Apparatus and method for transporting containers within a packaging system

A method of transporting containers from a first station to a second station within a container filling machine. Each container defines opposing first and second end sections, with the second end section forming a longitudinal recess defined by an inner surface of a sidewall. The method includes providing a carrier plate having at least one mounting piece. A container is loaded onto the mounting piece such that the second end section is positioned over the mounting piece and the mounting piece frictionally engages the interior surface of the longitudinal recess. The carrier plate is moved from the first station to the second station with the mounting piece securing the container relative to the carrier plate during movement of the carrier plate.

BACKGROUND

The present invention relates to container packaging systems. More particularly, it relates to transporting of containers within a packaging system, such as a system for packaging flowable food products in containers.

One area where the use of plastic containers has become widespread is in the food packaging industry. Accordingly, it is common for these plastic food containers to serve as the end display package as presented for sale to the customer. A number of different container configurations have been devised, although a few shapes are more prevalent than others. For example, frustoconical containers (i.e., having a sidewall that tapers from a larger diameter top to a smaller diameter bottom) are commonly used for products such as cottage cheese, sour cream, applesauce, or the like. Conversely, there are also currently available thermoformed containers that have a reverse tapered sidewall (or reversed frustoconical shape) with a larger diameter bottom. This type of thermoformed plastic food containers is typically used to package yogurt (e.g., flavored yogurt) as well as other products. A multitude of other plastic food container designs are also available (such as those having a non-tapering sidewall and/or non-circular in transverse cross-section), and can contain a wide variety of other types of products, that may or may not be food products.

Regardless of the exact container configuration, packaging systems used to produce filled containers on a mass production basis generally entail two or more stations at which the containers are loaded, filled, and closed. A drive system transports the containers from station-to-station. In the context of container packaging, conventional drive systems include carrier plates that are adapted to receive and maintain a number of individual containers. A series of the so-constructed carrier plates are linked to one another and driven in a conveyor-like fashion. The mechanism by which the individual containers are maintained relative to the carrier plate will vary, depending upon the container shape and related constraints. As a general statement, however, accepted container mounting techniques are premised solely upon receiving and supporting the container at or along an exterior surface thereof.

For example, U.S. Pat. No. 5,155,971 describes a packaging apparatus in which containers are sequentially transferred from a loading station to a filling station by a drive system including a plurality of transport carriers12. More particularly, and as shown in FIG. 2 of U.S. Pat. No. 5,155,971, each transport carrier12includes a plate38forming a series of holes40sized to receive a container14. Further, a support ring41and a plurality of posts42extend upwardly from the plate38at each hole40. The container14is received within hole40and the ring41that otherwise contacts an exterior of the container14. The posts42generally center the container14relative to the ring41via contact with a lip36of the container14. The ring41does not tightly engage the container14, but instead simply supports the lip36. This approach is highly viable due to the frustoconical shape of the container14whereby the bottom30of the container14has a smaller diameter as compared to the top/lip36. In this manner, the container14slides within the hole40and the support ring41such that the lip36(or top) of the container14is fully supported by the plate38in an upright position. Thus, the container14will not readily tip relative to the plate38.

While the above-described transport device configuration is well accepted, it can only be used with frustoconically-shaped containers whereby the desired, upright container orientation places the smaller diameter end below the larger diameter end. For example, and again with reference to FIG. 2 of U.S. Pat. No. 5,155,971, were the container14orientation to be reversed (i.e., the smaller diameter end30being open and oriented above a closed, larger diameter end36), the container14could not be received over or within the ring41. Similarly, a uniform diameter container (e.g., defining a right cylinder, other shapes with non-tapering sidewalls, etc.) could not be supported by the ring41. A common technique for addressing this problem is to simply remove the ring41, leaving only the posts42. One example of this configuration is shown inFIG. 1of the present application that otherwise illustrates a container50, a carrier plate52, and groupings of three posts54. As a point of reference, the carrier plate52ofFIG. 1is adapted to maintain up to five containers, but is illustrated as supporting the one container50. The container50ofFIG. 1has a reversed frustoconical shape including an open, top end56and a closed, bottom end58, with the bottom end58having a diameter greater than a diameter of the top end56. The container50is maintained relative to the carrier plate52by a set of the three posts54equidistantly spaced about a hole60in the carrier plate52(it being understood that the hole60associated with the container50is hidden in the view ofFIG. 1). A diameter of the hole60is less than that of the container bottom end58. That is to say, the bottom end58rests on the carrier plate52, with the posts54preventing overt movement of the container50via periodic contact with the bottom end58. Notably, due to machining tolerance requirements, a collective diameter defined by a spacing of the posts54is greater than a diameter of the bottom end58, on the order of 0.25 inch. As such, the container50readily moves between the posts54(for example, upon movement of carrier plate52), possibly leading to alignment concerns. Perhaps even more problematic is the ease with which the container50can tip relative to the carrier plate52. In particular, and especially prior to filling, a center of gravity of the container50is at or above a height of the posts54. Thus, with movement of the carrier plate52and thus movement of the container50, the container50can easily tip over the posts54, causing major delays in production. With taller containers, this tippage concern is amplified.

Packaging systems for handling, transporting, filling, and closing containers on a mass production basis are widely employed in the packaging industry. Unfortunately, for many container configurations, accepted transport devices are unworkable and/or less than optimal. As such, a need exists for an improved container transport device and method for use with product filling systems.

SUMMARY

One aspect of the present invention relates to a method of transporting containers from a first station to a second station within a container filling machine. Each container defines opposing first and second end sections, with the second end section forming a longitudinal recess defined by an interior surface of a sidewall. With this in mind, the method includes providing a carrier plate having at least one mounting piece. A container is loaded onto the mounting piece such that the second end section is positioned over the mounting piece and the mounting piece frictionally engages the interior surface of the longitudinal recess. The carrier plate is moved from the first station to the second station with the mounting piece securing the container relative to the carrier plate during movement of the carrier plate. In one preferred embodiment, a multiplicity of carrier plates, each including a multiplicity of mounting pieces, are provided, with the method further including loading and transporting a multiplicity of containers.

Another aspect of the present invention relates to a container filling system for filling containers. Each container defines opposing first and second end sections, with the second end section forming a longitudinal recess defined by an interior surface of a sidewall. With this in mind, the system includes a first, container loading station, a second, container filling station, and a transport device. The transport device transports containers from the first station to the second station and includes a carrier plate and at least one mounting piece. The carrier plate is mounted to a drive system and defines a top surface and a bottom surface. The mounting piece is assembled to the carrier plate and extends from the top surface thereof. In this regard, the mounting plate is adapted to engage the interior surface of the longitudinal recess of a container and secure the container relative to the carrier plate. Finally, the transport device is characterized by the absence of posts adjacent the mounting piece. In one embodiment, the mounting piece includes a base extending from the carrier plate and a shoulder extending from the base opposite the carrier plate. The base defines a diameter greater than that of the shoulder.

Yet another aspect of the present invention relates to a transport device for use as part of a filling system for filling containers. Each container defines opposing first and second end sections, with the second end section forming a longitudinal recess defined by an interior surface of the sidewall. With this in mind, the transport device includes a carrier plate and at least one mounting piece. The carrier plate defines a top surface and a bottom surface. The mounting piece is assembled to the carrier plate and extends from the top surface. The mounting piece is adapted to engage the interior surface of the longitudinal recess of a container and secure the container relative to the carrier plate. Finally, the transport device is characterized by the absence of posts adjacent the mounting piece. In one preferred embodiment, the mounting piece includes a base that is circular in transverse cross-section.

DETAILED DESCRIPTION

The present invention relates to a method and apparatus for handling and transporting containers within a packaging system, more particularly, a packaging system adapted to dispense product into a container. With this in mind,FIG. 2generally illustrates an exemplary packaging system70with which the present invention is useful. In general terms, the packaging system70processes a plurality of containers72through various operations performed at two or more stations74(referenced generally inFIG. 2). To this end, the packaging system70includes a drive system76that is supported by a frame78relative to the stations74. The drive system76includes at least one transport device80that, in one embodiment, is driven in a conveyor-like fashion by a drive mechanism82. The drive mechanism82can assume a variety of forms, and generically links (such as by a chain and/or belt84) the transport device(s)80to a motor (not shown) or other device capable of moving the linkage and thus the transport device(s)80. Regardless, and as described in greater detail below, the transport device(s)80is configured to receive and rigidly maintain the container(s)72mounted thereto as the drive system76transports the container(s)72to the various stations74.

It will be understood that the simplified illustration ofFIG. 2represents but one possible configuration of a packaging system in accordance with the present invention. Numerous other stations, handling devices, and/or processing mechanisms can be provided. For example, the stations74have been shown in block form, but will inherently entail complex mechanisms configured to perform the desired operation. With this in mind, and in one embodiment, the stations74include a first, container loading station74A, a second, container filling station74B, and a third, cover station74C. In general terms, the loading station74A is configured to locate or mount individual ones of the containers72onto a respective transport device80. The filling station74B is configured to dispense a desired product (e.g., a flowable product such as yogurt) into the containers72. Finally, the cover station74C is configured to apply a cover or seal to the filled containers72. Once again, the stations74A–74C can include a variety of mechanisms and/or associated devices not shown inFIG. 2. Further, additional station(s)74can be provided and/or one or more of the stations74A–74C eliminated. One exemplary packaging system is available from Autoprod, Inc., of Clearwater, Fla., under the trade name FP 2X12 CIP filler, although a wide variety of other packaging systems are equally applicable.

With the above general constraints in mind, a portion of the drive system76, including two transport devices80(designated as80aand80b) in accordance with the present invention is shown inFIG. 3. By way of reference, the drive system76can include any number of the transport devices80, including a single transport device80. Regardless, each transport device80a,80bincludes a carrier plate90and at least one mounting piece92. The carrier plates90are connected to the linkage84that otherwise causes the transport device(s)80to move when driven by an appropriate mechanism (not shown), such as a motor. The mounting piece(s)92is connected to a corresponding carrier plate90and, as described in greater detail below, is adapted to retain a respective one of the containers72(FIG. 2).

The carrier plate90can assume a variety of forms, but is preferably an elongated body defining opposing upper and lower surfaces94,96, respectively. With specific reference to the transport device80bthat otherwise illustrates the carrier plate90apart from the mounting pieces92, the carrier plate90defines a plurality of receiving zones100(referenced generally), each characterized by an aperture102extending between the upper and lower surfaces94,96. While the carrier plate90ofFIG. 3is shown as providing four of the receiving zones100, and thus four of the apertures102, any other number is equally acceptable, and is a function of the overall length of the carrier plate90and a size of the containers72(FIG. 2).

Respective ones of the mounting pieces92are connected to the carrier plate90at respective ones of the receiving zones100. With specific reference to the transport device80aofFIG. 3, each mounting piece92is positioned so as to extend from the upper surface94of the carrier plate90. In one embodiment, each mounting piece92includes a base110and a shoulder112. The base110extends from the upper surface94of the carrier plate90, whereas the shoulder112extends from the base110opposite the carrier plate90. The base110defines a maximum transverse outer dimension of the mounting piece92, whereas the shoulder112defines a maximum outer dimension less than that of the base110. To this end, exact shapes and dimensions of the base110and the shoulder112are a function of the container72(FIG. 2) otherwise received by the mounting piece92. With the one embodiment ofFIG. 3, the base110and the shoulder112are circular in transverse cross-section, although, as described in greater detail below, other shapes are equally acceptable. With additional reference toFIG. 4A, the base110and the shoulder112have a ring-like construction, each defining a passage114,116, respectively. The passages114,116are co-axially aligned. Further, the base110defines an exterior surface118, whereas the shoulder112defines an exterior surface120. With the one embodiment ofFIG. 4A, the exterior surface118of the base110generates a reversed frustoconical shape in lateral extension from a bottom side122to a top side124. That is to say, an outer dimension (e.g., diameter) at the bottom side122is greater than an outer dimension (e.g., diameter) at the top side124. With this but one acceptable configuration, the exterior surface118of the base110is adapted to receive a container (not shown) having a similar, reversed frustoconical shape as described below.

In one embodiment, the reversed frustoconical shape of the base is characterized by the exterior surface118defining an angle θ of at least 91° relative to horizontal in extension from the bottom side122to the top side124, more preferably in the range of 91°–105°, and even more preferably approximately 95° as best shown inFIG. 4B. For example, in one embodiment, the base110has a longitudinal length in the range of 0.2–0.4 inch, more preferably approximately 0.270 inch, and tapers in diameter (from the bottom side122to the top side124) an amount in the range of 0.005–0.1 inch, more preferably approximately 0.048 inch. Alternatively, a wide variety of other dimensions and shapes can be employed.

The shoulder112extends from the top side124of the base110. In one embodiment, the exterior surface120of the shoulder112defines a right cylinder in extension from the base110to a leading end126. Alternatively, the shoulder112can define a frustoconical or reversed frustoconical shape. Regardless, a longitudinal height of the shoulder112, as well as an overall height of the base110/shoulder112(i.e., extension from the bottom side122of the base110to the leading end126of the shoulder112) is preferably selected as a function of the container72(FIG. 2) to be received by the mounting piece92. In one embodiment, the extension of the mounting piece92from the upper surface94of the carrier plate90(i.e., combined height of the base110/shoulder112) is in the range of 0.3–0.6 inch, more preferably approximately 0.455 inch, although other dimensions are equally acceptable. An outer dimension (e.g., diameter) of the shoulder112is smaller than that of the base110so as to not interfere with assembly of a container72to the base110. In one embodiment, an outer transverse dimension (e.g., diameter) of the shoulder112is in the range of 0.1–0.4 inch, more preferably approximately 0.257 inch, less than that of the base110, although other dimensions are equally acceptable. Even further, the mounting piece92can be constructed so as to not include a discernable shoulder. For example, the base110can be constructed to have a continuous height approximating a height of the combined base110/shoulder112ofFIGS. 4A and 4B. Alternatively, the shoulder112ofFIGS. 4A and 4Bcan simply be eliminated.

The mounting piece92can be comprised of a wide variety of rigid materials, such as metal or plastic. The base110and the shoulder112are integrally formed in one embodiment, but can instead be separately formed and subsequently assembled. Further, and in one embodiment, the base110is directly secured to the upper surface94of the carrier plate90(such as by a weld or other known technique) as shown inFIG. 3. Alternatively, and with specific reference toFIG. 4C, in an alternative embodiment, the mounting piece92′ further includes a foot130extending from the base110opposite the shoulder112. The foot130is adapted to be received by, and frictionally retained within, the aperture102of the carrier plate90and thus, in one preferred embodiment, is circular in transverse cross-section, defining an outer diameter less than that of the base110. Once again, a wide variety of other shapes are equally acceptable, selected as a function of the shape of the aperture102. As a point of reference, current carrier plate configurations include the circular aperture102in combination with posts extending from the upper surface94(for example, the posts54of the prior art transport device50ofFIG. 1). With this in mind, and in one preferred embodiment, the prior art carrier plate52(FIG. 1) serves as the carrier plate90of the present invention, with the posts54(FIG. 1) being removed and the mounting piece92, and in particular the foot130, being captured within the aperture102upon final assembly, as shown inFIG. 4C. With this construction, the foot130forms a passage132that is otherwise co-axially aligned with the passages114,116of the base110and the shoulder112, respectively. Once again, however, a wide variety of other constructions are equally acceptable for securing the mounting piece92′ or92(FIG. 4A) to the carrier plate90, such that the foot130can be eliminated. Upon final assembly of the selected mounting piece construction, however, the base110, and where provided the shoulder112, extend from the upper surface94of the carrier plate90.

The above-described transport device80construction is useful for handling and transporting a wide variety of differently configured containers. To this end, an exemplary container140is shown inFIGS. 5A and 5B. This one exemplary container140includes a sleeve member or upper main body portion142, a lower bottom closure member144, and a lid member or seal portion146. The main body portion142has a sidewall148that is generally reversed frustoconical in shape so that it tapers from a smaller diameter open top150to larger diameter open bottom152. An annular rim154of the main body portion142projects radially outwardly from the sidewall148. The closure member144includes a transverse panel wall156and a reversed frustoconical shaped sidewall158that depends downwardly from a periphery of the transverse panel wall156. A bottom peripheral edge of the sidewall158is formed with an annular rim160. Similar to the annular rim154of the body portion142, the annular rim160of the closure member144projects radially outwardly from the sidewall158. In one preferred embodiment, the body portion142and the closure member144of the container140can be separately formed from a thermoplastic material using an injection molding process. Finally, the lid member146can assume a wide variety of forms and is configured for attachment to the main body portion142at the open top150thereof, for example following a filling operation.

Once again, the present invention is useful with a number of other container configurations that may or may not be entirely different from the container140described above. Regardless, and with specific reference toFIG. 5B, manufacture of the container140entails first securing the bottom closure member144to the main body portion142at the open bottom152of the main body portion142. For example, the annular rims154,160can be ultrasonically welded to one another. Regardless, and in more general terms, the resultant assembly provides the container140with opposing first and second end sections170,172along with an internal storage region174. Prior to application of the lid member146(FIG. 5A), the first end section170is open to the internal storage region174, whereas the second end section172is closed relative to the internal storage region174, such as by the transverse panel wall156. Regardless of the number of components employed to form the second end section172(e.g., the main body portion142can be constructed to integrally form the transverse panel wall156such that the closure member144can be eliminated; component(s) in addition to the main body portion142and/or the closure member144are used to form the second end section172; etc.), an internal, longitudinal recess176is defined, extending from an open, trailing end178of the second end section172to the transverse panel wall156(or other transverse stop surface). More particularly, an inner surface180of a sidewall of the second end section172(such as the sidewall158of the closure member144) defines the longitudinal recess176that is otherwise open at the trailing end178. Further, the second end section172defines an exterior surface182opposite the inner surface180(for example, an exterior surface of the sidewall148of the main body portion142). With the one embodiment ofFIG. 5B, the longitudinal recess176and in particular the inner surface180, forms a reversed frustoconical shape in extension from the trailing end178, although a wide variety of other shapes are equally acceptable.

With the above description in mind,FIGS. 6 and 7illustrate mounting of the exemplary container140to the transport device80in accordance with the present invention. With initial reference toFIG. 6, the container140is positioned above a respective one of the mounting pieces92(one of which is shown inFIG. 6) otherwise assembled to the carrier plate90as previously described. In particular, the container140(that may or may not include the lid member146(FIG. 5A)) is oriented in an upright fashion such that the second end section172is adjacent the mounting piece92and the first end section170extends in an opposite direction. The container140is then lowered onto the mounting piece92such that the mounting piece92is received within the longitudinal recess176. With additional reference toFIG. 7, the base110of the mounting piece92contacts and frictionally engages the inner surface180of the second end section172. In one embodiment where a shape of the base110matches a shape of the inner surface180, intimate contact between the base110and the inner surface180is achieved along an entirety of a longitudinal height of the base110. Alternatively, intimate contact need not be achieved along an entirety of the base110. Preferably, however, the base110contacts and rigidly engages the inner surface180at the trailing end178of the container140as well as at a point longitudinally spaced from the trailing end178. In another embodiment, intimate contact between the base110and the inner surface180is achieved at a point at least 0.1 inch from the upper surface94of the carrier plate90along which the trailing end178of the container140otherwise rests. With this assembly, then, the container140is rigidly secured to the carrier plate90via the mounting piece92, with an interface between the mounting piece92and the container140impeding, preferably preventing, lateral movement of the container140relative to the carrier plate90.

As shown inFIG. 7, extension of the shoulder112from the base110is preferably sized in accordance with a height of the longitudinal recess176such that the leading end126of the shoulder112contacts the transverse panel wall156of the container140, thereby providing further support. Alternatively, the mounting piece92can be configured such that the shoulder112does not contact the transverse stop surface156of the container140; in fact, the shoulder112can be eliminated entirely. Preferably, however, the shoulder112facilitates placement of the container140onto the mounting piece92, such as by guiding the second end section172onto the base110as previously described. Notably, securement of the container140to the transport device80is achieved without the inclusion of posts or other components that would otherwise interface with the exterior surface182of the second end section172. Finally, by providing the mounting piece92with the passages114,116(and132(FIG. 4C)) where the foot130(FIG. 4C) is provided as part of the mounting piece) and the carrier plate90with the aperture102, air that might otherwise be entrapped as the container140is forced onto the mounting piece92readily escapes the transport device80such that a possible impediment to complete mounting of the container140is avoided.

Returning toFIG. 2, and with additional reference toFIGS. 6 and 7, general operation of the packaging system70includes operating the first station74A to place one or more of the containers72(or the container140) onto respective ones of the mounting pieces92otherwise provided by the transport devices80. As a point, of reference, with the one embodiment ofFIG. 2, the so-loaded containers72,140do not include a cover (such as the lid member146ofFIG. 5A) such that the containers72,140are “open” following operation of the first station74A.

The drive system76then maneuvers the transport device80(otherwise loaded with one or more of the containers72,140) from the first station74A to the second station74B. During movement of the transport device80, the mounting piece92essentially prevents the container72or140from tipping or otherwise disengaging from the transport device90. That is to say, upon assembly of the container72,140to the mounting piece90, a contact interface is established between the inner surface180and the base110. This contact interface (e.g., surface area) remains substantially constant, more preferably does not change, with movement of the carrier plate90.

The second station74B is then operated to fill the container(s)72,140with a desired product. As used throughout the specification, the terms “fill” or “filling” are in reference to dispensing a flowable product into the container72,140. The amount or volume of the product dispensed within the container72,140can vary from application-to-application, such that following operation of the second station74B, the container72,140may be partially or completely filled.

Regardless, following processing by the second station74B, the drive system76is again operated to maneuver the transport device80, that otherwise maintains the now completely filled or partially filled container(s)72, from the second station74B to the third station74C. The third station74C is then operated to apply a cover (such as the lid member146ofFIG. 5A) to the container(s)72,140. Once again, the rigid engagement achieved between the mounting piece92and the container72,140impedes or prevents the container72,140from tipping relative to the carrier plate90or otherwise disengaging the transport device80. Following operation of the third station74C, the completed, filled containers72are ready for subsequent processing/distribution.

The above-describe method can be employed with a wide variety of containers and a wide variety of flowable products. For example, the flowable product otherwise dispensed to the containers72,140can be yogurt and the containers72,140sized to receive 6 ounces (170 grams) of yogurt. However, it will be understood that the size and dimensions of the containers72,140can be varied from that described herein, as can the flowable product, and still fall within the scope of the present invention. Thus, the flowable product can be liquid or solid (e.g., in particulate form) and can be something other than a food product.

While the mounting piece92of the present invention has been described as being circular in transverse cross-section, a wide variety of other constructions are also within the scope of the present invention. For example,FIG. 8Aillustrates an alternative embodiment transport device190including the carrier plate90and one or more mounting pieces192. The mounting piece192defines a square in transverse cross-section, and is characterized by a non-tapering wall and the absence of a shoulder. Yet another alternative embodiment transport device200is shown inFIG. 8Bthat includes a mounting piece202defining a triangle in transverse cross-section. Once again, a wide variety of other shapes can also be employed.FIG. 8Cillustrates yet another alternative embodiment transport device210including the carrier plate90and a mounting piece212. The mounting piece212includes three discontinuous sections214a–214cthat combine to define a circular perimeter in transverse cross-section. WhileFIG. 8Cillustrates three of the sections214a–214c,any other number is equally acceptable, as is a shape of the transverse, cross-section perimeter. Regardless, and with this one construction, contact between the mounting piece212and the container72,140(FIGS. 2 and 5A) occurs at less than an entirety of a transverse perimeter of the inner surface180(FIG. 5B) upon final assembly. Preferably, however, contact is achieved at at least three points along the transverse, inner surface180perimeter.

The system and method of the present invention provide a marked improvement over previous packaging system designs. By engaging an inner surface of the individual containers, the transport device of the present invention consistently and rigidly secures each container, virtually eliminating the opportunity for highly undesirable container tipping.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the present invention.