An applicating machine for applying a flexible carrier to a plurality of containers provided from an infeed includes a jaw drum moveable between an operating position and a storage position away from the operating position. In the operating position the jaw drum is positioned with respect to the infeed to accept the plurality of containers and apply the flexible carrier to the plurality of containers. A second jaw drum may be moveable into the operating position to enable packaging of containers having different dimensions and/or packages having different configurations.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a machine for unitizing a plurality of containers using a flexible container carrier.

2. Description of Prior Art

Container carriers connect two or more containers into a sturdy unitized package of containers. Carriers are generally planar arrays of rings, sometimes referred to as “six-pack carriers,” typically formed from a thermoplastic sheet material. Carriers are applied to containers of various sizes and shapes along various points along the sidewall or under the chime of the container. A preferable machine would be capable of application of a container carrier to a wide range of container sizes in a number of different package sizes in one of several positions along the container sidewall and/or chime.

Prior art multi-packaging devices and methods generally require several different versions or configurations of machines to accommodate different container carrier, package sizes and package configurations. Machines are traditionally a limitation on the range of container diameters, size of package or configuration of package that can be effectively packaged by a single system.

In addition, different machines or complex set-up procedures would also be required for different sizes of packages, for instance 4-packs, 6-packs and/or 12-packs. Each different package size would typically require different machines and/or complex set-up of machine configurations to accommodate division and diversion of differently sized packages.

Finally, different machines or complex set-up procedures would also be required for containers having different heights or requiring application along different points along the container sidewall and/or chime. Two traditional configurations of container carrier to container are the sidewall-applied carrier (SAC) position and the rim-applied carrier (RAC) position. A sidewall-applied carrier requires that the carrier is applied lower along the container than the rim-applied carrier. In addition, containers having different heights typically require positioning of the carrier along different heights of the sidewall. As such, different machines and/or set-up procedures are traditionally required to bring the carrier up or down along the container. Likewise, such different equipment and/or set-up procedures are traditionally required to package containers having different overall heights.

Conventional applicating machines include a single jaw drum used to apply carriers to individual containers. The conventional jaw drum is typically fixed into position on the applicating machine and used in connection with a fixed range of container diameters, such as a range of approximately 0.2 inches and up to a range of approximately 0.5 inches, based upon the size of the jaw drum. Such conventional applicating machines typically include an infeed conveyor for supplying a plurality of containers within a limited range of diameters to the jaw drum. Additionally, a reel stand is positioned upstream of the jaw drum to supply a reel of carriers to a feed drum and then on to the jaw drum.

The string of carriers are then traditionally applied to the containers and, following application, cut into a desired package configuration. The resulting package is then fed into a turner-diverter that moves and/or rotates the package to a correct position for placement on a pallet or similar shipping unit.

Accordingly, an entirely distinct applicating machine is typically required when packaging a second plurality of containers outside of a size range that can be accommodated with the standard applicating machine.

SUMMARY OF THE INVENTION

It is one object of this invention to provide a machine that combines speed, flexibility, quick changeover and ease of operation and maintenance.

It is another object of this invention to provide a machine for unitizing a plurality of containers having a range of possible container heights, diameters and/or sizes.

According to one preferred embodiment of this invention, a machine for packaging multiple containers includes one or more jaw drums moveable between a storage position out of line with the machine and an operating position inline with the machine. When a changeover is desired, a first jaw drum is moveable from an operating position to a storage position and a second jaw drum is moveable from either the same or different storage position to the operating position.

As such, according to a preferred method of operation of the subject invention, the machine utilizes a first jaw drum and a second jaw drum. Containers having a first diameter are provided to the machine having the first jaw drum in the operating position. A first carrier stock is moved through the machine and positioned over the containers having the first diameter to form the first unitized package. Next, should a different style, size and/or configuration of package be desired, a second jaw drum is moved from the storage position into the operating position with the first jaw drum and containers having the second diameter are provided to the machine. A second carrier stock is then moved through machine and positioned over the containers having the second diameter to form the second unitized package. In this manner, an operator can use a single machine to package a wide range of containers.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1-13show a system and machine for packaging multiple containers in a carrier according to one preferred embodiment of this invention. As shown inFIGS. 1-3, carrier stock15moves through machine10, specifically through jaw drum40, where it is applied to containers and then separated into individual, unitized packages. According to one preferred embodiment of this invention, if a uniform group of like-sized containers having a different size requires packaging and/or if a package is required having a different configuration and/or if a different carrier is required, a separate machine is unnecessary as machine10may be quickly reconfigured, following various adjustments to machine10, as described below.

Therefore, the machine10for packaging multiple containers in multiple size packages along multiple locations on the container sidewall according to this invention permits the use of a single machine in combination with a variety of sizes of containers, sizes of packages and configurations of packages. Traditional machines are typically fifteen or more feet long and six or more feet wide, therefore a reduction in the number of machines required in a packaging plant significantly reduces the required working floor space within the plant. In addition, quick and generally toolless set-up and changeover results in more efficient packaging operations.

Carrier stock15preferably moves through machine10from reel stand25where carriers are dispersed in a continuous string of carrier stock15and ultimately to packages where each carrier is separated into a unitized package, each package containing a plurality of uniform containers. A typical configuration for a package is a “six-pack” containing two longitudinal rows of containers in three transverse ranks. Additional desired packages such as four-packs, eight packs and twelve packs may be unitized using machine10according to this invention, and such additional sizes of packages are limited only by the consumer market for such additional sizes.

Carrier (and carrier stock) is preferably constructed from a flexible plastic sheet, such as low-density polyethylene. The flexible plastic sheet is punched or otherwise formed into a plurality of container receiving apertures aligned in transverse ranks and at least two longitudinal rows to form a continuous sheet of carriers.

According to one preferred embodiment of this invention, machine10for packaging multiple containers includes moving carrier stock15through machine10from reel stand25. Carrier stock15then enters machine10into jaw drum40(also referred to as “first jaw drum40” herein). Following application to containers, carrier stock15is divided into individual carriers using cut-off wheel100resulting in individually unitized packages of a desired size which are then dispersed to a case packer (not shown), for example, by using turner/diverter60.

According to a preferred embodiment of this invention, a plurality of containers each having a different diameter may also be packaged using the same machine10. According to a preferred embodiment of this invention, when a changeover is desired, first jaw drum40, such as shown inFIG. 5, is moved from an operating position70inline with carrier stock15, such as shown inFIG. 6, to a storage position75not inline with carrier stock15. Additionally, second jaw drum50is moved from a storage position75′ to the operating position70. Carrier stock15, typically having a new configuration to accommodate the different diameter, is then fed into second jaw drum50as previously described and multiple containers with the different diameter are then similarly packaged. As used herein, the term “inline” means that the respective jaw drum is positioned to receive and apply carrier stock15to containers.

As such, according to a preferred method of operation of the subject invention, that is, a method of packaging multiple containers in unitized packages wherein a first unitized package includes containers having a first diameter and a second unitized package includes containers having a second diameter, machine10utilizes first jaw drum40and second jaw drum50. Containers having the first diameter are provided to machine10having first jaw drum40in the operating position70. A first carrier stock15is moved through machine10and positioned over the containers having the first diameter to form the first unitized package. First jaw drum40is then moved to storage position70of machine10not inline with carrier stock15. Next, second jaw drum50is moved from the storage position75′ into the operating position70and containers having the second diameter are provided to machine10. A second carrier stock (not shown) is then moved through machine and positioned over the containers having the second diameter to form the second unitized package.

In this manner, an operator can use a single machine to package a wide range of containers. Specifically, it is desirable that machine10is capable of packaging containers within a diameter range of approximately 2 inches to approximately 3 inches, more specifically between approximately 2.3 inches and approximately 2.9 inches. In addition, it is desirable that machine10is capable of packaging containers within a height range of approximately 4 inches to approximately 12 inches, more specifically between approximately 4.75 inches and approximately 11 inches.

According to a preferred embodiment of this invention, machine10is capable of packaging between 1500 and 1800 containers per minute. It is desirable that machine10may be reconfigured between jaw drums within approximately 15 minutes.

One ore more operative components of machine10are preferably adjustable to permit packaging of containers having different sizes, such as heights and diameters, carriers having different sizes, packages having different sizes, such as six-packs and twelve-packs, and packages having different configurations, namely rim-applied carrier (RAC) configurations and side-applied carrier (SAC) configurations. In each of these different applications, multiple components of machine10may be adjusted, replaced and/or interchanged to permit application of carrier stock to containers. Several of these components are described in more detail below.

Reel Stand

As shown inFIGS. 7 and 8, reel stand25is positioned at an infeed end of machine10. Reel stand25preferably accommodates reels17of rolled carrier stock or cartons19of fan folded carrier stock, depending upon the desired configuration.

Carrier stock15is preferably dispersed from reel stand25to an operating position of jaw drum40in a generally continuous manner. As shown inFIG. 7, two reels17of carrier stock15are preferably positioned within reel stand25so that as one reel17is exhausted, the other reel17may be spliced into position to enable a generally continuous flow. Alternatively, as shown inFIG. 8, a carton19of fan folded carrier stock15may be positioned relative to reel stand25to permit generally continuous flow of stacks of fan folded carrier stock15.

Accordingly, depending on the desired format of carrier stock15, reel stand25is preferably moveable between a first position for accommodating reels17of carrier stock15and a second position permitting placement of carton19of carrier stock15relative to machine10.

As shown inFIGS. 7 and 8, infeed conveyor20may extend generally through reel stand25. Infeed conveyor20is preferably positioned to convey containers longitudinally into a platform of machine10, in preferably two longitudinal rows. According to a preferred embodiment of this invention and as shown inFIGS. 9 and 10, a pair of sidewalls30are positioned along infeed conveyor20between which containers pass beneath jaw drum40,50. Sidewalls30are preferably adjustable relative to each other depending upon a size of container to be packaged.

Infeed conveyor20may further include infeed lug centerline adjustability to accommodate a group of containers having a different diameter. As a result, the distance between sidewalls30in infeed conveyor20may be adjustable by adjusting a distance between opposing sets of lugs35. Infeed conveyor20may further comprise a plurality of lugs35extending along sidewalls30. Lugs35preferably move relative to sidewalls30to positively guide containers into position below jaw drum40,50. Accordingly, the plurality of containers move through machine10and each container is spaced apart from an adjacent container by lugs35. The spacing between adjacent containers as they enter machine10depends upon the relative sizing of lugs35which are preferably sized to accommodate the largest diameter container to be used in machine10.

A relative position of sidewalls30and/or configuration of lugs35may be adjustable and/or replaceable to accommodate varying and/or non-conventional container shapes, such as contoured bottles. As discussed in more detail below, carrier stock15is subsequently positioned over the plurality of containers whereby each container receiving aperture engages with one of the containers to form a package having a predetermined number of containers.

Jaw Drums

Accordingly, a plurality of containers is provided from infeed conveyor20to jaw drum40,50for application of carrier stock15to containers. As described, jaw drum40or second jaw drum50may be positioned in an operating position70with respect to infeed conveyor20to accept the plurality of containers. The following detailed description presumes use of jaw drum40(or “first jaw drum40”) in the operating position70, however, second jaw drum50preferably operates in the same or similar manner as jaw drum40described.

Carrier stock15proceeds from reel stand and/or infeed to jaw drum40, particularly to jaw pairs45located radially about jaw drum40. Jaw drum40preferably comprises a cylindrical member rotatable about a horizontal axis which transports carrier stock15to the plurality of containers which flow through jaw drum40. A plurality of jaw pairs45are preferably equally spaced around a perimeter of jaw drum40. Radial positions of jaw pairs45around the perimeter of jaw drum40are preferably permanently fixed.

As best shown inFIG. 5, according to one preferred embodiment of this invention, each jaw pair45comprises a fixed jaw and a moveable jaw (not shown). In one preferred embodiment of this invention, jaw pairs45are moved between an open position and a closed position. According to one preferred embodiment of this invention, each fixed jaw is aligned around one perimeter edge of jaw drum40and each moveable jaw is aligned opposite each corresponding fixed jaw. Each resulting jaw pair45is preferably spaced equidistantly around the perimeter of jaw drum40from each other jaw pair45.

Each jaw pair45is configured to grip carrier stock15with the moveable jaw and the fixed jaw engaged through each transverse pair of container receiving apertures in carrier stock15. The circumferential spacing between adjacent jaw pairs45is preferably approximately equal to a pitch of carrier, i.e., the distance between adjacent centers of container receiving openings. The lateral spacing between the moveable jaw and the fixed jaw in the closed position is preferably slightly less than a width between transverse pairs of container receiving apertures. Carrier stock15is engaged with jaw pairs45of jaw drum40immediately prior to application to containers.

As jaw pairs45move with the rotation of jaw drum40, container receiving apertures within carrier stock15stretch to accommodate a container. Carrier stock15in a stretched condition is positioned over a plurality of containers so that each container receiving aperture engages with one container. Upon engagement with the containers, carrier stock15is released from jaw pair45and grips a perimeter of container, either around a chime in a rim-applied carrier (RAC) configuration or, more preferably, around a sidewall in a sidewall-applied carrier (SAC) configuration.

Jaw drum40is preferably adapted to move between the operating position70and a storage position75. Second jaw drum50is likewise adapted to move between the operating position and a storage position75′. Although shown inFIGS. 2-4and described herein as different storage positions75,75′, jaw drum40and second jaw drum50may share a common storage position that may be adaptable to enable transfer between the operating position70and storage position75. Jaw drums40,50may be moved individually or as a module that includes other components of machine10, such as cutoff wheel100and/or other operative components.

According to a preferred embodiment of this invention, one or more rails or tracks80extend between the operating position70and the storage position75,75′. Jaw drum40and/or module containing jaw drum40may thereby slide on track80between operating position70and storage position75. Likewise, second jaw drum50and/or module containing second jaw drum50may slide on track between operating position70and storage position75′. Jaw drums40,50may be positioned on or with respect to linear bearings to permit movement along rails or tracks80.

More specifically, according to one preferred embodiment of this invention shown schematically inFIG. 4, first track85may extend from operating position70within machine10. Second track90may further extending generally perpendicular to first track85, preferably to form a ‘T’, so that first track85intersects second track90at junction95. Storage position75may be positioned on one side of junction95and storage position75′ may be positioned on opposite side of junction95. In this manner, jaw drum40and jaw drum50may be slid or otherwise moved into operating position70without removal of jaw drums40,50from track80and/or machine10.

Jaw drum40and second jaw drum50are preferably used in connection with different sets of containers and/or carriers. For example, according to one preferred embodiment of this invention, jaw drum40includes a different pitch between jaw pairs45, that is, jaw pairs45are circumferentially spaced at a different pitch length, than second jaw drum50. For example, jaw drum40may include a pitch between adjacent jaw pairs45of approximately 3 inches and the second jaw drum50includes a pitch between adjacent jaw pairs45of approximately 2.6 inches. As a result, jaw drum40may be used to package containers having a diameter of approximately 3.0 inches and second jaw drum50may be used to package containers having a diameter of approximately 2.6 inches.

First jaw drum40and second jaw drum50are preferably interchangeable between the operating position and the storage position without the use of tools, such as with locking levers which may be loosened by hand to permit sliding jaw drums40,50relative to tracks and/or rails.

To further accommodate various containers, specifically those having different heights, infeed conveyor20may be lowered or raised relative to jaw drum40,50so that jaw pairs45are positioned lower along the container to facilitate placement of carrier stock15around the sidewall of containers having different heights. Specifically, such as shown inFIG. 11, platform65may be positioned beneath the operating position70of a respective jaw drum40,50so that at least one of a vertical height and angle of the plurality of containers is adjustable relative to the operating position70. Platform65is preferably positioned integrally or inline with infeed conveyor20and output conveyor55. According to one preferred embodiment of this invention, platform65is adjustable to accommodate containers having heights between approximately 4 inches and approximately 12 inches or more specifically between 4.75 inches and 11 inches.

Cutoff Wheel

Output conveyor55preferably conveys the containers longitudinally from platform65and/or infeed conveyor20after carrier stock15has been applied After carrier stock15is stripped from jaw pairs45, a continuous string of unitized containers proceeds along output conveyor55and through cutoff wheel100, such as shown inFIG. 12. According to a preferred embodiment of this invention, cutoff wheel100is adjustable and/or replaceable with minimal use of tools to divide packages into any number of desired sizes.

Cutoff wheel100preferably includes a plurality of knives positioned around a perimeter of cutoff wheel100at appropriate increments based upon a desired size of the package. For instance, if a six-pack is desired, knives are positioned in between every three containers to cut carrier stock15into packages having three ranks of two rows of containers. Likewise, if an eight-pack is required, knives are positioned in between every four containers to cut carrier stock15into packages having four ranks of two rows of containers.

The knives are preferably removable and/or adjustable within cutoff wheel100preferably using methods that provide quick and efficient removability and replaceability. Alternatively, the entire cutoff wheel100may be replaceable to account for different package configurations.

An outfeed such as output conveyor55subsequent provides individual unitized packages of containers from the operating position70to turner-diverter60, such as shown inFIG. 13. Turner/diverter60is preferably positioned over discharge conveyor120and is used to move, align and/or realign the individual packages into a desirable discharge pattern for placement by a case packer into boxes and/or pallets and/or other shipping containers. For example, turner/diverter60may be used to rotationally realign six-packs from a two wide position as they emerge from the cutoff wheel100to a three wide position and on to a case packer to place in corrugated cardboard trays.

Turner/diverter60preferably includes a plurality of lugs extending from a continuous belt. The lugs may be removable and/or replaceable to accommodate various sizes and configurations of packages.

Turner/diverter60and/or discharge conveyor120are preferably adjustable up and down relative to each other, such as by using one or more linear actuators controlled electronically and/or manually. Adjustment of linear actuators enable turner/diverter60to properly address packages of different heights. In addition, discharge guides62may be removeable and replaceable to enable different discharge patterns.

Machine Drive

According to one preferred embodiment of this invention, one or more of the operative components of machine10preferably includes an associated drive, either electrical or mechanical. The associated drive may include a servo motor providing power and feedback or a simple motor providing only power. According to one preferred embodiment of this invention, a drive electrically connects one component of machine10with respect to at least one other component of machine10including jaw drums40,50, infeed conveyor20, reel stand25, turner/diverter60and/or cutoff wheel100.

According to a preferred embodiment of this invention, a drive speed of each moving component of machine10is timed and maintained using suitable electronic controls. Additionally or alternatively, various heights of individual components of machine10may be maintained using such suitable electronic controls. A controller, such as a PLC, is preferably electrically connected to a suitable moving component of machine10, for instance to jaw drums40,50, reel stand25, infeed conveyor20and/or turner/diverter60resulting in coordinated movements of these mechanisms relative to each other. As described herein, each referenced component (jaw drum40, feed drum70, etc.) may include a corresponding motor that powers a respective drive of such referenced component.

As a result, jaw drum40,50may be registered relative to a home position of a container based upon signals received from the controller. Likewise, turner/diverter60preferably operates to position packages along discharge conveyor120at a speed and/or height responsive to signals received from the controller. As a result of the described relationship among the various drive mechanisms in machine10, various mechanical adjustments are unnecessary among such drive mechanisms when switching between different jaw drum40,50, different containers, different carriers, different package configurations and other changes that may result in a change in operating characteristics of machine10.