Abstract:
Devices that have the capability to simultaneously manipulate the curling screws of a lip rolling machine while it is in operation and lip rolling machines so modified.

Description:
This application claims priority from Provisional Patent Application 60/487,033, filed on Jul. 14, 2003. 

   BACKGROUND OF THE INVENTION AND PRIOR ART 
   This invention deals with devices that have the capability to simultaneously manipulate the curling screws of a lip rolling machine while it is in operation and lip rolling machines so modified. 
   Lip rolling machines are well-known in the prior art and initially were developed during the late 1960&#39;s and early 1970&#39;s into modern manufacturing equipment. Such devices are used for folding lips or rims of plastic containers operating on a single plastic container delivered from a stack or nest of containers provided to the device. The major component of such devices are the lip rollers and the lip rollers consist of a series of parallel or nearly parallel helical screws having the capability of providing a spiral rim folding maneuver for the containers. Each of the screws has spiral rim folding grooves on the surface for receiving containers having pre-heated lip areas. The rim folding roller is angularly offset relative to the axis of the stack or nest of such containers, such that the portions of the grooves receiving the rims lie in planes perpendicular to the axis of the stack. 
   One of the earliest devices is disclosed in U.S. Pat. No. 3,337,919, that issued on Aug. 29, 1967 to Brown in which there is described an apparatus for curling the rims or flanges of plastic containers using a plurality of circumferentially spaced forming members, wherein one of the forming members comprises a driven rotatable roll having a rim curling spiral groove adapted to accommodate therein the rims or flanges of the containers (the lip rolling screw), and the other forming members comprising generally smooth surface crowding members maintaining the flange or rim in the groove under such force as to effect conjoint rotation and relative axial movement of the container and the groove-forming member. This prior art device does not have the capacity to manipulate the curling screw while the device is operating. 
   In another, related patent, U.S. Pat. No. 3,914,102 to Brown, that issued on Oct. 21, 1975 another device is described. It should be noted that the Brown device as described in this patent also does not have the capacity to manipulate the curling screws while the device is running. 
   In a more recent series of patents, there exists U.S. Pat. No. 6,129,537 that issued on Oct. 10, 2000 to Merz, in which there is described for the first time, a means of adjusting the lip rolling screws. Although this device provides a means for adjusting the lip rollers essentially simultaneously, this can only be accomplished while the device is stopped and not while the equipment is in operation. 
   In addition, two U.S. patents that issued to Lamson, one, U.S. Pat. No. 6,135,754 that issued on Oct. 24, 2000 and the second, U.S. Pat. No. 6,164,949, that issued on Dec. 26, 2000 disclose devices that allow for the simultaneous manipulation of roller screws while the devices are in operation. Both devices depend on the use of separate systems of slide and common linkages which are described therein as “. . . a plurality of curling screws arranged about a circular space about a center axis, each curling screw rotated to carry out said forming, each curling screw formed with a helical groove engaging said container rim and progressively forming a lip as said container is axially advanced between said curling screws by rotation thereof; a mount for each curling screw for enabling selective adjusting movement causing a selective increase or decrease of the radius of said spacing circle to enable adaptation to different sized containers; said mounting including means for constraining simultaneous radical adjustment movement of said curling screws together while maintaining the location of said center axis of said spacing circle and a selectively operable adjuster acting on all of said curling screws simultaneously to cause said simultaneous movement . . . ”, wherein, “. . . said curling screw mounting comprises a series of pivoted mounting plates each carrying a respective curling screw, said series of mounting plates linked together by a linkage system to pivot in unison with each other.” 
   U.S. Pat. No. 6,135,754 describes a three roller device, and the U.S. Pat. No. 6,164,949 describes a four roller apparatus, the more common device used today in manufacturing. 
   THE INVENTION 
   What is disclosed and described herein is a novel means for simultaneously adjusting the roller screws of a lip rolling machine while the machine is in operation. This is accomplished by a series of pocket cassettes associated with each roller screw wherein each pocket cassette is configured such that is can be controlled precisely, and simultaneously by one mechanism while the lip rolling machine is operating. The control mechanism is controlled by a gear box and a single cam plate, while the movement of the pocket cassettes is accomplished by a series of pulleys and a single drive belt wherein the drive belt is driven by a motorized pulley and controlled by an adjusting mechanism. 
   By this means, the curling screws can be moved to fit different sized containers being fed to the lip rolling machine while the machine is in an operating condition. 
   Therefore, in some further detail, this invention deals with an adjustable curling screw mechanism for a lip rolling machine adapted to form a rolled lip on the rim of a container by means of the curling screw mechanism. 
   The curling screw mechanism comprises a plurality of curling screws arranged about a circular space about a center axis, each curling screw rotated to carry out the forming, wherein each curling screw is formed with a helical groove engaging the container rim and progressively forms a lip as the container is axially advanced between the curling screws by rotation of the screws. 
   There is a mounting for each curling screw for enabling selective adjusting movement causing a selective increase or decrease of the radius of said spacing circle to enable adaptation to different sized containers. 
   There is a mounting that includes means for causing simultaneous radial adjusting movement of the curling screws together while maintaining the location of the center axis of the spacing circle. In addition, there is a selectively operable adjuster acting on all of the curling screws simultaneously to cause the simultaneous movement of the curling screws. 
   The curling screw mechanism comprises a curling screw mounting comprising a series of pocket cassettes as a carrier for each respective curling screw, each pocket cassette having surmounted thereon a rotatable pulley and a perpendicular roller bearing pin. The series of pocket cassettes are linked together by a single drive belt associated with each rotatable pulley to provide a drive means for each curling screw in association with a motorized drive pulley. 
   The operable adjuster for the curling screws comprises a single circular cam plate having an outer edge, a center axis, a large centered opening, and a plurality of configured semi-circular openings through the cam plate. The circular cam plate is rotatably held in place by a plurality of rotatable support pulleys at the outer edge of the cam plate such that each perpendicular roller bearing pin of each pocket cassette is moveably held in a configured opening. 
   The cam plate has a back surface and a lower edge, and attached to the back surface near the lower edge is a channeled track. The channeled track has a configured bottom in the channel that enables it to accommodate the drive wheel of a drive mechanism. 
   The drive mechanism comprises a gear box containing a gear drive mechanism, the gear drive mechanism having a shaft driven by the drive mechanism. The shaft has a distal end and affixed to the distal end of the shaft is a drive wheel, the drive wheel having an outside edge, the outside edge having a configuration that is accommodated by the configuration in the bottom of the channel of the track such that the wheel moves in the track and moves the circular cam plate accordingly. The shaft is typically horizontally mounted. There is a means for adjusting the tautness of the single drive belt that links the pocket cassettes. 
   Another embodiment of the invention is the use of a braking system on the slidable pocket cassette and yet another embodiment of the invention is the use of a measuring device to track and maintain the settings of the curling screws after they are adjusted. 
   Another embodiment of the invention is the use of the device on a lip rolling machine. 
   There is a system of curling screw machines that are interchangeable with each other. The cassette is quickly removed while another is set in its place to accommodate different ranges within family sizes. 
   Also in place is the ability to independently change the diameter of either the feed end or the finished end. Also these ends do not have to have a diameter of equal distance; one can be greater or smaller than the other. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a full side view of a lip rolling machine of this invention mounted on a support stand which only a portion thereof is shown. 
       FIG. 2  is a full front view of a drive end of a lip rolling machine equipped with a device of this invention in a fully open position that leaves the lip rolls the greatest distance from the centered axis of the curling screws. 
       FIG. 3  is also a full front view of a drive end of a lip rolling machine equipped with a device of this invention in a fully open position that leaves the greatest distance from the centered axis of curling screws that is used to clarify additional components of the device. 
       FIG. 4  is a full front view of a pocket cassette for the device of the delivery end of the device of this invention in the full closed position. 
       FIG. 5  is a side view of a pocket cassette. 
       FIG. 6  is a full view of a pocket cassette of the drive end of the device of this invention in the full open position. 
       FIG. 7  is a full front view of single belt system and drive belt with pulley system. 
       FIG. 8  is a full view of the front of the circular cam plate of a device of this invention in the full open position. 
       FIG. 9  is a front of the braking system. 
       FIG. 10  is a side view of the braking system of  FIG. 9  and in addition, there is shown an arbor, a bearing and the end of a curling screw. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Turning to  FIG. 1 , wherein there is shown a full side view of a lip rolling machine  1  of this invention sitting on the top surface of a support stand  2  wherein only a portion of the support stand  2  is shown. For purposes of a description of this invention and to help provide clarity around the invention, the usual ovens and auxiliary equipment have not been shown. Shown on the support stand  2  is a support frame  29  having an exit plate  6  as one end, a delivery end plate  26  as the opposite end, and top rails  27  and bottom rails  28 . Also present is the heat shield  79  located between the delivery end plate  26  and cammed plate  33 . Cam plate gear boxes  81  are located just inside each bottom corner of support frame  29 . The cam plate gear box adjusts the cam plate and displays the movement. The quick disconnect fasteners  88  located inside the support frame  29  allow the entire lip rolling cassette  1  to be removed easily. The quick disconnect fasteners  88  are loosened allowing the entire lip roller cassette  1  to be removed and another lip roller cassette unit can easily be fastened into place. 
   Shown mounted underneath the support stand  2  is a drive motor  3  for the lip rolling machine  1 , which is shown as a direct drive to the lip rolling mechanism described infra, through a drive shaft  4  and coupling unit  5 . There is also shown a exit mounting plate  6 , through which the main pulley drive shaft  89  connected to the main drive shaft pulley coupling  90  passes to the outside of the machine, and to which there is mounted a main drive pulley  7  that will accommodate a single drive belt  8 , shown in  FIGS. 2 and 3 , for example. 
   With reference to  FIG. 2 , shown above the main drive pulley  7  are two guide pulleys,  71  and  50  of the drive system, and it should be understood that there is a series of such guide pulleys, all of which are similarly constructed and mounted. With reference to  FIGS. 2 and 3 , there is shown the idler pulleys  70  and  51 . The idler pulleys are mounted on mounting plates  35  which are mounted on posts  83 , which are in turn rigidly mounted to the exit plate  6 . The rigidly mounted adjuster pulley  72 , it will be noted from  FIG. 2 , is capable of being adjusted by the use of holes  13  through the exit plate  6 . The rigidly mounted adjuster pulley  72  is affixed to the exit plate  6  by a fastening device such as a bolt  12 , so that it can be removed and moved throughout the series of holes  13  for adjustment purposes. 
   Not easily visible from  FIG. 1  and with reference to  FIGS. 2 and 3 , there is showing the distally mounted adjusting pulley  48 , which is mounted on the swing bar  15  at the distal point  16  thereof. This mechanism is part of the tautness adjusting mechanism for the main drive belt  8 , and consists of, in addition to the swing bar  15 , and a distally mounted adjusting pulley  48 , a drive mechanism  18  for the swing bar  15 , the drive mechanism  18  can be powered with a gas, such as air, or can be hydraulically driven, the components parts of which are not shown therein as not critical to the invention. The distal end  24  of the drive mechanism  18  is rotatably anchored to the exit plate  6  through an attachment means  25 . The drive rod  19  of the drive mechanism  18  has an attachment means  20  at its near end  21 , which attachment means  20  is used to rotatably attach the swing bar  15  to the drive rod  19 . On the median point  22  of the swing bar  15  is a means for rotatably attaching the median point  22  of the swing bar  15  to a post  23 , which anchors the swing bar  15  to that position, but allows for a partial rotation of the swing bar  15  to accommodate the movement of the drive rod  19 . In this manner, when the main drive belt  8  is mounted on the distally mounted adjusting pulley  48 , the tautness of the main drive belt  8  can be adjusted and maintained. 
   Referring now to the upper portion of the exit plate  6  there is shown mounting posts  30 , which are rigidly attached to the front surface  31  of the exit plate  6  and which have surmounted on them, rotatable support pulleys  32 , which are used to support the single circular cam plate  33 . The rotatable support pulleys  32  are configured such that the circular cam plate  33  sits down inside the center of the support pulleys  32  so that the circular cam plate  33  cannot jump out of the support pulleys  32  during use. The circular cam plate  33  is comprised of a single unitary structure that is configured with a large centered opening  44 . By large, what is meant is that the opening  44  must be large enough to allow for the movement of the slidable elements of the pocket cassettes  37  back and forth within the centered opening  44 , which slidable elements are discussed infra. The circular cam plate  33  also has a center axis  43  running through the center of the opening  44  and exiting through the centered opening of the second circular cam plate  91  ( FIG. 1 ) located on the opposite end of the lip rolling cassette  92 , which second circular cam plate  91  will be discussed infra. The circular cam plate  33  also has regularly spaced, semi-circular openings  45  ( FIG. 3 ) through it which accommodates the perpendicular roller bearing pins  42  therein. This accommodation allows the perpendicular roller bearing pin  42  to slide therein along the configuration of the semi-circular openings  45  to assist in and participate in the adjustment of the curling screws of the machine 
   In addition, there are also mounting posts  34  rigidly attached to the front surface  31  of the exit plate  6 , upon which are further surmounted a set of guide pulleys  71  and  50 . There are also present mounting posts  83  rigidly attached to the front surface of exit plate  6 , upon which are further surmounted a mounting plate  35 . Rigidly surmounted upon the mounting plate  35  are idler pulleys  65  and  66 . 
   There is yet another mounting post  36 , which is rigidly attached to the front surface  31  of the exit plate  6 , which is used to support the pocket cassettes  37  of this invention.  FIGS. 4 ,  5  and  6  show the detail of a pocket cassette  37  ( FIG. 2 ) with various components in detail. Each such pocket cassette  37  is essentially the same in construction and is similarly situated with regard to the mounting of it, and in  FIGS. 2 and 3 , the location of the pocket cassettes  37  can be observed. Each pocket cassette  37  is comprised of two pieces  38  and  40  that are slidable with regard to each other, in that the end  38  of the pocket cassette  37  that is most internal to the device is slidable along rails  39  of the opposite end  40  of the pocket cassette  37 . Each slidable rail  39  is rigidly attached to the opposite end  40  of cassette pocket mount  37  by the pocket cassette rail attachments  84  and  85 . Mounted on the top surface  41  of the end  38  is a roller bearing pin  42  that is perpendicular to the surface  41 . As indicated supra, this perpendicular roller bearing pin  42  is insertable in the semi-circular opening  45  of the circular cam plate  33  and moves within it when the curling screws are to be adjusted. Attached to the opposite end of  40  is the end of pocket cassette cap  10 . The opposite end of the pocket cassette cap is  11  within the end of pocket cassette cap  10  and the opposite end  11  is a bore  14 , within the bore  14  is a bearing  46 . Within the bearing  46  rests the end of the curling screw  47 . The opposite end of pocket cassette cap  11  has two fastening devices  74  and  75  that connect it to the end of pocket cassette cap  10 . Internal to the end of the pocket cassette  38  is a braking system  93  ( FIG. 9 ). This internal braking system is used to symmetrically lock the position of the pocket cassette  37  against the rails  39  before and after the pocket cassette  37  has been adjusted. Pressure is exerted on the system forcing the brake plunger(s)  82  ( FIG. 5 ) against the slidable rails  39  of opposite end  41 . This locks the position of all of the pocket cassettes  37  so all of the containers rims are of a consistent configuration. 
     FIGS. 6 and 7  shows that there is also a set of two carrier pulleys  52  and  54  mounted on the pocket cassette  37 , which carrier pulleys  52  and  54  are intended to provide a means of carrying the single drive belt  8  from a idler pulley, for example  51 , around the inside of a first carrier pulley, for example  52 , around the outside of the lip roller drive wheel, for example  53 , around the inside of the second carrier pulley, for example,  54  to an idler pulley, for example  55 . 
   In addition, there is one set of guide pulleys designated  50  and  71  and a set of idler pulleys  70  and  51 , wherein the numbers  70  and  51  designate the upper idler pulleys, and the number  71  and  50  designate the lower guide pulleys, that are mounted on the front surface  31  of the exit plate  6 , and below the carrier pulleys  69  and  52 , the purpose of which is to guide the single drive belt  8  from the median mounted adjusting pulley  48  and the rigidly mounted adjusting pulley  72  to the remainder of the pulleys in the system. 
   The single drive belt  8  is mounted in the following fashion, and with reference to  FIGS. 2 ,  3  and  7 , and beginning with the top of the main drive pulley  7 , down and around the guide pulley  17 , around the inside of guide pulley  9 , around the outside of the rigidly affixed adjuster pulley  72 , inside the guide pulley  50 , around the outside of the idler pulley  51 , around the inside of a first carrier pulley  52 , around the outside of the first curling screw wheel  53 , inside the second carrier pulley  54 , around the outside of the idler pulley  55  and idler pulley  56 , around the inside of the third carrier pulley  57 , around the outside of the second curling screw wheel  58 , around the inside of the fourth carrier pulley  59 , around the outside of the idler pulley  60  and idler pulley  61 , around the inside of the fifth carrier pulley  62 , around the outside of the third curling screw wheel  63 , around the inside of the sixth carrier pulley  64 , around the inside of the idler pulley  65  and idler pulley  66 , around the inside of the seventh carrier pulley  67 , around the outside of the fourth curling screw wheel  68 , around the outside of the eighth carrier pulley  69 , around the outside of the idler pulley  70 , around the inside of the guide pulley  71 , around the outside of the distally mounted adjusting pulley  48 , around the outside of the guide pulley  73 , and up to the top of the main drive pulley  7  to complete the circuit of drive belt  8 . It should be understood that each of the pulleys named above, along with the drive wheels are all aligned in the same plane so that the travel of the drive belt  8  is uniform. 
   Turning to  FIG. 8 , featuring the front view of the cammed plate  33  in the full open position, there is attached to the front surface of the cammed plate  86 , a channeled gear track  76  that facilitates the engagement and movement of the cammed plate  33 . The channeled gear track  76  is attached at attachment locations  77 . There are also present dowel holes  78  in the channeled gear track  76 . Also present is the cam plate gear  80 . 
     FIGS. 9 and 10  show the approximate location of the brake plungers  82  that are incorporated within the pocket cassettes  37 . The hydraulic seals  87  are also present internally of pocket cassette  37 . The braking system  93  systematically holds the pocket cassette  37  at a predetermined position before and after the adjustment. Also shown is the top surface of  38  which is  41 . The perpendicular roller bearing pin is also shown in perspective. A side view of the association of the of the pocket cassette  37  with the bearing  46  and the arbor  47 .