outwardly and the rear portion is folded inwardly. The greater relative speed of the first set of chains 84 enables the panels 910, 912 to be pulled forward faster than the carrier 3 itself is moving forward. This movement enables the carrier to become opened in a squared-up condition wherein the bottom panels 910, 912 "catch up" with the center portion of the carrier 3. After the carrier 3 has been erected in the first gripper chain 84 section the panel grippers 82 of the second set of gripper chains 86 engage the bottom panels 910, 912 of the carrier 3 and pull the carrier 3 open further to the maximally-opened condition illustrated in Figs. 16 and 17. The second set of chains 86 of the gripper assembly also passes opened carriers 3 on to the next carrier-handling portion of the apparatus 10, namely, the carrier lowering section 90. The grippers 82 and chains 84 of the second set of gripper chains do not move at a greater relative speed than the carrier transport mechanism but move in synchronous downstream motion (as indicated by the direction arrow 83) with the nip belts 72 or inserts 262. The grippers 82 continue to hold the respective bottom panels 910, 912 outward during movement. Figs. 16 and 17 illustrate the end of carrier 3 opening in which the carrier 3 is fully opened and ready to be passed on to the declination belt assembly 90. Fig. 17 is an elevational illustration of a fully-opened carrier 3 engaged by elements of the nip belt assembly 70 and panel grippers 82. Referring now momentarily to Fig. 5, a pair of opposing conveyors in the form of endless chains 88 assist in passing opened carriers 3 from the first set of chains 84 to the second set of chains 86. As carriers 3 leave the first set of chains 84, lugs 89 mounted upon the chains 88 engage the front and rear of open carriers to help them maintain their opened position as the bottom panels 910, 912 are again grasped by the grippers 82 of the second set of chains 86.

A plan layout of the grippers 82, chains 84, 86, 88 and lugs 89 is illustrated in Fig. 18. In the preferred embodiment of the invention, as the grippers 82 travel the closed circuit defined by the gripper chains 84, 86 they are caused to translate outwardly toward the opposing set of grippers and then inwardly away from the opposing set of grippers (and thus outwardly of the centerline 901 of the carriers) through utilization of a cam follower mounted upon each gripper 82 which travels in a camming groove, or track, 292.

An additional guide structure may be used in the gripper assembly to help maintain the carriers in their "squared-up" condition and to help maintain the bottom panels in their horizontal position. Though not shown, a suitable guide is an L-shaped elongated member extending forwardly with respect to the apparatus wherein the right angle formed at the intersection of a vertical side wall and a horizontal bottom panel abuts the right-angled corner of the L-shaped guide. A guide is aligned along each side of the carrier and apparatus. Each guide flares slightly outwardly of the center of the apparatus at the second set of grippers to allow for the additional width of the carrier which is created when the grippers pull further outwardly to form the bevelled corners of the carriers as described above.

Bottle Metering and Transport

As previously mentioned, a starwheel 105 meters bottles from the bottle infeed conveyor into groups for loading into the carriers. After metering, timed, spaced transport of the groups of bottles is achieved through use of a conveyor 106 which travels under the bottles and a bottle-gripper conveyor 112 which engages the sides of the bottles. A bottle transport conveyor 106 has a spaced-apart pair of endless chains upon which bottle lugs are mounted and each of which is flanked by a pair of bottle support rails. The rails serve as ledges which help support the outer periphery of the bottom of bottles. The lugs engage the rearmost bottle in each column of a bottle grouping. Although a single lug may be used to engage the rearmost bottle in a column, paired sets of lugs allow more stable contact with bottles because two points on the bottle are contacted rather than one. The slot, or spacing, extending longitudinally between the chain structures provides a travel path for the tabs when carriers are lowered onto groups of bottles. This aspect will be explained in greater detail below.

Referring now to Fig. 5, bottles are maintained in the groupings and spacings metered out by the starwheel 105 by means of a pair of bottle-gripper conveyors 112. The bottle-gripper conveyors 112 work in conjunction with the bottom-engaging bottle conveyor described immediately above to transport bottles. Each bottle-gripper conveyor 112 has bottle grippers 113 mounted upon an endless chain 111. Each bottle gripper 113 is a block-like member with a series of adjacent C-shaped cavities for receiving bottles 1. The number of C-shaped cavities corresponds to the number of bottles to be contained in each column of the carrier 3. For example, a carrier for six bottles would have three bottles per column and a carrier for eight bottles would have four bottles per row. The invention employs a single chain 111 to circulate the bottle grippers 113 while maintaining the grippers 113 in a constant orientation facing the center of the apparatus 10.

Carrier Lowering Section

After opening, carriers 3 are lowered onto groups of bottles 1 moving in a parallel path beneath the path of the carriers 3. With reference now to Figs. 5 and 26, carrier lowering is accomplished through the combination of a carton gripping and declination belt assembly 90 and an overhead declination block assembly 100. When the erect carrier 3 leaves the nip belt 70 and gripper 80 assemblies it is upright with its bottom panels 910, 912 extended outwardly of a center line 901 of the carrier 3. As the erect carrier 3 leaves the nip belt assembly 70 and the grippers 82 mounted upon the second gripper chain 86, it is directed toward the declination assembly where the extended bottom panels 910, 912 are respectively received by left and right opposing pairs of declination belts 92, 94 and 93, 95. Referring now generally to Figs. 5 and 26 but more particularly to Figs. 27 and 28, the pairs of belts 92, 94 and 93, 95 of the declination belt assembly 90 are spaced apart so that the carriers 3 may pass between them. For reference, one pair of upper 92 and lower 94 belts is considered the "right" declination belts while the opposing upper 93 and lower 95 belts are considered the "left" pair. Each of the four belts 92, 93, 94, 95 is an endless belt. The spacing shown between the facing surfaces of each pair of belts is for illustration purposes. The facing surfaces of each pair of belts 92, 94 and 93, 95 belts are disposed closely enough so that the panels 910, 912 of the carrier 3 are wedged between each pair of moving belts. The carriers 3 are thus translated along the apparatus 10 by the moving belts.

Although only the general structure of the belts assembly 90 is shown it can be appreciated that means of endless belt movement commonly used by those skilled in the art are employed. For example, the use of a circular roller mechanism 91 disposed at the ends of the belt runs with additional rollers disposed between the ends of the runs to maintain opposing belts in surface-to-surface contact (as is illustrated in Fig. 9 with reference to the rollers 74 in the nip belt assembly 70). The belts' 92, 94 and 93, 96 movements are in synchronization with the movement of the bottle-group conveying mechanism (that is, the bottle-gripper conveyors 112). Each carrier 3 is received by the declination belts such that each carrier 3 overlies a group of bottles 5. Referring now particularly to the side elevational view of Fig. 26, an optimum angle of declination of the pairs of belts 92, 94 (and 93, 95 which are parallel to 92, 94 but not visible in Fig. 26) and the horizontal plane of the groups of bottles 5 is shown as an angle denoted "A" of 4 degrees. The angular orientation of the declination belts 92, 94 and 93, 96 causes the carriers 3 to gradually descend upon the groups of bottles 5. Lowering of the carriers 3 is aided by the overhead declination block assembly 100 in which a series of handle-engaging blocks 102 are mounted upon an endless chain which in turn is in alignment and synchronization with the declination belts. Referring momentarily particularly to Fig. 27, each block 102 has a groove or slot 103 for receiving the handle of a carrier 3. The overhead assembly is disposed with respect to the declination belts 92, 94 and 93, 96 such that as carriers are moved by the belts 92, 94 and 93, 96 the apex of the carrier 3, that is, the top of the handle portion, is engaged by the groove/slot 103 and helps stabilize and reinforce the movement of the downward traveling carriers. The blocks may be spaced for synchronization but a simple means of utilization as illustrated is to have the blocks 102 abut one another so that essentially a continuous groove or slot is formed.

Referring momentarily to Fig. 28, to further ensure stable movement of carriers 3 an alternate version of the declination belt assembly 90 includes a guide 98, 99 positioned to engage the fold line created between each bottom panel 910, 912 and an adjacent side wall of the carrier 3. The guide 98, 99 is parallel and coextensive with the length of the belts 92, 94 and 93, 96. The guides 98, 99 thus further aid in lowering the carriers 3 and further stabilization of the carriers 3 as they are lowered.

To obtain optimum performance and reliability from the apparatus 10, rather then being completely lowered over a group of bottles 5, each carrier is only substantially lowered prior to the departure of the carrier panels 910, 912 from the declination belts 92, 94 and 93, 96 and departure of the handle portion from the overhead declination blocks 102.

Completed lowering of each carrier 3 over a group of bottles 5 is achieved in the seating wheel assembly 120 which follows the declination belt assembly 90 and overhead declination block 100 assemblies. Carriers 3 and groups of bottles 5 exit the declination belt 90 and overhead declination block 100 assemblies as a unit denoted by the number 6 in Fig. 26. The carrier-bottle unit 6 is a package in which the fully-erected carrier 3 is substantially but not completed lowered over the bottle grouping 5. The carrier 3 is either angularly disposed with respect to the bottle-grouping 5, due to the angular placement of the carrier 3 over the bottles 5, or the carrier 3 may be horizontally disposed as it exits the declination section due to contact of the rearmost end of the carrier handle by the last declination block 102.

Placement of the carrier 3 over a group of bottles 5 is thus completed and the carrier is fully "seated" with respect to the group of bottles 5. The unit of a group of bottles 5 and a fully-seated carrier 3 is denoted by the reference numeral 7 in Fig. 26. The unit 7 is now ready for closure.

The seating blocks 122 may be spring-loaded such that if a bottle is engaged rather than a carrier handle the resistance will cause the seating block to be pushed backward toward its point of coupling. In this manner damage and jamming is prevented if a misaligned bottle is engaged by a seating block 122.

In Figs. 26 and 27 the bottles 1 are shown in groupings 5 of two by three arrays, a total of six bottles per group. However, as previously mentioned, it is noted that the system of the invention works well with various multiples of bottles to be packaged. To reinforce this point, the description and illustrations of the preferred embodiment utilize both six- and eight-bottle configurations. For example, the bottle grippers 114 illustrated in the isometric schematic of Fig. 5 is configured for an eight-bottle group while the carriers 3 and bottle groupings in other illustrations depict a six-bottle configuration. The principles of the invention are equally applicable to both six- and eight-bottle configurations as well as other arrayed configurations.

Folder and Gluer

Referring now again particularly to Fig. 5, upon leaving the seating portion 120 of the apparatus 10 each package 7 is engaged and transported by a package lug assembly 130. The package lug assembly 130 primarily consists of a pair of opposing endless chains 132 upon which are mounted lugs 134 that engage each package 7. Closure of the carton 3 of each package 7 is accomplished in the folding and gluing area 140 of the apparatus 10 as the packages are moved along by the package lugs 134.

Glue is applied to the interior side (that is, the side which faces the inside of the erected carrier 3) of the so-called greater bottom wall panel 912 of the carrier 3. Glue is applied to adhere the riser panel support tabs 961, 963, 971, 973 to the interior side of the greater bottom wall panel 912. In a version of the carrier without support tabs 961, 963, 971, 973 folding and adherence of the support tabs would obviously not be necessary for such a carrier. The elements of the folder-gluer assembly 140 are positioned to fold the elements of the carrier 3 in sequence.

In the folding section, the bottom panels 910, 912 are first folded vertically downward, then under the carrier 3 into face-to-face relationship for later locking. The support tabs 961, 963, 971, 973 are folded into a horizontal position. The support tab folding elements are contained in what is conveniently referred to as a tab folding block 141. Consistent with the carrier orientation discussed above, the greater bottom panel flap 912 is the first of the two bottom panel flaps 190, 912 engaged.

As the conveyor continues to transport a package 7 downstream, glue is applied by conventional means such as a glue gun to the downwardly-extending greater bottom wall panel 912 as mentioned above. Glue is applied to the central portion of the panel 912 in a position suitable for the support tabs 961, 963, 971, 973 to be adhered thereto when the greater panel is folded up into flat face relation with the bottom of the package 7.

After glue has been applied to the bottom panel 912 the bottom of the carrier 3 is closed and locked in successive stages.

Closure of the Carrier

Closure of the bottom of the carrier 3 may be achieved by several means. For example, adherence of the bottom panels 910, 912 to one another by an adhesive. Another effective means for closure is the use of a locking mechanism known as a "punch lock" in the packaging field wherein the outermost of the two bottom panels has male locking members that are superimposed over corresponding female apertures and members formed in the inside bottom panel. To help effectively close the bottom of the carrier 3, particularly if the carrier will be closed utilizing a punch lock, the two bottom panels 910, 912 can be drawn inwardly to help align the two bottom panels 910, 912. This is particularly useful, and necessary, to engage male and female lock features and is also useful to generally ensure that the carrier 3 is in its optimum squared-up condition with the bottom panels 910, 910 overlapping by a predetermined amount.

Claims (7)

1. An apparatus for loading containers into open-bottomed carriers (3) having transversely extendable panels (910, 912) extending from side walls (920, 930) the apparatus comprising carton lowering means to lower the carton onto said groupings of containers, characterised in that the carton lowering means comprises a carton gripper and lowering assembly (92, 94, 93, 95) for grasping and pulling the bottom panels (910. 912) of the carriers outwardly with respect to a centerline thereof such that the bottom panels are substantially transversely disposed with respect to side walls (920, 930) of the carriers as the carriers are transported in synchronous downwardly-declining linear motion over respective ones of said groupings of predetermined numbers of containers.
2. An apparatus according to claim 1 wherein said gripper assembly comprises a downwardly-declining pair of opposing elongated endless belt pairs (92, 94; 93, 96) in face-to-face relationship forming a pathway therebetween for receiving and gripping transversely extending bottom panels (910, 912) of the carriers.
3. The apparatus of claim 1 or claim 2, further comprising a seating assembly (100) having a plurality of seating members (102) for engaging tops of handles of the carriers, said seating members in rotatable cooperative disposition with respect to the carriers which have been placed over said groupings of containers such that as said seating members rotate bottommost ones thereof engage the respective tops of handles of the carriers.
4. The apparatus of any of claims 1 to 3, wherein said at least one column of a series of groupings of containers comprises at least two columns.
5. A packaging machine for loading containers into open-bottomed carriers (3), by carton loading apparatus according to any of claims 1 to 4 the packaging machine further comprising:

   a container feeder assembly having conveyor mechanism (112, 113) for translating at least one column of a series of groupings of predetermined numbers of containers (5) along a first level;

   a carrier feeder (50) for retrieving the carriers from a carrier infeed supplier;

   a carrier timer-transport assembly (60; 260) disposed in operative communication with said carrier feeder (50) for receiving the carriers from said carrier feeder and initiating transport of the carriers (3) in synchronous parallel motion with said at least one column of a series of groupings of predetermined numbers of containers at a second level above said first level such that the carriers are aligned over respective ones of said groupings of predetermined numbers of containers and a bottom panel closure mechanism (130, 140, 182) for securing the bottom panels of each carrier together.
6. A method for loading containers into bottom-loading carriers, the carriers (3) having a pair of transversely extending panels (910, 912) extending from side walls (920, 930) thereof, the method comprising: translating the containers (5) along a first level in at least one column of a series of groupings of predetermined numbers of the containers; retrieving the carriers (3) from an infeed supply of the carriers and transporting the carriers in synchronous parallel motion with said at least one column of a series of groupings of predetermined numbers of containers at a second level above said first level such that the carriers are aligned over respective ones of aid groupings of predetermined numbers of containers; as the carriers are translated,
      grasping and pulling the bottom panels (910, 912) of the carriers outwardly with respect to a longitudinal centerline thereof such that the bottom panels are substantial transversely disposed with respect to side walls (920, 930) of the carriers;engaging the bottom panels of the carriers and transporting the carriers in synchronous downwardly-declining linear motion over respective said groupings of predetermined numbers of containers; and securing the bottom panels of each carrier together to form a closure therewith.
7. The method of claim 6, where the step of translating the containers along a first level in at least one column comprises translating the containers along a first level in at least two columns of a series of groupings of predetermined numbers of the containers.

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