US3112590A

US3112590A - Packaging system and apparatus

Info

Publication number: US3112590A
Application number: US127969A
Authority: US
Inventors: Robert J O'brien
Original assignee: EKCO CONTAINERS Inc
Current assignee: EKCO CONTAINERS Inc
Priority date: 1961-07-31
Filing date: 1961-07-31
Publication date: 1963-12-03
Anticipated expiration: 1980-12-03
Also published as: GB957695A; CH400889A; DK111872B; DE1411995A1

Description

Dec. 3, 1963 R. J. OBRIEN PACKAGING SYSTEM AND APPARATUS Filed July s1, 1961 13 Sheets-Sheet 1 Inventor' ROBERT J. OBRIEN fl-Horne@ he. m

Dec. 3, 1963 R. J. oBRlEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 51, 1961 15 sheets-sheet 2 /4 'I IH" Illul "um" L1 Inventor' l ROBERT d. OBRIEN ,MaMM/1 Mum8 gq'ornegs Dec. 3, 1963 R. J. o'BRlEN PACKAGING SYSTEM AND APPARATUS 15 Sheets-Sheet 3 Filed July 51, 1961 nlllnnmmnmmlfm m./v. 0e: O lll."- w l .w O anw w .nl M Ir H I u m o mw ,Il w Il mh M Him 2\1.| .0... w MMI n Inventor ROBERT J. OBRIEN Bg Manu., wwuMx/fluuk.

.H-Htornegs Dec. 3, 1963 R, J. O'BRlEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 5l, 1961 l5 Sheets-Sheet 4 n Y r cARmaR PLATE BP 44M 't or Pumas Inverzor ROBERT J. OBRIEN B. Mau, ,H-Hrornegs Dec. 3, 1963 R. J. oBRlEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 5l, 1961 13 Sheets-Sheet 5 Grue gs Dec. 3, 1963 R. J. oBRlEN PACKAGING SYSTEM AND APPARATUS 15 Sheets-Sheet 6 Filed July 5l, 1961 mv: N:

Dec- 3, 1953 R. J. oBRlEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 5l, 1.961v 13 Sheets-Sheet 7 1.: cf; i? we Cf-; i l" 1M i; jimi. L." m.. HW his du ROBERT J. OBRIEN Dec. 3, 1963 R. J. o'BRlEN PACKAGING SYSTEM AND APPARATUS 15 Sheets-Sheet 8 Filed July 3l, 1961 49 Illu.

' "Ulm C O O .O O O .lith-H1 O Q 3 Z wund -mun w. A Il l I 9 :IHIW

Inventor ROBERT J. QBRIEN Dec. 3, 1963 R. J. O'BRIEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 5l. 1951 13 SheetsfSheet 9 Inventor RoBER-r .Cvsm

Dec. 3, 1963 R. J. OBRIEN PACKAGING SYSTEM AND APPARATUS 13 Sheets-Sheet l0 Filed July 51. 1961 DlRECTlON 0F PLATE TRM/EL Inventor ROBERT J. O'BRxEN B Mmm,

Dec. 3, 1963 R. J. oBRlEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 31, 1961 13 Sheets-Sheet l1 E N U;

O g; /ir

Inventor' RoBERT J. OBRIEN fHrtornes Dec. 3, 1963 R J, Q'BRlEN 3,112,590

PACKAGING SYSTEM AND APPARATUS Filed July 5l, 1981 13 Sheets-Sheet l2 Ifzverzl'or ROBERT J. OBRI EN 3g. Mmm, @m &

orneg Dec. 3, 1963 R. J. OBRIEN 3,112,590

PACKAGING -SYSTEM AND APPARATUS Filed' July 51, 1961 13 sheets-sheet 13 nvenor Rosen-r J. @BRIEN B. Mam. 8L Jn/wf :H-Hrornes 3,112,590 PACKAGING SYSTEM AND APPARATUS Robert J. QBrien, Evanston, Ill., assigner to Eitco Containers Inc., a corporation oi Illinois Filed July 31, 1961, Ser. No. 127,969 18 Claims. (Cl. 531-232) This invention relates to a system and apparatus for packaging materials or products in sealed individual containers, and is concerned particularly with the attainment of increased eiiiciency and reliability in the loading, sealing and subsequent boxing and handling of the sealed containers.

Individual sealed containers in a Wide variety of sizes and shapes are utilized in merchandising many different kinds of products including iiowable materials such as liquids, jelles, pastes, and granular, powdered and pelleted materials, and products such as pills, capsules, machine parts, electrical parts and the like, and the present invention in its broad aspect finds its use in this general field of packaging. Where products of the aforesaid character have thus been packaged in individual sealed containers, the loading, sealing and subsequent boxing and handling of the containers have required the use of relatively slow and complex equipment which lacked reliability and which restricted production.

The primary object, therefore, of the present invention is to provide a new and improved packaging system of high capacity and increased reliability, and objects related to the foregoing are to provide an automatic container handling and packaging system capable of greatly increased production volume; and to provide an automatic container handling and packaging system for processing a number of containers simultaneously and continuously through a sequence of functions that include one or more of the following: depositing, filling, sealing, and group removal and packing ofthe sealed containers.

Other and further objects related to the foregoing are to provide an automatic container handling and packaging operation utilizing simplified equipment that is readily adaptable to include or omit one or more of the usual container processing functions and that is readily convertible to handling containers of various shapes and sizes; to provide an automatic container handling and packaging operation utilizing a continuously running conveyor to provide smooth travel and eliminate spillage and related problems peculiar to intermittent motion equipment; and to provide for sealing of the containers as they are in continuous motion through the packaging apparatus.

Other objects and advantages will become apparent during the course of the following description.

vIn the accompanying drawings forming a part of this specification and in which like numerals are employed to designate like parts throughout the saine;

FIG. l is a diagrammatic plan View of a container packaging apparatus constructed and arranged in accordance with the present invention;

FIG. 2 is a side elevation of the container packaging apparatus of FIG. 1;

FIG. 2A is a side elevation of a die unit for use with the apparatus of FIGS. 1 and 2;

FIG. 3 is a plan view illustrating the arrangement and and interconnection of the power driving mechanism;

FIG. 4 is a side elevational view of the power driving mechanism;

FIG. 5 is a vertical section taken along the line 5-5 of FIG. 1;

FIG. 6 is a detailed fragmentary side elevational view and is Vtaken as indicated by the line 6 6 of FIG. 5;

FIG. 7 is a fragmentary vertical sectional View through the lower end of a container depositing magazine and is taken as indicated by the line 7 7 of FIG. 8;

citt Fatenr 3,112,599 Patented Dec. 3, 15263 FIG. 8 is a fragmentary horizontal sectional view through the lower ends of adjacent container depositing magazines and is taken on the line 3-8 of FIG. 7;

FIG. 9 is an enlarged fragmentary View illustrating the container separating elements located at the base of the container storage magazine;

FIG. 10 is a fragmentary plan view of the container depositing station;

FIG. l1 is a fragmentary plan View of a carrier plate;

FIG. 12 is an enlarged fragmentary detailed sectional Y view taken on the line 12-12 of FIG. 11;

FIG. 13 is an enlarged detailed fragmentary sectional view taken on the line 13-13 of FIG. 11;

FIG. 14 is a fragmentary sectional View through a. sealer roll shown engaged upon a sheet of cover stock to impression seal the same across a row of containers;

FIG. 15 is a greatly enlarged view illustrating a sheet of cover stock applied across a container rim;

FIG. 16 is a fragmentary plan View, partly in section, illustrating a knife unit that is located prior to the container discharge station;

FIG. 17 is a front elevational View, partly in section, and illustrating the knife unit;

FIG. 18 is a vertical sectional View through the knife unit;

FIG. 19 is a plan View of the guide rails and delivery belt structure at the discharge station;

FIG. 20 is a fragmentary side sectional View through the discharge station;

FIG. 21 is a fragmentary vertical sectional view taken on the line 21-21 of FIG. 14 and iliustrating the mounting and drive arrangement for the lifter fingers;

FIG. 22 is a fragmentary plan view illustratinT the discharge end of an alternative form of packaging apparatus that provides for automatic container separation and packing;

FIG. 23 is a side sectional view through the apparatus of FIG. 22;

FIG. 24 is a fragmentary plan view, schematic, illustrating an arrangement for cutting out rectangular containers after filling and sealing;

FIG. 25 is a side sectional view through the apparatus of FIG. 24;

FIG. 26 is a perspective view of a rectangular type of container such as is handled by the apparatus of FIGS. 24 and 25;

FIG. 27 is a side sectional View through a packaging apparatus of modified form;

FIG. 28 is a plan View of the of FIG. 27;

FIG. 29 is a plan view illustrating a container carrier plate having a sheet of cover stock deposited in registering relation thereon;

FIG. 30 is an enlarged fragmentary perspective View illustrating the construction of the cover sheet and its application to a container;

FIG. 31 is an enlarged detailed sectional view through a completed container and cover sheet package;

FIG. 32 is a fragmentary plan View of a filler apparatus;

FIG. 33 is a lengthwise sectional View taken on the line 3.3-33 of FIG. 32;

FIG. 34 is a sectional View on the line 34-34 of FIG. 33;

FIG. 35 is a sectional view on the line 35-35 of FIG. 33;

FIG. 36 is a transverse sectional View through a roller assembly and its mounts;

FIG. 37 is an enlarged sectional View through a carrier plate construction used with the roller of FIG. 36;

FIG. 38 is an end view, partly in section, of the sealer roll of FIG. 36;

apparatus arrangement FIG. 39 is an end view of an adjustable support for the sealer roll;

The Packaging System in General Under and in accordance with the present invention, separately formed, open top individual containers arranged automatically in a predetermined pattern or grouping, move continuously through or along a production line, and during continuous advancing movement are loaded, covered and sealed and are then discharged at a final packing station in physically associated groups so as to simplify handling and packing. The system of this invention is particularly suitable for handling aluminum foil containers such as the container C of the kind where the open top is bordered by a marginal rim, and the system is applicable to such containers in a wide variety of sizes and shapes.

At the input end of the system the containers from any suitable source are put in place automatically in the desired pattern on a constantly moving conveyor so that transverse rows of containers are moved in succession and in a continuous manner into and through a loading station where the containers of the successive rows are loaded automatically with the product or material. The loaded containers continue to advance into and through a cover applying area or station where cover stocl; in the form of a web or individual sheets is put in position over across the advancing rows of loaded containers, and as the containers and the cover material advance further, the cover material is progressively sealed onto the advancing rows of containers.

The sealing of the cover material to the containers involves the use of a sealant which may be either a press'ure sensitive or pressure-heat sensitive material, and in the system as herein shown a heated presser roll engages the continuously advancing cover stock with a progressive rolling action to squeeze the cover stock and the container rims together progressively along a line transverse to the path of movement of the conveyor, and one Aof the opposed pressure surfaces is resilient so that despite variations in the rims or cover stock, an effective hermetic seal is produced between the rim and cover stock. Once the containers have been sealed to the cover material, the individual containers are consituted as elements of a major group the size of which depends upon the size and extent of the cover sheet. When this group is exceptionally large or is continuous as would be the case where cover material in the form of a web is utilized, these major groups of individual containers are thereafter separated into smaller groups of a size and extent suitable for handling and packing so that when the sealed containers are discharged at the end of the packaging line, the containers are arranged in groups and are handled as groups as they are placed in the packing boxes.

The physically associated groups in which the containers are finally discharged for packing may be provided under this invention either by physical association of the individual sealed containers through the medium of the cover sheet, or may be provided by a carrier tray in which groups of individual or separated containers are placed as a final step in the packaging system.

The Apparatus in General For purposes of disclosure the invention is herein illustrated as embodied in a packaging system that is particularly adapted for handling unit container packages each of which comprises a container C of one ounce capacity, but it is to be understood that containers of either larger or small size and of round or rectangular shape may be handled by the apparatus of this invention. The container C for which the illustrated apparatus is specifically designed is usually of aluminum foil with its top opening encircled by a marginal rim to which a cover applied across the container may be hermetically sealed. The closure may be formed from different cover stock materials such as aluminum foil, paper-foil laminate, foilboard laminate or other flexible film materials.

The physical arrangement and location of the processing stations for a typical container filling and sealing apparatus constructed in accordance with this invention are shown in FIGS. l and 2 wherein the apparatus is illustrated as having a horizontally elongated main frame di) that rotatably mounts a conveyor head shaft 4l located at its output end and equipped with chain drive sprockets 41S and a-conveyor tail shaft 42 located at its input end and equipped with a pair of chain guide sprockets 42S. A set of link chains 43 extend the full length of the machine frame and are trained over corresponding sets of sprockets 41S and 42S. The frame includes substantially full length table 46T for supporting the chains 43 along their upper flight. An endless series of carrier plates 44 are bridged across the chains 43 and connected thereto at their respective sides to move in adjacent lengthwise successive alignment and preferably in a generally horizontal direction. The travel of the carrier plates along the upper fiight of the conveyor chain establishes a substantially horizontal processing path.

In the arrangement illustrated for handling unit containers, each carrier plate is shown with 2() container mounting cavities in a five ine array providing four transverse rows of cavities, with iivevcavities per row. This array mates with 2O cavity molded pulp packaging trays currently available on the market and, as will become apparent, it minimizes the handling required in transferring .sealed containers from the carrier plates to the packaging trays. Obviously, the equipment may be matched to packaging trays of any size, shape, and capacity.

Facilities are mounted on the frame 40 to provide a depositing station do adjacent the input end of the proc- Y essing path for simultaneously depositing five containers in each transverse row of cavities, a iillingstation 47 spaced along the processing path in the direction of container movement and including a set of five transversely spad spouts for simultaneously filling each container of -a transverse row, a sealing station 43 spaced further along the processing path receives a sheet of cover stock of a width corresponding -to that of the array of container mounting cavities and simultaneously applies the cover stock to the rims of each container of a transverse row to seal the cover stock :on to the container rims, and nally a discharge station 4% is provided adjacent the output end of the processing path for :separating the Vsealed containers from the carrier plates and for conveying the separated containers to la packagingst-ation. Y

In the Specific arrangement illustrated inPlGS. l and 2, the depositing station Aff-5 has a set of live tubes servthis depositing station may be adapted to receive and deV posit containers made at a point closely adjacent to the input end of the apparatus shown in FIGS. l and 2.

The container iilling station 47 for the illustrated afrrangement is not shown in detail and it may be embodied in various forms known to those skilled in this art.

Fil S3 Moreover, the present invention has utility in a simplified form wherein the apparatus omits container depositing and filling equipment and is merely arranged to receive and seal containers which are already filled.

In the packaging system of the present invention, provision is made for assuring a perfect hermetic seal for all of the containers even when unexpected inaccuracies or variations are present in the thickness or caliper, surface smoothness or flatness, or other variable characteristics of the cover sheet or the container rims. In a broad sense such reliability in the sealing action is attained by progressively squeezing 4the opposed cover sheet 'and the rims together along a contact line extending transversely of the conveyor 4% and this line in effect progresses across the containers as the containers advance along the packaging path. In attaining the desired seal, one of the opposed squeezing surfaces is hard and rigid While Vthe other is resilieritly deformable so that regardless of usual variations in the cover sheet and the rim, these parts are progressively squeezed together with a substantial force in all of their opposed sealing areas.

As illustrated in FIGS. l to 4 and 14, lsuch opposed squeezing or pressing surfaces are provided by the hard and rigid border portions of the container receiving cavities of the carrier plates 44, and a sealer roll Si? that has a resiliently deformable external surface SR. The roll is heated to activate a heat sensitive sealant material coating on the cover stock. The sealer roll Sti is driven at a sur-face speed and in a direction at the conveyor side thereof lthat corresponds to the movement of the containers on the carrier plates 44. The carrier plates 44 are supported directly beneath the presser roll Si) by a backup roll 56B, as shown in FIGS. 1 to 4, so that application of the desired sealing pressure is assured. As is indicated generally in IFIGS. l and 2, Vdriving power for lthe sealer roll Sil is supplied by a chain 51 and meshed gears 51G driven from a shaft 52 that underlies the table 49T. The lower gear SlG is driven by the chain 51, and the upper gear 51G is carried by sealer roll Si) so as to facilitate -removal and cleaning of the roll 50.

A continuous web W of cover stock is fed transversely over a right angle feed roller 53 to move underneath and then over an oblique guide roller 54 that spans the processing path and leads the web to the upper periphery of the sealer yroll 5t), the rotation of which continuously feeds the web into simultaneous overlying relation across an entire transverse width of the row of containers. The web W of cover stock is heated by the troll SQ, and is pressed into sealing contact with tlie rims along aprogressively advancing transverse line as the cover stock and the rims move beneath the roll 5t?.

Other web feeding arrangements are contemplated such, for example, as a direct feed system utilizing a feed roller mounted in front of lthe sealer roll and disposed crosswise of the processing path and elevated thereabove. On FIGS. 41 and 42, a continuous web W of cover stock is supplied from a roll 189 mounted on a shaft 181 that is bridged across the processing path and journalled in upstanding support structures 182 that are fixed to the table 48T in flanking relation to the processing path. Each support structure 182 also includes a mounting arm 183 for mounting

idler shafts

184 and 185 through which the web of cover stock is 'fed in its travel to the sealer roll 5l?.

Tracking adjustment facilities 186 are shown on the right hand support structure 182 for centering the web with respect to the carrier plates moving along the processing path. Brake facilities 137 are shown on the left hand support structure 182 'for regulating the tension on the continuous web W. As is indicated in FIG. 14, the sealer roll 50 is of welded steel construction having a steel sleeve 56S bridged between end plates SQP and wound with a resistance wire (not shown). A facing carrier plate, may be successively fed on -to each carrier plate as it approaches the sealer roll 50. Alternatively such individual sheets may be fed around the sealer roll 5G in which the sealer roll would again perform the multiple functions of feeding the cover stock, impressing it upon the containers, and heating it lto activate its sealant coating.

In the arrangement illustrated herein, wherein a continuous web W of cover stock is employed, a knife unit 6? is located in advance of the discharge station 49. The knife unit 6l) is operable, under the control of cam surfaces provided on each carrier plate 44, to cut the web transversely at points thereof intermediate of successive carrier plates. The mounting arrangement and cam control elements for the knife unit stl are shown in FIGS. 16, 17 and 18 and are described hereinafter. No knife is required where the cover stock is fed in individual sheets matched to the carrier plate sizes.

The discharge station is also equipped with rotating sets of lifter fingers 61F mounted on a `transverse shaft 6i that is rotatably driven in synchronized relation to the movement of the carrier plates such that a set of lifter fingers engages and raises the containers in the forward row of each carrier plate. This lifting action of the fingers 61? facilitates automatic or manual removal of the containers from their carrier plate. In the arrangement illustrated herein, the discharge station has a pivoted framework 62 that mounts an exit conveyor that mounts a delivery belt 63 for transferring an entire sealed group of containers from its carrier plate to a packaging station. The approach to this exit conveyor is equipped with a set of transversely spaced upwardly inclined rails 64 projecting outboard of the framework to engage the cover stock at points thereof intermediate each line of containers and act as inclined guides for transferring a group of containers from its carrier plates 44 to the delivery belt 63. The details of the lifter fingers, guide rails and delivery belt mechanism are shown in FIGS. 19 to 2l and are described hereinafter.

Each group of containers discharged from the delivery belt 63 is ready for insertion in a die machine 7i) (see FG. 2A). The die machine 75l is arranged to receive a sealed group G of 20 containers and a molded pulp packing tray T of matching configuration and it is arranged to operate and deposit each container in a separate pocket provided in the packing tray.

For this purpose the frame 71 of the die machine has an upper slide 79D in the form of a die for receiving and temporarily supporting a group G of containers, and a lower slide 70C in the form of a carrier or support for receiving a packing tray T with its pockets underlying the containers. The slides 76C and 70D are interconnected as by racks 70R and an interposed pinion 176i for simultaneous inward and outward movement with respect to the frame 71, thus to facilitate loading and unloading. An upper reciprocating punch head 7tP carries punches 72, and when a group G is moved into position within the frame 71, the punch head 701 is operated and the sealed containers C are cut from the cover stock and drop into the corresponding pockets of the tray T.

Drive Mechanism In the machine illustrated in FIGS. 1 and 2 for purposes of disclosure, the facilities at the depositing station 46, the filling station 47, the sealing station 43, and the discharge station 49, are powered and synchronized from a common drive mechanism, the details of which are best shown in FIGS. 3 and 4. A main drive motor Si? is located approximately centrally within the bottom of the main frame 4t? and is equipped with a drive pulley Sti? for a transversely running belt 81 that is trained about a pulley SZP at the input of a speed reducing unit 82 that has its output shaft equipped with a drive sprocket 82S.

A main control shaft 83 for the machine is located forwardly of the motor S and is equipped with a sprocket 83S and chain S4 that is trained about the drive sprocketSZS of the speed reducer unit 32. Themain control shaft 83 is equipped with an inboard sprocket 85S having a drive chain 3S connected to a sprocket 86S on a power and control shaft 86 for the lling station 47. The shaft 86 has a slave sprocket 87S equipped with a chain 87 trained over a power and control shaft 38 for the container depositing station 46.

At lits other end, the main control shaft S3 has an outboard mounted spur gear SSG meshing with arlarge diameter spur gear SSG on one end of an idler shaft 89, the other end of which is equipped with a sprocket 39S having a chain 90 drivingly connected to a sprocket 90S on the head shaft 41 of the conveyor. As is best illustrated in FIG. 20, the conveyor head shaft 41 has another sprocket 91S equipped with a chain 91 for driving the lifter fingers lF on the eiector shaft 61 and is equipped with a second sprocket 92S having a chain 92 drivingly connecting a head shaft 93 for the delivery belt 63.

In FIG. 4, a rotating brush assembly 95 is shown mounted within the bottom of the machine partially immersed in a detergent bath 96 and in position to surface scrub each carrier plate 44 during its travel along the lower flight of t e conveyor. The shaft of the brush assembly 95 is shown equipped with a sprocket 95S engaged by a chain 96 that is driven from a sprocket 96S mounted outboard on the idler shaft S9.

Various adjustments may be provided in the drive mechanism to facilitate synchronization with the travel of the carrier plates of the operation at each station along the processing path.

Container Depositing S tation Referring now to FlGS. to l0, the container depositing station is shown as including a support bridge 100 spanning the processing path to mount a transversely aligned row of container magazines tM. Adjacent its opposite sides the bridge is provided with double grooved saddles ltl for supporting and guiding transversely extending

slide bars

102 and 103 that flank the lower ends of the magazines and each carry individual sets of sharp edged slicer and support elements 194 and 165, respectively, for each magazine. On one side, the corresponding ends of the slide bars are interconnected through a reversing linkage 1% so that left-to-right movement of slide bar 102 produces corresponding right-to-left movement of slide bar 103.

To actuate the container depositor, its power and control shaft 8S is provided with a carn 197 (see FlGS. 5 and 6) having a radially outwardly spiraling cam surface 107C terminating at a sharp drop-olf that creates a rapid container depositing stroke timed with the position of the container mounting cavities in the carrier plates 44. The rotary position of this cam on its shaft is adjustable for providing exact synchronization. An actuating rod 108 is mounted on a side frame 109 for vertical sliding movement and carries a roller 108K riding on the cam 107 to determine the motion cycle of this rod. A bias spring 1088 normally urges the rod downwardly. At its upper end, the rod is connected to drive a bell crank 110 for transmitting motion to the slide bars 102 and 103.

Normally, the lowermost container C in each magazine 100M rests upon its slicer elements 104 located to partially overlie its support elements y105. The slide bars i102 and 103 are driven in opposite directions to withdraw the slicer elements 104 and permit the lowermost container to drop on to the support elements 105 (this position being Aillustrated in FIG. 8). When the slide bar?1 "r restored, the support elements 10S are with- O drawn to release the lowennost container. Meanwhile, the slicer elements 104 move in to pick up the rim of the next container. During each cycle, a set of ve containers is released to drop into a transverse row of cavities in the carrier plate 44.

Carrier Plates Each carrier-plate 44 for the arrangement illustrated in FlGS. 1 and 2 is preferably formed of metal such as steel, cast iron, or aluminum, and is provided with an array of 2.0 cavities having five lengthwise oriented lines to define four transverse rows. As is best seen in FIGS. 1, 11 and 12, each side of the carrier plate has a marginal recess 44R and a cor-responding internal lengthwise slot 44S to accommodate spaced arm connection links 43L that project upwardly from the conveyor chains 43 and are secured at their upper ends by suitable locking pins 4BP. A metal strip 44M spans the recess 44K and is secured into the car-rier plate to mask these connections.

The carrier plates 44 are relieved on each side at their trailing corners to present a cam surface 44C for controlling ope-ration of the unit 60. In this connection, each `carrier plate has a full sized lleading corner to present a forwardly facing Iabutment surface 44A bordering the cam surface 44C on the trailing corner of the immediately preceding carrier plate. The control,

function of these carrier plate corner surfaces is described in detail with reference to the knife unit of FIGS. 16 to 18.

As is best illustrated in FIG. 12, a coating 44T is applied throughout the entire exposed surface of each carrier plate to act as a heat insulator, as an agent for facilitating container release, and as an agent for eliminating contaminant deposit. A plastic material such as is marketed under the trade name Teflon has these properties and is preferred though equivalent materials known to those skilled in this art are also contemplated.

Sheet material typically used for the cover stock W has a total thickness of .0043, consists of aluminum foil .001" thick laminated with a paper backing on one face that is .003 thick and coated with a sealant material such as vinyl resin .0003 thick on its other face. in order for the sealer roll 50 to activate the sealant coating, it is operated at a temperature on the order of 350 to 400 F. to produce a temperature of 320 F. at the sealant. The interface temperature between the sealant and the container rim would then be about 240 F. and in order to maintain this temperature, the coating 44T on the carrier plate provides a heat insulating eect to isolate the thermally conductive plate from the roll. With this arrangement, a sealant may readily be activated by the roll during their brief period ofcoutact. As pointed out previously, other suitable sealant materials may be employed.

When the roll contacts the cover stock, its elevated temperature causes an expansion of the aluminum cover stock, and subsequent cooling of the foil causes a contraction of the aluminum foil in the cover stock, tending to look the containers within their mounting cavities and inhibit free release thereof under the lifting action of the ejector ngers. The lubric property of the slick surface presented by the Teflon coating 44T encourages easy release of containers from the carrier plate. Fi-

nally, the slick surface of the Teflon coating sheds -any 'contaminants deposited thereon.

Traveling Knife The traveling knife unit which is indicated at 60 in FIGS. l and 2 is shown in detail in FIGS. 16 to 18. The knife mechanism includes slide block assemblies for mounting on the mainframe table 40T in flanking relation to the lengthwise edges of the carrier plate. These slide block assemblies 11i? are bridged by a knife carriage that includes a T-bar 111 extending transversely of the direction of carrier plate travel and mounting a transverse carrier bar 112 along which a knife blade 113 is secured. The T-bar is provided with upstanding support posts 114 (see FIG. 17) for mounting a knife operating solenoid assembly 115. A protective housing 116 is provided for enclosing the knife operating solenoid assembly.

Each of the slide block assemblies 11d includes a stationar/ lower section 117, a movable upper section 118 slidable on the lower section, and a cam mechanism 119 disposed between these sections and movably carried by the upper section 118.

The cam mechanism 119 (FIGS. 16 and 17) includes a carrier 12d hinged to the upper section 11S about a vertical pin 129P and lfitted with a cam roller 1.21 located with a :central recess 117K provided in the lower section and an external cam roller 122 located to engage against the cam control surfaces `at the sides of the carrier plates. The central recess 117i` of the lower section is shaped to provide a cam track portion 117i extending parallel to the direction of carrier plate travel and a cam track portion 1178 extending obliquely outwardly. The cam mechanism 119 is biased inwardly -towards the carrier plates by means of a leaf spring 123 so that the external roller 122 rides against the side -surfaces of the carrier plates and so that the internal roller 121 rides against the cam track portions provided on the lower slide block section 117.

Referring now to FIG. 16 it will ibe noted that as the trailing edge of a carrier plate l4d moves past the knife mechanism 643, the external roller 122 moves inwardly as provided by the relieved cam `surface 44C on the trailing corner of the carrier plate. The leading `corner of the next carrier plate has its forwardly facing abutment surface 44A arranged to pick up this external roller 122 and drive it forwardly with the plate. This forward motion imparted to the roller 122 causes the upper section 118 to slide forwardly along the lower section 117 of ythe slide block assembly and brings into play the cam track portions 1171 and 1178.

The forward travel imparted to the upper sections 11? of the slide blocks moves the knife carriage forwardly -with its knife blade 113 maintained in precise registration over the traveling gap existing between successive carrier plates 44 and upon suitable operation of the solenoid mechanism 115 the knife is brought down to cut the cover sheet along the line of the gap. The cam track portion 117P is about 2" long and at some point during this travel the knife operating solenoid mechanism is actuated. For this purpose, the upper slide block section 11S as viewed on the right-hand side in FIGS. 16 and 17 is equipped with a lateral projection 113i arranged to `operate a sensing switch l1215 that is stationarily mounted on the mainframe table 46T (see FIG. 1).

Upon further travel of the sections 113, the internal cam roller 121 rides outwardly along the oblique cam track 1178 to swing the carrier plate 129 outwardly and withdraw the cam roller 122 to allow the carrier plate to move on. Thereupon, the upper section 1118 is restored by a return spring assembly 124.

The knife operating solenoid assembly 115 includes a solenoid 128 for operating the knife blade 113, and a knife return solenoid 129. Tripping of the microswitch 126 energizes solenoid'128 to actuate the knife and the operation of solenoid 128 is sensed by facilities (not shown) which automatically energize solenoid 129 to return the mechanism and restore the knife 113 to its initial elevated position. The

solenoids

123 and 129 are spaced apart laterally and are connected through rod end bearings 128B and 129B anchored to a common plate 131?. The plate 13d is hinged at its center to one end of a pivotally mounted link 131 which carries a pin 131P at its lower end. The pin 131? extends through a vertical slot 112.5 in the knife carrier bar 112 and extends through an intersecting slot 1118 in the vertical web of the T-bar 111.

The knife carrier bar 112 and the knife blade 113 move as a unit and are equipped with mounting pins 132 that ride in angled guideways 111G provided in the vertical web of the T-bar. Therefore operation of solenoid 11.3 pivots the link 131 to swing the pin 13113 and jointly drive the knife carrier bar 112 and knife blade 113 towards the right as viewed in FIGS. 16 and 17. This horizontal knife movement is translated into angularly downward movement as provided by the angled guide slots 111G. Correspondingly, the drive pin 131i of the pivoted link floats upwardly vided in the carrier bar.

Discharge Station The discharge station shown at 49 in FIGS. l and 2 is illustrated in detail in FIGS. 19 to 2l. In general, the forward row of containers in each carrier plate 44 is discharged by means of the synchronized movement of the rotating lifter fingers 611:*` which raise the forward row of each sealed group of 2G containers to facilitate engagement of the inclined ramp lingers 64 underneath the cover sheet at locations between adjacent containers. The iingers 6d then act as rails and the group of containers is progressively pushed upwardly therealong as provided by the continued motion of the carrier plate from which they are being removed. Ultimately the group of containers rides on to the separately mounted delivery belt 63 for transport to a die cutting and packing station such as is shown at 7G in FIG. 2A.

The delivery belt 63 is mounted on a separate framework 62 that comprises lengthwise extending siderails 149, a cross-brace 141 mounting the assembly of ramp fingers 64, a tail shaft 1452, and idler shaft 143, and a driven head shaft 93. The belt 63 is trained about the

shafts

93, 1452 and 143, and is driven continuously by the chain 92. A rigid pivot arm 144 is provided in depending relation intermediately along each siderail 141i and projects beneath the mainframe table 40T to engage the head shaft 41 which functions as a pivot axle.

The framework 62 is normally held in the upwardly tilted attitude in which it is illustrated, this position being determined by stop pins 101i?? provided in each siderail at the entrance end of the discharge station. These stop pins engage the mainframe table 46T. To bias the framework 62 to this position, each siderail 140 is equipped with a depending arm 149A. that connects to the upper end of a relatively freely yieldable elongated coil spring 145 the lower end of w 'ch is anchored to the mainframe 40 at a point adjacent the ground. The arrangement is such that the entire discharge station may be manually pivoted in a clockwise direction, as viewed in FIG. 20, if there is any jamming of containers arriving at the ramp lingers 6d. Thereupon, successive containers may pass beneath the ramp to avoid any serious loss.

Other Closure Separating and Container Discharge Arrangements In FIGS. 22 and 23 the facilities at the discharge end of the processing path are shown in modified form. These modied facilities are preferably used where the closure sheet constitutes a continuous web and they are arranged to provide automatic die-cutting and container packaging funct1ons. As is apparent, no traveling knife unit such as was shown at 60 in FIG. 1 is employed.

The discharge station which is again designated 49 and which includes the ramp lingers 64 and delivery belt 63 may be essentially identical to that shown in detail in FIGS. 19 to 2l. Therefore, the output from the carrier plates comprises a continuous sheet of cover stock which is adhered to the containers to provide a composite product that flows as a continuous stream up the fingers 6d, along with the delivery belts 63 and then into a separating station Where the individual containers C of the successive transverse rows thereof are die cut from the cover web in the vertical slot 1125 pro-V and are dropped into corresponding pockets of trays T for group packing. The web of associated containers C, being constantly fed or advanced, is allowed to bend downwardly at the end of the conveyor 63, thus to form a depending loop 6 from which the web is fed intermittently by the intermittent feed roll 150 to a single row die cutter 151, the die cutter 151 being disposed over a conveyor belt 152 so that trays T may be advanced with Va step-by-step motion beneath the die block 151D. The

cutter ISI includes a punch ISiP, and the die block ISID, and the punch ISIP and the die block H) are moved toward and away from each other in timed relation to the step-by-step advance of the feed roll T50 so that the openings of the die block may encircle each newly presented row of containers for the desired die cutting operation. When the die block ISID is withdrawn downwardly, the web of containers, and any scrap strip produced, are supported as by rollers ISIR. The trays T are loaded onto the conveyor 152 at the left of the die cutter 15l, and are moved step-by-step beneath the die 151D to receive the rows of containers C as they are cut from the web. The trays T are thus loaded in succession and may then be placed in packing boxes or the like.

An arrangement particularly suitable for separating and discharging rectangular containers which have been sealed by a continuous web W of closure sheet material is shown in FIGS. 24 and 25. The final packaged product is shown in FIG. 26 wherein the container is designated C and its sealing closure is designated S. A roll type slitter i59 is shown bridged across the processing path and is equipped with cutting wheels 159W registering with the spaces between adjacent containers. It is followed by a traveling knife mechanism of the type shown at 6? in FIGS. l and 2. The cutting wheels IS9W of the roll slitter cut the continuous web along lengthwise lines 161 and the traveling knife 60 cuts the web along transverse lines 162.

In the arrangement of FIGS. 24 and 25, it is preferable that the traveling knife operate to cut the cover sheet between adjacent rows of containers :rather than between adjacent groups. To facilitate this the carrier plates lfor the containers may be formed with transverse grooves between adjacent rows of cavities and with lengthwise grooves between adjacent lines of cavities. Lifter fingers 6IF` may be provided for engaging and raising each container in each row in order to facilitate removal of the containers from the carrier plates.

Alternative Embodz'ment of Packaging Apparatus FIGS. 27 and 28 show a packaging apparatus for providing a simplified group package wherein each group of containers is sealed by a sheet `or closure board 2d@ of cardboard, plastic, or the like, that also functions as a packing Itray suitable for handling and shipping in the usual bulk shipping containers. A fragment of such a group package is shown in FIGS. 3()y and 3l wherein it will be noted that the closure board feti@ is precut or perforated to define separately identifiable closure elements 269C for each container C, with each closure element 209C being represented as including a tab ZflT to facilitate its removal at the time of use of the container. Thus, the containers of each group are joined together into a composite package as provided by the cover sheet 2th) and this composite package is immediately suited for handling, packing, and shipping. Moreover,.the precut closure elements ZC which register and seal across each container and link it to removably or separately to the cover sheet 26d, make it possible to remove the containers from the group individually at the time of use.

Since the closure boards are precut to define the actua closure elements, facilities are provided for insuring registry with the individual containers which they are to seal. For this purpose, the carrier plates 44 are provided with register pins 44? (see FIG. 29), these register pins being located to flank the contact surface of the sealer roll for avoiding confiict therebetween. The closure boards eX- tend laterally a sufiicient distance to engage these register pins and, in the illustrated arrangement, they are formed with corresponding register holes ZtiiI-I for this purpose, though edge recesses would also be suitable. Other registry techniques known to those skilled in this art are also contemplated.

The apparatus shown in FIGS. 27 and 28 provide-s the same essential functions as the apparatus of FIGS. l and 2 except that no traveling knife is required. Moreover, the use lof separate closure boards simplifies initial adjustment and start up of the equipment. Accordingly, the stations provided along the processing path in the `apparatus of FIGS. 27 and 28 comprise a depositing station 24:6 adjacent the input end of the processing path for simultaneously depositing ve containers in each transverse row of cavities, a filling station 21E/7 spaced along the processing path in the direction of container movement and including a set of five transversely spaced, lengthwise extending lines of discharge nozzles, a sealing station 24S spaced along the processing path a distance sufficient to provide clearance for supplying the closure boards Zed to the carrier plates and arranged to seal the closure boards to the container rims, and finally a discharge station 2.4% is provided adjacent the output end of the processing path. Y

An improved form of filling station 247 is provided and it is shown in detail in FIGS. 32 to 35.

`"-Jhereas in the arrangement of FIGS. 1 and 2, the seal was obtained by providing the sealer roll with a resilient facing that is pressed toward the rigid carrier plates, in the arrangement shown in FIGS. 27 and 28 the sem is obtained by mounting ring-shaped inserts 2@ of resilient plastic material in each cavity of the carrier piate and providing a hardened yfacing on the sealer roll. The details of the carrier plate inserts are shown in FIG. 37 and the details of the sealer roll are shown in FIGS. 36 and 38 to 40.

A board feeding device 256 is shown in FIGS. 27 and 28 and includes a reciprocably swingab'le arm 25d carrying a suction cup assembly 252 to move this assembly between a pick-up position overlying a stack of closure boards Ztl@ where it picks up the uppermost board and a deposit position overlying the carrier plate emerging from the filler station 247 where the board is deposited in registering relation on the filled containers in this carlrier plate. The details of board feeder :devices of this type are known to those skilled in this art.

Filler Station The arrangement of the fil-ler station is shown generally in FIGS. 27 and 28 and is shown in detail in FIGS. 32 to 35. In the illustrated machine arrangement the carrier plates provide five lengthwise extending lines of containers and each such line is equipped with an interrupted iiow type of rotary metering and dispensing valve 239. A feed line to each valve is shown at 211i and it branches into three separate conduits 212 to provide a plurality of appropriately spaced entrances into each valve 21d. Each feed line may lead from a common cooking kettle for the material that is being packaged and a circulating pump (not shown) is provided -to suppiy the material from the cooking kettle through the feed lines 2li tot the five separate valves 21%. Where simultaneous multiple product fill is desired, separate cooking kettles and supply equipment may be provided to each valve.

As is best shown in FIG. 33, each dispensing valve mechanism 210 employs a lengthwise elongated block 2M providing a lengthwise extending distribution chamber 214C of cylindrical cross-sectional configuration in which is mounted a lengthwise extended rotary sealing and feed screw 2&5. A series of feed holes Zidi-I provided in the block 2M establish communication between the branch feed lines 212 and the distribution chamber 214C. A series of discharge ports or nozzles 2id lead from the bottom end of the distribution chamber and `are arranged in closely spa-:ed single ille relation along the lengthwise direction of container travel. An elongated slide valve plate 27 (see FIGS. 33 and 34) is disposed in an elongated slot 2278 within the bottom of the valve block 214i and is shiftable lengthwise under the control of a manually operable mechanisr. The slide plate 2l? is provided with holes 2l7-l forming passage extensions matched to the spacing of the discharge ports 216. In `one position of the slide plate 2G17, its holes are in register with the ports .216 to complete a full set of flow discharge paths and in its opposite position, its holes are out of registry `vith the ports 2te and the ilow discharge paths are blocked.

Each of the metering and dispensing valves 2li) functions to continuously discharge a curtain of material into each container during its travel beneath the length of the valve and this results in a high feed rate and permits a significant increase in the production capacity. To avoid contamination, however, it is important that no material should be discharged toward the spaces between adjacent containers. Accordingly, each metering and dispensing valve provides a traveling seal moving in timed relation with the travel of the containers to overlie and seal particular discharge ports beneath which the spaces between adjacent containers are passing. To accomplish this the rotating screw 215 has dat surfaced helically winding upraised threads 25T formed thereon and capable of sealing across the discharge ports 216 leading from the bottom of the distribution chamber. The screw 25 is driven from a transverse shaft 22) that bridges the processing path and carries individual bevel gears 223i engaging bevel gears 222 on outwardly projecting ends of the screw shaft ZESS. The transverse drive shaft 22d is driven from a chain 223 (FIG. 27) that is suitably connected to the main driving system and that is synchronized with the movement of the carrier plates.

It may also be noted that the seal thread 2252 on the rotating screw is capable of sealing the inlet feed holes 214H and their arrangement is such that only of the three feed holes 214H is sealed at any one time. This insures an adequate supply of liller material.

The rotating metering screw 215, because of its sealing action within the distribution chamber, develops a pumping etfect continually forcing ller material lengthwise of the distribution chamber in the direction of container travel. To avoid undesired pressure buildups a return line 225 leads from the downstream end of each distribution chamber for connection to the suction side of the circulating pump. Thus, filler material is continuously recirculated from the circulating pump (not shown) through the

feed lines

211 and 212, through the distribution chamber 214C, and through the return line to the suction side of the circulating pump. Concurrently, filler material is being drawn from the cooking kettle and a corresponding amount is being discharge into the containers.

Sealer Roll As mentioned previously, in the arrangement of FlGS. 27 and 28 the cover stock is pressed against and sealed to the container rims by utilizing carrier plates equipped with resilient plastic insert rings in conjunction with a sealing roll having a rigid facing, and with the arrangement progressively advancing, line sealing action is attained as hereinbefore described. Each carrier plate 44 is counterbored around each of its container cavities to provide mounting seats for receiving the ring-shaped plastic inserts 239, FIG. 37, which may be of nylon or similar material, with the inserts having an upstanding peripheral lip 230L projecting above the plane of the carrier plate to yield, as necessary, in response to the pressures applied from the rigid sealer roll 250, FIG. 36.

The sealer roll construction employed in the embodiment of Fl'GS. 27 and 28 comprises a cylindrical external ld l steel shell 251 loosely surrounding an insulating sleeve 252 that is provided with spiral grooves in which are nested heated wires 252W that wind around the outer periphery of the insulating sleeve. Separate supply conductor wires 253 are shown connected to internally mounted terminals 25d carried on the insulating sleeve 252. An inner metal shell 255 is provided within the sleeve 252 and is fixed to a set of end rings 256 that are also sealed to the outer shell 251 to encapsulate the heater wire and insulatin assembly. Circular end plates 257 are provided for engaging the composite shell structure against abutment collars provided on a rotatable central shaft 259 for the sealer roll. The right-hand end plates 257 is welded in place and the other is releasably secured by fasteners 261).

Transversely aligned, generally U-shaped support yokes 252 are hinged between spaced

Weldments

263 and 264 provided on the mainframe table 4911 in anking relation to the processing path.

Where, as disclosed herein for purposes of illustration, a heated sealer roll is used it is important to elevate it above the containers whenever the equipment is stopped momentarily. Accordingly, the support yokes 262 are hingedly mounted about pivot pins 262P that are carried in the adjacent weldments 263 and 264' provided on the mainframe table LidT. Raising and lowering of the sealer roll 250 is controlled by a manually rotatable eccentric shaft 2638 that is shown equipped with a handle 263H.

Each yoke 262 is fitted with a bearing block 265 for mounting the rotating shaft 259 of the sealer roll. Flat vertical side surfaces are provided on the portions of each bearing block that is within the slot of its yoke 262 to loclr it against rotation within the support yoke. The

caring blocks ride on

complementary wedge pieces

266 and 267, the lower one 266 of which is held stationary by an anchor screw 2668 and the upper one 257 which is movable under the control of an adjustment screw 2678 to vary the support position of the bearing blocks and hence of the sealer roll.

The top of each yoke slot is bridged by an anchor bar 268 that carries a vertically adjustable screw 2685 acting upon telescoping enclosures 269 and 27d that house a compression spring 271. Adjustment of the vertical screw 2633 regulates the pressure exerted by the compression spring and correspondingly regulates the pressure `of the sealer roll on the containers.

When the equipment is operating and the sealer roll 256 is pressure loaded towards the carrier plates by the action of the compression springs 271 in the telescoping cups 269 and 270, the sealer roll floats freely as suggested by the clearance space shown at 272 between the underside of the bearing blocks 265 and the upper wedge 267 (see FIGS. 36 and 39).

As best seen in FIGS. 36, 38 and 40 the right-hand end of the sealer roll shaft is equipped with slip-rings 273 that are mounted in insulating relation thereon and separate brush assemblies 274 are mounted within a slip-ring casing 275 of generally oval crosssectional form and are biased to ride against the slip-rings for connecting external power to the rotating sealer roll assembly. The internal connection wires 253 are brought through the rotating shaft 259 and extend through a radial hole 2591-1 to connect to the heater wire terminal. A heat shield (not shown) is preferably provided to enclose the rotating sealer roll. The heat shield may be of any suitable construction and is preferably insulated against heat loss and is highly polished to reflect infra-red rays back to the sealer roll 250.

Summary From the foregoing description it will be apparent that the present invention provides a new and improved packaging system whereby high production and increased reliability may be attained, and it will also be evident that the packaging system of this invention, by reason of the con-

Claims

1. A PACKAGING SYSTEM COMPRISING ELONGATED CONVEYOR MEANS FOR SUPPORTING OPEN TOP RIMMED CONTAINERS IN A SERIES OF TRANSVERSE ROWS WHILE ADVANCING THE SAME CONTINUOUSLY AND AT CONSTANT SPEED ALONG A PREDETERMINED PATH FROM AN INPUT END TO AN OUTPUT END OF THE PATH, MEANS AT SAID INPUT END OF THE PATH FOR DEPOSITING CONTAINERS ON SAID CONVEYOR MEANS IN SUCCESSIVE TRANSVERSE ROWS DURING CONTINUOUS ADVANCING MOVEMENT OF THE CONVEYOR MEANS, MEANS PROVIDING A LOADING STATION ALONG SAID CONVEYOR MEANS FOR DEPOSITING THE PRODUCT TO BE PACKAGED IN THE CONTAINERS OF EACH ROW AS THE ROW IS MOVING THROUGH THE LOADING STATION, MEANS PROVIDING A COVER APPLYING STATION FOR APPLYING COVER STOCK TO THE ROWS OF FILLED CON-