CONTAINER-PACKING UNIT, SYSTEM HAVING A CONTAINER-PACKING UNIT, AND METHOD OF PACKING A CONTAINER

Description

PRIORITY CLAIM

This application claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/662,616, filed Jun. 21, 2024, which is expressly incorporated by reference herein in its entirety.

BACKGROUND

The present disclosure relates to packaging, and particularly to packing containers. More particularly, the present disclosure relates to a system for packing a container with articles.

SUMMARY

According to the present disclosure, a container-packing system includes container-packing unit configured to facilitate loading of articles in a container at a loading station. The container-packing system further includes an article conveyor configured to transport articles to the loading station and a container conveyor configured to transport an empty container to the loading station and a loaded container away from the loading station.

In illustrative embodiments, the container-packing unit is located at the loading station and is configured to facilitate filling of the container with the articles. The container packing unit includes a foundation, an agitator, and a motion control system. The foundation is configured to rest on a surface to support the container above the surface at the loading station. The agitator is coupled to the foundation and is configured to impart vibrations on at least a portion of the foundation and the container as the container is filled with the articles to cause the articles to settle within the container prior to the container leaving the loading station. The motion-control system is coupled to the foundation and is configured to control movement of the container relative to the foundation before and after activation of the agitator.

In illustrative embodiments, the motion-control system includes a container-guide system and a packing-unit conveyor. The container-guide system is configured to engage the container at the loading station to block movement of the container relative to the foundation while the agitator is activated and the container is filled with the articles. The packing-unit conveyor is configured to transfer the container to and from the loading station across the foundation.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which:

FIG. 1 is a perspective view of a container-packing system including a container-packing unit configured to facilitate loading of articles in a container at a loading station and then transfer the container in a downstream direction after the container is filled with the articles;

FIG. 2 is an exploded assembly view showing that the container-packing unit includes a foundation, an agitator coupled to the foundation and configured to impart vibrations on the foundation and the container; and a motion-control system configured to control movement of the container relative to the foundation;

FIG. 3 is another exploded assembly view showing that the motion-control system includes a packing-unit conveyor configured to transport the container across the foundation and a container-guide system having a first clamp and a second clamp configured to engage the container on the foundation to block movement of the container relative to the foundation when the agitator is activated;

FIG. 4 is a cross section taken along line 4-4 in FIG. 1 showing that the packing-unit conveyor includes a conveyor belt configured to engage the container and move the container across the foundation, a conveyor actuator configured to move the conveyor belt, and a plurality of rollers coupled to the foundation and oriented transversely to the downstream direction to allow movement of the conveyor belt and the conveyor in the downstream direction;

FIG. 5 is an enlarged perspective view of the conveyor actuator showing that the conveyor actuator includes an actuator motor, a gearbox coupled to the actuator motor, and a pair of conveyor rollers each configured to drive movement of a corresponding conveyor belt in the same direction and at the same rate;

FIG. 6 is a cross section taken along line 6-6 in FIG. 1 showing that foundation includes a foundation base configured to rest on a surface, a container support spaced apart vertically from the foundation base, and a suspension system interconnecting the foundation base and the container support to allow movement of the container support and the container supported thereby relative to the foundation base when the agitator is activated; and

FIG. 7 is a side elevation view of the container packing unit showing that the container support is formed with dimensions to allow use with standard size pallets.

DETAILED DESCRIPTION

A container-packing system 10, in accordance with the present disclosure, includes a container-packing unit 12 configured to facilitate loading of articles 100 in a container 102 at a loading station 104 and then transfer the container 102 in a downstream direction 106 after the container 102 is filled with the articles 100 as shown in FIG. 1. As the articles 100 are loaded in the container 102 at the loading station 104, the container-packing unit 12 is configured to agitate the container 102 so that the articles 100 settle therein. As a result, empty space within the container 102 is minimized and more articles 100 are able to be packed in each container 102 at the loading station 104.

The container-packing system 10 further includes an article conveyor 14 and a container conveyer 16 as shown in FIG. 1. The article conveyor 14 is configured to transport the articles 100 to the loading station 104. The container conveyor 16 includes a first conveyor segment 18 configured to transport the container 102 to the loading station 104 and a second conveyor segment 20 configured to transport the container 102 away from the loading station 104 after being filled with the articles 100. In some embodiments, the articles 100 are configured to be stacked or nested with one another in the container 102 and may include caps, lids, cups, bins, tubs, or any other article that is nestable with one another for storage and transportation. In other embodiments, the articles do not nest with one another in the container 102.

The container-packing unit 12 is located at the loading station 104 and cooperates with the article conveyor 14 and the container conveyor 16 to fill the container 102 with articles 100 and then transport the filled container 102 in the downstream direction 106. The container-packing unit 12 includes a foundation 22, an agitator 24, and a motion-control system 26. The foundation 22 is configured to rest on a surface to support the container 102 above the surface. The foundation 22 is located in-line with the first conveyor segment 18 and the second conveyor segment 20 of the container conveyor 14. The agitator 24 is coupled to the foundation 22. The agitator 24 is configured to induce movement the foundation 22 and the container 102 as the container 102 is filled with the articles 100 to cause the articles 100 to settle within the container 102 prior to the container 102 leaving the loading station 104 with the second conveyor segment 20. The motion-control system 26 is coupled to the foundation 22 and is configured to control movement of the container 102 relative to the foundation 22 before and after activation of the agitator 24.

The motion-control system 26 includes a container-guide system 30, a packing-unit conveyor 32, and a control system 34. The container-guide system 30 is configured to engage the container 102 at the loading station 104 to block or restrict movement of the container 102 relative to the foundation 22. When the container-guide system 30 engages the container 102, the container 102 remains on the packing-unit conveyor 32 and moves with the foundation 22 while the agitator 24 is activated and the container 102 is filled with the articles 100. The packing-unit conveyor 32 is configured to transfer the empty container 102 from the first conveyor segment 18 of the container conveyor 16 to the loading station 104 on the foundation 22 in the downstream direction 106. Once the container 102 is filled with articles 100, the packing-unit conveyor 32 is configured to transfer the filled container 102 from the loading station 104 on the foundation 22 to the second conveyor segment 20 in the downstream direction 106. The control system 34 controls operation of the container-guide system 30, the packing-unit conveyor 32 and the agitator 24 to control filling and transportation of the container 102 with the articles 100. In some embodiments, the control system 34 may also control operation of the article conveyor 14 and the container conveyor 16.

The container-guide system 30 includes a first clamp 36 coupled to a first side of the foundation 22 and a second clamp 38 coupled to an opposite, second side of the foundation 22. The first and second clamps 36, 38 are configured to engage the container 102 when the container 102 reaches the loading station 104. In this way, the clamps 36, 38 block movement of the container 102 relative to the foundation 22 as the agitator 24 moves the foundation 22 and the container 102 with the foundation 22 and the container 102 is filled with articles 100.

The container-guide system 30 further includes a pair of first linear actuators 40 coupled to the first clamp 36 and a pair of second linear actuators 42 coupled to the second clamp 38. The first and second linear actuators 40, 42 are configured to move the first and second clamps 36, 38 between a retracted position and an extended position. In the retracted position, the first and second clamps 36, 38 are spaced a first distance from one another prior to the container 102 reaching the loading station 104. In the extended position, the first and second clamps 36, 38 are spaced a second distance from one another less than the first distance. The actuators 40, 42 are configured to move to the clamps 36, 38 to the extended position after the container 102 reaches the loading station 104 to exert a compressive force on the container 102 prior to the agitator 24 activating and the container 102 being filled with the articles 100. In some embodiments, the actuators 40, 42 are omitted and the clamps 36, 38 are biased toward one another to the extended position by one or more springs, for example, and the springs provide the compressive force on the container 102 at the loading station 104. An upstream end of each clamp 36, 38 includes a tapered segment 37, 39 to guide the container 102 between the clamps 36, 38 as the container 102 moves in the downstream direction 106 to the loading station 104.

The first and second actuators 40, 42 are operated by pneumatics (i.e. air or another gas) and include a piston 41, 43 that extends in response to a force (i.e. positive or negative pressure) applied to the piston 41, 43. Each piston 41, 43 is coupled with the first clamp 36 and the second clamp 38, respectively, so that the first clamp 36 and the second clamp 38 can be moved toward or away from one another in the extended position and the retracted position. In the illustrative embodiment, each piston 41, 43 is also threaded so that the clamps 36, 38 can be adjusted relative to the pistons 41, 43 to a desired distance from one another in one or both of the extended position or the retracted position.

The packing-unit conveyor 32 includes first and second conveyor belts 44, 45, a conveyor actuator 46 configured to drive the conveyor belts 44, 45, and first and second plurality of rollers 48, 50 coupled to the foundation 22. The first and second conveyor belts 44, 45 are configured to move along the foundation 22 in the downstream direction 106. The conveyor actuator 46 is configured to drive each of the conveyor belts 44, 45 in unison with one another. The plurality of rollers 48, 50 are oriented transversely to the downstream direction 106 to allow movement of the container 102 and the conveyor belts 44, 45 in the downstream direction.

The conveyor belts 44, 45 form a loop around the first and second plurality of rollers 48, 50, respectively. The first and second plurality of rollers 48, 50 underlie a portion of each conveyor belt 44, 45 to locate portion of the conveyor belts 44, 45 between the plurality of rollers 48, 50 and the container 102. In some embodiments, the packing-unit conveyor 32 may include only one conveyor belt and only one plurality of rollers as opposed to two separate, spaced apart conveyor belts 44, 45 and sets of rollers 48, 50.

The conveyor actuator 46 includes a conveyor motor 52 coupled to the foundation 22, a first actuator roller 54 coupled to the conveyor motor 52 and to the first conveyor belt 44 to move the first conveyor belt 44 relative to the first plurality of rollers 48, and a second actuator roller 56 coupled to the conveyor motor 52 and the second conveyor belt 45 to move the second conveyor belt 45 relative to the second plurality of rollers 50. The conveyor motor 52 is coupled to the foundation 22 between the first and second actuator rollers 54, 56, the first and second conveyor belts 44, 45, and the first and second plurality of rollers 48, 50.

The conveyor actuator 46 further includes a gearbox 58 coupled between the conveyor motor 52 and the first actuator roller 54 and between the conveyor motor 52 and the second actuator roller 56. The gearbox 58 is configured to rotate the first and second actuator rollers 54, 56 in the same direction and at the same time to drive the first and second conveyor belts 44, 45 in the same direction and at the same rate.

The agitator 24 includes an agitator motor 60 and a pair of eccentric weights 62, 64 coupled to the agitator motor 60 and driven in rotation by the agitator motor 60. The agitator motor 60 rotates the weights about an axis to impart vibrations on the foundation 22 when activated.

The foundation 22 includes a foundation base 66 configured to rest on a surface, a container support 68 spaced apart from the foundation base 66 and, and a suspension system 70 interconnecting the foundation base 66 and the container support 68. The foundation base 66 supports the container support 68 and the suspension system 70 above the surface that the foundation base 66 rests on. The container support 68 is configured to support the container 102 above the surface. The suspension system 70 allows movement of the container support 68 relative to the foundation base 66 while the agitator 24 is activated.

The suspension system 70 includes a plurality of spring guides 72 and a plurality of springs 74 located in internal spaces defined at least partially by the plurality of spring guides 72. Each of the plurality of spring guides 72 includes a foundation-base guide 76 coupled to the foundation base 66 and a container-support guide 78 coupled to the container support 68. Each of the plurality of springs 74 is surrounded by at least one of the foundation-base guide 76 and the container-support guide 78.

Each foundation-base guide 76 is a first guide post and the container-support guide 78 includes a cylindrical tube 80 surrounding one of the springs included in the plurality of springs 74. Each spring 74 surrounds one of the first guide posts 80 to locate the spring 74 radially between the first guide post 76 and a corresponding cylindrical tube 80. Each container-support guide 72 further includes a second guide post 82. Each spring 74 also surrounds the second guide post 82 to locate the spring 74 radially between the second guide post 82 and the cylindrical tube 82.

The suspension system 70 may further include one or more flexible ties 84 interconnecting the container support 68 and the foundation base 66 as shown in FIG. 6. The flexible ties 84 block separation of the container support 68 away from the foundation base 66 past a predetermined amount, but allow movement of the container support 68 toward the foundation base 66 as the springs 74 compress while the agitator 24 is activated. The flexible ties 84 may be removable from one or both of the container support 68 and the foundation base 66 to allow separation of the container support 68 from the foundation base 66 for service.

The container support 68 includes a support plate 86 coupled to the packing-unit conveyor 32, a first side wall 88 coupled to a first lateral end of the support plate 86, and a second side wall 90 coupled to a second lateral end of the support plate 86. The support plate 86 supports the packing-unit conveyor 32 relative to the rest of the foundation 22. The first and second side walls 88, 90 extend in an upward direction away from the support plate 86 and support the first and second clamps 36, 38, respectively, above the support plate 86.

The container support 68 is preferably sized to support a standard size pallet having a length of 48 inches, a width of 40-42 inches and a height of 6 inches. The container support 68 may be sized to support non-standard size pallets or other container support structures. The first and second side walls 88, 90 are spaced apart from one another by a distance 92 within a range of about 40 inches to about 46 inches. The first and second clamps 36, 38 are spaced apart from the support plate 68 by a distance 94 of at least 6 inches. In this way, a standard size pallet is able to fit between the first and second side walls 88, 90 and pass below the first and second clamps 36, 38 so that the clamps 36, 38 engage the container 102 in the extended position.

The foundation 22 further includes an actuator support bracket 96 coupled to the container support 68 and configured to support the conveyor actuator 46 on the container support 68 as shown in FIGS. 5 and 6. The actuator support bracket 96 includes a base panel 120 and a pair of side panels 122, 124 coupled to opposite ends of the base panel 120. The actuator motor 52 is fixed to the base panel 120. The side panels 122, 124 extend upwardly from the base panel 120 and are attached to the first and second side walls 88, 90, respectively. The conveyor actuator rollers 54, 56 are simply supported between the gearbox 58 and the first and second side panels 122, 124, respectively.

The conveyor actuator 46 may further include first and second pairs of guide rollers 130, 132 as shown in FIGS. 4 and 5. Each pair of guide rollers 130, 132 is positioned below each respective plurality of rollers 48, 50 with one of the guide rollers 130, 132 on each side of each respective actuator roller 54, 56. The guide rollers 130, 132 engage and guide each conveyor belt 44, 45 toward each respective conveyor roller 44, 45.

The control system 34 is configured to control operation of each component included in the motion-control system 24 (and other components in the system 10 such as conveyors 14 and 16). The control system 34 includes one or more processors and memory storing instructions that, when executed by the one or more processors cause each component to operate in a container-loading sequence or method to load the container 102 with articles 100 and transport the container 102 away from the loading station 104.

Once the empty container 102 reaches the container-packing unit 12, the packing-unit conveyor 32 is activated by the control system 43 to transfer the empty container 102 from the first conveyor segment 16 in the downstream direction 106 to the loading station 104 directly on top of the container support 68. The control system 34 deactivates the packing-unit conveyor 32 while the container 102 is filled with the articles 100.

The control system 34 then actuates the first and second actuators 40, 42 to move the first and second clamps 36, 38 from the retracted position to the extended position engaged with the container 102. Filling of the container 102 with articles may begin before the clamps 36, 38 engage the container 102 or after.

As the articles 100 are loaded into the container 102, the control system 34 activates the agitator 24 to impart vibrations on the container 102 to cause the articles 100 to settle within the container 102. The agitator 24 may be continuously activated as the articles 100 are loaded or may periodically activate at intervals as the articles are loaded. The clamps 36, 38 engage the container 102 whenever the agitator 24 is activated.

The control system 34 may include one or more sensors 140 configured to monitor the amount of articles 100 present in the container 102 throughout the loading sequence. The sensors 140 can be one or more of an optical sensor, infrared sensor, weight scale, laser, etc. The control system 34 may activate the agitator 24 when the amount of articles 100 in the container 102 reaches one or more predetermined levels. The control system 34 may also adjust a vibration frequency of the agitator 24 as the container 102 is filled.

Once the container 102 is filled, the control system 34 releases the clamps 36, 38 and again activates the packing-unit conveyor 32 to transfer the filled container in the downstream direction 106 from the loading station 104 to the second conveyor segment 20. The second conveyor segment 20 then transports the filled container elsewhere for further packing, storage, and/or transportation.