Container orienting holder with roller supports and a container orienting method

The invention primarily is directed to an orienting holder for a container that is being filled with a product on a container filling line. The container holder (10) has at least two rollers (18) and a base portion (12). The rollers are made of an elastic material which can be an elastomer inclusive of polymeric foams. The rollers are on arms (15, 16) that project above the base portion and usually will contact the container (30) at an upper part of the container. The arms which support the rollers can pivot. The elastic material of the rollers provide for a positive gripping of the container on the filling line, including a positive grip onto containers which may be partially out of the specified tolerances. The compressibility of the elastic material of the rollers can be enhanced through forming channels (27) in the roller structure.

CROSS-REFERENCE OF RELATED APPLICATIONS

This application is a U.S. national stage entry under 35 U.S.C. §371 of Patent Cooperation Treaty Patent Application No. PCT/US2010/041293, filed Jul. 8, 2010, the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates to an orienting holder for containers that are being processed on an automated processing line. This invention also relates to a method of holding a container at a particular orientation on a container processing line. More particularly this invention relates to a holder that stabilizes and moves a container along a processing line, such as a filling line, and in addition holds the container in a preset orientation throughout processing. This will allow the container to be in the proper orientation with regard to applying a closure and for any subsequent operations.

Holders, such as pucks, are used in the manufacturing of a variety of products. However, a main use is in the filling and handling of containers. Many containers are filled with a product on an automated filling line. These filling lines operate at filling speeds of 50 to 300 containers per minute or more. The containers if substantially rectangular can move along the filling line without a holder by each container being stabilized by the trailing container. In order to maintain such containers in the proper orientation the containers will have bumping flats. These are flat areas on containers where the containers will be in contact, one to the other. This will prevent a “shingling” of the containers on the filling line. However, for containers of unstable, unique or decorative shapes, or for containers which are substantially circular in cross-section, a holder usually will be used. This particularly is the case where the container subsequent to the filling must be maintained in a particular orientation for applying a closure, labeling, case packing or for some other operation. A holder also will properly orient the container with regard to a filling line filling nozzle. This will prevent filling errors and spills on the filling line.

Pucks are a type of holders for containers and are available in various shapes and types. The type and shape will be dictated by the shape of the container being filled and the requirements of the filling line. In general pucks will have a base which is adapted to fit onto the filling line and an inner area for placement of the container. This inner area can be a recess within the puck into which the container will fit. The puck can have a surrounding wall that extends only around the base of the container or that substantially encloses the container. In addition the puck can be comprised of the base and only two upwardly extending arms to support the container. This type of puck is known as a “goal post” or a “labeling” puck. A variety of such pucks are available from suppliers such as Advantage Pucks Technologies of Corry, Pa.

Various container holders and container transfer devices are disclosed in the patent prior art. U.S. Pat. No. 4,159,762 discloses an article holder and transferring device. Here there is a plurality of holders with each holder having four gripper arms. The gripper arms will move toward a container located within a recess of the device to grip and hold the container as needed in an operation and will move away from the container to release the container. The gripper arms are disclosed as rods with attached plates. U.S. Pat. No. 4,807,421 discloses the holding of a container for processing using a plurality of extending flexible members. The flexible members can hold the container in a set orientation. In addition the flexible members can accept containers with some variation in the shape of the containers. U.S. Pat. No. 5,479,762 discloses carrier pucks for a container and for a closure for the container. The carrier puck for the container is sized to accommodate the container with no other particular features. The carrier puck for the closure has four gripper members that are secured to pivoting gripper arms. The gripper members are rollers which are comprised of a solid polymeric material such as polyurethane. These four gripper rollers rotate to secure the closure to the container. U.S. Pat. No. 6,068,110 discloses a holder for a cell that is being assembled. It consists of a rigid outer portion and an elastic inner portion to accommodate and hold the cell during its manufacture. There is no use of rollers.

Although these prior art documents disclose various structures for pucks and various holders, nevertheless there is still a need in the art for improved orienting holders for containers which are to be processed on a line such as a filling line. In particular, there is still a need for an orienting holder which can provide for the effective handling of containers on a filling line, and in particular containers of a unique shape such as those having a substantially circular cross-section.

The invention aims at least partially to solve the problem of reliably and securely holding the container in its initial set orientation with regard to its surface bearing the primary graphics while moving along the filling line and while a non-round closure is being attached, such as a closure having a combined pump dispenser.

There is also a need in the art for an orienting holder which can reliably and securely prevent the container from rotating while on the filling line, in particular in an application in which a spout of each successively attached pump dispenser of a series of containers will need to be in a set orientation with regard to the container graphics, and each container needs to have the spout of the attached pump dispenser in the same orientation for subsequent operations such as case packing.

Further, there is also a need in the art for an orienting holder which can provide uniformity of the container structure and labeling which in turn can provide for a neater product array when a number of identical products are displayed on a store shelf.

Also, there is a need in the art for an orienting holder which can provide the ability to quickly insert and to remove containers from the orienting holders and the filling line for case packing.

Finally, there is a need in the art for a low cost solution for improved round container handling on a processing line such as a filing line.

BRIEF SUMMARY OF THE INVENTION

Accordingly, the invention provides an orienting holder for holding a container in a desired orientation on a container processing line, the orienting holder comprising a unit having a base portion for supporting a container disposed thereon, a cavity for receiving a container and at least two rollers located around the cavity for engaging an exterior surface of a container received within the cavity, at least one of the rollers being located at a respective one of at least two positions located around the cavity.

The invention is directed to an orienting holder for containers. The unit is adapted to hold the container in an upright orientation when the base portion is horizontally oriented. This is a holder that in addition to moving a container along a processing line, such as a filling line, will in addition maintain the container in an initial set orientation during such processing. This orienting holder comprises a unit having at least two rollers, the unit having a base portion, the rollers being connected to the base portion and in contact with the container to be processed on its exterior surface, the rollers in one preferred embodiment being compressible material rollers.

The rollers are on arms attached to the base portion, and in another preferred embodiment contact the container at an upper part of the container. There are at least two arms with at least one roller on each arm. The arms optionally can flex or rotate whereby the rollers can move towards and away from the container. The arms, by flexing or rotating, can increase or decrease the contact pressure against the container.

The at least two positions located around the cavity may comprise positions on opposite sides of the cavity, and/or may comprise only two opposite positions. Typically, the at least two positions located around the cavity are positioned so that the rollers at least partly surrounding the cavity temporarily capture a container disposed therein. The rollers may be adapted to provide an inwardly and downwardly oriented holding force on a container disposed in the cavity. Optionally, there is a structure on the base portion adapted to interact with the container processing line. The structure defines forward and rearward ends of the unit, and the at least two positions located around the cavity may comprise positions on opposite sides of the unit, the sides extending between the forward and rearward ends.

The present invention also provides a container processing line comprising a series of orienting holders according to the present invention.

The present invention also provides a method of holding a container at a particular orientation on a container processing line, the method comprising the steps of: locating a container on a base portion mounted on a processing line and holding an exterior surface of a portion of the container between opposed rollers mounted above the base portion, the rollers holding the container at a particular orientation.

The rollers are comprised of elastic materials. The elastic materials of the rollers include elastomers. Elastomers are inclusive of polymeric foams. Polymeric foams are a type of a compressible material. In one embodiment the rollers have a plurality of channels to enhance the elasticity and/or the compressibility of the rollers. In another embodiment the rollers are of a continuous structure with no channels. In a further embodiment the rollers have a modified outer surface to enhance contact with the container. The elastomer can be a natural or a synthetic material such as natural or synthetic rubbers, a polymer or copolymer containing ethylene units, a polymer or copolymer containing propylene units or a polymer or copolymer containing butylene units. When a polymeric foam is used the elastomer can be a polyurethane foam, a polyethylene foam, an ethylene-vinyl acetate foam, or a polypropylene foam.

The rollers will have a stiffness factor of about 0.8N to about 80N per 4 mm deflection, and preferably about 3 to about 18N per 4 mm deflection. As a result rollers can be chosen from these ranges to suit the needs for a particular container. This increases the versatility of the holders which can then be used for various shaped containers.

The holder according to the preferred embodiments of the present orienting holder can provide for the effective handling of containers on a filling line, and in particular containers of a unique shape such as those having a substantially circular cross-section. It solves the problem of holding the container in its initial set orientation with regard to its surface bearing the primary graphics while moving along the filling line and while a non-round closure is being attached, such as a closure having a combined pump dispenser. The holders prevent the containers from rotating while on the filling line. Additionally, in many instances the spout of each pump dispenser will need to be in a set orientation with regard to the container graphics, and each container needs to have the spout of the attached pump dispenser in the same orientation for subsequent operations such as case packing. Further, it provides for a neater product array when displayed on a store shelf. Also provided is the ability to quickly insert and to remove containers from the orienting holders and the filling line for case packing.

These advantages and technical effects may all be accomplished by a holder having rollers in contact with the container surface. The rollers are comprised of an elastic material, and in one preferred embodiment, are comprised of a compressible elastic material. Elastic materials are those that can deform upon the application of a force, but which will upon the removing of the force substantially regain their original shape. Compressible materials are a type of elastic material which have a higher degree of deformation upon the application of a force but which will likewise substantially regain their original shape upon the removal of the force. The rollers by rotating will minimize the required inserting and removing forces, and by being in contact with the container will hold the container in an initial set orientation while on the filling line. The use of holders with rollers provides for these significant advantages over other holders. The use of compressible rollers provides for an enhancement of these advantages. These are low cost solutions for improved round container handling.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described in its preferred embodiments with reference to the attached drawings. It is to be understood that the preferred embodiments disclose a concept for a novel holder that can be subject to modifications for adaption to specific environments and particular uses. All such modifications are deemed to be within the present concept.

FIG. 1shows the orienting holder10in combination with a container in front elevation with part of the inner structure the base portion12of the holder10in dashed lines. The base portion12has a bottom surface11. Shown are holder first side wall23and holder second side wall24. Arm15is attached to the inner surface of first side wall23and arm16is attached to the inner surface of second side wall24. Arm15supports a roller18and arm16supports another roller18. Typically, the arms15,16are rigid, or flexible, and the rollers18are compressible. Each roller18rotates on an axle19which has a fastener17to maintain the axle on its respective arms. Each roller18is mounted at a common height above the base portion12. Shown as a part of the base portion12is a holder cup20and vertical supports43and45. Also shown in a lower part13of the front wall22of the base portion12is a slot14. The slot14interacts with a projection on a processing line to maintain the holder on the processing line. The processing line usually will be a filling line.

Also shown in this view is a container30supported in holder cup20. The container is received in a cavity defined above the holder cup20.

The container has an enclosing surface31and a closure32. The closure32has an attached pump dispenser comprised of an actuator34with a spout33, a pump body37and a dip tube35. The product in the container30will exit the container through spout33. The closure32is attached the neck of the container by mating threads36which are on both the closure and the container. Essentially any conventional pump dispenser can be used.

FIG. 2is a right side elevation view of the base portion12with container30ofFIG. 1. Shown is base portion front wall22and rear wall21. The lower part13of the base portion12has slots14for interacting with a structure of the processing line. The container30is supported in holder cup20. The roller18is supported within arm16which has two support parts for the axle19. Another roller18is similarly supported by arm15. Optionally the arms15and16can be of a one piece construction solely with an opening for the mounting of the rollers. The axles19with the rollers18are secured to arms15and16by fasteners17. The container30has the same components as inFIG. 1and will not be described with regard to this view.

FIG. 3is a top plan view of the holder10ofFIG. 1. Shown is the base portion12with front wall22, rear wall21, first side wall23and second side wall24. Vertical supports43and45reinforce each of the front and rear walls22,21. Arms15and16reinforce first side wall23and second side wall24respectively as well as serving as mounting structures for the rollers18when attached to these side walls23,24. As an alternative, the arms15,16can be attached to the bottom wall11of the base portion12. The rollers18are supported on arms15and16by their respective axles19and fasteners17. Horizontal supports40and42disposed beneath the holder cup20and extending between the first side wall23and second side wall24provide support for lower parts of the vertical supports43and45which extend inwardly form the which in turn support the holder cup20. The container30has the same components as inFIG. 1and will not be described in detail with regard to this view.

FIG. 4is a front cross-sectional view of the holder10and container30.FIG. 5is the same cross-sectional view but without the container30. The container30has the same components as inFIG. 1and will not be described in detail with regard to this view. The holder cup20has a bottom wall25with an aperture26to assist in unloading the container from the holder. During such an unloading step, an ejection pin (not shown) moves up through the aperture26to contact the container30and move the container30upwards. The rollers18are shown as having a plurality of channels27. The channels27extend substantially radially outwardly, the channels preferably being arcuate and arranged in a spiral configuration, from a radially central part129of the roller18adjacent to the axle19to an outer circumferential surface29of the roller18. These channels27function to increase the degree of compression, in a substantially radial direction, of the roller18during contact with the container wall31. In this view, the surface29of the rollers18is shown as compressed against the container surface31. The structure of the base portion12is described in detail in the description of the prior Figures. It has a first side wall23and a second side wall24. There is a slot14for interaction with a processing line structure. Vertical supports43and45reinforce the front wall22and rear wall21.

FIG. 6is a right side view of the holder10with the container30removed. The base portion12is shown with lower part13with slot14for interaction with the processing line. Shown is the front wall22, the rear wall21and the holder cup20with bottom wall25. Also shown are vertical reinforcing supports43,45. The roller18has a surface29and is mounted to arm16by axle19and fastener17.

FIGS. 7 and 8are top and bottom plan views respectively of the base portion12. In each view there is shown front wall22, rear wall21, first side wall23and second side wall24. Holder cup20is shown with bottom wall25which has an aperture26. The holder cup20is supported by inwardly located ends of lower portions of the reinforcing supports43,45and of the arms15,16. The rollers18are supported by arms15and16. The rollers have a surface29which will contact the container surface31. The rollers rotate on axle19which has a fastener17to attach it to an arm15or16.

FIGS. 9 and 10are elevation views, in partial section, showing an additional embodiment of the orienting holder of the invention.

FIG. 9shows the embodiment of the orienting holder10with a container30andFIG. 10without the container30. In this embodiment the rollers18are not in a fixed relationship relative to the base portion12, and consequently to the container30when in use, but rather are movable relative to the base portion12and the container30. The rollers18also are adjustable relative to the container30.

The base portion12is similar to that for the embodiment ofFIGS. 1 to 8. The difference primarily is in the structure for holding the rollers18. The base portion12has first and second side walls23and24respectively. The lower part13has slot14for interaction with the processing line. The holder cup20has side wall38and lower wall25with aperture26. Vertical supports43and45reinforce front wall22and rear wall21. In this embodiment, the rollers18have the same construction as described for the first embodiment ofFIGS. 1 to 8.

The rollers18are attached to movable arms47and48, each being mounted at a respective opposite side of the base portion12, adjacent to and inwardly of a respective side wall23,24. The rollers18constitute upper rollers18and are attached to respective upper ends100of arms47and48by axles19and fasteners17. The arms47and48pivot on fasteners49, a central part102of each arm47,48being mounted to a respective fastener49which constitutes a pivot mount for the respective arm47.48. Each fastener49is located substantially at an elbow104of the respective arm47,48, the elbow104being the junction of upper and lower portions106,108of the arm47,48. The concave side of the elbow104is directed inwardly from the respective side wall23,24, and oriented towards the container30in use. Pivoting arm47is attached to support brace55by fastener49, support brace55being disposed at the inner surface of first side wall23. Pivoting arm48is attached to support brace56by another fastener49, support brace56being disposed at the inner surface of second side wall24. The lower end110of each arm47,48has mounted thereon a respective lower roller50. The lower roller50is rotationally supported on an axle53. Each upper roller18is mounted at a common first height above the base portion12and each lower roller50is mounted at a common second height above the base portion12.

The lower roller50in this embodiment has the same construction as that of the upper roller18, in particular is compressible and provided with a plurality of substantially radially directed channels51, which are arcuate and spirally arranged. The arms47,48, each carrying a respective upper and lower roller18,50pair, can pivot about fastener49so that the upper and lower rollers18,50can move in the same rotational direction but opposite translational directions with respect to the respective side wall23,24, and the container30in use. The upper roller18can contact an upper surface of the container30while the lower roller50contacts a lower surface of the container30and/or the exterior surface38of holder cup20. In this way, by providing pairs of upper and lower rollers on opposite sides of the container to be held, some variations in the shape of the containers30can be accommodated by the same orienting holder10. Also, the container30is more securely held within the orienting holder10.

FIGS. 11 to 13show three respective alternative constructions for the rollers18,50for use in the embodiments of the present invention. The various roller constructions described may be used independently or in any combination, either for the opposite sides of the orienting holder and/or for the upper and lower rollers.

FIG. 11is an enlarged view of the compressible roller18of the embodiment ofFIGS. 1 to 8. The same construction may be provided for upper and lower rollers18,50of the embodiment ofFIGS. 9 and 10. The roller18has a central shaft opening39for an axle. There is a peripheral circumferential outer surface29. The outer surface29and the axle opening39are circular in cross-section. A plurality of spirally arranged arcuate channels27is provided in the roller, each extending between opposed inner and outer channel ends130,131from the radially central part129to the circumferential outer surface29of the roller18. Each channel27has a longitudinal direction extending in an axial direction through the roller18. The substantially radially oriented channels27enhance the compressibility of the roller18when the outer surface29is compressed, for example by contact with the outer surface of the container30in a substantially radial direction. The roller18can also rotate in order to more readily be deformed by compression when rolled against the container surface when the container30is inserted into or removed from the orienting holder10.

FIG. 12illustrates an alternate roller to that ofFIG. 11. This roller60is a solid roller composed of an elastic and compressible material which is not provided with channels. Roller60has a central opening61for an axle (not shown). The roller60has a continuous region63between the opening61and the peripheral surface62. The peripheral surface62may have, as illustrated, an irregular three-dimensional relief profile64on at least a part of the surface62. The relief profile64may comprise ridges and/or grooves, typically extending circumferentially around the surface62, so that the surface62may resemble that of a vehicle tire. This relief profiling can enhance the gripping of a container30by the roller60as the container30is inserted into or removed from the holder10.

FIG. 13illustrates a further alternate roller. The roller70is again solid, as the roller ofFIG. 12, and has a continuous region73between the axle opening71and the peripheral surface72. The peripheral surface72has an undulating surface with hills and valleys, the undulations being oriented in an axial direction of the roller70. This likewise can enhance the gripping of a container30by the roller70as the container30is inserted into or removed from the holder10.

The rollers18,50,60,70are elastic and are composed of an elastic material such as an elastomer, for example a polymeric foam. The polymeric foam may be an open cell or closed cell foam. Categories of elastomers are compressible to varying degrees depending on their stiffness. The rollers18,50,60,70preferably exhibit at least some compressible deformation at the point of contact with the container30, or the holder cup20for the lower roller50, in order to better hold the container30and to accommodate variations in container shapes. The rollers18,50,60,70regain their original shape upon the removal of the deforming force since they are composed of elastically deformable material.

The elastomer may form a solid body, with or without pores, and may contain additives to adjust the elasticity. Elastomeric polymers that are useful for the rollers include natural and synthetic rubbers, ethylene polymers and copolymers, propylene polymers and copolymers, and butylene polymers and copolymers. Elastomeric polymers, in particular suitable for forming foams, are well known to those skilled in the art. Useful elastomeric foams are polyurethane foams, ethylene-vinyl acetate foams, and expanded polyethylene foams and expanded polypropylene foams. Closed cell foams are preferred since they are more easily maintained in processing operations because there are no open cells to absorb contaminants or liquid debris. Durable elastomer materials, such as polyurethanes, are generally preferred. Such materials have good wear resistant properties while retaining compressibility. This results in less processing line maintenance. Elastic materials further have the advantage that they can automatically adjust to imperfections in a container surface.

Depending on the degree of the imperfections rollers composed of a solid elastomer or a foam elastomer may be sufficient to effectively hold the container in the set orientation. However, where the imperfections can be more significant, elastomers with channels may be preferred since they will more readily conform into the imperfections to grip and hold the container in the set orientation. The channels can be of essentially any shape and size. The selected shape and size depend on the particular elastomer and the degree of compressibility desired. The objective in the use of channels is to increase the compressibility of elastomers, such as durable elastomers. Channels can also be used with foam elastomers. As a result rollers can be chosen for a particular container shape. Thus the holders are versatile and can be used for differing container shapes through the selection of the best rollers for a container.

The rollers preferably have a stiffness factor of about 0.8N to about 80N per 4 mm deflection, and preferably about 3N to about 18N per 4 mm deflection (N=Newtons). The stiffness factor is determined using an Instron test machine, such as an Instron 4301. The rollers with the axles in place are placed between two flat plates. The upper plate is attached to the head of the Instron test machine and is lowered at a rate of 12.7 mm per minute for a distance of 4 mm. The surface a roller is deflected against each surface. The deflection force required is indicated directly by the Instron test machine.

In the use of the holder10there are a plurality of these holders10fitted onto a container processing line, such as a container filling line. While the line is operating continuously, the empty containers to be filled are inserted into the holders. The containers are inserted into the holders in a set orientation. It is important that the containers retain this orientation through the container filling step until removal of the containers from the filling line. The rollers allow for the containers to be readily inserted into the holders and to be removed from the holders. Without the rolling action, the force required to insert the container into the holder would be greater than it is with the rolling action. The rollers rotate to provide for the easy inserting and removal of the containers. By being comprised of an elastic material, the roller can grip onto the container surface to an extent to maintain the container in the designated orientation. The container cannot rotate as the holder carrying the container moves along the filler line. The grip of the rollers onto the containers is sufficient to insure that the initial container orientation is maintained throughout the filling process, and any preliminary or subsequent processing steps, prior to removal of the container from the processing line.